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Genie GS-3390 GS-4390 GS-5390 Service Manual 72863 – PDF DOWNLOAD
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Genie GS-3390 GS-4390 GS-5390 Service Manual 72863 – PDF DOWNLOAD
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Description
Genie GS-3390 GS-4390 GS-5390 Service Manual 72863 – PDF DOWNLOAD
Language : English
Pages : 352
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GS-3390 GS-4390 GS-5390 Service Manual 72863 – PDF DOWNLOAD
Front Cover......................................................................................................... 1 Important Information............................................................................................... 2 Revision History.................................................................................................... 3 Serial Number Legend................................................................................................ 5 Safety Rules........................................................................................................ 6 Table of Contents................................................................................................... 8 Section 2 • Specifications.......................................................................................... 17 Machine Specifications.......................................................................................... 17 Performance Specifications...................................................................................... 18 Hydraulic Specifications........................................................................................ 18 Hydraulic Components Specifications ............................................................................ 19 Manifold Component Specifications............................................................................... 21 Valve Coil Resistance Specifications............................................................................ 21 Ford LRG-425 EFI Engine......................................................................................... 22 Deutz F4L 1011F Engine.......................................................................................... 23 Deutz F3L 1011F Engine.......................................................................................... 24 Deutz F3L 2011 Engine........................................................................................... 25 Deutz D2011L03i Engine.......................................................................................... 25 Hydraulic Hose and Fitting Torque Specifications................................................................ 26 SAE and Metric Fasteners Torque Charts.......................................................................... 27 Section 3 • Scheduled Maintenance Procedures........................................................................ 29 Introduction.................................................................................................... 29 Pre-delivery Preparation Report................................................................................. 31 Maintenance Inspection Report................................................................................... 33 Checklist A Procedures.......................................................................................... 35 A-1 Inspect the Manuals and Decals......................................................................... 35 A-2 Perform Pre-operation Inspection....................................................................... 36 A-3 Perform Function Tests................................................................................. 36 A-4 Perform Engine Maintenance - Ford Models............................................................... 37 A-5 Perform Engine Maintenance - Deutz Models.............................................................. 37 A-6 Test the Oscillate Axle - GS-90 Models ................................................................. 38 A-7 Perform 30 Day Service................................................................................ 39 A-8 Perform Engine Maintenance - Deutz Models............................................................. 39 A-9 Perform Engine Maintenance - Ford Models.............................................................. 39 A-10 Check the Hydraulic Return Filter Condition Indicator (if equipped).................................. 40 A-11 Perform Engine Maintenance - Deutz 1011F Models...................................................... 40 A-12 Drain the Fuel Filter/Water Separator - Deutz Models................................................. 41 A-13 Perform Engine Maintenance - Ford Models............................................................. 42 Checklist B Procedures.......................................................................................... 43 B-1 Inspect the Battery.................................................................................... 43 B-2 Inspect the Electrical Wiring.......................................................................... 44 B-3 Perform Engine Maintenance - Deutz 1011F Models........................................................ 45 B-4 Check the Exhaust System............................................................................... 45 B-5 Replace the Engine Air Filter.......................................................................... 46 B-6 Check and Adjust the Engine RPM........................................................................ 47 B-7 Confirm the Proper Brake Configuration................................................................. 49 B-8 Inspect the Tires and Wheels (including lug nut torque)................................................ 49 B-9 Check the Oil Level in the Drive Hubs.................................................................. 50 B-10 Test the Key Switch................................................................................... 50 B-11 Test the Emergency Stop............................................................................... 51 B-12 Test the Automotive-style Horn........................................................................ 51 B-13 Test the Fuel Select Operation - Ford Models.......................................................... 52 B-14 Test the Drive Brakes................................................................................. 53 B-15 Test the Drive Speed - Stowed Position................................................................ 53 B-16 Test the Drive Speed - Raised Position................................................................ 54 B-17 Perform Hydraulic Oil Analysis........................................................................ 55 B-18 Inspect the Fuel Tank Cap Venting System.............................................................. 56 B-19 Replace the Engine Air Filter Element - Ford Models.................................................... 57 B-20 Perform Engine Maintenance - Ford Models.............................................................. 57 Checklist C Procedures.......................................................................................... 58 C-1 Test the Platform Overload System (if equipped)........................................................ 58 C-2 Replace the Engine Air Filter Element - Duetz Models.................................................... 59 C-3 Perform Engine Maintenance - Deutz Models.............................................................. 60 C-4 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil........................... 60 C-5 Perform Engine Maintenance - Ford Models............................................................... 60 Checklist D Procedures.......................................................................................... 61 D-1 Check the Scissor Arm Wear Pads........................................................................ 61 D-2 Check the Free-Wheel Configuration..................................................................... 62 D-3 Replace the Drive Hub Oil.............................................................................. 63 D-4 Replace the Fuel Filter/Water Separator - Deutz Models................................................ 63 D-5 Replace the Hydraulic Filters.......................................................................... 64 D-6 Test the Oscillate Axle ................................................................................ 66 D-7 Perform Engine Maintenance - Deutz Models............................................................. 68 Checklist E Procedures.......................................................................................... 69 E-1 Test or Replace the Hydraulic Oil...................................................................... 69 E-2 Perform Engine Maintenance - Deutz 1011F Models........................................................ 71 E-3 Perform Engine Maintenance - Ford Models............................................................... 72 E-4 Perform Engine Maintenance - Deutz Models.............................................................. 72 E-5 Perform Engine Maintenance - Deutz 2011 Models......................................................... 73 E-6 Perform Engine Maintenance - Ford Models (before serial number GS9003-41369)........................... 73 Section 4 • Repair Procedures....................................................................................... 74 Introduction.................................................................................................... 74 Platform Controls............................................................................................... 75 1-1 Circuit Boards.......................................................................................... 76 1-2 Joystick Controller..................................................................................... 76 1-3 Controller Adjustments (before serial number GS9003-41523).............................................. 78 1-4 Software Configuration (before serial number GS9003-41523).............................................. 84 Platform Components............................................................................................. 88 2-1 Platform................................................................................................ 88 2-2 Platform Extension Deck................................................................................. 90 Scissor Components.............................................................................................. 91 3-1 Scissor Assembly, GS-3390............................................................................... 92 3-2 Scissor Assembly, GS-4390............................................................................... 98 3-3 Scissor Assembly, GS-5390...............................................................................108 3-4 Wear Pads...............................................................................................120 3-5 Lift Cylinder(s)........................................................................................122 Engines.........................................................................................................126 4-1 RPM Adjustment..........................................................................................126 4-2 Engine Fault Codes - Ford Models.......................................................................126 4-3 Flex Plate..............................................................................................126 4-4 Oil Temperature and Oil Pressure Sending Units - Deutz Models...........................................130 4-5 Coolant Temperature and Oil Pressure Sending Units - Ford Models........................................131 Ground Controls.................................................................................................132 5-1 Auxiliary Platform Lowering.............................................................................132 5-2 Controller Adjustments (after serial number GS9003-41522)...............................................132 5-3 Software Configuration (after serial number GS9003-41522)...............................................143 5-4 Level Sensor - Models without Outriggers (before serial number 41158)...................................147 5-5 Level Sensor - Models without Outriggers (after serial number 41157)....................................150 5-6 Level Sensor - Models with Outriggers...................................................................152 5-7 Engine Fault Codes - Ford Models........................................................................157 Hydraulic Pumps.................................................................................................159 6-1 Lift/Steer Pump.........................................................................................159 6-2 Drive Pump..............................................................................................161 Manifolds.......................................................................................................163 7-1 Function Manifold Components - Models with Outriggers (before serial number 40519)......................163 7-2 Function Manifold Components - Models with Outriggers (after serial number 40518).......................165 7-3 Function Manifold Components - Models without Outriggers (before serial number 40519 )..................167 7-4 Function Manifold Components - Models without Outriggers (after serial number 40518)....................169 7-5 Drive Manifold Components (before serial number GS9004-41691) ..........................................171 7-6 Drive Manifold Components (after serial number GS9004-41690) ...........................................173 7-7 Oscillate Manifold Components (optional after serial number GS9004-41690) ..............................175 7-8 Valve Adjustments - Function Manifold...................................................................177 7-9 Valve Adjustments - Drive Manifold......................................................................179 7-10 Generator Manifold Components..........................................................................181 7-11 Valve Adjustments - Generator..........................................................................182 7-12 Valve Coils............................................................................................183 Fuel and Hydraulic Tanks........................................................................................185 8-1 Fuel Tank...............................................................................................185 8-2 Hydraulic Tank..........................................................................................186 Steer Axle Components...........................................................................................188 9-1 Yoke and Drive Motor....................................................................................188 9-2 Steer Cylinder.........................................................................................190 9-3 Tie Rod.................................................................................................191 9-4 Oscillating Axle Option (after serial number GS9004-41690)..............................................192 Non-steer Axle Components.......................................................................................193 10-1 Drive Motor and Brake..................................................................................193 10-2 Drive Hub..............................................................................................194 10-3 Oscillating Axle.......................................................................................194 Outrigger Components............................................................................................195 11-1 Outrigger Cylinder.....................................................................................195 Platform Overload Components....................................................................................196 12-1 Platform Overload System...............................................................................196 Section 5 • Fault Codes.............................................................................................206 Introduction....................................................................................................206 Fault Code Chart (before serial number GS9003-41523)............................................................208 Fault Code Chart (after serial number GS9003-41522).............................................................210 Ford Engine ECM Fault Code Chart (before serial number GS9003-41369)............................................213 Ford Engine ECM Fault Code Chart (after serial number GS9003-41368).............................................215 Section 6 • Schematics..............................................................................................220 Electrical......................................................................................................221 Electronic Control Module Layout (before serial number GS9003-41523)........................................221 Electronic Control Module Pin-out Legend (before serial number GS9003-41523) ...............................222 Electronic Control Module Layout (after serial number GS9003-41522).........................................223 Electronic Control Module Pin-out Legend (after serial number GS9003-41522).................................224 Ford Engine Relay Layout....................................................................................225 Ford Engine Harnesses ......................................................................................233 Wiring Harness - Ford LRG-425 EFI (before serial number GS9003-41369)...................................233 Wiring Harness - Ford LRG-425 EFI (from serial number GS9003-41369 to GS9004-41693).....................235 Wiring Harness - Ford LRG-425 EFI (after serial number GS9004-41693)....................................237 Wiring Diagram - Platform Control Box (before serial number GS9003-41523)...................................226 Wiring Diagram - Platform Control Box (after serial number GS9003-41522)....................................227 Electrical Schematics Abbreviation and Wire Color Legends...................................................228 Limit Switch Legend.........................................................................................229 Electrical Symbols Legend...................................................................................231 Electrical Schematic - Platform Overload (option)(before serial number GS9003-41523)........................232 Electrical Schematics - Ford and Deutz, ANSI and CE to GS9003-41522 .......................................239 Electrical Schematic, Ford Models (before serial number 40428)..........................................239 Electrical Schematic, Ford Models (from serial number 40428 to 40793)...................................243 Electrical Schematic, Ford Models (from serial number 40794 to 40995)...................................247 Electrical Schematic, Ford Models (from serial number 40996 to 41065)...................................251 Electrical Schematic, Ford Models (from serial number 41066 to GS9003-41368)............................255 Electrical Schematic, Ford Models (from serial number GS9003-41369 to GS9003-41522).....................259 Electrical Schematic, Deutz Models (before serial number 40428).........................................299 Electrical Schematic, Deutz Models (from serial number 40428 to 40737)..................................303 Electrical Schematic, Deutz Models (from serial number 40738 to 40941)..................................307 Electrical Schematic, Deutz Models (from serial number 40942 to 41065)..................................311 Electrical Schematic, Deutz Models (from serial number 41066 to GS9003-41350)...........................315 Electrical Schematic, Deutz Models (from serial number GS9003-41351 to GS9003-41522)....................319 Electrical Schematics - Ford and Deutz, ANSI from GS9003-41523 .............................................263 Electrical Schematic, ANSI Models with Ford Power (from serial number GS9003-41523 to GS9004-41693).....263 Electrical Schematic, ANSI Models with Ford Power (from serial number GS9003-41694 to GS9005-42143).....267 Electrical Schematic, ANSI Models with Ford Power (from serial number GS9005-42144 to GS9005-42203).....271 Electrical Schematic, ANSI Models with Ford Power (from serial number GS9005-42204 to GS9005-42685).....275 Electrical Schematic, ANSI Models with Deutz Power (from serial number GS9003-41523 to GS9005-42143)....323 Electrical Schematic, ANSI Models with Deutz Power (from serial number GS9005-42144 to GS9005-42685)....327 Electrical Schematics - Ford and Deutz, CE from GS9003-41523 ...............................................279 Electrical Schematic, CE Models with Ford Power (from serial number GS9003-41523 to GS9004-41693).......279 Electrical Schematic, CE Models with Ford Power (from serial number GS9003-41694 to GS9005-42143).......283 Electrical Schematic, CE Models with Ford Power (from serial number GS9005-42144 to 42203)..............287 Electrical Schematic, CE Models with Ford Power (from serial number GS9005-42204 to 42411)..............291 Electrical Schematic, CE Models with Ford Power (from serial number GS9005-42412 to GS9005-42685).......295 Electrical Schematic, CE Models with Deutz Power (from serial number GS9003-41523 to GS9005-42143)......331 Electrical Schematic, CE Models with Deutz Power (from serial number GS9005-42144 to 42411).............335 Electrical Schematic, CE Models with Deutz Power (from serial number GS9005-42412 to GS9005-42685)......339 Hydraulic.......................................................................................................343 Hydraulic Schematics Component Call-out Legend..............................................................343 Hydraulic Symbols Legend....................................................................................344 Hydraulic Schematic (before serial number 40519)............................................................345 Hydraulic Schematic (from serial number 40519 to GS9004-41690)..............................................347 Hydraulic Schematic (from serial number GS9004-41691 to GS9005-42685).......................................349 Back Cover..........................................................................................................352
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