Genie GS-3384 Service And Repair Manual Download Page 100

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Service and Repair Manual

September 2016

Repair Procedures

GS-84 • GS-90

Part No. 1272222

7-10 G ener at or Reli ef Valve Manif old C om ponent s

7-10
Generator Relief Valve Manifold Components

The generator relief valve manifold is located in the hydraulic manifold compartment.

Index
No.

Description

Schematic

Item

Function

Torque

Relief valve, 3500 psi / 241 bar

Generator pressure circuit

25 ft-lbs / 34 Nm

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.

Summary of Contents for GS-3384

Page 1: ...includes Repair procedures Fault Codes Electrical and Hydraulic Schematics GS 3390 from GS84F 45500 from GS9013 48427 to GS 4390 GS9015 51063 from GS9016F 51064 to GS9016F 53299 GS 5390 from GS90F 53300 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1272222 Rev A1 September 2016 ...

Page 2: ...Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for i...

Page 3: ...n Date Section Procedure Page Description A 3 2016 Initial Release A1 9 2016 Introduction Serial Number Legend Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ... Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label located inside cover 6 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial label located inside cover 5 Serial number stamped on chassis ...

Page 5: ...serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental re...

Page 6: ...crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from fla...

Page 7: ...afety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Specification 3 Hydraulic Component Specifications 5 Manifold Component Specifications 6 Ford MSG 425 EFI Engine Specifications 7 Deutz D2011 L03i Engine Specifications 8 Deutz D 2 9 L4 Engine Specifications 9 Hydraulic Hose and Fitting Torque Specifications 11 Torque Pro...

Page 8: ... Assembly GS 3384 and GS 3390 20 How to Disassemble the Scissor Assembly 20 How to Disassemble a Scissor Arm Pair 24 3 2 Scissor Assembly GS 4390 26 How to Disassemble the Scissor Assembly 26 How to Disassemble a Scissor Arm Pair 30 3 3 Scissor Assembly GS 5390 33 How to Disassemble the Scissor Assembly 33 How to Disassemble a Scissor Arm Pair 38 3 4 Wear Pads 39 How to Replace the Scissor Arm Wea...

Page 9: ...igh Torque Drive Speed 52 How to Adjust the Raised Drive Speed 53 How to Adjust the Lift Speed 55 How to Adjust the Platform Lower Speed 56 How to Adjust the Platform Settling Speed 57 How to Adjust the Steer Speed 58 5 3 Software Configuration 58 5 4 Level Sensor Models without Outriggers 63 How to Install and Calibrate the Level Sensor Models without Outriggers 63 5 5 Level Sensor Models with Ou...

Page 10: ... Relief Valve 83 How to Adjust the Steer Relief Valve 84 7 7 Valve Adjustments Traction Manifold 85 How to Adjust the Charge Pressure Relief Valve 85 7 8 Generator Manifold Components 86 7 9 Valve Adjustments Generator Manifold 87 How to Adjust the Generator Voltage 87 7 10 Generator Relief Valve Manifold Components 88 7 11 Valve Coils 89 Fuel and Hydraulic Tanks 91 8 1 Fuel Tank 91 8 2 Hydraulic ...

Page 11: ...2 12 2 Platform Overload Recovery Message software version B3 and later 111 Section 4 Fault Codes 113 Introduction 113 Control System Fault Codes 115 Control System Fault Codes 115 Fault Code Display Deutz Models 119 How to Retrieve Active Engine Fault Codes Deutz D 2 9 L4 Models 119 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 Models 120 Soft Key Functions and Icons Deutz D 2 9 L4 M...

Page 12: ...g Diagram 12 kW Hydraulic Generator option 153 Electrical Schematics Engine Harness 155 Ford MSG 425 EFI Engine Wire Harness 156 Deut D 2 9 L4 Engine Wire Harness 157 Hydraulic Schematics 159 Hydraulic Schematic To Serial Numbers GS8415 42316 and GS9015 50184 160 Hydraulic Schematic From Serial Numbers GS84154 42317 and GS9015 50185 162 Electrical Schematics ANSI and CSA Models 165 Electrical Sche...

Page 13: ...in x 16 in 83 8 cm x 41 cm Wheel diameter x width 19 5 in x 14 in 49 5 cm x 35 6 cm Weight foam filled 419 lbs 10 lbs 190 kg 4 5 kg Weight air filled 157 lbs 71 2 kg Pressure air filled 38 psi 2 6 bar Rough Terrain foam filled GS 90 Tire size LSW 305 546 NHS Tire ply rating 10 Tire weight new foam filled minimum Rough terrain 265 lbs 120 kg Tire diameter x width 33 in x 12 in 83 8 cm x 30 cm Rough...

Page 14: ...form stowed 4 mph 40 ft 6 8 sec 6 4 km h 12 2 m 6 8 sec Platform raised 0 7 mph 40 ft 39 sec 1 1 km h 12 2 m 39 sec Braking distance maximum High range on paved surface 60 in 152 4 cm Gradeability See Operator s Manual Function speed maximum from platform controls with maximum rated load in platform GS 3384 and GS 3390 Platform up Platform down 40 to 50 seconds 24 to 34 seconds GS 4390 Platform up...

Page 15: ...nt UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable...

Page 16: ...hevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt...

Page 17: ...si 1 7 bar bypass Auxiliary power unit Relief valve 3700 psi 255 bar Function manifold System relief valve pressure maximum GS 3384 and GS 3390 2700 to 2900 psi 186 to 200 bar System relief valve pressure maximum GS 4390 and GS 5390 2900 to 3100 psi 200 to 214 bar Steer relief valve pressure GS 3384 2700 to 2900 psi 186 to 200 bar Steer relief valve pressure GS 3390 GS 4390 and GS 5390 1950 to 225...

Page 18: ... min Generator manifold option Relief valve 2400 psi 165 5 bar Flow rate maximum 4 3 gpm 16 3 L min Welder manifold option Relief valve 270 psi 18 6 bar Hydraulic motor welder option Displacement 1 28 cu in 21 cc Manifold Com ponent Specificati ons Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No...

Page 19: ...point 7 to 9 psi 0 48 to 0 62 bar Oil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Electronic fuel pump Fuel pressure static 60 psi 4 1 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Igni...

Page 20: ...ssure 3046 psi 210 bar Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Lubrication system Oil pressure 20 to 44 psi 1 4 to 3 bar Oil capacity including filter 9 5 quarts 9 liters Oil change capacity including filter 7 35 quarts 7 liters Oil viscosity requirements Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engi...

Page 21: ...y including filter 9 4 quarts 9 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Temperature switch point 257 F 125 C Oil ...

Page 22: ...gine continued Starter motor Current draw normal load 250A to 400A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Battery Type 12V DC Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 95A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm ...

Page 23: ...Flats 4 7 16 20 2 6 9 16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable ...

Page 24: ...ngs 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Using a permanent ink marker make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illustration 1 Illustration 1 1 hex nut 2 reference mark 3 body hex f...

Page 25: ...e appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following config...

Page 26: ...ert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not a...

Page 27: ...ontrols Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Loosen the platform control box lid retaining fasteners Open the control box lid 3 Visually locate the circuit board mounted to the inside of the platform control box lid 4 Secure the control box lid in a level position 5 Tag and disconnect the wire connectors from the red E...

Page 28: ... The link set cross tube can be damaged if excessive force is applied Do not continue to lower the platform after the safety arm makes contact with the cross tube 4 Cut the zip ties that secure the power to platform wiring to the bottom of the platform Component damage hazard Be sure not to cut the power to platform wiring 5 Cut the zip ties that secure the platform controls wiring to the bottom o...

Page 29: ... if used to lift the platform Do not attach the lifting straps to the platform railings 20 Place a lifting strap from a second overhead crane under the platform at the non steer end of the machine for support Do not apply any lifting pressure Component damage hazard The platform railings can be damaged if used to lift the platform Do not attach the lifting straps to the platform railings 21 Remove...

Page 30: ...cated above the platform V roller wheels 4 At the platform extension deck to be removed position a fork lift with the forks even with the bottom of the platform extension deck 5 Lift the platform extension deck lock handle 6 Carefully slide the platform extension deck out until the platform extension deck makes contact with the carriage on the forklift 7 Attach a strap from the platform extension ...

Page 31: ... end 5 Number 2 outer arm 6 Number 2 inner arm 7 Number 2 pivot pin non steer end 8 Number 1 inner arm 9 Lift cylinder barrel end pivot pin 10 Number 1 pivot pins non steer end 11 Number 3 outer arm 12 Lift cylinder rod end pivot pin 13 Number 3 pivot pin steer end 14 Number 2 center pivot pin Qty 2 15 Number 2 pivot pin steer end 16 Number 1 outer arm 17 Number 1 center pivot pin Qty 2 18 Chassis...

Page 32: ...ning fasteners from the lift cylinder rod end pivot pin index 12 Do not remove the pin 4 Attach a lifting strap from an overhead crane to the lifting eye at the rod end of the lift cylinder 5 Use a soft metal drift to remove the lift cylinder rod end pivot pin index 12 Lower the rod end of the lift cylinder down onto the number 2 inner arm index 6 Crushing hazard The lift cylinder will fall if not...

Page 33: ...the machine 17 Use a slide hammer to remove both number 3 pivot pins index 13 from the steer end of the machine 18 Carefully remove the number 3 inner and outer arms index 2 and 11 from the machine Crushing hazard The number 3 inner and outer arms could become unbalanced and fall when they are removed from the machine if not properly supported by the overhead crane Note If further disassembly of t...

Page 34: ...asteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 6 36 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray onto the number 1 inner arm index 8 Crushing hazard The cable tray may fall if not properly supported by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched 37 Secure bo...

Page 35: ...number 1 inner and outer arms index 8 and 16 at the non steer end of the machine Do not apply any lifting pressure 49 Remove the pin retaining fasteners from both chassis centering link pivot pins index 18 at the number 1 inner arm 50 Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis 51 Remove the pin retaining fasteners f...

Page 36: ...ing strap to the end of the scissor arm that has the casting pointing upwards 1 outer arm 2 inner arm 2 Attach a lifting strap from a second overhead crane to the end of the inner arm Note Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards 3 Raise the scissor arms with the overhead cranes approximately 12 inches 30 cm 4 Place a 12 inch 30 cm block under th...

Page 37: ...r pivot pin Qty 2 8 Number 2 inner arm 9 Number 2 pivot pin non steer end 10 Number 1 inner arm 11 Lower lift cylinder barrel end pivot pin 12 Number 1 outer arm 13 Number 1 pivot pins non steer end 14 Number 4 inner arm 15 Number 4 pivot pin steer end 16 Number 3 outer arm 17 Lower lift cylinder rod end pivot pin 18 Number 3 inner arm 19 Number 3 pivot pin steer end 20 Number 2 outer arm 21 Numbe...

Page 38: ... suitable device 5 Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 14 and 2 at the steer end of the machine Do not apply any lifting pressure 6 Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 14 and 2 at the non steer end of the machine Do not apply any lifting pressure 7 Remove the pin retaining fasteners from both ...

Page 39: ...t or spray 20 Cut the zip ties attaching the hydraulic hoses to the lift cylinder Lay the hoses out of the way Component damage hazard Hoses can be damaged if they are kinked or pinched 21 Remove the cables from the number 3 inner arm index 18 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 22 Remove the pin retaining fasteners from th...

Page 40: ...fting pressure 34 Remove the pin retaining fasteners from the number 1 pivot pins index 13 at the non steer end of the machine 35 Use a slide hammer to remove both number 1 pivot pins index 13 from the non steer end of the machine 36 Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm 37 Place a 6 x 6 x 32 inch 15 x 15 x 80 cm long block across both sides of th...

Page 41: ...t apply any lifting pressure 53 Remove the pin retaining fasteners from both number 2 pivot pins index 9 at the non steer end of the machine Do not remove the pins 54 Remove the pin retaining fasteners from both number 2 pivot pins index 21 at the steer end of the machine Do not remove the pins 55 Use a slide hammer to remove both number 2 pivot pins index 9 from the non steer end of the machine 5...

Page 42: ...machine Crushing hazard The number 1 inner and outer arms could become unbalanced and fall when they are removed from the machine if not properly supported by the overhead crane Note If further disassembly of the scissor arm pair is required refer to Repair Procedure How to Disassemble a Scissor Arm Pair How to Disassembl e a Scissor Arm Pair How to Disassemble a Scissor Arm Pair Bodily injury haz...

Page 43: ...r of the scissor arm pair Lower the scissor arm pair onto the block 5 Remove the external snap rings from both center pivot pins 6 Use a soft metal drift to remove both center pins 7 Carefully separate the scissor arm pair Crushing hazard The scissor arms could become unbalanced and fall if not properly supported by the overhead cranes ...

Page 44: ... center pivot pin Qty 2 12 Number 2 center pivot pin Qty 2 13 Number 2 pivot pin non steer end 14 Number 1 inner arm 15 Lower lift cylinder barrel end pivot pin 16 Number 1 outer arm 17 Number 1 pivot pins non steer end 18 Number 5 outer arm 19 Number 5 pivot pin steer end 20 Number 4 inner arm 21 Upper lift cylinder rod end pivot pin 22 Number 4 pivot pin steer end 23 Number 3 outer arm 24 Lower ...

Page 45: ...other suitable device 5 Attach a lifting strap from an overhead crane to the number 5 inner and outer arms index 2 and 18 at the steer end of the machine Do not apply any lifting pressure 6 Attach a lifting strap from an overhead crane to the number 5 inner and outer arms index 2 and 18 at the non steer end of the machine Do not apply any lifting pressure 7 Remove the pin retaining fasteners from ...

Page 46: ...move both number 4 pivot pins index 7 from the non steer end of the machine 22 Use a slide hammer to remove both number 4 pivot pins index 22 from the steer end of the machine 23 Support the rod end of the upper lift cylinder with a suitable lifting device 24 Carefully remove the number 4 inner and outer arms index 20 and 5 from the machine while guiding the rod end of the upper lift cylinder out ...

Page 47: ...index 8 and 23 together with a strap or other suitable device 37 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the steer end of the machine Do not apply any lifting pressure 38 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the non steer end of the machine Do not apply any lifting pressure ...

Page 48: ...number 1 outer arm index 16 onto the block Crushing hazard Keep hands clear of moving parts when lowering the arms onto the block 51 Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder 52 Remove the lift cylinder barrel end pivot pin retaining fasteners 53 Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 15 54 Carefully remove the lif...

Page 49: ...steer end of the machine Do not remove the pins 67 Use a slide hammer to remove both number 2 pivot pins index 13 from the non steer end of the machine 68 Use a slide hammer to remove both number 2 pivot pins index 28 from the steer end of the machine 69 Carefully remove the number 2 inner and outer arms index 26 and 27 from the machine Crushing hazard The number 2 inner and outer arms could becom...

Page 50: ...y supported by the overhead crane Note If further disassembly of the scissor arm pair is required refer to Repair Procedure How to Disassemble a Scissor Arm Pair How to Disassembl e a Scissor Arm Pair How to Disassemble a Scissor Arm Pair Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and ...

Page 51: ... Scissor Arm Wear Pad 1 Place a lifting strap from an overhead crane under the platform at the steer end of the machine for support Do not attach the lifting straps from the overhead crane to the platform railings 2 Place a lifting strap from a second overhead crane under the platform at the non steer end of the machine for support Do not attach the lifting straps from the overhead crane to the pl...

Page 52: ...ns and the pin retaining fasteners How to R eplace the C hassis Scissor Arm W ear Pads How to Replace the Chassis Scissor Arm Wear Pads Note If removing the steer end slide blocks the engine top and side covers need to be removed first Proceed to step 1 Note If removing the non steer end slide blocks proceed to step 11 1 Start the engine from the ground controls and raise the platform approximatel...

Page 53: ...e off the slide block pivot pins 14 Remove the pin retaining fasteners from the chassis slide block pivot pin 15 Use a slide hammer to remove the chassis slide block pivot pin Remove the slide block from the machine by sliding it out the end of the slider channel Crushing hazard The platform will fall when the platform slide block pivot pins are removed if it is not properly supported by the overh...

Page 54: ...the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Start the engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 2 Release the safety arm latch lift the safety arm and rotate to a vertical ...

Page 55: ...pin Crushing hazard The lift cylinder will fall unless it is properly supported 10 Carefully lower the cylinder onto the cross tube of the number 2 inner arm Protect the cylinder rod from damage Component damage hazard The counterbalance valve on the lift cylinder can be damaged if it is allowed to come in contact with the scissor arm cross tube 11 Remove the lift cylinder barrel end pivot pin ret...

Page 56: ...aise the platform approximately 18 feet 5 5 m from the ground 2 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Note Be sure that the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off Crushing hazard Keep hands clear of the safety arm when lowering the platform Component dam...

Page 57: ... it is properly supported 10 Carefully lower the cylinder to a horizontal position Protect the cylinder rod from damage Component damage hazard The counterbalance valve on the lift cylinder can be damaged if it is allowed to come in contact with the scissor arm cross tube 11 Remove the lift cylinder barrel end pivot pin retaining fastener Use a soft metal drift to remove the pin Note Use of the ov...

Page 58: ...s Refer to Fault Codes Section for your specific model of engine Use the Fault Code Charts to aid in identifying the fault 4 3 Fl ex Plate 4 3 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump 1 pump 2 pump shaft 3 coupler 4 flex plate 5 flywheel 6 7 16 inch 11 mm gap Deutz models 0 080 inch 2 ...

Page 59: ...gine fasteners 13 Carefully pull the pump and bell housing away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 14 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel How to R emove the Flex Pl ate D eutz M odels How to Remove the Flex Plate Deutz Models 1 Release the latches on the engine tray and fu...

Page 60: ...to 40 ft lbs 54 Nm Flex plate bolt torque sequence 4 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 1 pump 2 pump shaft 3 coupler 4 flex plate 5 flywheel 6 7 16 inch 11 mm gap 5 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm 6 D...

Page 61: ...tz models Torque the bell housing mounting bolts labeled C in sequence to 40 ft lbs 54 Nm Ford models Torque the bell housing mounting bolts labeled A and B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm 8 Ford models Install the air cleaner mount bracket onto the bell housing Install the fasteners and torque to 28 ft lbs 38 Nm ...

Page 62: ...roller Adjustments All machine function speeds are determined by the percentage of total ECM voltage output The speeds of the following machine functions may be adjusted to compensate for wear in the hydraulic pump and drive motors Stowed drive speed High torque drive speed Raised drive speed Platform lift speed Platform lower speed Steer speed Platform settling speed For further information or as...

Page 63: ...yellow platform down buttons Pull out the red Emergency Stop button to the on position at the ground controls Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to max fwd high speed drive Result MAX FWD HIGH SPEED DRIVE is showing in the diagnostic display window 7...

Page 64: ... resulting in death or serious injury Note On machines with software revision B1 or lower high torque drive speeds in forward and reverse are simultaneously adjusted resulting in both directions of travel operating at the same speed On machines with software revision C0 or higher the high torque forward drive speed and the high torque reverse drive speed may be adjusted independent of one another ...

Page 65: ...ush in the red Emergency Stop button to the off position at the ground controls How to Adj ust the Raised Drive Speed How to Adjust the Raised Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury Note On machines with soft...

Page 66: ... mode 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button 10 Press the lift function enable button 11 Use the yellow platform down arrow to scroll to max rev high speed drive Result MAX REV RAISED DRIVE SPEED is showing in the diagnostic display window 12 Press the lift function enable button 13 Press the yellow platform down button to decreas...

Page 67: ...the ground controls Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to lift speed Result MAX LIFT SPEED is showing in the diagnostic display window 7 Press the lift function enable button 1 diagnostic display 2 blue platform up button 3 lift function enable butto...

Page 68: ...amming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to descent speed Result MAX DESCENT SPEED is showing in the diagnostic display window 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the platform des...

Page 69: ...able button 6 Use the yellow platform down arrow to scroll to settling speed Result MAX SETTLING SPEED is showing in the diagnostic display window 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the platform settling speed or press the blue platform...

Page 70: ...Emergency Stop button to the off position at the ground controls 5 3 Softw are Confi gur ation 5 3 Software Configuration The Electronic Control Module ECM contains programming for all configurations of the GS 84 and GS 90 Machines can be adjusted to a different configuration using the buttons at the ground controls To determine the software revision level refer to Repair Procedure How to Determin...

Page 71: ...the on position at both platform and ground controls Result The revision level of the ECM will appear in the LED display window Note the result 2 Push in the red Emergency Stop button to the off position at the ground controls 3 Press and hold both the blue platform up and yellow platform down buttons Pull out the red Emergency Stop button to the on position at the ground controls Result TUNE SPEE...

Page 72: ...ow Result OVERLOAD OFF is showing in the diagnostic display window Press the lift function enable button to activate the overload option 14 Use the yellow platform down arrow to scroll to sim operation Result SIM OPERATION ON is showing in the diagnostic display window Result SIM OPERATION OFF is showing in the diagnostic display window Press the lift function enable button to activate the sim ope...

Page 73: ...4 yellow platform down button 4 Use the yellow platform down arrow to scroll to select model Result SELECT MODEL is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button Result GS68 DUAL FUEL is showing in the diagnostic display window 6 GS 84 models with gasoline LPG power Use the yellow platform down arrow to scroll to GS84 DUAL FUEL ...

Page 74: ... option Note For AS and CE models the sim operation option should be deactivated or in the off position 15 Use the yellow platform down arrow to scroll to beacons option Result BEACONS OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the beacons option Note For this option to function the machine must be equipped with flashing beacons ...

Page 75: ...Remove the platform controls from the platform If you are not installing a new level sensor proceed to step 9 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Remove the ground control panel retaining fasteners and open the panel 4 Locate the level sensor behind the ground control panel 5 Tag and disconnect the wire harness from the level sensor 6 Remove the l...

Page 76: ...ting nuts just until the level sensor alarm does not sound 16 Lower the platform to the stowed position 17 Raise the machine slightly 18 Remove the blocks from under both wheels 19 Lower the machine and remove the jack 20 Center a lifting jack under the drive chassis at the engine side of the machine 21 Raise the machine approximately 4 inches 10 cm 22 Models with RT tires Place a 3 x 10 x 10 inch...

Page 77: ...machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Remove the ground control panel retaining fasteners and open the panel 3 Locat...

Page 78: ...yellow wire at the level sensor 16 Adjust the side to side axis of the level sensor until the multimeter reads 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut Note Be sure there are threads showing through the top of each adjusting nut 17 Disconnect the positive lead of the multimeter from the level sensor wire harness Adjust the front to back axis ...

Page 79: ... the drive chassis at the tank side of the machine 36 Raise the machine approximately 6 inches 15 cm 37 Models with RT tires Place a 3 x 10 x 10 inch 7 62 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine Models with flotation tires Place a 3 15 x 10 x 10 inch 8 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 38 ...

Page 80: ...54 Raise the machine approximately 6 inches 15 cm 55 Models with RT tires Place a 4 36 x 10 x 10 inch 11 07 x 25 x 25 cm thick steel block under both wheels at the steer end of the machine Models with flotation tires Place a 4 58 x 10 x 10 inch 11 63 x 25 x 25 cm thick steel block under both wheels at the steer end of the machine 56 Lower the machine onto the blocks 57 Raise the platform approxima...

Page 81: ...the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Note The hydraulic tank shutoff valves can be accessed from under the hydraulic tank tray 2 Release the latches on the engine tray and fully slide the engine tray out 3 Insert a 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller whee...

Page 82: ...lic Hose and Fitting Torque Specifications 1 Remove the lift steer pump Refer to Repair Procedure How to Remove the Lift Steer Pump 2 Disconnect the electrical connections at the Electronic Displacement Controller EDC located on the drive pump 3 Tag disconnect and plug the hydraulic hoses from the drive pump Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and...

Page 83: ...oth the ground and platform controls 3 Ford models Close the valve on the LPG tank then disconnect the hose from the tank if equipped Move the fuel select toggle switch at the ground controls to the LPG position Deutz D2011 L031models Hold the manual fuel shutoff lever clockwise in the closed position 1 manual fuel shutoff valve 4 Crank the engine with the starter motor for 15 seconds wait 15 seco...

Page 84: ...eutral adjustment screw at the top of the EDC 7 Turn the adjustment screw in a clockwise direction until the reading on the pressure gauge drops to its lowest point Note the position of the screw 8 Turn the adjustment screw in a counter clockwise direction until the reading on the pressure gauge reaches it highest point Continue to turn the adjustment screw in a counter clockwise direction until t...

Page 85: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 73 This page intentionally left blank ...

Page 86: ...sure Circuit 3 Relief valve 3500 psi 241 3 bar AC System relief 25 ft lbs 34 Nm 4 Proportional solenoid valve AD All functions 46 54 ft lbs 62 73 Nm 5 Relief valve 2000 psi 138 bar AE Steer and outrigger circuit 50 ft lbs 68 Nm 6 Diagnostic port AF Pressure Circuit 7 Solenoid valve 3 position 4 way AG Platform up down 30 35 in lbs 3 4 Nm 8 Solenoid valve 3 position 4 way AH Steer left right 45 ft ...

Page 87: ...ce and Repair Manual Manifolds Part No 1272222 GS 84 GS 90 75 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 88: ... 40 45 ft lbs 54 61 Nm 2 Diagnostic port AB Pressure Circuit 3 Relief valve 3500 psi 241 3 bar AC System relief 25 ft lbs 34 Nm 4 Proportional solenoid valve AD All functions 46 54 ft lbs 62 73 Nm 5 Relief valve 2000 psi 138 bar AE Steer circuit 50 ft lbs 68 Nm 6 Diagnostic port AF Pressure Circuit 7 Solenoid valve 3 position 4 way AG Platform up down 30 35 in lbs 3 4 Nm 8 Solenoid valve 3 positio...

Page 89: ...ce and Repair Manual Manifolds Part No 1272222 GS 84 GS 90 77 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 90: ...t lbs 34 41 Nm 6 Solenoid Valve 2 position 3 way EF 2 speed motor shift circuit 20 ft lbs 27 Nm 7 Orifice Plug 0 035 inch 0 9 mm EG Brake circuit 8 Orifice Plug 0 045 inch 1 1 mm EH 2 speed motor shift circuit 9 Shuttle valve 2 position 3 way EI Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allow slow pressure flow path for brake release and 2 speed motor shi...

Page 91: ...ce and Repair Manual Manifolds Part No 1272222 GS 84 GS 90 79 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 92: ... 2 position 2 way DA Oscillate circuit 45 ft lbs 61 Nm 2 Relief valve 3500 psi 241 3 bar DB System relief 25 30 ft lbs 34 41 Nm 3 Relief valve 900 psi 62 bar DC Float circuit relief 25 30 ft lbs 34 41 Nm 4 Priority flow regulator 1 gpm 3 8 L min DD Oscillate circuit 45 50 ft lbs 61 68 Nm 5 Solenoid Valve 2 position 3 way DE Right oscillate circuit 40 ft lbs 54 Nm 6 Solenoid Valve 2 position 3 way ...

Page 93: ...ce and Repair Manual Manifolds Part No 1272222 GS 84 GS 90 81 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic ...

Page 94: ...er valve 80 90 ft lbs 108 122 Nm 2 Orifice 0 030 inch 76 mm FB Delays shift to drive 35 40 ft lbs 47 54 Nm 3 Solenoid Valve 2 position 3 way FC Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve 270 psi 18 6 bar FD Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Check valve 3 psi 21 bar FE Prevents oil to generator 35 40 ft lbs 47 54 Nm Note alpha callouts refer to corresponding notes on...

Page 95: ... platform 5 Determine the test weight for your machine Refer to the specifications below Rated work load at full height maximum GS 3384 and GS 3390 2500 lbs 1135 kg GS 4390 most models refer to capacity indicator decal 1500 lbs 680 kg GS 4390 some models refer to capacity indicator decal 1800 lbs 816 kg GS 5390 1500 lbs 680 kg 6 Using a suitable lifting device place the test weight determined in s...

Page 96: ...djust the internal hex socket Turn it counterclockwise to decrease the pressure Install the relief valve cap 19 Start the engine 20 Repeat this procedure beginning with step 15 21 Turn the machine off and remove the weight from the platform How to Adj ust the Steer R elief Valve How to Adjust the Steer Relief Valve Note Refer to Function Manifold Component list to locate the steer relief valve 1 C...

Page 97: ...achine slowly in the direction indicated by the blue arrow on the platform controls and observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Components Specifications 4 Component damage hazard Driving the machine in reverse will place excessive pressure on the pressure gauge and will damage the gauge Do not drive the machine in a reverse direction 5 Turn the engine ...

Page 98: ...ed below the ground controls Index No Description Schematic Item Function Torque 1 Solenoid operated 2 position 3 way directional valve AL Generator on off 25 ft lbs 34 Nm 2 Flow regulator valve 4 3 gpm 16 3 L min AM Generator speed 20 ft lbs 27 Nm 3 Relief valve 3000 psi 206 8 bar AN Generator circuit 20 ft lbs 27 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic ...

Page 99: ...Result The generator should activate and the engine should go to high rpm 4 Connect an electrical tool which does not draw more than 15A to the electrical outlet at the platform controls and run the tool at full speed 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical outlet at the generator Result The reading on the multimeter should be 112 to 118...

Page 100: ...ts 7 10 Generator Relief Valve Manifold Components The generator relief valve manifold is located in the hydraulic manifold compartment Index No Description Schematic Item Function Torque 1 Relief valve 3500 psi 241 bar AR Generator pressure circuit 25 ft lbs 34 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic ...

Page 101: ...Test the coil resistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in ...

Page 102: ...on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Conn...

Page 103: ...platform approximately 18 feet 5 5 m from the ground 3 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Note Be sure that the safety arm is locked in the vertical position 4 Lower the platform onto the safety arm Turn the engine off Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Attach a lifting stra...

Page 104: ...n and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter condition indicator How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause sev...

Page 105: ...nnel of the condition 9 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Specifications Machine Specifications Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Tag disconnect and plug th...

Page 106: ...drive motor guard Remove the hose clamps 6 Remove the retaining fasteners from the drive motor guard Remove the drive motor guard from the yoke 7 Tag disconnect and plug the hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually D...

Page 107: ...se the machine approximately inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if not properly supported 4 Remove the wheel lug nuts Remove the tire and wheel assembly 5 Remove the hose clamps retaining fasteners from the drive motor guard Remove the hose clamps 6 Remove the retaining fasteners from the drive motor guard Remove the drive motor guard from ...

Page 108: ... pin Note Note the location and the amount of the spacers at the barrel end of the steer cylinder 4 Remove the steer cylinder from the machine 9 3 Oscillating Axle Opti on GS 90 M odels 9 3 Oscillating Axle Option GS 90 Models How the Oscillating Axle Functions When driving the GS 90 with the platform in the stowed position the oscillating axle function ensures that all four wheels maintain solid ...

Page 109: ...will be lost Terminal 86 of CR85 receives power from pin J1 A4 while drivin is engaged and the ECM is powered J1 A4 is disabled when an outrigger is lowered to the ground Oscillate Limit Switches LS22 LS23 The right and left oscillating limit switches LS22 and LS23 respectively are normally closed limit switches held in the open position when the machine is on a level surface When the left rear or...

Page 110: ... Specifications Hydraulic Hose and Fitting Torque Specifications 1 Block the steer wheels 2 Tag disconnect and plug the hydraulic hoses from the drive motor and brake Cap the fittings on the drive motor and brake Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squir...

Page 111: ... of ample capacity under the drive chassis at the steer end of the machine 3 Loosen the wheel lug nuts Do not remove them 4 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will fall if not properly supported 5 Remove the wheel lug nuts Remove the tire and wheel assembly 6 Place a second lifting jack under the drive hub for suppor...

Page 112: ...vice and Repair Manual September 2016 Non steer Axle Components 100 GS 84 GS 90 Part No 1272222 10 3 Oscillati ng Axl e 10 3 Oscillating Axle Refer to Repair Procedure Oscillating Axle Option GS 90 Models ...

Page 113: ...Tag and disconnect the wiring from the outrigger cylinder solenoid valve 4 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Attach a lifting str...

Page 114: ... wire harness and the platform controls wire harness Note This connection is just below the ground controls 5 Tag and disconnect the platform controls wire harness from the ECM wire harness 6 Securely connect the platform controls to the ECM wire harness 7 Using a suitable lifting device place a test weight corresponding to the maximum load as indicated on the capacity indicator decal in the cente...

Page 115: ... to the maximum load position of the capacity indicator decal before raising the platform Result The engine continues to run Proceed to step 16 Result The engine has stopped and an alarm is sounding Proceed to step 17 Set the pressure switch 16 Turn the nut or adjustment screw of the platform overload pressure switch out of the hydraulic line until the overload alarm sounds and the engine stops ru...

Page 116: ...tch cam fasteners Remove the cam from the machine so that the limit switch will not be activated 25 Raise the platform until it is approximately 65 cm less than full height 26 Raise the platform in 5 cm increments until the overload alarm sounds and the engine stops running Proceed to step 27 Result The alarm does not sound and the engine continues to run when the platform reaches full height Repe...

Page 117: ... the platform overload system to reset Note Wait a minimum of 3 seconds between each quarter turn of the adjustment screw to allow the platform overload system to reset 33 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capa...

Page 118: ...rm overload system delay wait 3 seconds between each quarter turn of the adjustment screw Note To allow the platform overload system to reset the red Emergency Stop button must be cycled after each quarter turn of the adjustment screw 36 Activate the dual pressure switch limit switch located on the cylinder by fully rotating the roller arm of the limit switch Secure the roller arm in the activated...

Page 119: ... position 45 Lower the platform to the stowed position Set the maximum height limit switch 46 Using a suitable lifting device place a test weight in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 5390 680 kg 47 Raise the platform to approximately 6 m 48 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety...

Page 120: ...ncrements until the alarm does not sound and the engine will start and run Repeat this procedure beginning with step 47 Note To allow for the platform overload system delay wait 3 seconds between each adjustment Note To allow the platform overload system to reset the red Emergency Stop button must be cycled after each adjustment All models Disable the descent delay function 59 Push in the red Emer...

Page 121: ...the outside of the machine rotate the load sense delay limit switch cam in a clockwise direction until the cam lobe is approximately 1 mm lower Tighten the fasteners Do not over tighten 73 Return the safety arm to the stowed position 74 Raise the platform approximately 1 m 75 Repeat this procedure beginning with step 68 Enable the descent delay function 76 Push in the red Emergency Stop button to ...

Page 122: ... the stowed position 93 Repeat this procedure beginning with step 86 94 Lower the platform to the stowed position and remove the weight from the platform Result The platform lowers to the stowed position Proceed to step 99 Result The platform stops lowering The down limit switch needs to be calibrated Proceed to step 95 95 Raise the platform to approximately 6 m 96 Release the safety arm latch lif...

Page 123: ...position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press and hold both the up and down buttons Pull out the red Emergency Stop button to the on position at the ground controls Result Tune speeds is showing in the LCD screen 3 Use the down button to scroll to select options 4 Press the function enable button Result Descent delay is showing in the LCD s...

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Page 125: ...perating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydrauli...

Page 126: ... tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displayed The codes listed in the Fault Code Chart describe malfunctions and can aid in...

Page 127: ...d Replace ECM 25 LEFT TURN SW FAULT Red Left turn switch fault Malfunctioning steer left microswitch Troubleshoot steer left microswitch 26 RIGHT TURN SW FAULT Red Right turn switch fault Malfunctioning steer right microswitch Troubleshoot steer right microswitch 27 DRIVE ENABLE SW FLT Red Function enable switch on joystick is activated when machine is turned on Machine functions disabled Release ...

Page 128: ...trols 36 RIGHT REAR OUTRIG SW FLT Red Right rear outrigger enable button fault at platform controls Outriggers disabled Troubleshoot button OR replace printed circuit board at platform controls 37 AUTO LEVEL SWITCH FAULT Red Outrigger auto level enable button fault at platform controls Outriggers disabled Troubleshoot button OR replace printed circuit board at platform controls 49 DRIVE COIL 1 FAU...

Page 129: ... REVERSE 2 COIL FAULT Red Reverse 2 coil Y5A fault Drives slow or not at all when elevated Troubleshoot coil OR wiring 64 OSCILLATE LEFT COIL Red Value to low or Value to high Elevated drive and platform up disabled Troubleshoot oscillate left valve coil Y93 or wiring 65 OSCILLATE RIGHT COIL Red Value to low or Value to high Elevated drive and platform up disabled Troubleshoot oscillate right valv...

Page 130: ...G COIL FLT Red Right rear outrigger coil Y34 fault Right rear outrigger function inhibited Troubleshoot coil OR wiring 84 OUTRIGGER EXT COIL FLT Red Outrigger extend coil Y40 fault Outrigger extend function disabled Troubleshoot coil OR wiring 85 OUTRIGGER RET COIL FLT Red Outrigger retract coil Y39 fault Outrigger retract function disabled Troubleshoot coil OR wiring 86 OUTRIGGER SLOW COIL FLT Re...

Page 131: ...f an engine fault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm When operating from the platform if the red Emergency Stop button is pushed in the active fault code s will be erased from the display Start the engine from the ground control box and operate various boom functions to verify that an active engine fault oc...

Page 132: ... service Solid fault acknowledged Contact service 2 Left red LED Flashing engine fault detected Contact service Flashing with right flashing amber LED engine soot level over 140 Engine shut down Contact service 3 Right green LED Flashing engine fault detected Contact service Solid fault acknowledged Contact service 4 Right red LED Flashing engine fault detected Contact service Flashing with right ...

Page 133: ...121 Soft Key Functions and Icons Deutz D 2 9 L4 Models Soft Key Functions and Icons Deutz D 2 9 L4 Models 1 Next menu Exit Back one screen Decrease brightness 2 Brightness Contrast Scroll up Increase Increase brightness 3 Scroll down Decrease Decrease contrast 4 Select Next Main menu Increase contrast ...

Page 134: ...Service and Repair Manual September 2016 Fault Code Display Deutz Models 122 GS 84 GS 90 Part No 1272222 Main M enu Str ucture Deutz D 2 9 L4 Model s Main Menu Structure Deutz D 2 9 L4 Models ...

Page 135: ... Actuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressure warning th...

Page 136: ...load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low battery voltage...

Page 137: ...411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR Setpoint 597...

Page 138: ...imeout Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal range check h...

Page 139: ...1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank ...

Page 140: ...523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Function Mode Co...

Page 141: ...etection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail pressure ...

Page 142: ...KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value pro...

Page 143: ...3936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calibration inject...

Page 144: ...al value downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator due to overloa...

Page 145: ...meout error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame SCR2 524117 9...

Page 146: ...es Note Before the fault codes are displayed the check engine light will blink a code 1 6 5 4 three times After the fault codes the check engine light will blink a code 1 6 5 4 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit co...

Page 147: ...ern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side short to Ground 268 Injector Coil Shorted 270 Inje...

Page 148: ...y coil open 628 FPump motor loop open or high side shorted to ground 628 Fpump relay control ground short 629 FPump motor high side shorted to power 629 Fpump relay coil short to power Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 Fuel rev limi...

Page 149: ...r than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high Code Description 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog PD2 high 1562 AUX analog PD2 low 1...

Page 150: ...voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage Code Description 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1 2 simultaneous voltages out of range 2139 FPP1 lower than IVS limit...

Page 151: ...ry Loop Open or Low side Short to Ground 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2618 Tach output ground short 2619 Tach output short to power For further engine fault code troubleshooting and diagnostic information refer to the Ford MSG 425 EFI Diagnostic Man...

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Page 153: ... obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all r...

Page 154: ...sion LED Fuse with amperage Circuit breaker with amperage Connection no terminal Circuits crossing no connection Quick disconnect terminal Level sensor without outriggers Power relay Coil solenoid or relay Contact solenoid or relay Button normally open Limit Switch not held Limit Switch held Red emergency stop button normally closed Resistor with ohm value Starting aid or glow plug Electric motor ...

Page 155: ...lenoid operated 3 position 4 way directional valve Solenoid operated 3 position 5 way directional valve Solenoid operated 2 position 3 way directional valve Solenoid operated 2 position 2 way directional valve Filter with bypass relief valve Relief valve with pressure setting Solenoid operated proportional valve Differential sensing valve Pilot operated flow regulator valve Dual piloted relief val...

Page 156: ...n GCON C1 Capacitor 4700 uF CB Circuit breaker CB2 System power 20A CB6 Controls 7A CB7 Throttle 25A Deutz models Item Description FB1 Flashing beacons option G Gauge G6 Hour meter GND Ground H Horn or Alarm H1 Alarm PCON H2 Automotive style horn H5 Alarm GCON JC9 Joystick Controller KS1 Key Switch M Motor M2 Auxiliary pump M3 Engine starter M4 Fuel pump N C Normally Closed N O Normally Open P Pow...

Page 157: ... Y35 Left front outrigger Y36 Right front outrigger Y39 Outrigger retract Y40 Outrigger extend Y51 Electronic displacement control Y93 Left oscillate Y94 Right oscillate Y95 Oscillate float Y100 Oscillate enable Wire Color Legend Item Description BL Blue BK Black BR Brown GY Grey OR Orange PP Purple RD Red WH White YL Yellow Wire Color Legend Ford Engine Item Description BL Blue BK Black BR Brown ...

Page 158: ...ngi ne Rel ay Layout Ford MSG 425 EFI 1 Power Relay 2 Fuel Pump Relay 3 Empty 4 Starter 20A 5 Fuse 1 10A Battery voltage to EPR 6 Fuse 2 5A Ignition voltage to GCP and relays 7 Fuse 3 10A Battery voltage to GCP 8 Fuse 4 15A Fuel pump 9 Fuse 5 15A Battery voltage out of Power Relay 10 Fuse 6 10A Alternator ...

Page 159: ...147 Electronic C ontrol M odule Layout 1 pump 2 engine 3 to outriggers 4 to platform overload 5 down limit switch 6 up limit switch 7 platform controls 8 to flashing beacon 9 electronic control module 10 level sensor 11 horn 12 ground controls 13 function manifold 14 drive manifold 15 oscillate manifold ...

Page 160: ... EDC Y51 output B4 Proportional coil Y9 output B5 Right front outrigger coil Y36 output B6 Outrigger extend coil Y40 output B7 Outrigger retract coil Y39 output B8 Plug B9 Left front outrigger coil Y35 output B10 Left rear outrigger coil Y33 output B11 Right rear outrigger coil Y34 output B12 LPG select output C1 Plug C2 Platform overload input C3 Right front outrigger limit switch LS13 input C4 R...

Page 161: ...ut B1 Level sensor S8 blue input B2 Level sensor S8 black input B3 Level sensor S8 yellow input B4 Plug B5 Plug B6 Plug B7 Engine start relay CR1 terminal 86 output B8 Ignition relay CR8 terminal 86 output B9 Engine high idle output B10 Level sensor S7 or S8 red output B11 Horn relay CR5 terminal 86 output B12 Alarm output C1 System power input C2 System power input C3 System power input C4 Engine...

Page 162: ...E Stop K3 Starter K4 Ignition K5 Horn K6 Auxiliary down K7 Load sense AS CE models K8 Oil cooler option K9 1st up enable GS 5390 models K10 2nd up enable GS 5390 models K11 Oscillate stowed option K12 Oscillate elevated option K13 2nd load sense AS CE models K14 3rd load sense AS CE models K15 Descent overload K16 Coil cutout K102 Telematics CR4 High rpm Deutz models ...

Page 163: ...September 2016 Service and Repair Manual Wiring Diagram Platform Control Box Part No 1272222 GS 84 GS 90 151 Wiring Diagram Pl atform C ontrol Box ...

Page 164: ...d controls side 4 load sense delay LS25 CE models ground controls side 5 maximum height LS24 CE models ground controls side 6 dual pressure switch LS26 GS 5390 CE models 7 outrigger deployed all models left front LS12 right front LS13 left rear LS14 right rear LS15 1 outrigger deployed GS 5390 CE models lower left front LS12A right front LS13A left rear LS14A right rear LS15A 2 oscillate axle GS 9...

Page 165: ...September 2016 Service and Repair Manual Wiring Diagram 12 kW Hydraulic Generator option Part No 1272222 GS 84 GS 90 153 Wiring Diagram 12 kW Hydraulic Gener ator option ...

Page 166: ...high RPM 2 The SX controller is turned ON supplying power to the bypass valve and the change over relay The EDC valve is switched over to the output of the SX controller 1 When the AC generator is turned OFF the SX module will ramp the output to the EDC to threshold preventing cavitation to the hydraulic motor powering the generator When the threshold is reached the bypass valve is turned OFF 2 Th...

Page 167: ...September 2016 Service and Repair Manual 155 Electrical Schematics Engine H arness Ford MSG 425 Engine Wire Harness ...

Page 168: ...Service and Repair Manual September 2016 156 GS 84 GS 90 Part No 1272222 Ford M SG 425 EFI Engine Wire H arness Ford MSG 425 EFI Engine Wire Harness ...

Page 169: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 157 Deutx D 2 9 L4 Engine Wire Har ness Deutz D 2 9 L4 Engine Wire Harness ...

Page 170: ...Service and Repair Manual September 2016 158 Deutz D 2 9 L4 Engine Wire Harness ...

Page 171: ...September 2016 Service and Repair Manual 159 Hydraulic Schematics Hydraulic Schematic To Serial Numbers GS8415 42316 and GS9015 50184 ...

Page 172: ...ice and Repair Manual September 2016 160 GS 84 GS 90 Part No 1272222 Hydraulic Schem atic To Serial N umbers GS8415 42316 and GS9015 50184 Hydraulic Schematic To Serial Numbers GS8415 42316 and GS9015 50184 ...

Page 173: ...September 2016 Service and Repair Manual 161 Hydraulic Schematic From Serial Numbers GS8415 42317 and GS9015 50185 ...

Page 174: ... and Repair Manual September 2016 162 GS 84 GS 90 Part No 1272222 Hydraulic Schem atic From Serial N umbers GS84154 42317 and GS9015 50185 Hydraulic Schematic From Serial Numbers GS8415 42317 and GS9015 50185 ...

Page 175: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 163 Hydraulic Schematic From Serial Numbers GS8415 42317 and GS9015 50185 ...

Page 176: ...Service and Repair Manual September 2016 164 Hydraulic Schematic From Serial Numbers GS8415 42317 and GS9015 50185 ...

Page 177: ...September 2016 Service and Repair Manual 165 Electrical Schematics AN SI and C SA Models Electrical Schematic Ford Engine Models ANSI CSA ...

Page 178: ...Service and Repair Manual September 2016 166 GS 84 GS 90 Part No 1272222 Electrical Schem atic For d Engine M odels ANSI C SA Electrical Schematic Ford Engine Models ANSI CSA ...

Page 179: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 167 Electrical Schematic Ford Engine Models ANSI CSA ...

Page 180: ...Service and Repair Manual September 2016 168 Electrical Schematic Ford Engine Models ANSI CSA ...

Page 181: ...September 2016 Service and Repair Manual 169 Electrical Schematic Deutz Engine Models ANSI CSA ...

Page 182: ...Service and Repair Manual September 2016 170 GS 84 GS 90 Part No 1272222 Electrical Schem atic Deutz Engine M odels ANSI CSA Electrical Schematic Deutz Engine Models ANSI CSA ...

Page 183: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 171 Electrical Schematic Deutz Engine Models ANSI CSA ...

Page 184: ...Service and Repair Manual September 2016 172 Electrical Schematic Deutz Engine Models ANSI CSA ...

Page 185: ...September 2016 Service and Repair Manual 173 Electrical Schematics A S and C E Models Electrical Schematic Ford Engine Models AS CE ...

Page 186: ...Service and Repair Manual September 2016 174 GS 84 GS 90 Part No 1272222 Electrical Schem atic For d Engine M odels AS CE Electrical Schematic Ford Engine Models AS CE ...

Page 187: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 175 Electrical Schematic Ford Engine Models AS CE ...

Page 188: ...Service and Repair Manual September 2016 176 Electrical Schematic Ford Engine Models AS CE ...

Page 189: ...September 2016 Service and Repair Manual 177 Electrical Schematic Deutz Engine Models AS CE ...

Page 190: ...Service and Repair Manual September 2016 178 GS 84 GS 90 Part No 1272222 Electrical Schem atic Deutz Engine M odels AS C E Electrical Schematic Deutz Engine Models AS CE ...

Page 191: ...September 2016 Service and Repair Manual Part No 1272222 GS 84 GS 90 179 Electrical Schematic Deutz Engine Models AS CE ...

Page 192: ...Service and Repair Manual September 2016 180 Electrical Schematic Deutz Engine Models AS CE GS 84 GS 90 Part No 1272222 Service and R epair M anual September 2016 ...

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