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1. LL re EE OE das ir 1 OSCILLATING AXLE B OUTRIGGERS GS 90 E STANDARD ON 65 5390 OPTION PLATFORM LIFTCYLINDER LIFT CYLINDER OPTION ON 05 3384 05 3390 AND 018 4380 OVERLOAD ALLMODELS 65 530 OPTION 1 LEFT RIGHT RIGHT LEFT E WE 7 REAR REAR oo E eo TEI El 69 E UI Me KI 1 Hee EI le v iSTETS DESP iL od o I ELM Me 4 4 J L a mg T lo Thy 65 3384 1800 psi 124 bar STEER CYLINDERS STEER CYLINDER Ej p B YET 68 3300 1800 psi 124 bar 65 90 GS 64 8 4390 1800 psi 124 bar LEFT gt GS 5390 1100 psi 76 bar AB i 70 8 12 si 52 LEVi _LEV2 900 amp 2bar Eed DS FUNCTION 4 cas MANIFOLD w 1 1 te H
2. QD3 4 BK POWER TO PLATFORM 3 RD POWER GROUND 1 1 A WH GROUND O J5 PINI 2 2 BL DATALINK HIGH 45 PIN4 _ 5 5 OR DATALINK LOW 45 PINS OUTRIGGERS STANDARD 68 5390 OPTION ON GS amp 3384 3390 and 4390 J5 O 2 x lav pe 6000 cord 07 PLATFORM CONTROLS VOLTAGE PRINTED CIRCUIT BOARD REGULATOR 6 J2PIN1 YL 58 da VIN2 O GENERATOR i 2 AXIS game lo EE 1812 1813 1814 1815 TILT LEVEL o BN CONTROLLER LF RF LR RR SENSOR J2 PIN3 LIMIT LIMIT LIMIT 2 SWITCH SWITCH SWITCH SWITCH 3 2185 Eb C L 9Y SW5 SW6 28 12 2 OR l FUNCTION ENABLE T 2 STEER OF OF 1 0 7 TITT Even lom 4 4 4 4 orFrR J2PIN7 C L Shag eg o LWABL c E Et Et C L rd T T DEENSE ovu gt gt gt 9 21 8 9
3. iS eee od al ME AE ad OUTRIGGERS STANDARD ON 65 5390 OPTION ON G 3384 3390 and 4390 sal U3 D7 PLATFORM CONTROLS VOLTAGE Tav DC PRINTED CIRCUIT BOARD REGULATOR EES J2 PIN HALL EFFECT 58 J2PIN2 GENERATOR 2 AXIS J2 PIN12 LI JOYSTICK LS12 LS13 1814 1815 TILT LEVEL EE CONTROLLER LF RF LR RR SENSOR J2PIN3 C LMT LIMIT 5 SWITCH SWITCH SWITCH SWITCH 2112 5 2220155 5 o L 9Y SW5 SW6 Nos HEE Zl 5 jo PINE FUNCTION ENABLE T 2 STEER A i ZAA BK 4 X LEFT RIGHT Vj OF 3 32 J2PIN6 3 8 amp J2 lt RD J2 PINS 1 42 214 E 6 cC a T rd 8 8 1222 05 PIN2 HORN ELECTRONIC CONTROL MODULE PINS STARTING AID ENGINE START BN2 c 7 g g Bg 1 1 W 1 T h 8 3 8S 8 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 4 Y29 Y36 Y34 Y40 HIGH IDLE BN4 i T N 4 BA BOK EA COX LF OUTRIGGER ENABLE 5 4 OUTRIGGER ENABLE 86 X X Q Al ACH A EA 17 2 1 LR OUTRIGGER ENABLE BN
4. or either Emergency Stop button power to terminal J2 CV C3 30 of CR85 will be lost LS6 pown NC Terminal 86 of CR85 receives power from pin BED J1 A4 while drivin is engaged and the ECM is J2 C5 poneren crap 84 5 J1 A4 is disabled when an outrigger is lowered to POWER STOWED RAISED T the ground AON ORS GON Oscillate Limit Switches 1522 1523 85 87 85 877 85 is The right and left oscillating limit switches EE LIT LS22 and LS23 respectively are normally closed NGHO limit switches held in the open position when the CB2 28 1622 machine is on a level surface ONE LIMIT SWITCH LIMIT SWITCH t gt Bi a Y54 Y56 ER sd amp cX EES Y57 Y55 Y2 5 2 8 5 S J 5 m m o m 7 m m 5 2 Gri 140 GS 84 GS 90 Part No 162336 April 2015 Service Manual 10 1 Drive Motor and Brake How to Remove a Drive Motor and Brake Component damage hazard Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer Non steer Axle Components 3 Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the brake and remove the drive motor from the machine
5. BACKLTGREEN 18 seven o EP GnavvELLOW B 6 HO2S 2 BED IG BLAGKAT BLUE 18 TWR Er vra GASQUNE BROWNWHITE18 INTERFACE WHITE GREEN 15 WHITEAT GREEN 18 DK GREEN PURPLE 18 ORANGE LT GREEN 18 GRAYAT BLUE 18 GRAYIYELLOW 18 LTGREEN RED 18 BROWNAWHITE 18 5 GRAY RED 18 GBAY RED 18 0 BLACKAT BLUE 18 1 1 8 7 BLACKWHITE 16 16 16 BEDAT GREEN 18 uf XL REDATGREEN 18 TBLUERRED 1 36 ROADSPEED VSW DKGREENBLACK18 35 ROADSPEED 18 24G0V SELECT 1 C126RPM 24 ORVBK LOW IDLE INPUT 12V TANLTRLUE16 ECM LT BLUEBLACK 18 14 FPP1 GREEN 18 1 VSW R23BAT 1 WH KEYSWITCH EAM EIE AE oiia BLACKVELLOW 23G0VSELECT2 2 BKAD HIGH IDLE SWITCH INPUT 12 E BLUENNHITE 18 DKGREENORANGE 18 32 ANAAUXPDI EENS DK BLUEWHITE 18 37 AUX ANAPUXB RD BAAN IKONE GREEN 18 4 WHITE 18 DK GREENWHITE 8 2501 PRES RED 12 REDITAN 16 TANNELLOW 18 2 CATRPM 2 OREK ENGINE SPEED 2 PULSESRI PINKAT GREEN 18 6 MIL 6 BLIWH DIAGNOSTIC GOM 3 WATT ORANGEILT GREEN 18 39 AUX OUT 00575839
6. BOL XI COO J2 Connector Pin Description ra Description A1 Right turn output A1 He lial witch LS5 input A2 Left turn coil Y4 output A2 Down limit switch LS6 input A3 Up coil Y8 output A3 Aux down power input A4 Brake coil Y2 output A4 Aux down relay CR23 terminal 86 output A5 Plug A5 Key switch terminal 3 input A6 Plug AG Level sensor S7 white input AT Plug AT Plug A8 Plug A8 Plug A9 Down coil Y7 output A9 Plug A10 2 speed coil Y1 output A10 Platform controls ground input A11 Plug A11 Platform controls data input A12 Plug A12 Platform controls data input B1 Generator coil Y29 output B1 Level sensor S8 blue input B2 Reverse coil EDC Y51 output B2 Level sensor S8 black input B3 Forward coil EDC Y51 output B3 Level sensor S8 yellow input B4 Proportional coil Y9 output B4 Plug B5 Right front outrigger coil Y36 output B5 Plug B6 Outrigger extend coil 40 output B6 Plug B7 Outrigger retract coil Y39 output B7 Engine start relay CR1 terminal 86 output B8 Plug B8 Ignition relay CR8 terminal 86 output B9 Left front outrigger coil Y35 output B9 Engine high idle output B10 Left rear outrigger
7. Code Description Code Description 301 Emissions catalyst damaging misfire 642 5VE1 low voltage 302 Emissions catalyst damaging misfire 643 5VE1 high voltage 303 Emissions catalyst damaging misfire 650 MIL open 304 Emissions catalyst damaging misfire 652 5VE2 low voltage 305 Emissions catalyst damaging misfire 653 5VE2 high voltage 306 Emissions catalyst damaging misfire 685 Relay Coil Open 307 Emissions catalyst damaging misfire 686 Relay Control ground short 308 Emissions catalyst damaging misfire 687 Relay coil short to power 326 Knock 1 Excessive Signal 1111 Fuel rev limit 327 Knock 1 sensor Open 1112 Spark rev limit 331 Knock 2 Excessive Signal 1121 FPP1 2 simultaneous voltages out of range 332 Knock 2 sensor Open 1122 FPP1 2 do not match each other or the IVS 336 Crank sync noise 1151 CL high LPG 337 Crank loss 1152 CL low LPG 341 Cam sync noise 1153 CL high NG 342 Cam loss 1154 CL low NG 420 Gasoline cat monitor 1155 CL high gasoline bank1 430 Gasoline cat monitor 1156 CL low gasoline bank1 524 Oil pressure low 1157 CL high gasoline bank2 562 Battery Voltage Low 1158 CL low gasoline bank2 563 Battery Voltage High 1161 AL high LPG 601 Flash checksum invalid 1162 AL low LPG 604 RAM failure 1163 AL high NG 606 COP failure 1164 AL low NG 615 Start relay coil open 1165 LPG cat monitor 616 Start relay control ground short 1166 NG cat monitor 617 Start relay coil short to power 1171 Megajector del
8. ToS E ea N i lt T 7 H1 ALARM BK N 2 S 1 p RD e G JESE P2 EMERGENCY STOP OR JC1 JOYSTICK WH CONTROLLER 221114919191 ah J5 A E J3 U3 4 PLATFORM CONTROLS CIRCUIT BK BOARD PP YL WH BL 1elelelelelelelelelelelslele Hd GY Bi J2 OR RD WH BN e 6 BK TS20 s BL OR oar TS21 Ji eo 520 PLATFORM UP DOWN TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS N 521 PLATFORM UP DOWN OUTRIGGER UP DOWN TOGGLE SWITCH MODELS WITH OUTRIGGERS Genie BRAND 170 GS 84 GS 90 Part No 162336 April 2015 Service Manual Limit Switch Legend 1 up limit switch LS5 GS 5390 models hydraulic tank side 2 up limit switch LS5A GS 5390 models hydraulic tank side 3 down limit switch 156 ground controls side 4 load sense delay 1525 models ground controls side 9 5 maximum height LS24 CE models ground controls side 8 outrigger deployed GS 5390 CE models lower 6 dual pressure switch LS26 e left front LS12A GS 5390 CE models e right front LS13A 7 outrigger deployed all models left rear LS14A left front 1512 e right rear LS15A e right front LS13 9 oscillate axle GS 90 models located inside axle left rear LS14 e left axle LS23 right rear 15
9. 9 9 9 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 162336 GS 84 GS 90 119 Service Manual TTT eee Manifolds 7 2 April 2015 Function Manifold Components Models without Outriggers The function manifold is located in the chassis tray on the ground controls side of the machine Description ne Function Torque 1 Check valve 5 psi 0 3 bar AA Platform down circuit 20 ft lbs 27 Nm 2 Diagnostic nipple AB Testing 3 Relief valve 3500 psi 241 3 bar AC System relief 20 ft lbs 27 Nm 4 Proportional solenoid valve AD All functions 35 ft lbs 47 Nm 5 Relief valve 2000 psi 138 bar AE Steer circuit 25 ft lbs 34 Nm 6 Diagnostic nipple AF Testing 7 DOS valve 3 position 4 way AG Platform up down 30 35 in Ibs 3 4 Nm 8 Solenoid valve 3 position 4 way AH Steer left right 25 ft lbs 34 Nm 9 Orifice Plug 0 150 inch 3 8 mm Al Platform down circuit 10 Flow regulator 0 1 gpm 0 38 L min AJ Bleeds off proportionalvalve to 20 ft lbs 27 Nm tank Genie 120 GS 84 GS 90 Part No 162336 April 2015 Service Manual ay Al Wy Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha nume
10. Item Description Item Description JC1 Joystick Controller PS2 Platform Overload Pressure Switch KS1 Key Switch Q Solenoid L LED or Light Q3 High idle L2 Check engine Q8 Fuel shut off L50 System status QD Quick Disconnect LS Limit Switch QD3 Control cable to ground LS5 Platform up 5390 only QD4 Control cable to platform LS6 Platform down R6 Resistor 510 ohm 1512 Left front outrigger 5 Sensor 1513 Right front outrigger 55 Platform overload pressure switch option LS14 Left rear outrigger S7 Level sensor models without outriggers LS15 Right rear outrigger 58 Level sensor models with outriggers LS22 Right oscillate SW Switch LS23 Left oscillate swt Engine coolant temperature LS24 Maximum height SW2 Engine oil pressure LS25 Load sense delay SW3 Engine oil temperature LS26 Dual pressure switch 5390 4 Hydraulic temperature M Motor SW5 Function enable M1 Cooling fan SW6 Steer left right M2 Auxiliary pump U Electronic Component M3 Engine starter U3 Platform controls circuit board M4 Fuel pump U5 Electronic control module N C Normally Closed U32 Glow plug option N O Normally Open P Power Switch P1 Emergency stop button ground P2 Emergency stop button platform Genie Part No 162336 BRAND GS 84 GS 90 173 Service Manual April 2015 Electrical Component and Wire Color Legends Item Description Wire Color Legend Y Valve Coil Item Description
11. ID System Ready LED Condition Result Solution 56 RIGHT TURN Red Right turn fault Machine will not Troubleshoot coil OR wiring COIL FAULT turn right 57 LEFT TURN Red Left turn coil Y4 fault Machine will not Troubleshoot coil OR wiring FAULT turn left 58 BRAKE COIL Red Brake release coil Y2 fault Brakes will not Troubleshoot coil OR wiring FAULT release 60 FORWARD 1 Red Forward 1 coil Y6 fault Drives slow or not Troubleshoot OR wiring COIL FAULT at all when elevated 61 REVERSE 1 Red Reverse 1 coil Y5 fault Drives slow or not Troubleshoot OR wiring COIL FAULT at all when elevated 62 FORWARD 2 Red Forward 2 Y6A fault Drives slow or not Troubleshoot coil OR wiring COIL FAULT at all when elevated 63 REVERSE 2 Red Reverse 2 coil Y5A fault Drives slow or not Troubleshoot OR wiring COIL FAULT at all when elevated 66 LOW OIL Red Low oil pressure Engine stops Check the engine oil level OR PRESSURE check wiring from the oil pressure switch to ECM OR replace the oil pressure switch 67 HIGH COOLANT Red High coolant temperature High engine Gasoline LPG models Check TEMPERATURE temperature OR defective engine the engine radiator coolant level OR check the wiring from the coolant or oil water temperature switch to temperature ECM OR replace the water switch temperature switch Diesel models Check the engine oil level OR check the w
12. GE Mt eae SWITCH 1 SENSOR 1 SWITCH t FAN MOTOR MODELS WITHOUT 22 L s BATTERY 12 0 OUTMIGGERS BK gt EB EB E B E on c t c f t 9 BENE S 2 amp 6 la AE BE RE SA ie OER TO RUNE U BN23 91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIARY DOWN ENABLE 42 610 ee J dE J2 B9 x 3 E 85 B zu 38 4 Y1 Y9 Y51 i EDC V aX ALOA A t 4 i M5 7 4 dX IE NO yet Y7 sws sw2 11 i i i 5 i 2 0 5 8 8 4 8 8 a 7 gt gt g m d 3 2 Dm 4 2 m m m 29 a a 89 5 o d 22 9 9 2 m n 2 X 2 2 J m 2 mm DE 59 4 9 8 85 E 5 Z d 3 25 2 amp m 2 9 8 o m e 2 e m gt d 3 9 m 8 E MACHINE SHOWN IN THE STOWED ES7164K POSITION WITH THE POWER OFF Genie 184 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Deutz Engine Models ANSI CSA Part 3 of 3
13. ce SESE HS BS 9 9 amp 9 5 ae 1 ELECTRONIC CONTROL MODULE J2 64 42 010 EU RES gt 147 89 010 1 uE m S 5 ES 9E B 86 30 K9 4 EE CPI E S Jens ga od ENABLE LE ef LS24 pown S25 1 2 GS 5390 ONLY max ENABLE LOAD 8 sol HEIGHT SENSE CR82A 5 4 uMr 88 DELAY 4 Y1 Y9 Y51 SWITCH ELS LIMIT 1 1 EDC ENABLE 8 sl 8 7 SWITCH L N sd Tem acy wan 2 LA TA ABB 7 t i k Al QNI ARA KU vel C5 sow Y2 2 29 x 4d 3 4 a o I I gt d H Hm gg 3 m m 2 2 a a 2 2 2 gg 2 3 m 2 m n 9 m DE m m gt 9 4 2 9 EO r m 2 3 y Q 4 5 gt ME m 9 m 2 2 3 m m 2 D m gt d z d 3 3 T MACHINE SHOWN IN THE STOWED ES7175P POSITION WITH THE POWER OFF s Genie 190 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Deutz Engine Models CE AS Part 3 of 3 003 P2 x EMERGENCY d 4 4 L BK POWER TO PLATFORM STOP
14. 83 3 5 Lift CYNA E Senon EER EE RE 84 How to Remove the Lift Cylinder GS 3384 GS 3390 GS 4390 84 How to Remove the Lift Cylinder 65 5390 86 Geni 1 1 1 1 1 1 1 GS 84 GS 90 xi April 2015 Ka EE EE BEE Table of Contents 89 4 1 RPM ee ee Re AR ee AR ee 89 4 2 Engine Fault Codes Ford 89 4 3 Engine esse 89 4 4 Flex Plate EE OR N 90 How to Remove the Flex Plate Ford 90 How to Remove the Flex Plate Deutz 91 How to Install the Flex 40400 nnn tens 91 Ground Controls esse Ee EE Eer EE ER Ee EE cete ke rime Ke Ee Ee EE EE GR bee imma Ee ek ke GR Ee ek id 93 5 1 Auxiliary Platform Lowering iese ee ee ee ee Re ee ee ke ee ee ke emen 93 5 2 Controller Adjustments 93 How to Determine the Revision Level 94 How to Adjust the Stowed Drive 94 How to Adjust the High Torque Drive 95 How to Adjust the Raised Drive 96 How
15. 58 Platform Components Ee EER KEER EA EE Ee EE nnne nnne nene trn tente nnn 59 2 1 Platform eia eet e idle idea 59 How to Remove the 59 2 2 Platform Extension 61 How to Remove a Platform Extension 61 Scissor Components easet ii e Rao aanas raaa 62 3 1 Scissor Assembly 65 3384 and 5 3390 63 How to Disassemble the Scissor 63 How to Disassemble a Scissor Arm 67 3 2 Scissor Assembly 55 4390 69 How to Disassemble the Scissor 69 How to Disassemble a Scissor Arm 73 3 3 Scissor Assembly GS 5390 sss 76 How to Disassemble the Scissor 76 How to Disassemble a Scissor Arm 81 93 4 RR EE EE NE EE ER NE 82 How to Replace the Scissor Arm Wear 82 How to Replace the Chassis Scissor Arm Wear
16. BRAND 186 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Ford Engine Models CE AS Part 2 of 3 GS 5390 ONLY I hag LS12A 2 LOWER OIL COOLER LIMIT SWITCH OPTION 187 1 J2 C12 BATTERY 12V 4 LS13A 19 OJ 55 8 tower O 8 18 swat m uwrSwmcH HYDRAULIC N ei i 4 91608 im OIL TEMP 24 14 4 9 EE tye 156 Lowen 0 78 CR17 es i LR 3 UXI ayprauuc EE eoan ET BAT LIMIT SWITCH ast azal OILCOOLER DOWN 1 j LIMIT LS15A PUT l CUN S7 LEVEL LOWER 2 7 amp T 1 sensor RR ORIG __ FAN MOTOR i 4 LIMIT SWITCH LIMIT MODELS WITHOUT 2 1510 switcH L 4 BATTERY 12V OUTRIGGERS 1 010 RES EE a
17. BK PINS J8PIN1 O L RD H1 J8PIN2 o BK ALARM PLATFORM MACHINE SHOWN INTHE 220 POSITION WITH THE POWER OFF er CONTROLS is Genie 188 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Deutz Engine Models CE AS Part 1 of 3 FQsaruse P1EMERGENCVSTOP 1 R25 LS26 L 50HM DUALPW PS2B PLATFORM OVERLOAD PRESSURE SWITCH KEY SWITCH LET KS1 EE B1 d 1 PLATFORM CONTROL Y 52 PLATFORM OVERLOAD PRESSURE SWITCH AV LL gt i 3 3 SS MEN GROUND GS 5390 ONLY ii CONTROL V CR77A 86 ao Kia DOWN io ENABLE 85
18. nennen nennen nennen enne nns 135 Gonio BRAND Part No 162336 GS 84 GS 90 xiii April 2015 Ka EE EE BEE Table of Contents Steer Axle Components eei SERE ROER EUR R RE ER Se EE EES nnmnnn ER Ee 137 9 1 Yoke 137 How to Remove the Yoke and Drive 137 How to Remove a Drive 138 9 2 Steer 139 9 3 Oscillating Axle Option GS 90 Models 139 Non steer Axle 444 22 4 141 10 1 Drive Motor and Brake iese ee Re ee 141 How to Remove a Drive Motor and Brake 141 10 2 EE RE EE 142 How to Remove a Drive Hub iese see ees se ke ee ee ee ke ee ee ee ke ee ee ee ke ee ee ke ee ee ke ee ee 142 10 3 OselllatingAxle 2 se EE ee Ee se skade 142 Outrigger Component see ee EE RR RE ER ER RR RE ER ER RE RE ER ER RE Re ER ER RE Ee Ee RR RE Ee ER RR RE nennt 143 11 1 Outrigger Cylirider odit d eg dekades SR Ee aee dece lee 143 How to Remove an Outrigger Cylinder 143 Platf
19. REE eje gt ko A o o v gt o ON 157 214 210 20 570 762 83 791 778 1055 682 925 09 1233 Genie BRAND 12 GS 84 GS 90 Part No 162336 April 2015 Service Manual Scheduled Maintenance Procedures Observe and Obey AWARNING NAN RN 5 Part No 162336 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified of the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless otherwise specified perform each Genie BRAND GS 84 GS 90 13 procedure with the machine in the following configuration e Machine parked on a firm
20. m 9 5 gd d 30 2 2 5 3 8 5 2 BE 5 505 A 2 3 8 3 56 gt m f in 3 o 9g 4 s 8 8 Bl amp 8 B i m l is 9 7 m m D m m lt d 2 5 gt OSCILLATING AXLE x NOTE F21 ADDED TO MACHINE D GS 90 9 GS 84 AFTER SERIAL NUMBER GS8407 41372 2 GS 90 AFTER SERIAL NUMBER GS9007 44126 OPTION E NOTE NOTE F17 REPLACED WITH 25 AMP CIRCUIT BREAKER CB8 MACHINE SHOWN IN THE STOWED GS 84 AFTER SERIAL NUMBER GS8406 41256 POSITION WITH THE POWER OFF GS 90 AFTER SERIAL NUMBER GS9006 43638 ES7164K Genie BRAND Part No 162336 GS 84 GS 90 183 Service Manual April 2015 Electrical Schematic Deutz Engine Models ANSI CSA Part 2 of 3 GS 5390 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V PLAT NC 1018 5 5 Up O laas lo oce LMT Ns CB7 T SWITCH DA e 20 x Od 4 sel 17 t ut z er NE 156 ED HYDRAULIC Er 2 155 a sl zaj
21. POUT U5 PIN2 HORN BNS ELECTRONIC CONTROL MODULE PRO STARTING AID z amp 1 5 z PM ENGINE START BN2 e e o T 1 n n T n ow T o 8 8 8 amp 249 PINS HA 3 HIGH TORQUE 651 PING OE GENERATOR BN7 PN o2 4T LPG SELECT BN14 Y29 96 4 40 PING HIGH IDLE BN4 i bo Pew ctt oY wa TON T OX PING HIE LF OUTRIGGER ENABLE BN85 i i i ll Pinto co RF OUTRIGGER ENABLE 86 X EES a X Wl Daa m 4 4 4 24 LR OUTRIGGER ENABLE BN87 H5 FB1 p OG Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 l i i i n i lt lt 5 lt x lt o I S sam Fl 1 8 8 S 32g FUNCTION BN9 2 2 Q o Wo d 5 m 5 m E lom or n S 5 x 5 2 Sea ORGR AUTOLEVEL ENABLE BN20 3 3 amp d d d 428 5 B 2 2 m m fo 3 3 S SYSTEM STATUS L50 5 d 8 g amp 2 8 o o 5 4 f 9 5 1 5 3 m 2 2 9 PLATFORM UP DOWN 7820 2 5 2 4t Pins OR 6 4 5 EN PLATFORM amp OUTRIGGER o m m ol ml UPIDOWN m 2 2 JI PIN O lt O f Ho 0 Hi o LA ALARM PLATFORM MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF CONTROLS Genie BRAND Part N
22. 176 Wiring Diagram 12 kW Hydraulic Generator 178 Electrical Schematics ANSI CSA Re ER ER RE RE ER ER RE RE ER ER RE nnn 180 Electrical Schematic Ford Engine Models 180 Electrical Schematic Deutz Engine Models 183 Electrical Schematics 5 ER RR RE Ee ER RR RE Ee ER RR RE KEER ee 186 Electrical Schematic Ford Engine Models 5 186 Electrical Schematic Deutz Engine Models 5 189 Hydraulic Schematics erret oe GE RR Ken enia ate tran aane 192 Hydraulic Schematics Component Call out 192 Hydraulic Symbols 194 Hydraulic 195 Genie BRAND Part No 162336 GS 84 GS 90 XV Service Manual April 2015 _ This page intentionally left blank 1 1 1 1h 16 GS 84 GS 90 Part No 162336 April 2015 Service Manual Specifications Machine Specifications Fluid capacities Rough Terrain foam filled GS 90 Tire size LSW 305 546 N
23. 0 5 ECM connector J2 ECM wiring panel relay ECM connector J1 ak Gri 1 1 1 168 GS 84 GS 90 Part No 162336 April 2015 Service Manual Ford Engine Relay Layout Ford MSG 425 EFI OMNINO 9 Power Fuel Relay Pump Empty Relay 6 starter KON amp 3 Empty F3 10A 4 15 eEmpty 9 Empty F6 10A 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 10 Battery voltage to GCP 8 Fuse4 15A Fuel pump 9 Fuse 5 15 Battery voltage out of Power Relay 10 Fuse 6 10A Alternator Genie BRAND Part No 162336 GS 84 GS 90 169 Service Manual April 2015 Wiring Diagram Platform Control Box ASSEMBLY
24. 3 4 40 22 4 40 30 20 10 0 14 32 50 68 86 104 122 10 20 30 40 50 C Ambient air temperature Chevron hydraulic oil 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046D Chevron Rando HD premium oil MV Genie BRAND GS 84 GS 90 3 Part No 162336 Service Manual April 2015 Specifications Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil 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 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maxi
25. 3500 m p 1 241 3 bar L bb AH 4 gpm 1 14 40 1 kr te i 1 OSCILLATE t DAO amp SEE NOTE BELOW MANIFOLD Hyss _ DC SERE e NOTE PME SYSTEMRELIEF NOTE VALVE PRESSURE n H STEER RELIEF GENERATOR SCHEMATIC ITEM T VALVEPRESSURE OPTION 65 3384 2700 to 2900 psi SCHEMATIC ITEM T66to200bar 2 96 9000 27000200 1 Ee S 45 gpm H 05 3390 1950 to 2250 pel id 9674990 20000210028 195 to 155 bar t GB 5890 2600t08100 pal 95 4300 1960102260 psi ya ER ono o 214 bee 13810 155 ummuuanuuuuussuuuaus 099 5390 19500225005 135 155bar an 3000 psi ERR 207 bar OE EE NOTE AUXILIARY GENERATOR OPTIONNOT 200p POWER AVAILABLE ON MACHINES UNIT 1 EQUIPPED WITH WELDER OPTION i AC G Note alpha callouts refer to components shown In the manifold Illustrations HS7037L Refer to the Repair Section Genie BRAND 196 GS 84 GS 90 Part No 162336 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 9
26. 1 loss 1317 Misfire detected 1613 RTI 2 loss 1318 Misfire detected 1614 loss 1511 AUX analog PU1 high 1615 A D loss 1512 AUX analog PU1 low 1616 Invalid interrupt 1513 AUX analog PU2 high 1621 Rx Inactive 1514 AUX analog PU2 low 1622 Rx Noise 1515 AUX analog PD1 high 1623 Invalid Packet Format 1516 AUX analog PD1 low 1624 Shutdown Request 1517 AUX analog PU3 high 1625 Shutdown Request 1518 AUX analog PU3 low 1626 CAN Tx failure 1521 CHT higher than expected 1 1627 CAN Rx failure 1522 CHT higher than expected 2 1628 CAN addresss conflict failure 1531 IVS Brake Trans Park interlock failure For further engine fault code troubleshooting and 1541 AUX analog PUD1 high diagnostic information refer to the Ford MSG 425 1542 AUX analog PUD1 low 9 Manual EDI part number 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low Ford MSG 425 EFI Diagnostic Manual 1545 AUX analog PUD3 high Genie part number 162067 Genie Part No 162336 65 84 GS 90 161 Service Manual ie Ford MSG 425 Engine Fault Codes April 2015 Code Description Code Description 1629 J1939 TSC1 message receipt lost 2130 IVS stuck at idle 1 2 match 1630 J1939 ETC message receipt lost 2131 IVS stuck off idle FPP1 2 match 1631 PWM1 Gauge1 open ground short 2135 TPS1 2 simultaneous voltages out of range 1632 PWM1 Gauge1 short to powe
27. 28 Apply a thin layer of oil to the new oil filter gasket D 5 Test the Oscillate Axle GS 90 Models Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first The oscillate system is designed so that all four tires maintain firm contact to the ground on unlevel terrain improving traction and machine stability Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over Note Perform this procedure on a firm level surface with the platform in the stowed position in a safe secure location away from obstacles and with an area working height of 20 feet Note The outriggers must be fully retracted if equipped 1 Disconnect and remove the platform controller from the platform 2 Open the ground control panel door and locate the cable connector below the ground controls Unplug the control cable from the ground control plug and connect the platform controller to the cable 3 Remove the two retaining fasteners from the ground control panel and set aside Tilt the control panel out towards you exposing the wiring and relays Genie 48 GS 84 GS 90 Part No 162336 April 2015 es 2 Test the down limit switch and relay K11 8 Note Perform this test using the platform controls while standing on the ground as desc
28. Part No 162336 GS 84 GS 90 21 Service Manual April 2015 Checklist A Procedures Test the Oscillate System elevated position 4 and hold the lift function enable button and raise the platform between 7 ft 213 cm to 9 ft 274 cm 5 Drive the left steer tire into a 4 10 cm deep hole Result All four tires should maintain firm contact with the ground 6 Drive the right steer tire into a 4 in 10 cm deep hole Result All four tires should maintain firm contact with the ground Note Verify there are no fault codes shown on the ground control display A 6 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance Perform the following maintenance procedures Ford models e B 7 Inspect the Tires Wheels and Lug Nut Torque e B 17 Perform Engine Maintenance Ford Models e D 4 Replace the Hydraulic Filters Deutz models e B 4 Check and Adjust the Engine RPM e B 7 Inspect the Tires Wheels and Lug Nut Torque e C 4 Replace the Fuel Filter Water Separator Deutz Models e D 4 Replace the Hydraulic Filters 22 GS 84 GS 90 Part No 162336 April 2015 Service Manual A 7 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 100 ho
29. Scheduled Maintenance Procedures Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure E Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Es Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours 0 Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled i
30. _ FQsaruse P1EMERGENCY stop EE EE EE t IKS1 KEY swircH t AF PLATFORM CONTROL N 1 B GROUND CONTROL CB2 20a CR41 CR42 CR1 CR23 CR84 CR85 CONTROL POWER CR5 CR8 ENGINE AUXILIARY osciLLATE OSCILLATE SYSTEM ESTOP 2 HORN IGNITION START DOWN STOWED RAISED ESTOP 1 Ai 1 1 86 86 304 K2 85 K5 86 304 86 ao Ka 85 85 2 ER N ER EM Ep MAT EMG EA EA 85 87 85 s 87A B5 87 85 87 85 B7A 87 87 7 85 87 4 4 4 l4 L t 2 N CH O N C H O as 1923 o o 1822 66 04 OF H 01 gt v LET RIGHT J lt 1 OSCILLATE H2 a LIMIT SWITCH LIMIT SWITCH 4 ABIS F21 1 BERE 70A FUSE CR4 280 HIGH IDLE 1 15 omy Q9 y STARTING 30 EN B1 1 AID A RR 4 2 ca 273 DE 87 87 Y54 Y56 k 65 OFAI7 igen ina 45 41 18AFUSE __ 1 7 4 A Ed U32 ter 4 GLOW var AUX amp cEX AC ano FUEL OPTION SHUT OFF HIGH IDLE 1 SOLENOID if mm Y57 Y55 z B 28 9 SN 8 s E 8 a ds d s ga ge d
31. fully slide the engine tray out 114 Genie Insert a 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving Tag disconnect and plug the hydraulic hoses from the lift steer pump Cap the fittings on the pump AWARNING 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 Remove the pump mounting fasteners Carefully remove the pump GS 84 GS 90 Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Part No 162336 April 2015 Service Manual 6 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center Contact the Genie Product Support to locate your local authorized service center How to Remove the Drive Pump 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
32. 14 Use a soft metal drift to remove the lift cylinder rod end pivot pin index 17 Lower the rod end of the lift cylinder down AWARNING Crushing hazard The lift cylinder could fall if not properly supported when the pin is removed 15 Block the steer end wheels and center a lifting jack of ample capacity under the non steer end of the drive chassis 16 Loosen the wheel lug nuts on one of the non steer wheels Do not remove them 17 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis will fall if not properly supported 18 Remove the wheel lug nuts Remove the tire and wheel assembly 19 Tag disconnect and plug the hydraulic hoses from the lift cylinder Cap the fittings on the cylinder AWARNING 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 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 22 23 24 25 26 27 Genie ATIRDI BAD 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 Remove the pi
33. 27 Nm 7 Solenoid valve 2 position 2 way DG Oscillate float 25 ft lbs 34 Nm Genie 124 GS 84 GS 90 Part No 162336 April 2015 Service Manual Manifolds D b Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 162336 GS 84 GS 90 125 Service Manual April 2015 ca HUI Manifolds 7 5 Welder Manifold Components option The welder manifold is located under the drive manifold Index Schematic No Description Function Torque 1 Directional valve FA Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice disc 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 Ibs 47 54 Nm FE Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Lo Qai 1 1 126 GS 84 GS 90 Part No 162336 April 2015 Service Manual 7 6 Valve Adjustments F
34. GS 4390 use one lift cylinder the GS 5390 uses two Each lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Lift Cylinder GS 3384 GS 3390 and GS 4390 AWARNING Bodily injury hazard The counterbalance valve in the lift cylinder is factory set Do not attempt to adjust the counterbalance valve Attempting to adjust the counterbalance valve could result in death or serious injury and significant component damage Dealer service is strongly recommended Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING Note When removing a hose assembly or fitting 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 Genie GS 84 GS 90 Part No 162336 April 2015 Service Manual 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 position Lock the safety arm in position Note Be sure that the sa
35. Oscillating Axle When installed on the machine the oscillating axle option must be enabled Generator 3kW If drive or lift function is operated while the generator is ON the generator will turn OFF while the function is operating After stopping the function the generator will turn back ON Generator 12kW The drive function is deactivated when the generator is turned ON When the generator is turned off the drive function will remain deactivated for 4 seconds After the 4 second delay the drive function will be available If any other function is operated while the generator is ON the generator will turn OFF while the function is operating After stopping the function the generator will turn back ON ANSI and CSA models with all software revisions 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to 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 inthe 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 SPEEDS is showing in the diagnostic display window x 7 1 diagnostic display 2 blue platform up button 3 lift function enable button 4
36. WHRD COOLANT TEMP SENDER YELLOWIDK BLUE 18 1 7 FUEL SELECT COOL BURD FUEL SELECT SWITCH INPUT 12V PURPLELT BLUE 18 10 AUX ANAPDIB anemie TM Asa aar TANGREEN 18 27 AUX OUT 2 WHITEALT BLUE 18 4 BRAKE ki ALTERNATOR S TERMINAL Li EA 1 ANS 16 bu ENGINE Gh ee FA GAN 2 TL rg WIRES jT SS DEGFOOT ME ORANGE 18 39520 GA DIAGNOSTIC SWITCH INPUT GND rp mn i5STARTCOMMAND FAGSTR 15 BK ENGINE START TANYELLOW 18 PINKBLACK 16 5 FUEL PUMP FUEL PUMP 20 PINKAT GREEN 18 BLACK RED 16 18 FUEL PUMP CISSRET 18 BL FUEL PUMP GND YELLOWIDK BLUE 18 PURPLEATBLUE 18 WHITEAT BLUE 18 EE b OlLPRESSURE O Q DIAGNOSTIC GONNECTOR OD ROWNANHITE 18 2 3 DK GREEN 18 pramo 1 dd 4 ORANGE 18 TST WES JEG FOOT FULL LENGTH 3 2 ORANGEAT GREEN 18 _ af 7 77 BK GREEN PURPLE 18 DOOOOOG BED BLACK 18 ORAT GREEN 18 T pA TERMINATION CONNECTOR BLACK RED 18 LT BLUEIPINK 18 WHITE 18 EP DEPR DKGRBEENPURPLE 18 CAN r WHITE 18 CAN TERM rar BLACKWHITE 18 _ GROUND a CAN HA s e b BED TAN 18 BED TAN 18 VBAT x J BED1 amp f INKIBLACK 16 Da LT BLUE ORANGE 18 i pu men Hi sai EA MA FUBLPUMPRELA
37. 15 16 17 18 19 20 21 Part No 162336 cylinder could fall when the upper lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane Remove the cables from the number 4 inner arm index 20 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Secure both ends of the number 4 inner and outer arms index 20 and 5 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 20 and 5 at the steer end of the machine Do not apply any lifting pressure Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 20 and 5 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both number 4 pivot pins index 7 at the non steer end of the machine Do not remove the pins Remove the pin retaining fasteners from both number 4 pivot pins index 22 at the steer end of the machine Do not remove the pins Use a slide hammer to remove both number 4 pivot pins index 7 from the non steer end of the machine Use a slide hammer to remove both number 4 pivot pins index 22 from the steer end of the machine Service Manual Scissor Components 23 Support the rod end of the upper lift cylinder with a suitable lifting device 24 Carefully rem
38. 7 T 8 8 T Rb POWER TO GROUND A ae 1 1 wH GROUND WH J5 PIN NSE 2 BL DATALINK HIGH 8 8 OR DATALINK LOW ME eae OUTRIGGERS STANDARD GS 5390 OPTION ON 98 3384 3390 and 4390 45 PIN2 T 601 0072 U3 D7 PLATFORM CONTROLS VOLTAGE sy PRINTED CIRCUIT BOARD REGULATOR o 1 1 aj L EFFECT S8 J2PIN2 of XH JC1 2 AXIS JaPINi2 O L WH LI Joystick 1612 1813 1814 1815 TILT LEVEL pnts o CONTROLLER LF RF LR RR SENSOR Bec OE LIMIT LIMIT UMIT LIMIT 2 SWITCH SWITCH SWITCH SWITCH 2 21253 GY 2328 85335 JS PINS SW5 NOs G 9 155 japing FUNCTION ENABLE 3 2 5 ABA o OH
39. CONTROL Y 20a CR41 CR42 CR1 CR23 CR84 CR85 CONTROL CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM ESTOP 2 HORN IGNITION START DOWN STOWED RAISED ESTOP 1 T 86 Ki 86 86 30 K4 66 30 Ka 86 86 K12 sd ES EA EA 8 wa 857 a7 851 a5 est 85 4 4 4 NCHO or of P LS23 7 1522 L2 LEFT 4 RIGHT Mj OSCILLATE OSCILLATE H2 Lum LIMIT SWITCH LIMIT SWITCH DIR As 7 mm GOV SPEED SELECTOR RD 23 FUELSELECTBKWH 7 FORD COM MALFUNCTION LED BL KEY ON WH i KEEP ALIVE POWER WH gt gt B1 SW20 ENGINE SELF TEST 701 7 01 Es 9 e 8 SELF TEST SWITCH BK RD 54 M Y56 Da ee FUEL PUMP BLAWH aaa FUEL PUMP GND 157 od Es Pape e ADA AN FORD ENGINE 1 1 STARTER NL 2 era eee N M4 AM EED FUEL PUMP Liss Lal LE be 57 Y55 i 4 4 4 n 4 4 2 8 z E 8 2 gt N T x m kd T e S 3 2 2 2 lt a gt mm m x gt D t o 9 m 3 mz 7 g m 20 lt m d m m 9 2 2 xz 5 E gt 5 lt 9 8 5 lt z 6 n d m o a 5 m m a n 5 gt 2 3 9 lt 4
40. Genie 0 Part No 162336 GS 84 GS 90 51 Service Manual April 2015 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications Refer to Specifications Hydraulic Specifications 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 Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting 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 Specificat
41. Part No 162336 65 84 GS 90 1 Service Manual April 2015 Specifications Performance Specifications Drive speed maximum GS 90 Function speed maximum from platform controls with maximum rated load in platform GS 3384 and GS 3390 Platform stowed Smph Platform up 42 to 52 seconds 40 ft 5 5sec Platform down 25 to 35 seconds 8 km h 12 2 5 5 065 4390 Platform raised 0 7 mph Platform up 50 to 60 seconds 40 ft 39 sec Platform down 32 to 42 seconds 1 1 km h GS 5390 12 2 9 DOR Platform up 70 to 90 seconds Drive speed maximum GS 84 Platform down 42 to 52 seconds Platform stowed 4mph Airborne noise emissions 107 dB 40 ft 6 8 sec 6 4 km h Maximum sound level at normal operation workstations 12 2 6 8 Weighted 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 60 in surface 152 4 cm Gradeability See Operator s Manual Genie 2 GS 84 GS 90 Part No 162336 April 2015 Service Manual Hydraulic Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration su
42. Raise the platform slightly and return the safety arm to the stowed position Lower the platform to the stowed position Turn the machine off Locate the quick disconnect for the platform controls under the platform at the steer end of the machine Tag and disconnect the platform controls from the control cable at the steer end of the machine Remove the platform control box from the platform and lay it off to the side Remove the mounting fasteners that hold the platform controls quick disconnect plug to the platform Lay the platform controls wiring off to the side Component damage hazard The platform controls wiring can be damaged if it is kinked or pinched Remove the AC power to platform outlet bracket mounting fasteners GS 84 GS 90 59 Service Manual is Platform Components 15 Remove the AC outlet box and bracket from the platform and lay them off to the side Do not disconnect the wiring Component damage hazard The AC power to platform wiring can be damaged if it is kinked or pinched Note If your machine is equipped with an air line to platform option the air line must be 20 April 2015 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 platfor
43. Repair Procedures 7 8 Generator Manifold Components The generator manifold is located below the ground controls Index Schematic No Description item Function Torque 1 Solenoid valve 2 position 3 way AL Generator on off 25 ft lbs 34 Nm 2 Flow regulator 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 Note alpha callouts refer to corresponding notes on the hydraulic schematic Gri o 130 GS 84 GS 90 Part No 162336 April 2015 Service Manual Manifolds 7 9 5 Connect the positive and negative leads from Valve Adjustments Generator a multimeter of sufficient capacity to the Manifold electrical outlet at the generator Result The reading on the multimeter should be 112 to 118V AC Result If the reading the multimeter is not How to Adjust the Generator 112 to 118V AC proceed to step 6 Voltage 6 the key switch to the off position AWARNING Bodily injury hazard Spraying 7 Use a wrench to hold the generator flow hydraulic oil can penetrate and regulator valve item AM and remove the burn skin Loosen hydraulic cap connections very slowly to allow the oil pressure to dissipate Adjust the internal hex socket Turn it gradually Do not allow oil to clockwise to increase the AC voltage or squirt or
44. if CR41 CONTROL CR42 CR1 CR23 84 85 lt SYSTEM POWER CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE ESTOP 1 ESTOP 2 HORN IGNITION START DOWN STOWED RAISED 1 1 A81 I I Ed p E 5 E El ki2 l st ya 87 85 3 MESA BE Tera a at ora 4 4 2 4 4 H CB2 20A 2 1 N C H O i f N 7 F NT G6 LS23 O O LS22 1 D1 gt NL LZ I LEFT 1 lt il OSCILLATE OSCILLATE H2 LIMIT SWITCH LIMIT SWITCH EG HI n 4 ABIS F21 FUSE CR4 1 HIGH IDLE B CR15 gui y O9 y STARTING es 304 at 1 AID EE gt es 1 22 el 54 Y56 ELIA t l DT eet Yea CB8 len 5 AN 41 EA 4 254 5 U32 der T 108 BE AUX amp cEX e PLUG 103 PUMP SHUT OFF menpe 1 4 if 2 1 57 55 5 gt D lt lt lt lt 5 222 gt z a EE 5 d EE d 42 g E ES 4 d 2 az 5 2 2 3 m m 5 BE gt 97 9 3 m 5 9 E gt d z DS m lt 5 9 8 8 m Bo 2 o 8 3 b 4 E 3 2 m 2 lt m m lt d 3 2 m m
45. m m f gt m OSCILLATING AXLE x GS 90 2 OPTION MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie hi rd 180 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Ford Engine Models ANSI CSA Part 2 of 3 BET es ER 65 5390 OIL COOLER OPTION LS5A 42 612 BATTERY 12V 1 PLAT _ N C 5 UP W4 mas e ad AI ME OIL TEMP 1 d 3 N Ma T ad E CR17 else 156 ED HYDRAULIC ABT PLAT 85 87 COOLER BENE DOWN 156 I ed LIMIT R NG SWITCH 1 S7 n SWITCH Y FANMOTOR MODELS WITHOUT ga BE bad LL Barmen tava OUTRIGGERS BK rM c c c Ee 9 RELJEF 9 a 5 2 6 le ee T eae ie ee Ee ee GN AE N EE ero ton l 1 67 BN23 BN91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIARY DOWN ENABLE 42 610 1289 gt ee Se lt 2 UE J1 B12 5 gt z
46. sure to open the two hydraulic tank valves and prime the pump after installing the pump Note Always use pipe thread sealant when installing the drain plug and strainers Genie GS 84 GS 90 Part No 162336 April 2015 Service Manual 9 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Note When removing a hose assembly or fitting 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 Block the non steer wheels and center a lifting jack under the drive chassis at the steer end of the machine 2 Loosen the wheel lug nuts Do not remove them 3 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support A WARNING 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 Steer Axle Components disconnect and plug the hoses from the drive motor Cap the fittings on the drive motor AWARNING 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 8 Support and secure the
47. to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Genie GS 84 GS 90 Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Platform in the stowed position Part No 162336 April 2015 Service Manual About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Repair Procedures Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazar
48. 11 Lift cylinder barrel end pivot pin 23 Chassis centering link 12 Number 1 outer arm 24 Number 1 pivot pins steer end Genie 68 GS 84 GS 90 Part No 162336 April 2015 Service Manual 3 2 Scissor Assembly GS 4390 How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting 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 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the cables from the platform centering link index 1 at the hydraulic tank side of the machine 3 Remove the cables from the number 4 inner arm index 14 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 4 Secure both ends of the number 4 inner and Scissor Components 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 Rem
49. 2 5 i ABi2 we Y4 Y1 Y9 7 T 157 Al X 4 171 ELN 1 bg 4 cx H 57 DZ T ZN 1 T Y8 Y7 Swi Y2 SW 2 i 1 ud i i i i i 5 i g 5 5 8 55 7 u T m 5 2 E 3 lt u OS 9 3 o 8 2 2 5 n 2 2 m 2 n E sc m 2 8 g h 9 So E 8 8 E z m 2 ga 7 2 v n c 5 E d m u m 2 d n 0 a c m a 5 9 9 9 2 2 j gt 5 MACHINE SHOWN IN THE STOWED ES7163G POSITION WITH THE POWER OFF Genie BRAND Part No 162336 GS 84 GS 90 181 Service Manual April 2015 Electrical Schematic Ford Engine Models ANSI CSA Part 3 of 3 PLATFORM p RD POWER TO GROUND H WH GROUND P2 C EMERGENCY STOP WH 5 95 PINI 5 5 H OR DATA LINK LOW 45 PIN4 HO J5 PINS 182
50. 2 2 28 1 3 LEFT RIGHT 4 4 4 SPER 5 J2 PINS 1 Lue o LWHEL i t j 20 c E Ee Ee x Y x T DEP i o 6 6 bone gt gt a POUTI U5 PIN2 HORN ELECTRONIC CONTROL MODULE PINS STARTING AID BN3 1 7 PIN O FEET 4 ENGINE START BN2 amp s fF 3 Ss bg n 5 n X 8 8 S PINS HIGH TORQUE 6 on PING GENERATOR BN7 PIN7 LPG SELECT 14 29 peas Y34 40 PINS HIGH IDLE BN4 i 1 N N X N aK 4 PINS LF OUTRIGGER ENABLE BN85 i i 10 RF OUTRIGGER ENABLE BNB6 ACOX AN cox O TAN 14 H5 FB1 PINTI LR OUTRIGGER ENABLE BN87 Y35 Y33 PINI2 RR OUTRIGGER ENABLE BN24 lt lt lt lt lt lt I 5 onm amp amp 8 5 8 ie B PIN13 LIFT FUNCTION BN gt 32x 2 hk kh 2 9 gl 8 pas c c 8 1 8 4 5 205 26 8 PINI4 ORGR AUTOLEVEL ENABLE BN20 a m m 2 2 ic 3 2 gg B m PIN15 SYSTEM STATUS 150 o z 2 T m m 4 2 z m 2 B o 8 85 f B 9 5 41 ping 1 GS d 3 5 2 E 9 T PLATFORM UP DOWN 7820 2 5 9 9 di pia O BL 2 8 o m E PLATFORM amp OUTRIGGER m D 7 OBB E J1 PINS NOTE Ja PINT o H1 jape o BK ALARM PLATFORM MACHINE SHOWN IN THE 224 POSITION WITH THE POWER OFF
51. 25 cm thick steel block under both wheels at the ground controls side of the machine 38 Lower the machine onto the blocks 39 Raise the platform approximately 16 feet 5 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning with step 9 Note For reference only the output of the level sensor should be approximately 3 3V DC To confirm connect the positive lead of a multimeter to the yellow wire at the level sensor and the negative lead to the black wire 40 Lower the platform to the stowed position 41 Raise the machine slightly 42 Remove the blocks from under both wheels 43 Lower the machine and remove the jack Confirm the front to back level sensor setting 44 Center a lifting jack under the drive chassis at the steer end of the machine 45 Raise the machine approximately 6 inches 15 cm 46 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 Genie 110 GS 84 GS 90 Part No 162336 April 2015 Service Manual 47 Lower the machine onto the blocks 48 Raise the platform approxi
52. Maximum allowable inclination of the chassis N A Gradeability N A Maximum allowable side force 100 Ib 445 Maximum number of platform occupants 2 Country of manufacture USA This machine complies with Terex South Dakota Inc 18340 NE 76th St PO Box 97030 Redmond WA 98052 USA PN 77055 Genie BRAND GS 84 GS 90 053005 12345 1 Model 2 Model year 3 Facility code for models manufactured in multiple facilities 4 Sequence number 5 Serial label located inside cover 6 Serial number stamped on chassis Part No 162336 April 2015 Service Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or 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 M You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations e applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie BRAND Part No 162336 GS 84 GS 90 V Service Manual April 2015 S
53. No 162336 Gen BRAND GS 84 GS 90 73 Service Manual Scissor Components How to Disassemble a Scissor Arm Pair AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Attach a lifting strap from an overhead crane to the end of the outer arm Note Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards 1 outer arm 2 inner arm 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 Raise the scissor arms with the overhead cranes approximately 12 inches 30 cm Service Manual April 2015 ses Scissor Components 4 Place a 12 inch 30 cm block under the center 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 A WARNING Crushing hazard The scissor arms could become unbalanced and fall if not properly supported by the overhead cranes 1 1 1 1 74 GS 84 GS 90 Part No 162336 April 2015 Ser
54. RD 2 SENSOR POWER 5 VDO pad 1 VW t BN IA BATTERY L 1200M 24 ohms 2nd E STOP VALVE 0 FWD COIL B2 VALVE 1 NG 5 RELAY 90 GN BK B8 DIGITAL OUTPUT BYPASS OMRON 8GND 58W INPUT TO 18 E STOP 5 RS232TxD VL EI no E 8K RELAY 87 gt R8232RxD GN c2 RxD 5 3 a 4 amp BOOT Z g WH D1 ANALOG 0 JOYSTICK 4 D2 ANALOG 1NG D3 DIG IN a NC V E1 NOT USED E E2 NOT USED NOT USED 2 1 DIG IND 5 WH GENERATOR ON 8X CONTROLLER See wR ope ee T GROUND CONTROLS OUTPUTS Y e Y108 sm 4 EB sy B3 8 3 a EE 8 5 3 6 Genie BRAND Part No 162336 GS 84 GS 90 179 Service Manual Electrical Schematic Ford Engine Models ANSI CSA Part 1 of 3 _ FQsaruse P1EMERGENCY STOP IKS1 KEY SWITCH t PLATFORM CONTROL N s GROUND
55. Speed until the Platform Settling Speed percentage is 3 to 5 points less than the Platform Lowering Speed percentage Press the lift function enable button Push in the red Emergency Stop button to the off position at the ground controls Part No 162336 April 2015 Service Manual How to Adjust the Steer Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Push in red Emergency Stop button to the off position at the ground controls Turn the key switch to ground control 4 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode Press the lift function enable button 6 Usethe yellow platform down arrow to scroll to steering speed Result STEERING SPEED is showing in the diagnostic display window CNN 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 steering speed or press the blue platform up button to increase the steering speed 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground control
56. Starter motor Exhaust gozom gozan drew no lead SUA 0 5 to 0 6 mm Brush length minimum 0 27 in eee 12 7 Fuel injection system Injection pump make Bosch Battery Injection pump pressure 15000 psi Type 12V Group 31 maximum 1034 bar Quantity 1 Injector opening pressure 3046 psi Cold cranking ampere 1000A 210 bar Reserve capacity 25A rate 200 minutes Fuel requirement Alternator output 60A 14V DC For fuel requirements refer to the engine Operator Fan belt deflection 3 8 to 1 2 inch Manual for your engine 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 84 05 90 Part No 162336 April 2015 Service Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque installed Seal Lok Fittings hose end ORFS SAE Dash Size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft Ibs 150 Nm 20 140 ft Ibs 190 Nm 24 1
57. Y1 Parallel BL Blue Y2 Brake release BK Black Y3 Steer right BR Brown Y4 Steer left GY Grey Y7 Platform down OR Orange Y8 Platform up PP Purple Y9 Proportional control RD Red Y29 Generator on option WH White Y33 Left rear outrigger YL Yellow Y34 Right rear outrigger Wire Color Legend Ford Engine Y35 Left front outrigger Item Description Y36 Right front outrigger BL Blue Y39 Outrigger retract BK Black Y40 Outrigger extend BR Brown Y50 LPG DB Dark Blue Y51 Electronic displacement control DG Dark Green Y54 Oscillate float GN Green Y55 Oscillate enable GY Grey Y56 Left oscillate LB Light Blue Y57 Right oscillate LG Light Green N Natural Pink P Purple R Red T Tan W White Y Yellow Genie 174 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Symbols Legend it Battery Motor Horn or alarm Flashing beacon Gauge 1 Sy F1 CB1 L3 Lx y 25 15A Diode Coil with suppression LED Fuse with amperage Circuit breaker with amperage TE Connection Circuits crossing no Quick disconnect Level sensor p ower relay terminal connection terminal without outriggers 538 86 86 30 30 22 21 22 21 See 3 85 85 i T 4 NO N
58. alarm sounds when the incline of the chassis exceeds 3 to the front or rear How to Install the Outrigger Level Sensor Models with Outriggers ADANGER Tip over hazard Failure to install or calibrate the level sensor as instructed will compromise 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 Locate the level sensor behind the ground control panel 4 Disconnect the platform controls from the machine at the platform 5 Open the large ground control panel door and locate the Electronic Control Module ECM wire harness to platform controls wire harness connection below the ground controls 6 Tagand disconnect the platform controls wire harness from the ECM wire harness 7 Securely connect the platform controls to the ECM wire harness If you are not installing a new level sensor proceed to step 12 Install the level sensor 8 Tagand disconnect the wire harness from the level sensor 9 Remove the three level sensor retaining fasteners Remove the level sensor from the machine 1 1 1 1 1 108 GS 84 GS 90 Part No 162336 April 2015 Servic
59. 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 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 CO or higher the high torque forward drive speed and the high torque reverse drive speed may be adjusted independent of one another Refer to Repair Procedure How to Determine the Revision Level 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Pushin the red Emergency Stop button to the off position at the ground controls Turn the key switch to ground control 4 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use yellow platform down arrow to scroll to max fwd high torque drive Result MAX FWD HIGH TORQUE DRIVE is showing in the diagnostic display window 7 Pressthe lift function enable button Genie BRAND GS 84 GS 90 95 Part No 162336 Service Manual April 2015 Ground
60. area that is firm level and free of obstructions Note Be sure the platform is fully retracted and lowered to the stowed position 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 4 Bring the machine to top drive speed before reaching the test line Release the function enable switch on the control handle or release the control handle when your reference point on the machine crosses the test line 5 Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 11 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Note Select a test area that is firm level and free of obstructions Note Be sure the platform is fully retracted and lowered to the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turnthe key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine from the platform controls 4 Lower the platform to the stowed position 5 Choo
61. 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 Service Manual Baas RE EE EE EE EE Scissor Components April 2015 4 Place a 12 inch 30 cm block under the 3 4 center of the scissor arm pair Lower the Wear Pads scissor arm pair onto the block 5 Remove the external snap rings from both center pivot pins How to Replace the Platform 6 Use a soft metal drift to remove both center Scissor Arm Wear Pad ping 1 Place lifting strap from an overhead crane 7 Carefully separate the scissor arm pair under the platform at the steer end of the machine for support Do not attach the lifting Crushing hazard The scissor straps from the overhead crane to the A WARNING arms could become unbalanced platform railings and fall if not properly supported 2 the overhead cranes 2 Placea 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 platform railings 3 Liftthe platform slightly using the overhead cranes just enough to take the pressure off the platform slide block pivot pins 4 Remove the pin retaining fasteners from each platform centering link pivot pin at the
62. barrel end pivot pin retaining fasteners 41 Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 11 42 Carefully remove the lift cylinder from the machine A WARNING Crushing hazard The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly supported by the overhead crane 43 Carefully lift the number 1 outer arm index 12 approximately 2 inches 5 cm and remove the block 44 Lower the number 1 outer arm index 12 onto the slide blocks A WARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the block 45 Secure the number 1 outer arm index 12 to the slide blocks Genie BRAND GS 84 GS 90 71 Service Manual is Scissor Components 46 47 48 49 Remove the strap installed in step 32 Support the cable tray with an overhead crane Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 8 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 10 53 55 April 2015 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 Remove the pin retaining fasteners from both number 2 pivot pins index 21 at the steer end of the machine Do no
63. beacons 16 Use the yellow platform down arrow to scroll to generator option Result GENERATOR OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the generator option Note For this option to function correctly the machine must be equipped with the required generator components 17 Use the yellow platform down arrow to scroll to outriggers option Result OUTRIGGERS OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the outrigger option Note For this option to function correctly the machine must be equipped with the required outrigger components Genie BRAND GS 84 GS 90 Part No 162336 103 Service Manual Ground Controls ANSI and CSA models with all software revisions 18 Use the yellow platform down arrow to scroll to return to the main menu Result RETURN TO MAIN MENU is showing in the diagnostic display window 19 Press the lift function enable button Result SELECT OPTIONS is showing in the diagnostic display window 20 Push in the red Emergency Stop button to the off position at the ground controls CE models with all software revisio
64. button to the on position at the ground controls Result tune speeds is showing in the diagnostic display window Use the yellow platform down arrow to scroll to select options Result select options is showing in the diagnostic display window The ECM is now in programming mode Press the lift function enable button Result descent delay off is showing in the diagnostic display window Press the lift function enable button to activate the descent delay option Result descent delay on is showing in the diagnostic display window Push in the red Emergency Stop button to the off position at the ground controls Pull out the red Emergency Stop button to the on position at the ground controls Calibrate the down limit switch 84 85 86 74 Raise the platform approximately 1 75 Repeat this procedure beginning with step 68 Enable the descent delay function 76 Push the red Emergency Stop button to the off position at the ground controls 77 Turn the key switch to ground control Genie Turn the key switch to platform control Start the engine Raise the platform approximately 1 m Lower the platform until the down limit switch activates and the platform stops lowering Quickly release the controls and then immediately attempt to lower the platform to the stowed position Result The platform stops for 4 to 6 seconds Release the joystick and proceed to step 94 Result The platform stops an
65. cylinder will extend causing the machine to tilt towards you This simulates closing the left rear limit switch causing the right oscillate cylinder to extend Result No movement Verify there is voltage on the jumper wire Check for voltage on relay K12 terminal 30 Oscillate operates in the incorrect direction Do not proceed Contact the Genie Service Department Note Remove the jumper wire from relay K12 and terminal D3 after the limit switch activates the oscillate in the opposite direction 15 Using the jumper wire jump from relay K12 terminal 87A to terminal D4 below the blue wire Result The left steer end oscillate cylinder will extend causing the machine to tilt away from you This simulates closing the right rear limit switch causing the left oscillate cylinder to extend Result No movement Verify there is voltage on the jumper wire Check for voltage on relay K12 terminal 30 Oscillate operates in the incorrect direction Do not proceed Contact the Genie Service Department Note Remove the jumper wire from relay K12 and terminal D4 after the limit switch activates the oscillate in the opposite direction 16 Using a volt meter check for voltage by connecting the positive lead to relay K12 terminal 87 and connecting the negative lead to the ground strip terminal Result The volt meter should read OV DC W Result The volt meter reads 12V DC or greater Check terminal 86 for volt
66. display window Result OVERLOAD OFF is showing in the diagnostic display window Press the lift function enable button to activate the overload option Note For CE models the overload option should be activated or in the on position 14 Use the yellow platform down arrow to scroll to sim operation Result SIM OPERATION OFF is showing in the diagnostic display window Result SIM OPERATION is showing in the diagnostic display window Press the lift function enable button to deactivate the sim operation option Note For CE models the sim operation option should be deactivated or in the off position Ground Controls 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 16 Use the yellow platform down arrow to scroll to generator option Result GENERATOR OFF is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the generator option Note For this option to function correctly the machine must be equipped with the required generator components 17 Use the yellow platform down arrow to scroll to outriggers option Result OUTRIGGERS OFF is showing in the diagnostic display window Press the
67. from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed 8 Install the filter element 9 Install the air filter canister end cap and the end cap retaining ring Genie 28 GS 84 GS 90 Part No 162336 April 2015 Service Manual Deutz models 1 Release the latches on the engine tray fully slide the engine tray out 2 Inserta inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Remove the air intake hose from the engine slide out tray 4 Disconnect the retaining clamp from the air cleaner canister 5 Remove the filter element 6 Clean the inside of the canister and the gasket with a damp cloth 7 nspectthe air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed 8 Install the filter element 9 Install the air filter canister end cap and connect the end cap retaining clamp Note Be sure the air cleaner intake hose is inserted in the hole in the front of the engine slide out tray Checklist B Procedures B 4 Check and Adjust the Engine RPM Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is es
68. ground controls 2 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine from the platform controls Press and hold the lift function enable button Raise the platform until it stops 5 Drive the machine in either direction Result The drive function should not operate 6 Measure the distance between the working surface and the platform deck Result The maximum height is 30 feet 9 1 m Result The maximum height exceeds 30 feet 9 1 m inspect the up limit switches and the limit switch cams Genie BRAND GS 84 GS 90 35 Part No 162336 Service Manual April 2015 Checklist B Procedures 7 Lower the platform If the platform is higher than 12 ft 3 6 m from the ground the outriggers will not lower 8 Push and hold the auto level button Activate and hold the up down rocker switch in the down position Result The outriggers should extend and level the machine A beep will sound when the machine is level 9 Raise the platform Result The platform should raise to full height B 14 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged su
69. 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 center of the platform floor Secure the weight to the platform Refer to the chart below GS 3384 and GS 3390 1878 kg GS 4390 most models refer to capacity 1286 kg indicator decal GS 4390 some models refer to capacity 1421 kg indicator decal GS 5390 1410 kg 8 Turn key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine 9 Raise the platform to approximately 6 m 10 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 11 Loosen the retaining ring and remove the Switch adjustment cover from the pressure switch es Note The pressure switch is located on the lift cylinder 12 Using a small slotted screwdriver turn the adjustment screw of the platform overload pressure switch es one quarter turn into the hydraulic line 13 Push in the red Emergency Stop button to the off position at the ground controls GS 3384 GS 3390 and GS 4390 models 14 Pull out the red Emergency Stop button to the on position at the ground controls Wait 3 seconds and start the engine Result The alarm doesn t sound and the engine will star
70. 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 the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 32 33 35 Part No 162336 Secure the non steer end of the number 2 inner and outer arms index 8 and 20 and the non steer end of the number 1 inner and outer arms index 10 and 12 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 1 outer arm index 12 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from the number 1 pivot pins index 13 at the non steer end of the machine Use a slide hammer to remove both number 1 pivot pins index 13 from the non steer end of the machine Service Manual Scissor Components 36 Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm 37 Place a6 x 6 x 32 inch 15 x 15 x 80 cm long block across both sides of the chassis under the barrel end of the lift cylinder 38 Lower the number 1 outer arm index 12 onto the block AWARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the block 39 Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder 40 Remove the lift cylinder
71. in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Turnthe manual fuel shutoff valves located at the fuel tank to the closed position Genie BRAND GS 84 GS 90 41 Part No 162336 Service Manual April 2015 Checklist C Procedures 4 Remove the fuel filter water separator with a filter wrench 1 oil filter 2 fuel filter water separator 5 Fill the new filter with fresh diesel fuel and apply a thin layer of diesel fuel to the new fuel filter gasket 6 Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 7 Use permanent ink marker to write the date and number of hours from the hour meter on the filter 8 Turnthe manual fuel shutoff valves located at the fuel tank to the open position 9 Startthe engine from the ground controls and inspect the fuel filter for leaks A DANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repa
72. increments 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 Emergency Stop button to the off position at the ground controls 60 Turn the key switch to ground control 61 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 speeds is showing in the diagnostic display window 9 o 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button 62 Use the yellow platform down arrow to scroll to select options Result select options is showing in the diagnostic display window The ECM is now in programming mode 63 Press the lift function enable button Result descent delay on is showing in the diagnostic display window 64 Press the lift function enable button to deactivate the descent delay option Result descent delay off is showing in the diagnostic display window Genie BRAND GS 84 GS 90 Part No 162336 149 Service M
73. is saal applied Do not continue to lower Ek R BERE SO G the platform after the safety arm makes contact with the cross tube upper cylinder 4 Support the platform using 5 ton 5000 kg overhead crane Do not apply lifting pressure at this time 5 disconnect and plug the hydraulic hoses from the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting lower cylinder this procedure without these 1 rodend skills and tools could result in e 2 lifting eye death or serious injury and significant component damage Dealer service is strongly 8 Attach a lifting strap from a second overhead recommended crane or similar lifting device to the lifting eye at the barrel end of the lift cylinder for support 6 LowerLift Cylinder 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 Genie BRAND Part No 162336 GS 84 GS 90 87 Service Manual April 2015 ses Scissor Components 9 Remove the lift cylinder rod end pivot pin retaining fastener Use a soft metal drift to remove the pin ACAUTION Crushing hazard The lift cylinder will fall unless it is properly supported 10 Carefully lower the cylind
74. kg decal GS 5390 375 Ibs 170 kg 15 Activate the platform up function and attempt to raise the platform Result The platform does not raise Proceed to step 21 Result The platform lifts Proceed to step 16 16 Lower the platform to the stowed position 17 Turn the machine off Hold the system relief valve with a wrench and remove the cap 18 Adjust 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 machine off and remove the weight 128 from the platform April 2015 How to Adjust the Steer Relief Valve Note Refer to Function Manifold Component list to locate the steer relief valve 1 Connect a 0 to 3000 psi 0 to 250 bar pressure gauge to the test port item AB on the function manifold 2 the engine from the platform controls 3 Press hold the function enable switch and hold the steer thumb rocker switch in the right direction Allow the wheels to completely turn to the right then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Specifications Hydraulic Component Specifications 4 the engine off Use a wrench to hold the relief valve and remove the cap item AE 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease t
75. lift function enable button to activate or deactivate the outrigger option Note For this option to function correctly the machine must be equipped with the required outrigger components CE models with all software revisions 18 Use the yellow platform down arrow to scroll to return to the main menu Result RETURN TO MAIN MENU is showing in the diagnostic display window 19 Press the lift function enable button Result SELECT OPTIONS is showing in the diagnostic display window 20 Push in the red Emergency Stop button to the off position at the ground controls Genie BRAND Part No 162336 GS 84 GS 90 105 Service Manual April 2015 Ground Controls 5 4 5 Level Sensor Models without Outriggers 6 The Electronic Control Module ECM is 7 programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 2 to the side or 3 to the front or rear How to Install and Calibrate the Level Sensor Models without Outriggers ADANGER Tip over hazard Failure to install or calibrate the level sensor as instructed will compromise 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 fir
76. lifting strap from an overhead crane to the number 2 inner and outer arms index 8 and 20 at the non steer end of the machine Do not apply any lifting pressure Genie 72 GS 84 GS 90 Part No 162336 April 2015 EEE SSS SST ee a ee 61 62 63 65 66 67 AWARNING Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 10 and 12 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both chassis centering link pivot pins index 23 at the number 1 inner arm Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis Remove the pin retaining fasteners from the number 1 inner arm slide blocks index 24 at the steer end of the machine Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 24 Use a slide hammer to remove the number 1 outer arm slide block pivot pins index 24 at the non steer end of the machine Carefully remove the number 1 inner and outer arms index 10 and 12 from the 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 Part
77. lowering the platform ADANGER Endine fuels ar bustibl 5 Attach a lifting strap from an overhead crane ee to the entry ladder on the hydraulic tank side Perform this procedure in an of the machine open well ventilated area away from heaters sparks flames and 6 Remove the entry ladder mounting fasteners lighted tobacco Always have an Remove the entry ladder from the machine approved fire extinguisher within easy reach AWARNING X Crushing hazard The entry ladder could become balanced and fall when it is Explosion and fire hazard When un ADANGER transferring fuel connect a the if it is grounding wire between the NOL propery MED End pump EGAN ANAT 7 Remove the retaining fasteners from the access plate located behind the hydraulic and ADANGER Explosion and fire hazard Never fuel tank tray drain or store fuel in an open container due to the possibility of 8 Locate and close the 2 fuel tank shutoff valves fire located at the fuel tank if equipped 1 Turn the key switch to ground control and pull and plug the fuel supply and out the red Emergency Stop buttons to the on LA Ee position at both the ground and platform 10 Remove the fuel filler cap from the tank controls 2 Start the engine and raise the 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 N
78. m 2 2 m OSCILLATING AXLE 5 GS 90 2 OPTION MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175P Genie BRAND Part No 162336 GS 84 GS 90 189 Service Manual April 2015 Electrical Schematic Deutz Engine Models CE AS Part 2 of 3 05 5390 ONLY 1 gm T TABS LS12A oe 8 OIL COOLER LIMIT SWITCH t EES OPTION 57 J2 C12 BATTERY 12V 4 5 LS13A Eis M Ug ium 3 LSBA swat pt e LIMIT SWITCH i HYDRAULIC NG LS14A lg P 8 SWITCH a O 8 7 E Trenes 69 156 7 NC ELXI HYDRAULIC NEE ABT PLAT LIMIT SWITCH a 85 a7 wA OILGOOLER y Sm LS15A a Lal swel LOWER 42 78 T Fan 1 87 SENSOR 4 LIMIT SWITCH LIMIT MOTOR MODELS WITHOUT RES 6516 SWITCH BATTERY 12V p DUTBIGGERS ABS BK lt Et
79. 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 2250 psi 135 to 155 bar Proportional valve flow regulator 0 1 0 38 L min Drive manifold Hot oil relief pressure 280 psi 19 3 bar Drive motors Displacement 2 speed motor 0 54 to 1 52 cu in 8 8 to 25 cc Drive hubs Fluid capacity 26 fl oz 0 77 liters Fluid type SAE 90 multipurpose hypoid gear oil service classification GL5 1 7 bar bypass Installation torque lubricated 180 ft lbs 244 Nm 2000 psi 137 9 bar Genie GS 84 GS 90 5 Service Manual April 2015 EE EE EE EE EE oes Specifications Oscillate manifold GS 90 option Manifold Component System relief valve pressure 3500 psi Specifications 241 bar Float relief valve pressure 900 psi Plug torque 62 bar SAE No 2 36 in lbs 4 Nm Oscillate flow regulator 1 gpm SAE No 4 10 ft lbs 13 Nm 3 8 L min AE No 6 14 ft Ibs 19 N Generator manifold option er SAE No 8 38 ft lbs 51 Nm Relief valve 3000 psi 207 bar SAE No 10 41 ft lbs 55 Nm Flow rate maximum 4 5 gpm SAE No 12 56 ft lbs 76 Nm 17 L min W
80. of the platform floor Secure the weight to the platform Refer to the chart below GS 3384 and GS 3390 1878 kg GS 4390 1286 kg standard GS 4390 1421 kg high capacity GS 5390 1410 kg 8 Turn key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine 9 Raise the platform to approximately 1 m 10 Apply a piece of tape to the underside of the platform at a point which corresponds to the maximum load position of the capacity indicator decal 11 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal A DANGER Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal Result The engine stops and an audible alarm sounds Service Manual April 2015 Checklist C Procedures C 2 Down Limit Switch Descent Delay if equipped Check the Down Limit Switch Height 1 Turn the key switch to platform controls Start the engine 2 Raise the platform approximately 15 ft 4 6 m Genie specifications require that this procedure be 3 Lower the platform until the
81. on signal from the ECU deactivates all other functions until that function is enabled which deactivates the generator function until the enabled 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 function is deactivated Furtharmiore tha 4 The time relay module keeps the SX controller generator on signal from the ECU switches ON four additional seconds after the ESTOP is the engine to high RPM pressed allowing for a controller ramp down of 9 9 the generator 2 SX controller is turned ON supplying Adjustment power to the bypass valve and the change over relay The EDC valve is switched over 4 to the output of the SX controller p NOHOLVHSN3D 8 Connect a digital multi meter DMM with frequency counter to the 110V AC outlet Adjust the potentiometer until a frequency of 66 5 HZ is obtained with no load on the generator GROUND CONTROLS INPUTS Be T G e E a GENERATOR CONTROLBOX 4 SECOND TIME DELAY MODULE m z 5 1k ohms 124 ohms A BATTERS NG 2
82. on protective clothing and eye wear 26 GS 84 GS 90 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Part No 162336 April 2015 Service Manual 10 11 Part No 162336 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One
83. or more battery cells display a specific gravity from 1 218 to 1 269 The battery is still usable but at a lower performance The battery will need to be recharged more often Proceed to step 11 Result One or more battery cells display a specific gravity from 1 217 to 1 173 The battery is approaching the end of it s life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill Install the vent caps and neutralize any electrolyte that may have spilled Checklist B Procedures B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the fol
84. other jewelry 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 Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Note Two persons will be required to safely perform some troubleshooting procedures Genie GS 84 GS 90 Part No 162336 153 Service Manual April 2015 Fault Codes About This Section When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction discovered Identify symptoms gt Troubleshoot problem still exists Perform Return to repair service problem solved 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 troubleshooting the machine by pinpoint
85. platform 5 Place arod through each platform centering link pivot pin and twist to remove the pin Rest the centering links on the scissor arms Genio 82 GS 84 GS 90 Part No 162336 April 2015 EEE SSS SST ee a ee 6 Remove the pin retaining fasteners from each platform slide block pivot pin Do not remove the pins 7 Usea slide hammer to remove each platform slide block pivot pin AWARNING Crushing hazard The platform will fall when the platform slider block pivot pins are removed if not properly supported by the overhead cranes 8 Move each slide block towards the center of the platform and carefully remove each platform slide block from the platform 9 Remove the retaining fasteners from the wear pads on the slide blocks Remove the wear pads 10 Install the new wear pads onto the scissor arm slide blocks 11 Install the slide blocks onto the platform 12 Align the holes in the slide blocks with the holes in the scissor arms 13 Install the slide block pivot pins and the pin retaining fasteners 14 Attach the platform centering links to the platform and install the platform centering link pivot pins and the pin retaining fasteners Service Manual Scissor Components 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 1
86. retaining fasteners from the number 1 pivot pins index 17 at the non steer end of the machine Use a slide hammer to remove both number 1 pivot pins index 17 from the non steer end of the machine Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm Place a 6 x 6 x 32 inch 15 x 15 x 80 cm long block across both sides of the chassis under the barrel end of the lift cylinder Lower the number 1 outer arm index 16 onto the block AWARNING Crushing hazard Keep hands 51 52 53 Part No 162336 clear of moving parts when lowering the arms onto the block Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder Remove the lift cylinder barrel end pivot pin retaining fasteners Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 15 54 AWARNING 55 56 Service Manual Scissor Components Carefully remove the lift cylinder from the machine Crushing hazard The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly supported by the overhead crane Carefully lift the number 1 outer arm index 16 approximately 2 inches 5 cm and remove the block Lower the number 1 outer arm index 16 onto the slide blocks AWARNING Crushing hazard Keep hands 57 58 59 60 Genie BRAND GS 84 GS 90 79 clear of moving parts
87. sequence to 28 ft lbs 38 tray from moving Nm 3 Remove the hose clamp from the air cleaner Component damage hazard To hose that connects to the engine secure the flex plate to engine 4 Remove the air filter mounting fasteners flywheel engine specifications Remove the air filter from the engine and lay it require that the fasteners be off to the side tightened in a specific order and that the torque used to tighten 5 Remove the exhaust pipe clamp from the the mounting fasteners be exhaust pipe support bracket increased gradually or in steps 6 Attach a lifting strap from an overhead crane 3 Ford models Torque the flex plate mounting the pump assembly for support Do not lift bolts in sequence to 20 ft lbs 27 Nm Deutz models Torque the flex plate 7 Remove all of the pump mounting plate to engine fasteners oes bolts in sequence to 40 ft lbs 54 8 Carefully pull the pump assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 9 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Flex plate bolt torque sequence Genie 0 162336 65 84 GS 90 91 Service Manual April 2015 Engines 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 200 pump pump
88. shaft pump coupler flex plate with raised spline engine flywheel 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 Deutz models Install the pump and bell housing assembly Torque the bell housing mounting bolts labeled C in sequence to 28 ft Ibs 38 Nm Ford models Install the pump and bell Deutz bell housing bolt torque sequence housing assembly Torque the bell housing 7 Deutz models Torque the bell housing mounting bolts labeled A in mounting bolts labeled C in sequence to sequence to 28 ft lbs 38 Nm and the 40 ft lbs 54 Nm mounting bolts labeled C to 49 ft Ibs 66 Nm Ford models Torque the bell housing mounting bolts labeled A and B in Component damage hazard sequence to 40 ft Ibs 54 Nm and the When installing the pump do not mounting bolts labeled C to 70 ft Ibs 95 force the pump coupler into the Nm flexplate or damage to the pump shaft seal may occur 8 Ford models Install the air cleaner mount bracket onto the bell housing Install the Component damage hazard Do fasteners and torque to 28 ft lbs 38 Nm not force the drive pump during installation or the flex plate teeth may become damaged Gri 1 1 1 92 GS 84 GS 90 Part No 162336 April 2015 Service Manual 5 1 Auxiliary Platform Lowering In the event of an engine failure activating the bac
89. the ierit rene ente ait ean easet eds 116 How to Adjust the Pump 117 Man ide e 118 7 1 Function Manifold Components Models with Outriggers 118 7 2 Function Manifold Components Models without Outriggers 120 7 3 Drive Manifold 122 7 4 Oscillate Manifold Components GS 90 124 7 5 Welder Manifold Components 126 7 6 Valve Adjustments Function 4 127 How to Adjust the System Relief Valve 127 How to Adjust the Steer Relief Valve ee ee ee AR ee AR ee AR ee ee 128 7 7 Valve Adjustments Drive Manifold ee ee ee 129 How to Adjust the Charge Pressure Relief 129 7 8 Generator Manifold 130 7 9 Valve Adjustments Generator 131 How to Adjust the Generator Voltage 131 7 10 Valve COIS N rette etc N N EN 132 How to Testa Coil Diode dinde in 133 Fuel and Hydraulic nennen Ee ER RR RE Re ER RR nn nennen 134 8 1 GE OR ee ad n p 134 8 2 Hydraulic
90. the on position at both the ground and platform controls Turn the key switch to ground controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position Result The check engine light should turn on The check engine light should begin to blink 5 Continue to hold the run test toggle switch in the test position Count the blinks and note the results Refer to the Fault Codes section for definition of engine fault codes Note Fault codes are two or three digits The check engine light will blink the first digit of a two digit code then will pause for 1 2 seconds and then blink the second digit For example the check engine light blinks 5 consecutive times pauses for 1 2 seconds and then blinks 1 time That would indicate code 51 The ECM is able to store up to six individual fault codes There will be a 2 4 second pause between codes Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM Refer to How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Locate the battery under the ground control panel 2 Disconnect the negative battery cable from the battery for a minimum of 20 minutes A WARNING El
91. to Adjust the Lift 98 How to Adjust the Platform Lower 99 How to Adjust the Platform Settling 100 How to Adjust the Steer 101 5 3 Software 101 5 4 Level Sensor Models without OutriggerS iese ees ee ee AR ee AR ee ee 106 How to Install and Calibrate the Level Sensor Models without 106 5 5 Level Sensor Models with 108 How to Install and Calibrate the Level Sensor Models with Outriggers 108 5 4 MSG 425 Engine Fault 00 112 How to Retrieve Engine Fault Codes Ford 56 425 112 How to Clear Engine Fault Codes from the 112 Genie xii GS 84 GS 90 Part No 162336 April 2015 EE ETE Table of Contents Hydraulic Pump 113 6 1 Lift Steer 113 How to Test the Lift Steer Pump 2 0046000 10 113 How to Remove the Lift Steer 114 6 2 Drive 115 How to Remove the Drive 115 How to Prime
92. 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 GS 84 models with diesel power Use the yellow platform down arrow to scroll to GS84 DIESEL GS 90 models with gasoline LPG power Use the yellow platform down arrow to scroll to GS90 DUAL FUEL GS 90 models with diesel power Use the yellow platform down arrow to scroll to GS90 DIESEL Genie 102 GS 84 GS 90 Part No 162336 April 2015 Service Manual 7 Press the lift function enable button to activate the model power option Result SELECT MODEL is showing in the diagnostic display window Usethe yellow platform down arrow to scroll to select options Result SELECT OPTIONS is showing in the diagnostic display window The ECM is now in programming mode 9 Press the lift function enable button Result DESCENT DELAY is showing in the diagnostic display window Press the lift function enable button to activate or deactivate the descent delay option 10 Use the yellow platform down arrow to scroll to motion alarm Result MOTION ALARM is showing in the diagnostic displa
93. 0 How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting 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 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the cables from the platform centering link index 1 and upper cable bridge at the hydraulic tank side of the machine 3 Remove the cables from the number 5 inner arm index 2 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 4 Secure both ends of the number 5 inner and outer arms index 2 and 18 together with a strap or 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 l
94. 0 increments just until the overload alarm doesn t sound and the engine will start and run Note To allow for the platform 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 42 Turn the screw of the platform overload pressure switch into the hydraulic line an additional one quarter turn 43 Deactivate the dual pressure switch limit Switch which was activated in step 36 44 Raise the platform slightly and return the safety arm to the stowed 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 arm in position 49 Remove the maximum height limit switch cam fasteners Remove the cam from the machine so that the limit switch will not be activated 50 Raise the platform until it is approximately 65 cm less than full height 51 Raise the platform in 5 cm increments until the overload alarm sounds and the engine stops running Proceed to step 52 Result The alarm does not s
95. 1 1 Start the engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 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 WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Component damage hazard 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 Release the latches on the engine tray and fully slide the engine tray out 5 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 6 Remove the retaining fasteners from the top engine cover plate Remove the plate from the machine 7 Loosen the retaining fasteners from each side engine cover plate Remove the engine side cover plates from the machine 8 Startthe engine from the ground controls Genie EE Part No 162336 65 84 GS 90 83 Service Manual Baas RE EE EE EE EE aa Scissor Components 9 Raise the platform slightly and return the safety arm to the stowed position 10 Lower the platform to the stowed position 11 Secure the ends of the scissor ar
96. 15 e right axle LS22 Genie BRAND Part No 162336 GS 84 GS 90 171 Service Manual April 2015 Electrical Component and Wire Color Legends Item Description Item Description B1 Battery CR Control relay BN Button CR1 Engine start BN1 Engine stop CR1A Power to starter BN2 Engine start CR4 High idle BN3 Starting aid CR5 Horn relay BN4 High idle CR8 Ignition BN5 Horn CR15 Starting aid BN6 High torque CR17 Oil cooler BN7 Generator CR23 Auxiliary down BN9 Platform up CR41 Control system BN12 High speed lift enable CR42 Power BN13 Low speed lift enable CR58 Forward reverse BN14 LPG select CR84 Oscillate stowed BN15 Horn left rear outrigger CR85 Oscillate raised BN16 Outrigger function enable D Power supply BN17 High torque left front outrigger D1 Alternator BN18 Generator right front outrigger D7 Voltage regulator BN20 Auto level FB1 Flashing beacons option BN23 Auxiliary down FL1 Fusible link battery to alternator BN24 Right rear outrigger G Gauge BN85 Left front outrigger G1 Volt meter 86 Right front outrigger G6 Hour meter BN87 Left rear outrigger G8 Diagnostic display BN91 Auxiliary down enable GND Ground C5 Capacitor 4700 uF H Horn or Alarm CB Circuit breaker H1 Alarm CB2 System power 20A H2 Automotive style horn CB7 Oil cooler 20A H5 Alarm Genie 172 GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Component and Wire Color Legends
97. 35 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 813 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
98. 5 Remove the brake from the drive hub Note There are two O rings on the drive motor and brake assembly One is installed between the brake and drive hub and another between the brake and drive motor Be sure that both O rings are in place when installing the brake and drive motor onto the machine Mounting bolt torque specifications Component damage hazard The Drive motor to drive hub dry 75 ft lbs work area and surfaces where 102 Nm this procedure will be performed Drive motor to drive hub lubricated 56 ft lbs must be clean and free of debris 76 Nm that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting 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 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 WARNING 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 Genie 0 0 Part No 162336 65 84 GS 90 141 Service Manual April 2015 Non steer Axle Components 10 2 Drive Hub
99. 7 501 49 664 43 583 me lL 14 37 501 49 664 50 678 70 947 61 827 20 41 555 55 745 60 813 80 10847 68 921 75 110164 89 10841 10 1 149 1 9 3 1 20 64 867 85 15 90 122 120 162 105 142 2 44 50 110841 10 1 149 1120 762 1 150 203 1 1 90 122 120 162 130 176 170 230 140 189 ss epee 1150 1 2031 1680217 1210 1 24 48 130 176 170 230 180 244 240 325 200 271 200 271 270 366 4 391 5151 320 1 16 220 298 300 406 310 420 420 569 350 474 ep 20 433 430 583 4 450 eto 8271 50 1 21 14 350 474 470 637 500 678 670 908 560 759 1 Hp 480 1 60 1 40 1 867 4 680 922 90 1 12321 70 12 530 718 710 962 750 1016 990 1342 840 1139 80 1 00 1 790 1 10711 970 13151 12901 1749 11090 12 ero 908 890 1206 1080 1464 1440 1952 1220 1654 Bo tise 4 420115184 13601 184111620 1 24671 1530 _2074 4 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 1 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 1640 2223 2190 2969 2670 3620 3560 4826 3000 METRIC FASTENER TORQUE CHART This chart 15 to be used as a guide only unless noted elsewhere in this manu
100. 8 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 29 Lower the machine onto the blocks 30 Pull out the red Emergency Stop button to the on position at platform controls Start the engine 31 Raise the platform approximately 16 feet 5 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning with step 9 Note For reference only the output of the level sensor should be approximately 1 7V DC To confirm connect the positive lead of a multimeter to the yellow wire at the level sensor and the negative lead to the black wire 32 Raise the machine slightly 33 Remove the blocks from under both wheels 34 Lower the machine and remove the jack 35 Center a lifting jack under the drive chassis at the tank side of the machine 36 Raise the machine approximately 6 inches 15 cm 3 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
101. 80 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection 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 Ibs 249 5 Nm Adjustable Fitting 1 jam nut Non adjustable fitting SAE O ring Boss Port SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7 16 20 2 SAE Dash Size Torque 6 9 16 18 1 4 ORFS 37 Adj 15 ft Ibs 20 3 Nm 28 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm ET EP i 37 Non adj 22 ft lbs 30 Nm me me U ONE 16 1 5 16 12 1 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 20 1 5 8 12 1 37 Adj Non adj 52 ftlbs 70 5 Nm 24 1 7 8 12 1 10 ORFS 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie Part No 162336 GS 84 GS 90 9 Service Manual April 2015 EE EE EE EE EE oes Specifications Tordue Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose Seal Lok fittings of the fitting body body hex fit
102. 87 H5 FB1 5 OUTRIGGER ENABLE BN24 lt lt lt lt lt lt I onm 8 9 8 8 2 z 8 959 LIFT FUNCTION 2 2 a s BE B 0 5 x ORGR AUTOLEVEL ENABLE BN20 3 d d a J Bj g fgg o 5 i 8 5 28 SYSTEM STATUS 150 9 2 gt m m m oc 2 9 m m e 5 F o c 8 m 9 5 1 d 3 2 PLATFORM UP DOWN 7820 2 o 9 5 5 2 9 OR 8 o m 2 PLATFORM amp OUTRIGGER m s 5 J1PIN5 BK O NOTE O L RD H1 J8PIN2 BK ALARM PLATFORM MACHINE SHOWN IN THE STOWED esse POSITION WITH THE POWER OFF CONTROLS ES7163G is Genie GS 84 GS 90 Part No 162336 April 2015 Service Manual Electrical Schematic Deutz Engine Models ANSI CSA Part 1 of 3
103. CH 22002 23s GE sw 328 JS PINS S SW6 NOS NOs BSF OR FUNCTION ENABLE Sd d ERST BK 4 2 LEFT RIGHT a Ix IR TE Je PINE 4 4 4 4 5 42 PIN7 BE J2 PINS L 2 214 E c QG OC x T 7 Pp vmm Q a 8 STAN POUTI U5 PIN2 HORN ELECTRONIC CONTROL MODULE PINS STARTING AID 5 PING ENGINE START BN2 7 7 g g n i b n a n 8 i 3 S S 3 SQ PINS HIGH TORQUE BN6 Ei PING GENERATOR PIN LPG SELECT BN14 Y29 Y36 Y34 40 PINE HIGH IDLE BN4 i lo I X ATA RAL LF OUTRIGGER ENABLE 5 p d RF OUTRIGGER ENABLE BN86 AN X DI PNT N 1 LR OUTRIGGER ENABLE BN87 H5 FB1 Y35 Y33 Y39 sw206 RR OUTRIGGER ENABLE BN24 5 5 lt 2 g zZ S fF 14602107797 S 8 9 8g 5 8 kd g 8 98 LIFT FUNCTION BN9 2 2 o da 1 m c Lom 9 Ee 7 89 9 X 5 2 3 ORGR AUTOLEVEL ENABLE BN20 3 4 2 di EIE 3 EE 27 A 5 3 8 zZz U 8 m gt 28 SYSTEM STATUS 150 9 2 gt T m m 4 m o 2 2 D 2 m o 8 8 8 m m 9 npn O YE Lo 1 GS d 3 5 m g PLATFORM UP DOWN 7820 2 0 5 9 O BL yos 8 5 p m PLATFORM amp OUTRIGGER D J1PINI o
104. Controls 8 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 9 Press the lift function enable button Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming 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 HIGH TORQUE DRIVE is showing in the diagnostic display window 12 Press the lift function enable button 13 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 14 Press the lift function enable button 15 Push the red Emergency Stop button to the off position at the ground controls How to Adjust the Raised Drive Speed ADANGER 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 d
105. D Sk OB se DKGREENPURPLEIS era UE TA E SR FOL 8 1 1 CAMSHAFT POSITION SENSOR 4 5 1 S T mes 2 ns IGNITION COIL CYL 4 AGN COL Ge IGNITION COIL CYL IGNITION COIL CYL 2 ILCYL I AUX ANA PDI 12 DK GREENORANGE 18 s 16 i AX bod ip m EMS 18 X 0004 DK GREEN PURPLE 18 ORNGELT CREE srg woo TE come oem 1 14 1 GRAY YELLOW 18 1 n LT GREEN RED 16 1 AUX ANA PDS 4 18 5V EXT 1 19 BRONNMHTE 18 BROWNWHTE 18 i 1 DRIN et 20 GRAY RED 18 SRAVIRED 18 01 4 GRAYAT BLUE 18 P 749 2 GRAYVELLOW 18 EE 9220 li eese OX BLAOKANHITE 18 CRANK 26 DK BLUE 18 4 27 GRIYRED 18 EED sg EE SPEED LT BLUERED 18 TWIST WIRES 10 TURNS G60 FULL LENGTH BVEXT2 3i IT GREENBLACK 1A 4 MAP V 5 BROWNAVHITE 1a a 5V PULSEIN GRAY 1 2 aT GOV 1 b gt 34 TANLTBLUE 18 EE mE 5 t ECT 37 LTGREENRED 18 AUX ANAPU gt 38 LT GREENMHITE 18 DK BLUEAVHITE 18 DK BLUEAVHITE 18 vu ANARO 4 LT BLUE YELLOW 18 LT BLUE YELLOW 18 lan BLACKYELLON 18 BLACHAELLOU 18 BLACKYELLOW 18 L M REDAT GREEN 18 REDAT GREEN 18 AUX ANA PUD 45 DK BLUEWHITE 18 cl BED 12 AUX ANA PUDI 4 5 PURPLELT BLU
106. E 18 1 1 TPS 11 47 GRAYMHITE 18 CRANK SENSOR f 1 52 4 8 YELLOWAVHITE 18 m m YELLOWIDK BLUE 18 mo m 1 KNOCK 4 51 YELLOWRED 18 Es E die LT BLUEBLACK 18 LT BLUE BLACK 18 LY BLUE OW 18 RN mE PC RX ae 56 ORANGE 18 BLACK ORANGE 18 BLACKIORANGE 18 KNOCK 2 DK GREENANHITE 18 DK GREENMHITE 18 f KNOCK 2 9 E TANNELLOW 18 TANVELLOW 18 1 PROT 59 PINKAT GREEN 18 PINKLT GREEN 18 YELLOW DK BLUE 18 YELLOW DK BLUE 18 m 8 Ee 18 PURPLEAT BLUE 18 PURPLEAT BLUE 18 Eo E in g BLACKAT GREEN 18 EE ELE E EE 2 77 BRONNLTBLE 16 Ps TELE e 8 4 5 5 LTBLUE DK GREEN 18 A H H BROWNWHITE 18 ib ET 8 BLACKAVHITE 16 GRAY RED 18 E s LPG LOCKOFF GRAYORANGE 18 1 1 ur WHITE SLACK 18 A 2 ugue Sim a i ai R GREEN 18 WER im BLACKRED 16 BEDIBLACK 18 RED BLACK 18 1 LOCKOFE P gt 77 WHITEBLACK 18 EEUE EED PEDT AHERN 10 1 FUEL PUMP AUX 4 B LTBLUE ORANGE 18 TANIGREEN 1 TAN GREEN 18 1 VBAT 4 79 REDITAN 16 9 PINK BLACK 16 PINKBLACK 16 DBW pa LTBLUE DK GREEN 18 BLACK RED 16 BLACKRED 16 GROUND Br z E LT BLUE PINK 18 LT BLUEPINK 18 WES 24 RES REDRLACK IE STARTER SOLENOID A 4 55 GRANGE GREEN 18 gt 66 REDWHITE 18 D ME 7 REG gt 88
107. G 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Genie BRAND GS 84 GS 90 43 Part No 162336 Service Manual April 2015 Checklist D Procedures D 1 Check the Scissor Arm Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the condition of the scissor arm wear pads is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions Note Perform this procedure on a firm level surface with the platform in the stowed position 1 Measure the thickness of each chassis wear pad at the steer end of the machine Result The measurement is 5 16 inch 8 mm or more Proceed to step 2 i Result The measurement is less than 5 16 inch 8 mm Replace both wear pads 2 Measure the thickness of each chassis wear pad at the non steer end of the machine Result The measurement is 5 16 inch 8 mm or more Proceed to step 3 i Result The measurement is less than 5 16 inch 8 mm Replace both wear pads 44 69 84 GS 90 Measure the thickness of each platform scissor arm wear pad at the steer end of the machine Result The measurement is 5 16 inch 8 mm or more Proceed to step 4 Result The measurement is less than 5 16 inch 8 mm Replace b
108. Genie A TEREX BRAND Serial Number Range GS 3384 neon GS 3390 mca GS 4390 nma GS 5390 nca Part No 162336 Rev A2 April 2015 Service Manual April 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group A Type 2 3 as defined by ISO 16368 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 improvement All communications will be carefully considered for future pri
109. Gri 98 GS 84 GS 90 Part No 162336 April 2015 EE hi i er ee en How to Adjust the Platform Lower Speed 1 Part No 162336 Pull out the red Emergency Stop button to the on position at the platform controls Push in the red Emergency Stop button to the off position at the ground controls Turn the key switch to ground control 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode Press the lift function enable button 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 Service Manual Ground Controls 7 Press the lift function enable button 8 Press the yellow platform down button to decrease the platform descent speed or press the blue platform up button to increase the platform descent speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 9 Press the lift function enable button 10 Push the red Emergency Stop button to the off position at the ground controls 11 Check th
110. HS Tire ply rating 10 Hy rauli tank 11 Tire weight new foam filled minimum 265 Ibs 1278 Rough terrain 120 kg Hydraulic system without outriggers 37 5 gallons Tire diameter x width 33inx12in including tank GS 3384 and GS 3390 142 liters 83 8 cm x 30 cm Hydraulic system with outriggers 38 25 gallons P 9 including tank 69 4390 ies Hydraulic system with outriggers 38 75 gallons Mire size 21990116 SNAS including tank GS 5390 146 7 liters ply rating minimum 8 Hydraulic system without outriggers 34 25 gallons Tire diameter x width 30 8 in x 10 4 in including tank GS 3384 and GS 3390 129 6 liters 78 2 cm x 26 4 cm Hydraulic system without outriggers 35 gallons Weight new foam filled minimum 224 Ibs including tank GS 4390 132 5 liters Rough terrain 101 6 kg Fuel tank 30 gallons Weight new foam filled minimum 228 Ibs 114 liters Rough terrain non marking 103 4 kg Tires and wheels Tires and wheels High Flotation air filled and foam filled all models Wheel lugs 9 5 8 18 Tire size 33 16LL500 Lug nut torque dry 125 ft lbs 169 5 Tire ply rating 10 Tire diameter x Tire width a3inx tein LYS NU torque lubricated 94 tips 127 4 Nm 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 Ibs 10 Ibs 190 kg 4 5 kg Weight air filled 157 Ibs 71 2 kg Pressure air filled 38 psi 2 6 bar Genie
111. How to Remove a Drive Hub Note When removing a hose assembly or fitting 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 Remove the drive motor Refer to Repair Procedure How to Remove a Drive Motor and Brake 2 Block the steer wheels and center a lifting jack 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 A WARNING 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 support and secure the drive hub to the lifting jack 7 Remove the drive hub mounting bolts that attach the drive hub to the axle Remove the drive hub A WARNING Crushing hazard The drive hub may become unbalanced and fall if itis not properly supported and secured to the lifting jack Mounting bolt torque specifications Drive hub to axle lubricated 180 ft lbs thread locker on bolt threads 244 Nm 10 3 Oscillating Axle Refer to Repair Procedure Oscillating Axle Option GS 90 Models Genie 142 GS 84 GS 90 Part No 162336 April 2015 Service Manua
112. Hydraulic Filter Elements 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Locate the medium pressure hydraulic filter mounted on the side of the engine near the pump 4 Remove the filter housing using a wrench on the nut provided on the bottom of the housing 5 Remove the filter element from the housing Inspect the housing seal and replace it if necessary Checklist D Procedures 7 Install the new filter and hand tighten the housing onto the filter head 8 Locate the high pressure hydraulic filter mounted next to the function manifold 9 Remove the filter housing using a filter wrench AWARNING 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 Remove the filter element from the housing 11 Inspect the housing seal and replace it if necessary 12 Install the new filter element and hand tighten the housing onto the filter head 13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters 14 Start the engine from the ground controls 15 Inspect the filter assembly to be sure that there are no leaks 16 Clean up any oil tha
113. LI EDXT A ELXJ Fa EA 85 8 eral m wt wa a za 25 a as aal 87 Vera 4 4 4 4 4 CB2 20A 4 2 J E N C H O G6 111523 7 1822 12 N LEFT RIGHT 1 OSCILLATE OSCILLATE H2 4 LIMIT SWITCH LIMIT SWITCH d E lc 4 j Es GOV SPEED SELECTORRD 23 FUEL SELECT BKWH 7 L 6 MALFUNCTION LED BL 11 KEY ON WH 124 KEEP ALIVE POWER WH 2 gt B1 20 i ENGINE SELF TEST r TO ea Ples 18 SELFTESTSWITCHBKRD I 654 pop 5 FUEL PUMP BL WH JOE Y54 e Y50 v iol i 7 TX pon 18 FUEL PUMP GND AX ALN 5 i 1 s 2 IX ct FORDENGINE 1 ECM 2 cm 1 P aga _ lt TIN EX ME M3 FUEL PUMP Y57 Y55 4 L n 4 4 z 2 8 2 S 2 8 8 8 gt gt gt x m N a a 2 9 2 R 9 lt gt dm m x 5 m a m 2 mz 5 4 o x je d 208 E x m Bod g m w 9 D 2 2 7 7 9 gt 2 5 gt j 6 m Sq 2 5 362 2 3 3 F m E m OSCILLATING AXLE 9 GS 90 2 OPTION MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174H Genie
114. Maintenance Ford 43 Checklist D Procedures ierit ER AE ee EE Re ER ee KEER Ee 44 D 1 Check the Scissor Arm Wear 44 D 2 Check the Free wheel Configuration 2 45 D 3 Replace the Drive Hub Oil 46 0 4 Replace the Hydraulic Filters 47 0 5 Test the Oscillate Axle GS 90 48 D 6 Perform Engine Maintenance Deutz 51 Checklist E 52 E 1 Test or Replace the Hydraulic 52 E 2 Perform Engine Maintenance Deutz Models 54 E 3 Perform Engine Maintenance Deutz Models 55 Genie GS 84 GS 90 Part No 162336 April 2015 Section 4 Part No 162336 Table of Contents Repair 56 56 Platform Controls nennen EE Ee EE nnne nine Ee 58 CCUIL BONG ER EE RE 58 How to Remove the Platform Controls Circuit
115. O Contact solenoid or Button Limit Switch Limit Switch Coil solenoid or relay relay normally open not held held 2 R14 6 Red emergency stop button Resistor with ohm Starting aid or glow Electric motor value plug normally closed Genie BRAND Part No 162336 GS 84 GS 90 175 Service Manual April 2015 Wiring Harness Ford MSG 425 EFI Part 1 of 2 YELLOW BLACK 18 _ SPK COLIA 4 1 YELDWRLACK ns CCOILIB 4 2 WHITEPINK 18 GRAYED 1p ____ 1 SPARK COIL2A amp 3 YELLOWRED 18 Pana te 1 SPK GND 4 4 BLACKAVHITE 16 EE
116. OR machine is turned on replace joystick 28 OFF NEUTRAL Red Drive joystick off neutral Machine functions Release joystick before power DRIVE when machine is turned on disabled up OR replace joystick JOYSTICK 29 PLATFORM LIFT Red Lift enable button fault at the Lift function Troubleshoot button OR replace SW FAULT platform controls disabled printed circuit board at platform controls 30 OFF NEUTRAL Red Up down switch off neutral Up down function Replace up down switch at LIFT JOYSTICK Part No 162336 Genie BRAND disabled GS 84 GS 90 platform controls 155 Service Manual April 2015 _____ Control System Fault Codes ID System Ready LED Condition Result Solution 31 PLATFORM Red Starting aid fault at the Starting aid Troubleshoot button OR replace CHOKE SW platform controls disabled printed circuit board at platform FAULT controls 32 PLATFORM Red Engine start button fault at Engine will not Troubleshoot button OR replace START SW platform controls start printed circuit board at platform FAULT controls 33 LEFT FRONT Red Left front outrigger enable Outriggers Troubleshoot button OR replace OUTRIG SW FLT button fault at platform disabled printed circuit board at platform controls controls 34 RIGHT FRONT Red Right front outrigger enable Outriggers Troubleshoot button OR replace OUTRIG SW FLT button fault at platform disabled
117. PEED COIL Red 2 speed coil Y1 fault High torque drive Troubleshoot coil OR wiring FAULT function disabled 92 DRIVE FWD Red Drive pump forward Drive forward Troubleshoot coil OR wiring PROP COIL proportional coil Y51 fault function disabled FAULT 93 DRIVE REV Red Drive pump reverse Drive reverse Troubleshoot coil OR wiring PROP COIL proportional coil Y51 fault function disabled FAULT 94 MACHINE TYPE Red Wrong machine type Machine will not Correct selection FAULT selected operate Genie 158 GS 84 GS 90 Part No 162336 April 2015 Service Manual a Ford MSG 425 Engine Fault Codes Code Description Code Description 16 Never crank synced at start 237 TIP Low Voltage 91 FP low voltage 238 TIP High Voltage 92 FP high voltage 261 Injector Loop Open or Low side short to 107 MAP Low Voltage Ground 108 MAP High Pressure 262 Injector Coil Shorted 111 IAT higher than expected 1 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted vonage 267 Injector Loop Open or Low side short to 116 ECT higher than expected 1 Ground 117 ECT CHT Low Voltage 268 Injector Coil Shorted 118 ECT CHT High Voltage 270 Injector Loop Open or Low side short to 121 TPS1 lower than TPS2 Ground 422 TPS1 low voltage 271 Injector Coil Shorted 123 TPS1 high vo
118. RAND GS 84 GS 90 31 Part No 162336 Service Manual April 2015 Checklist B Procedures B 7 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends cracked welds 3 Check each lug nut for proper torque Refer to Specifications Machine Specifications 4 Check the pressure in each air filled tire B 8 Check the Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate t
119. RAND Part No 162336 GS 84 GS 90 187 Service Manual April 2015 Electrical Schematic Ford Engine Models CE AS Part 3 of 3 WH PLATFORM p RD POWER TO GROUND P2 EMERGENCY STOP WH 5 95 PINT GROUND H OR DATA LINK LOW 45 PIN4 HO J5 PINS E OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3384 3390 and 4390 1001 20220 es U3 D7 PLATFORM CONTROLS VOLTAGE Tav DC PRINTED CIRCUIT BOARD REGULATOR EP J2 PIN HALL EFFECT 58 da FiNe GENERATOR 2 AXIS J2 PIN12 LI JOYSTICK 1512 1513115141515 TILT LEVEL pe CONTROLLER LF RF LR RR SENSOR ona ORIG ORIG J2PIN3 LMT LMT UMT LIMIT SWITCH SWITCH SWITCH SWIT
120. RED 18 STARTER RELAY 1 FP REC AUX REC 89 PINKIBLACK 16 FUEL PUMP AUX PWN 4 00 BLACK RED 16 LT BLUE PINK 16 acorns ME gt RED 16 LI TBLUEPINK 18 20A s Ic STARTER LT GREEN PURPLE 18 s Lp RELAY_OMRON_FFP LTBLUE ORANGE 18 WHITE 16 TUR RED YELLOW 18 BROWN YELLOW 16 BROWN LT BLUE 15 t 14 RED TAN 14 amp BED 18 18 4 BED 18 VVT SOLENOID INd CYL 4 CYL 2 INJ CYL 1 55 24 n Genie ATEREX BRAND 176 GS 84 GS 90 Part No 162336 April 2015 Service Manual DK BLUE ORANGE 18 Wiring Harness Ford MSG 425 EFI GRAYAT BLUE 18 1 RED 18 54 Part 2 of 2
121. The platform railings can be they are not secured to the damaged if used to lift the platform platform Do not attach the lifting straps to the platform railings Genie ATIRDI BAD 60 GS 84 GS 90 Part No 162336 April 2015 Service Manual Platform Components 2 2 6 Carefully slide the platform extension deck out Platform Extension Deck until the platform extension deck makes contact with the carriage on the forklift 7 Attach a strap from the platform extension How to Remove a Platform deck railings to the carriage on the forklift to Extension Deck help support the platform extension deck Note Perform this procedure with the platform in 8 Remove the three V roller and extension deck the stowed position and the platform extension lock bracket mounting fasteners from the deck s fully retracted and locked in position nd deck at the tank side of the Note If the machine is equipped with the dual extension deck option repeat this procedure for 2 a 4 the other platform extension deck di OUL Or Lene S 10 Remove the fasteners from the roller wheels 1 Steer end extension deck Remove the located under the platform extension deck platform controls from the platform and lay Remove the roller wheels them off to the side of the machine 2 11 Carefully slide the platform extension deck out 2 Remove the retaining pins from the four black of the platform and place it on a structure plastic railing
122. Y A BED VELLOW 18 BEDWELLOW18 E 7 RED TAN 14 4 ET va TBLUE 1 RED 16 POWERRELAY 10A ER F6 RED 16 7 18A RELAYED POWER RED 16 Part No 162336 Genie BRAND GS 84 GS 90 177 Service Manual April 2015 Wiring Diagram 12 kW Hydraulic Generator option 12 5 kW HYDRAULIC GENERATOR NEMA 4 CONTROL BRASS Y X 50 AMP 3 POLE CIRCUIT BREAKER WITH INTERGRAL GFI ON 7 208 L2 RED RED OUTLET 4 ORANGE L N 2 WHITE 3 Li BLACK BLACK BLACK 12 GA GREEN WHITE st GREEN CIRCUIT D BREAKER 8 GA 4 CONDUCTOR 8 GA5 CONDUCTOR ERA 120 VAC GFI BLACK 12 GA SIVERT N as 110 VAC GFI GREEN 12 GA eine SILVER v fg GREEN GREEN dE BLACK 12 CONDUCTOR Genie 178 GS 84 GS 90 Part No 162336 April 2015 Service Manual Wiring Diagram 12 kW Theory of Operation Hydraulic Generator option 1 Turning on the Generator sends a signal to 3 When the AC generator is turned OFF the SX the ECU which deactivates the function as long as the generator function is turned on In addition the Generator
123. afety Rules Personal 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 symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this Indicates a potentially hazardous situation which if not avoided could result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury A CAUTION Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it gt Be aware of potential 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 s
124. age If yes the drive controller is activated or the ECU needs to be replaced 17 Move the drive controller just of center safe driving direction Result The volt meter should read 12V DC or greater Result The volt meter reads OV DC Do not proceed Contact the Genie Product Support for assistance Genie 50 GS 84 GS 90 Part No 162336 April 2015 Service Manual 18 Push in red Emergency Stop button on the platform controller and on the ground controls Turn the key switch to the off position 19 Close the ground control panel and secure using the fasteners removed in Step 3 and securely tighten 20 Disconnect the platform controller from the control cable and securely connect the control cable to the ground control plug Close the ground control panel door 21 Install the platform controller in the platform 22 Perform the function tests Refer to the Operator s Manual on your machine 23 Return the machine to service Checklist D Procedures D 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 1000 hours All Models e Heating plugs e V belts e Engine mounting e Fuel filter e Valve clearance Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 Deutz 2011 Series Operation Manual Genie part number 139320
125. aintain solid contact with the ground delivering the maximum traction available When driving the GS 90 with the platform raised above the down limit switch height the oscillating axle function is limited in that the oscillating cylinders only respond to input from the oscillating axle limit switches located on the rear axle Oscillate Stowed Relay CR84 Terminal 30 of the Oscillate Stowed relay CR84 receives power from the Platform Down limit switch LS6 When the platform is raised above LS6 power to terminal 30 will be cut Terminal 86 of CR84 is connected to pin J2 C5 at the ECM Pin J2 C5 is powered anytime the Brake Release valve coil Y2 is energized thus energizing CR84 terminal 87 and ultimately all four oscillating valve coils allowing oil to pass between the oscillating cylinders J2 C5 continues to power terminal 86 for 0 5 seconds after Y2 is de energized Genie BRAND GS 84 GS 90 139 Part No 162336 Service Manual April 2015 Steer Axle Components Oscillate Raised Relay CR85 When the left rear or right rear wheel drops the limit switch will relax and close its circuit sending Terminal 30 of the Oscillate Raised relay CR85 power to the appropriate oscillating valve coil receives power from the Power relay CR42 When power is cut to terminal 86 of CR42 via key switch PONTHOES EMERGENCY STOP
126. aintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Checklist C 1 Test platform overload if equipped Checklist E YNR E 1 Hydraulic oil C 2 Down Limit Switch Descent Delay if equipped E 2 Engine maintenance Deutz models C 3 Engine air filter Deutz models Perform every 3000 hours E 3 Engine maintenance Deutz models C 4 Fuel filter separator Deutz models C 5 Engine maintenance Deutz models Inspector signature Inspector title Inspector company Instructions e Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection s to perform Daily or every 8 hours A Quarterly or every A B 250 hours Semi annually or A B C every 500 hours Annually or A B C D every 1000 hours Two yearor A B C D E every 2000 hours e Place a check in the appropriate box after each inspection procedure is completed e Use the step by step procedures in this section to learn how to perform these inspections f any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired 18 C 6 Breather cap models with optional oil Perfor
127. akes inttr emet metae tak Ld e sena da nd 34 B 11 Test the Drive Speed Stowed 34 B 12 Test the Drive Speed Raised 35 B 13 Check the Up Limit Switch Drive Cutout and Outriggers GS 5390 35 B 14 Perform Hydraulic Oil 36 B 15 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 37 B 16 Replace the Engine Air Filter 38 B 17 Perform Engine Maintenance Ford 38 Gonio BRAND Part No 162336 GS 84 GS 90 ix April 2015 Ka EE ET Table of Contents Checklist Ee Ee EE Ee EE nene nre nnne Ee Ke Ee Re ee nnn 39 C 1 Test the Platform Overload System if 39 C 2 Down Limit Switch Descent Delay if equipped 40 Replace the Engine Air Filter Element Deutz 41 C 4 Replace the Fuel Filter Water Separator Deutz Models 41 C 5 Perform Engine Maintenance Deutz 42 C 6 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 43 C 7 Perform Engine
128. al 4067 fn i di 9 di m ze to B E w A _ o gt OIE IND D gt o ES NO jo Co I gt A MAER gt IND rs rx bed had Sjop ESTE en ce lt gt 00 gt Io GIAN lo ak N N gt Y w o e w A EN N EIS gjoja jej tn o5 1 gt 0 j e mi gt 5 Se E PE Eo Joy pop S mid Fala REIN AIR Ojojoo gt gt _ N N N N O45 o N 2 en o tn A w gt A IAN j NON IN INT NIINI AAO DIN gt 1 65 c 1s 71 25 gi 9 ES Ko ZIR es e3 s Iv eo to O 4 O IN Ip Nj j ojo oj EIN NS fos ES foo LO ce gt a uU m 9 lt Uu m 9 9 lt Uu m amp lz lt a c Uu m
129. and lower the machine AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Steer wheels 20 000 Ibs 10 000 kg under the drive 7 chassis between the non steer tires 3 Lift the wheels off the ground and then place 8 jack stands under the drive chassis for support Genie BRAND Chock the non steer wheels to prevent the machine from rolling Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer tires Part No 162336 GS 84 GS 90 45 Service Manual April 2015 Checklist D Procedures 9 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub 1 brake disengaged position 2 brake engaged position 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands and lower the machine A WARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage D 3 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or annually whicheve
130. anual April 2015 Platform Overload Components 65 Push in the red Emergency Stop button to the off position at the ground controls 66 Pull out the red Emergency Stop button to the on position at the ground controls Note For more information on programming refer to Section 4 Repair Calibrate the load sense delay limit switch 67 Turn the key switch to platform control Start the engine 68 Lower the platform until the load sense delay limit switch activates and the platform stops lowering Release the joystick Result The alarm does not sound and the engine continues to run Proceed to step 76 amp Result The alarm sounds and the engine stops running The load sense delay limit switch needs to be calibrated Proceed to step 69 69 Raise the platform to approximately 6 m 70 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 71 Loosen the fasteners securing the load sense delay limit switch cam just enough to allow movement of the cam 72 Working from 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 78 79 80 81 82 83 Press and hold both the blue platform up and yellow platform down buttons Pull out the red Emergency Stop
131. ary Coil Shorted 2315 Primary 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 Manual EDI part number 1080030 Ford MSG 425 EFI Diagnostic Manual Genie part number 162067 Genie BRAND Part No 162336 GS 84 GS 90 163 Service Manual April 2015 _ This page intentionally left blank Gri 1 1 e 164 GS 84 GS 90 Part No 162336 April 2015 Service Manual Observe and Obey Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING MI Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine V Immediately tag and remove from service a damaged or malfunctioning machine A WARNING V Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate oper
132. asteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 6 Genie Part No 162336 BRAND GS 84 GS 90 65 Service Manual sis Scissor Components 44 Carefully remove the number 2 inner and outer arms index 5 and 6 from the machine AWARNING Crushing hazard The number 2 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 45 46 47 48 49 50 51 66 Remove the cables from the number 1 inner arm index 8 Secure both ends of the number 1 inner and outer arms index 8 and 16 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 8 and 16 at the steer end of the machine Do not apply any lifting pressure Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 8 and 16 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both chassis centering link pivot pins index 18 at the number 1 inner arm Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis Remove the
133. ate f gradually Do not allow oil to 22 Install the hydraulic tank strap squirt or spray 23 Install the two suction hoses ACAUTION Bodily injury hazard Beware of 24 Install the tank return hose hot engine parts and oil Contact with hot oil and or hot engine parts may cause severe burns Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves or tank Genie 4 Part No 162336 65 84 GS 90 53 Service Manual April 2015 Checklist E Procedures 25 26 27 28 29 30 31 54 Install the T fitting with the 2 hoses connected to it Fill the tank with hydraulic oil until the level is within the top 2 inches 5 1 cm from the top of the sight gauge Do not overfill Refer to Specifications Machine Specifications Clean up any oil that may have spilled during the procedure Open the hydraulic tank shutoff valves Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Refer to Repair Procedure How to Prime the Pump Install the access plate and install the access plate retaining fasteners E 2 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every two years e Replace V belts e Replace Heating plugs e Replace coolant Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Op
134. ator s manual on your machine V Be sure that all necessary tools and test equipment are available and ready for use Part No 162336 Genie BRAND GS 84 GS 90 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 Service Manual April 2015 EEE Electronic Control Module Layout To Flashing Beacon 4 To Platform Overload Electronic Control Module J1 J2 a Oscillate Manifold Level Sensor M lt Drive Manifold Hom 2 Ground Controls 5 d f Ma 1 1 pump 9 electronic control module 2 engine 10level sensor 3 to outriggers 11 horn 4 to platform overload 12 ground controls 5 down limit switch 13 function manifold 6 up limit switch 14 drive manifold 7 platform controls 15oscillate manifold 8 to flashing beacon Genie BRAND 166 GS 84 GS 90 Part No 162336 April 2015 Electronic Control Module Pin Out Legend Electronic Control J1 Connector Service Manual A
135. aximum load Sd 0 48 to 0 62 bar Alternator Cil viscosity requirements Alternator output 95A 13 8V DC Extreme operating temperatures may require the use of Battery alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine 12V DET dd Quantity 1 Cold cranking ampere 0 F 1000A Reserve capacity 25A rate 200 minutes Genie Part No 162336 GS 84 GS 90 7 Service Manual April 2015 Specifications Deutz D2011 1031 Engine Displacement Number of cylinders Bore and Stroke Horsepower Firing order Low idle Frequency High idle Frequency Compression ratio Governor Valve Clearance cold 142 cuin 2 33 liters 3 3 7 x 4 4 inches 94 x 112 mm 48 2800 rpm 36 kW 2800 rpm 1 2 3 1500 rpm 300 Hz 2500 rpm 500 Hz 19 01 centrifugal mechanical 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 7 35 quarts including filter 7 liters Cil viscosity requirements 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 300 F 149 C Oil Pressure switch Oil pressure switch point 22 psi 1 5 bar Intake 0 012 to 0 016 in 0 3 to 0 4 mm
136. below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Q 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 air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Proportional valve 12V DC 4 10 schematic item AD DO3 valve 3 position 4 way 10V DC 3 60 schematic items AG Solenoid valve 3 position 4 way10V DC with 7 20 diod
137. coil Y33 output B10 Level sensor 57 or S8 red output B11 Right rear outrigger coil Y34 output B11 Horn relay CR5 terminal 86 output B12 LPG select output B12 Alarm output C1 Plug C1 System power input C2 Platform overload input C2 System power input C3 Right front outrigger limit switch LS13 input C3 System power input C4 Right rear outrigger limit switch LS15 input C4 Engine starting aid output Left front outrigger limit switch 1512 input 5 Oscillate stowed relay CR84 terminal 86 output ce Left rear outrigger limit switch 1514 Input C6 Oscillate raised relay CR85 terminal 86 output C7 Alternator input C7 Ground output C8 Engine oil pressure SW2 input C8 Plug C9 Engine water temp SW1 OR oil temp SW3 input C9 Plug C10 Jug C40 Auxiliary down relay CR23 terminal 87 output Cit cR C11 Flashing beacons FS1 output Sie Plug C12 ECM power input Gonio BRAND Part No 162336 GS 84 GS 90 167 Service Manual April 2015 Ground Controls Wiring Panel Layout K1 K2 K3 K4 K5 K6 23 45 6 7 8 910 11 12 13 14 15 J2 DD TUT TTT TTT TTT J GND 1 2 34 5 6 7 8 9 1011121314 1516 17 18 C123 45 67 8 9 1011 12 13 14 15 D 1 23 45 6 7 8 9 10 11 12 13 14 15 K7 K8 K9 K10 K11 K12 N Iw 0 oO
138. connecting the negative lead to the ground strip terminal Result The volt meter should read OV DC Result The volt meter reads 12V DC or greater Check the down limit switch for a closed circuit Using a volt meter check for voltage by connecting the positive lead to relay K11 terminal 87 and connecting the negative lead to the ground strip terminal Result The volt meter should read OV DC Result The volt meter reads 12V DC or greater Check the relay K11 for an internal short to power Lower the platform to the stowed position GS 84 GS 90 49 Service Manual April 2015 Checklist D Procedures Oscillate Float Test Note The following procedure will require two people 13 Using a volt meter check for voltage by connecting the positive lead to terminals D2 D3 D4 and D5 Connect the negative lead to the ground strip terminal Slowly move the drive controller just off center Refer to photographs 1 and 2 AWARNING Crushing Hazard Stay clear of the machine when performing this procedure Movement of the machine could result in death or serious injury Result The volt meter should read 12V DC or greater Result The volt meter reads OV DC Do not proceed Contact the Genie Service Department for assistance Test the Oscillating Axle Limit Switches 14 Using the jumper wire jump from relay K12 terminal 87A to terminal D3 below the white wire Result The right steer end oscillate
139. ction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications Refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil Genie 36 GS 84 GS 90 Part No 162336 April 2015 Service Manual B 15 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often ADANGER Explosion and fire hazard Engine fuels are combustible Checklist B Procedures 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat
140. d then will immediately begin to lower again The down limit switch needs to be calibrated Proceed to step 87 150 GS 84 GS 90 Part No 162336 April 2015 TTF Platform Overload Components 87 89 90 Raise the platform to approximately 6 m Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Loosen the fasteners securing the down limit switch cam just enough to allow movement of the cam Refer to the illustration at step 51 Working from the outside of the machine rotate the down limit switch cam ina clockwise direction until the cam lobe is approximately 1 mm lower Tighten the fasteners Do not over tighten Note When adjusting the down limit switch cam do not move cam which activates the load sense delay limit switch 91 92 93 94 95 97 Part No 162336 Raise the platform approximately 1 m Return the safety arm to the stowed position Repeat this procedure beginning with step 86 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 Raise the platform to approximately 6 m Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Loosen the fasteners s
141. dous Genie BRAND situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Part No 162336 GS 84 GS 90 57 Service Manual April 2015 Platform Controls Platform controls The platform controls used to activate machine functions from the platform or while standing on the ground contain a printed circuit board joystick decal membrane pad buttons and LEDs All of these components are replaceable The function speed parameters in the Electronic Control Module are easily adjusted by moving the joystick pressing a button or activating a toggle switch in a specific order when the ECM is in the programming mode PS showing in the diagnostic display window For further information or assistance consult the Genie Product Support Sa Sg wr amp ere 2 ee df b dlo 1 alarm H1 2 red Emergency Stop button P2 3 joystick controller JC1 4 circuit board U3 5 platform up down and outrigger up down toggle switch TS21 1 1 Circuit Board How to Remove the P
142. down limit switch performed every 500 hours or six months activates and the platform stops lowering whichever comes first 4 Push the red Emergency Stop button to the a off position Check the Down Limit Switch 5 Measure the distance between the working Function surface and the platform deck 1 the key switch to platform controls Start GS 3384 95 to 107 in the engine GS 3390 2 4to 2 7 m GS 4390 106 to 118 in 2 gt the platform approximately 15 ft 4 6 m 271030m Lower the platform until the down limit switch GS 5390 118 to 130 in activates and the platform stops lowering 3 0to 3 3 m Quickly release the controls and then immediately attempt to lower the platform to the stowed position Result The platform stops for 4 to 6 seconds Release the joystick and proceed to step 4 5 Result The platform does not stop Confirm that the descent delay option has been selected to on See Repair Procedure 5 3 Software Configuration Repeat this procedure 4 Lower the platform to the stowed position Push in the red Emergency Stop button to the off position Genie 40 GS 84 GS 90 Part No 162336 April 2015 Service Manual C 3 Replace the Engine Air Filter Element Deutz Models Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Fail
143. e that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition w Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Mm Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie BRAND GS 84 GS 90 19 Part No 162336 Service Manual April 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shi
144. e 0 080 inch 2 mm Ford MSG425 rubber vibration isolators 11 Attach a lifting strap from an overhead crane supports nol ei any livia pressure Ford Models 12 Remove of the bell housing to engine 1 Release the latches on the engine tray and fasteners fully slide the engine tray out 13 Carefully pull the pump and bell housing away 2 Insert a6 inch 15 cm screwdriver or rod into from the engine and secure it from moving the engine tray lock hole located near the engine tray roller wheels to prevent the engine Component damage hazard tray from moving Hoses can be damaged if they are kinked or pinched 3 Tag and disconnect the exhaust gas sensor in the exhaust pipe adjacent to the engine 14 Remove the flex plate mounting fasteners exhaust manifold Remove the flex plate from the flywheel Genie 90 GS 84 GS 90 Part No 162336 April 2015 TLD ee ee ee ge How to Remove the Flex Plate Service Manual Engines How to Install the Flex Plate Deutz Models 1 Install the flex plate onto the engine flywheel 1 Release the latches on the engine tray and with the raised spline towards the pump fully slide the engine tray out 2 models Torque the flex plate mounting 2 Inserta 6 inch 15 cm screwdriver or rod into bolts in sequence to 14 71 5 19 Nm the engine tray lock hole located near the Deutz models Torque the flex plate engine tray roller wheels to prevent the engine mounting bolts in
145. e gradually Do not allow oil to Remove the entry ladder mounting fasteners duik ar spray Remove the entry ladder from the machine 10 Tag disconnect and plug the two suction Crushing hazard The entry ladder could become unbalanced and fall when it is hoses that are attached to the hydraulic tank shutoff valves e E 11 Tag disconnect and plug the tank return hose removed from the machine if it is at the tank not properly supported 12 Disconnect and plug the T fitting located at Remove the retaining fasteners from the the tank with the 2 hoses connected to it gin Peed and 13 Remove the hydraulic tank strap retaining MG ey is fasteners and remove the hydraulic tank strap Close the two hydraulic shutoff valves located from the machine at the hydraulic tank if equipped 14 Support and secure the hydraulic tank suitable lifting device 15 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition tank could become unbalanced and fall if it is not properly supported and secured to the lifting device when it is removed from the machine Component damage hazard Be
146. e schematic item AH Solenoid valve 2 position 2 way 10V DC 5 50 schematic items CA CB CC and CD Solenoid valve 2 position 3 way10V DC 60 schematic item AL Solenoid valve 2 position 2 way12V DC with 7 50 diode schematic item DA Solenoid valve 2 position 3 way12V DC with 100 diode schematic items DE and DF Solenoid valve 2 position 2 way12V DC with 100 diode schematic item DG Solenoid valve 2 position 3 way10V DC with 70 diode schematic items EF and EJ Solenoid valve 2 position 3 way10V DC 60 schematic item FC Genie 132 GS 84 GS 90 Part No 162336 April 2015 Service Manual How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance Refer to Repair Procedure How to Test a Coil 2 Connect a 10W resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 100 Genie part number 27287 Note Th
147. e Manual Ground Controls 10 Install the new level sensor onto the machine 15 Without disconnecting the wire harness from with the X on the level sensor base closest the level sensor connect the positive lead of to the steer end of the machine Install and the multimeter to the yellow wire at the level tighten the level sensor retaining fasteners sensor 16 Adjust the side to side axis of the level sensor Tip over hazard The tilt level A DANGER sensor must be installed with the X on the level sensor base closest to the steer end of the machine Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury Le 9 D N NI gt NI NI X ssl NI Level sensor models with outriggers 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 18 19 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the blue wire at the level sensor Adjust the front to back axis of the level sensor until the multimeter reads 2 43V DC Tap the top of the level sensor lightly with finge
148. e battery should read 9V DC or more when measured across the terminals Manifolds 2 hw 7 de AAA VEE dl 2 VN eu Je i ti Hei 4 pte tg Pu VV 1 multimeter 2 9v DC battery 3 100 resistor 4 coil 3 gt multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good amp Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Genie BRAND GS 84 GS 90 Part No 162336 133 Service Manual April 2015 Fuel and Hydraulic Tanks 8 1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard 4 Lower the platform onto the safety arm Turn the engine off AWARNING Crushing hazard Keep hands clear of the safety arm when
149. e lower speed of the machine Refer to Specifications Performance Specifications Genie BRAND GS 84 GS 90 99 Service Manual a Ground Controls How to Adjust the Platform Settling Speed 1 100 Pull out the red Emergency Stop button to the on position at the platform controls Push in the red Emergency Stop button to the off position at the ground controls Turn the key switch to ground control 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode Press the lift function enable button Use the yellow platform down arrow to scroll to settling speed Result MAX SETTLING SPEED is showing in the diagnostic display window 4 NL 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button Genie GS 84 GS 90 April 2015 Press the lift function enable button Press the yellow platform down button to decrease the platform settling speed or press the blue platform up button to increase the platform settling speed Component Damage Hazard The Platform Settling Speed is intended to slow the rate of platform descent just before the reaching the stowed position Adjust the Platform Settling
150. ealer service is recommended Note When removing a hose assembly or fitting 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 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 2 Start the engine and raise the 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 Genie BRAND GS 84 GS 90 135 Part No 162336 Service Manual April 2015 TERE EN ee ee ee Fuel and Hydraulic Tanks 4 Lower the platform onto the safety arm Turn 9 Remove the drain plug from the hydraulic tank AWARNING the engine off AWARNING Crushing hazard Keep hands and completely drain the tank into a suitable container Refer to Section 2 Specifications clear of the safety arm when AWARNING Bodily injury hazard Spraying lowering the platform hydraulic oil can penetrate and burn skin Loosen hydraulic Attach a lifting strap from an overhead crane connections very slowly to allow to the entry ladder on the hydraulic tank side the oil pressure to dissipate of the machin
151. eared by a person trained and qualified on the troubleshooting and repair of this machine Note Use the following illustration to identify the 7 description of each control button used in this procedure Ne 1 LCD screen 10 2 up button 3 function enable button 4 down button 1 Turn the key switch to the ground controls 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 Genie 152 GS 84 GS 90 Use the down button to scroll to select options Press the function enable button Result descent delay is showing in the LCD screen Use the down button to scroll to overload Press and hold the function enable button for 5 seconds Result A screen will appear asking for the overload recovery passcode Press the buttons in the following sequence down down up enable Result The LCD screen displays cleared and returns to the overload screen Use the down button to scroll to return to main menu Press the function enable button Result select options is showing in the LCD screen Push in the red Emergency stop button at the ground controls Part No 162336 April 2015 Service Manual Observe and Obey Troubles
152. eas for burnt chafed corroded pinched and loose wires e Scissor arms e ECM to platform controls e Power to platform wiring e Engine 10 Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 11 Raise the platform and return the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off B 3 Inspect the Engine Air Filter Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off Ford models 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Remove the retaining ring from the end cap of the air filter canister 4 Remove the end cap from the air cleaner canister 5 Remove the air filter retaining fastener Remove the air filter element 6 Clean the inside of the canister and the gasket with a damp cloth 7 I nspectthe air filter element If needed blow
153. eath or serious injury Note On machines with software revision B1 or lower raised 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 CO or higher the raised forward drive speed and the raised reverse drive speed may be adjusted independent of one another Refer to Repair Procedure How to Determine the Revision Level Note The GS 5390 will not drive with the platform raised above 33 feet 6 1 m 1 Pullout the red Emergency Stop button to the on position at the platform controls 2 Pushin the red Emergency Stop button to the off position at the ground controls 3 Turn the key switch to ground control 4 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode Genie 96 GS 84 GS 90 Part No 162336 April 2015 EE hi i er ee en Press the lift function enable button Use the yellow platform down arrow to scroll to max fwd high torque drive Result MAX FWD RAISED DRIVE speed is showing in the diagnostic display window Press the lift function enable button Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive spe
154. ectrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connect the negative battery cable to the battery 4 Startthe engine and allow it to idle for approximately ten minutes Result The check engine light should not turn on Result If the check engine light is on the ECM is detecting a fault code Refer to How to Retrieve Engine Fault Codes Genie 112 GS 84 GS 90 Part No 162336 April 2015 Service Manual Hydraulic Pump 6 1 3 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Lift SteerPump if equipped Move the fuel select toggle Note When removing a hose assembly or fitting switch at the ground controls to the LPG the O ring if equipped on the fitting and or hose end must be replaced All connections must be Deutz models Hold the manual fuel shutoff torqued to specification during installation Refer to lever clockwise in the closed position Specifications Hydraulic Hose and Fitting Torque Specifications How to Test the Lift Steer Pump 1 disconnect and plug the high pressure hydraulic hose from the lift steer pump AWARNING Bodily injury hazard Spraying EE hydraulic oil can penetrate and ia Per burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow o
155. ecuring the down limit switch cam just enough to allow movement of the cam 98 Service Manual Working from the outside of the machine rotate the down limit switch cam in a counter clockwise direction until the cam lobe is approximately 1 mm higher Tighten the fasteners Do not over tighten Note When adjusting the down limit switch cam do not move cam which activates the load sense delay limit switch 99 100 101 102 103 104 105 Genie BRAND GS 84 GS 90 Raise the platform to approximately 6 m Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Install the cover onto the platform overload pressure switch or switch box and securely tighten the cover retaining fasteners Do not over tighten Apply Sentry Seal to one of the cover retaining fasteners where it contacts the platform overload pressure switch box Return the safety arm to the stowed position Lower the platform to the stowed position Calibrate the system relief valve See 7 6 How to Adjust the System Relief Valve Service Manual April 2015 Platform Overload Components 12 2 3 Platform Overload Recovery Message E software version B3 and later If the ground controls LCD screen displays Ovrld 5 Recovery the emergency lowering system has been used while the platform was overloaded Note This message shall be cl
156. ed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 9 10 11 12 Part No 162336 Press the lift function enable button Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 1 diagnostic display 2 blue platform up button 3 lift function enable button 4 yellow platform down button Press the lift function enable button 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 Press the lift function enable button 13 Service Manual Ground Controls Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 14 15 16 Genie BRAND GS 84 GS 90 97 Press the lift function enable button Push in the red Emergency Stop button to the off position at the ground controls Check the raised drive speed of the machine Refer to the Maintenance procedure Test the Drive Speed Raised Position Service Manual April 2015 Ground Controls How to Adjust the Lift Speed 7 Press the lift function enable button Tip over hazard Do not ad
157. eed 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 running Note Turning the nut or adjustment screw out of 17 Slowly turn the nut or adjustment screw of the platform overload pressure switch one quarter turn into the hydraulic line 18 Push in the red Emergency Stop button to the off position at the ground controls 19 Pull out the red Emergency Stop button to the on position at the ground controls Wait 3 seconds and start the engine Result The alarm doesn t sound and the engine will start and run Proceed to step 20 Result The engine will not start and an alarm is sounding Repeat this procedure beginning with step 17 Note The red Emergency Stop button must be cycled after each quarter turn of the nut or adjustment screw to allow the platform overload system to reset Note Wait a minimum of 3 seconds between each quarter turn of the nut or adjustment screw to allow the platform overload system to reset 20 Return the safety arm to the stowed position Lower the platform to the stowed position Note After returning the safety arm to the stowed position use the auxiliary down function to lower the platform Set the maximum height limit switch 21 Using a suitable lifting device place a test weight in the center of the platform floor Secure the we
158. elder manifold option Relief valve 270 psi 18 6 bar Hydraulic motor welder option Displacement 1 28 cu in 21 cc Genie 6 GS 84 GS 90 Part No 162336 April 2015 Service Manual Ford MSG 425 EFI Engine Displacement 153 cu in 2 5 liters Number of cylinders 4 3 5 x 3 9 inches 89 x 100 mm Bore and Stroke Specifications Electronic fuel pump Fuel pressure static 60 psi 4 1 bar Fuel flow rate 0 43 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator Horsepower 60 2500 rpm Manual for your engine 45 kW 2500 rpm m E 7 EE lgnition system lend Spark plug type Motorcraft AYFS 32Y R Low function idle 1600 rpm computer controlled 53 3Hz Spark plug gap High function idle computer 2500 rpm controlled Angine aan Compression ratio 9 7 1 Capacity gt 1 Compression pressure approx Cylinder head temperature sending unit Pressure psi or bar of lowest cylinder must be at least 5 75 of highest cylinder Fault code set temperature 4 Lubrication system Engine shut down temperature 300 F Oil pressure operating 29 to 39 psi 149 C temperature 2500 rpm 2 to 2 7 bar Starter motor Oil capacity 6 7 quarts including filter 6 4 liters Normal engine cranking speed 200 to 250 rpm Current draw no load 140 200A Oil Pressure switch Oil pressure switch point 7 to 9 psi draw M
159. en CONTROLS Genie BRAND Part No 162336 GS 84 GS 90 191 Service Manual April 2015 Hydraulic Schematics Component Call out Legend Item Function Steer circuit Auxiliary pump circuit Steer circuit System relief Steer outrigger circuit Test port Steer left right All functions Platform up down Outrigger up down Outrigger extend circuit Outrigger retract circuit Platform down circuit Testing System relief Proportional differential sensing valve Steering and outrigger circuit Testing Wa Platform up down AH Steer left right Al Platform down circuit AJ Bleeds off proportional valve to tank AK Outrigger up down AL Generator on AM Generator relief AN Generator flow AO Accumulator AP Platform overload option 192 Item BA BB BC BD BE BF BG BH BJ BK BL BM BN BO BP BQ Genie GS 84 GS 90 Function High speed bypass High speed bypass Balances fluid flow from flow divider combiner BO to non steer end drive motors Balances fluid flow from flow divider combiner BP to steer end drive motors Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 motor shift Testing P1 pressure port Testing P2 pressure port Charge pressure circuit Brake release circuit 2 speed motor shift circuit Brake release circuit 2 s
160. er 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 overhead crane may be required for the pin to clear the link set CAUTION Crushing hazard The lift cylinder will fall unless it is properly supported 12 Carefully pull the lift cylinder out the non steer end of the machine through the scissor arms Remove the lift cylinder from the machine ACAUTION Crushing hazard The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly supported Gri 1 1 1 1 88 GS 84 GS 90 Part No 162336 April 2015 Service Manual 4 1 RPM Adjustment Refer to Maintenance Procedure Check and Adjust the Engine RPM 4 2 Engine Fault Codes Ford Models Refer to Repair Procedure Engine Fault Codes Ford Models BRAND Engines 4 3 Engine Repair Deutz repair procedures and additional engine information are available in the Deutz 2011 Operation Manual Deutz part number 0297 9929 OR the Deutz 2011 Workshop Manual Deutz part number 297 9959 Deutz 2011 Operation Manual Genie part number 84794 Deutz 2011 Workshop Manual Genie part number 112574 F
161. er valve EK Controls flow to non steer 30 ft lbs 41 Nm enddrive motors in forward and reverse 12 Flow divider combiner valve EL Controls flow to steer end drive 30 ft lbs 41 Nm motors in forward and reverse 13 Orifice Plug 0 090 inch 2 3 mm EM Balances flow from flow 25 ft lbs 34 Nm divider combiner item EA to front and rear drive motors 14 Diagnostic nipple EN Testing P1 pressure port Genie 122 GS 84 GS 90 Part No 162336 April 2015 Service Manual Manifolds Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 162336 GS 84 GS 90 123 Service Manual April 2015 Manifolds 7 4 Oscillate Manifold Components GS 90 option The oscillate manifold is located under the function manifold Index Schematic No Description Function Torque 1 Solenoid valve 2 position 2 way DA Oscillate activation 25 ft lbs 34 Nm 2 Relief valve 3500 psi 241 3 bar DB System relief 20 ft lbs 27 Nm 3 Relief valve 900 psi 62 bar DC Float circuit relief 20 ft lbs 27 Nm 4 Priority flow regulator 1 gpm 3 8 L min DD Oscillate circuit 25 ft lbs 34 Nm 5 Solenoid valve 2 position 3 way DE Right oscillate circuit 20 ft lbs 27 Nm 6 Solenoid valve 2 position 3 way DF Left oscillate circuit 20 ft lbs
162. eration Manual Deutz part number 0312 3547 Deutz 2011 Series Operation Manual Genie part number 139320 Install the entry ladder and install the entry ladder mounting fasteners Genie GS 84 GS 90 Part No 162336 April 2015 Service Manual Checklist E Procedures E 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 3000 hours e Replace toothed belt e Replace injection valve e Air cooler Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 Deutz 2011 Series Operation Manual Genie part number 139320 Genie BRAND Part No 162336 GS 84 GS 90 55 Service Manual April 2015 Repair Procedures Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start NAN 56 Read understand and obey the safety rules and operating instructions in the 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
163. ere component damage Dealer service is recommended Note When removing a hose assembly or fitting 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 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 Hydraulic Pump 3 disconnect and plug the hydraulic hoses from the drive pump Cap the fittings on the pump AWARNING 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 4 Support the drive pump with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard The pump s may become unbalanced and fall if not properly supported Component damage hazard When installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after i
164. es first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Remove the retaining ring from the end cap of the air filter canister 4 Remove the end cap from the air cleaner canister 5 Remove the air filter retaining fastener Remove the air filter element 6 Clean the inside of the canister and the gasket with a damp cloth Install the new filter element 8 Install the air filter canister end cap and the end cap retaining ring B 17 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 400 hours e Engine oil e Oil filter e Spark plugs Required maintenance procedures and additional engine information are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Genie 38 GS 84 GS 90 Part No 162336 April 2015 Service Manual C 1 Test the Platform Ove
165. essthe lift function enable button to activate the model power option Result SELECT MODEL is showing in the diagnostic display window 8 Use the yellow platform down arrow to scroll to select options Result SELECT OPTIONS is showing in the diagnostic display window The ECM is now in programming mode 9 Press the lift function enable button Result DESCENT DELAY ON is showing in the diagnostic display window Result DESCENT DELAY OFF is showing in the diagnostic display window Press the lift function enable button to activate the descent delay option Note For CE models the descent delay option should be activated or in the on position Genie _ amp h 9 3 GS 84 GS 90 Part No 162336 April 2015 Service Manual 10 Use the yellow platform down arrow to scroll to motion alarm Result MOTION ALARM is showing in the diagnostic display window 11 Press the lift function enable button to activate or deactivate the motion alarm option OR use the yellow platform down arrow to scroll to motion beacon Result MOTION BEACON is showing in the diagnostic display window 12 Press the lift function enable button to activate or deactivate the motion beacon option Note For this option to function correctly the machine must be equipped with flashing beacons 13 Use the yellow platform down arrow to scroll to overload Result OVERLOAD ON is showing in the diagnostic
166. essure gauge Result The hydraulic pressure should not 3 Connect a 0 to 5000 psi 0 to 350 bar exceed 3500 psi 241 bar pressure gauge to the test port on the function manifold Result The platform should lift and fully raise P d to step 13 4 Remove the platform controls from the platform Result The platform does not fully raise OR i t ily P d to step 10 Note Perform this test from the ground with the EL platform controls Do not stand the platform Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating 10 Turn the machine off Hold the system relief valve with a wrench and remove the cap Genie BRAND Part No 162336 GS 84 GS 90 127 Service Manual ge ee Manifolds 11 12 13 14 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Repeat this procedure beginning with step 7 Fully lower the platform Using a suitable lifting device add an additional weight to the platform not to exceed 20 of the maximum rated work load at full height Secure the weight to the platform Refer to the specifications below Additional test weight GS 3384 and GS 3390 500 Ibs 227 kg GS 4390 375 Ibs most models refer to capacity indicator 170 kg decal GS 4390 450 Ibs some models refer to capacity indicator 204
167. ety Rules is dea des V Section 2 jies Uie Aaii 1 Machine SpecificatiOnS ie se ee ER 1 Performance 2 Hydraulic Specification is ede Ee Se n eu Ld Reha da doas 3 Hydraulic Component see ee ee RR Re Ee ee ee ee ee Re ee ee 5 Manifold Component Specifications 6 Ford MSG 425 EFI Engine Specifications 7 Deutz 02011 1031 Engine 8 Hydraulic Hose and Fitting Torque Specifications 9 Torque Procedure 10 SAE and Metric Fasteners Torque 12 Genie BRAND Part No 162336 GS 84 GS 90 vii April 2015 O_o Table of Contents 21 13 Pre Delivery Preparation 16 Maintenance Inspection 17 Checklist A ProcedureS esse esse es see see EE EE EE ERA Ee Ee EE Ee EE Ee EE Ee AE Ee AE Ee KERE Ke ee nnn 19 A 1 Inspect the Manuals and 19 2 Perform Pre operation Inspection 20 A 3 Perform Function Tests dtl eiie Ge AE Rr ve pe s EE 20 A 4 Perform Engine Mainte
168. ey switch and tag the machine to inform personnel of the condition 10 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Specifications Machine Specifications 12 13 14 15 16 AWARNING 17 18 19 Service Manual Checklist E Procedures Tag disconnect and plug the tank return hose at the tank Tag disconnect and plug the T fitting located at the tank with the 2 hoses connected to it Remove the hydraulic tank strap retaining fasteners and remove the hydraulic tank strap from the machine Support and secure the hydraulic tank to a suitable lifting device Remove the hydraulic tank from the machine Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine If equipped remove the suction strainers from the tank and clean them using a mild solvent Rinse out the inside of the tank using a mild solvent If equipped install the suction strainers using Loctite 567 on the pipe threads Note Always use Loctite 567 on all pipe threads 20 Install the drain plug using Loctite 567 on AWARNING Bodily injury hazard Spraying the pipe threads hydraulic oil penetrate and Note Always use Loctite 567 on all pipe threads burn skin Loosen hydraulic connections very slowly to allow 21 Install the hydraulic tank onto the machine the oil pressure to dissip
169. fer to Illustration 2 Note Use the JIC 37 Fitting table in this section to determine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie BRAND Part No 162336 GS 84 GS 90 11 Service Manual April 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grades C Grade 8 62 LUBED LUBED LUBED indbs Nm in bs Nm in ibs Nm intbs Nm inibs Nm 44 20 80 9 100 113 110 124 140 158 7130 147 28 90 101 120 135 120 135 160 18 140 158 AMT ft lbs Nm ftibs Nm fttbs Nm Nm fibs Nm sig 8 13 176 17 23 18 24 25 339 21 284 24 14 19 19 257 20 271 27 366 24 325 16 23 312 31 42 33 447 44 596 38 515 24 26 352 35 474 3
170. fety arm is locked in the vertical position 3 Lowerthe platform onto the safety arm Turn the machine off A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Component damage hazard 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 Support the platform using a 5 ton 5000 kg overhead crane Do not apply lifting pressure at this time 5 Tag disconnect and plug the hydraulic hoses from the lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Gon BRAND Scissor Components 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 Attach a lifting strap from an overhead crane or similar lifting device to the lifting eye at the rod end of the lift cylinder for support 1 end 2 lifting eye 3 barrel end Attach a lifting strap from a second overhead crane or similar lifting device to the lifting eye at the barrel end of the li
171. flow regulator Gri 1 1 1 GS 84 GS 90 194 Part No 162336 April 2015 Service Manual Hydraulic Schematic Part 1 of 2 n RIGHT V RIGHT FRONT OL REAR 4 4 2 BRK MIA MIB EE lt lt EK IT MEE ee ER ML t 1 NES EJ 2 VAR EM 20m 3 mm N 25 oom ES Vo E T Jie ed ELE Ee BE B m 1 1 e x BE 0 043 0046 E me AC H Timm C 1 2mm L3 280 AT poe M o SUUM DRIVE Toi bar E E MANIFOLD a i Mes E L N AT LEFT LEFT J FRONT J REAR vni 15 1 P2 som 11 i PMP B CLR PMPA Le __4 3750 psi ee TT La fi lt TROADA mooo Iu Mx ME 1 A 10 6 gpm 9 1 010325
172. ft The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 20 GS 84 GS 90 Part No 162336 April 2015 Service Manual A 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first All Engine Models Check oil level e Check radiator level e Oil fuel or coolant leaks e Loose or missing fasteners Diesel Models Air filter e Fuel Filter Water Separator Required maintenance procedures and additional engine informatio
173. ft cylinder will fall if not properly supported when the pivot pin is removed Tag disconnect and plug the hydraulic hoses from the lift 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 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 Remove the cables from the number 2 inner arm index 6 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm index 2 Service Manual is Scissor Components 10 11 12 13 14 15 16 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard Cables can be damaged if they are kinked or pinched Secure both ends of the number 3 inner and outer arms index 2 and 11 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 2 and 11 at the steer end of the machine Do not apply any lifting pressure Attach a lifting strap from an overhead c
174. ft cylinder for support Remove the lift cylinder rod end pivot pin retaining fastener Use a soft metal drift to remove the pin CAUTION 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 Part No 162336 GS 84 GS 90 85 Service Manual April 2015 Scissor Components 11 Remove the lift cylinder barrel end pivot pin retaining fastener Use a soft metal drift to remove the pin Note Use of the overhead crane may be required for the pin to clear the link set ACAUTION Crushing hazard The lift cylinder will fall unless it is properly supported 12 Carefully pull the lift cylinder out the non steer end of the machine through the scissor arms and safety arm Remove the lift cylinder from the machine ACAUTION Crushing hazard The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly supported How to Remove the Lift Cylinder GS 5390 AWARNING Bodily injury hazard The counterbalance valve in the lift cylinder is factory set Do not attempt to adjust the counterbalance valve Attempting to adjust the counterbalance valve could result in death or serious injur
175. ft to drive FC Pilot valve to diverter FD Charge pressure circuit FE Prevents oil to generator Genie BRAND Part No 162336 GS 84 GS 90 193 Service Manual Hydraulic Symbols Legend April 2015 0 037 0 94 mm 4 Orifice with size Check valve Cylinder double acting 5 Accumulator Pump fixed displacement Om Pump prime mover engine or motor N C CN Pressure switch Needle valve LLLA S Solenoid operated 3 position 4 way directional valve Filter with bypass relief Solenoid operated 3 position 5 way directional valve 1 ee is Relief valve with pressure Solenoid operated 2 position 3 way directional valve Solenoid operated Solenoid operated 2 position 2 way directional valve Pilot operated flow regulator valve Dual piloted relief valve valve setting proportional valve L 4 8000 psi 4 dad 1811 ps 2 e OM di V Il LI E Counterbalance valve with pressure and pilot ratio Priority
176. ghest point Continue to turn the adjustment screw in a counter clockwise direction until the reading 1 pump neutral adjustment screw on the pressure gauge drops to its lowest 2 EDC point Note the position of the screw 3 large filter port 4 smaller filter port Genie BRAND Part No 162336 GS 84 GS 90 117 Service Manual April 2015 Manifolds 7 1 Function Manifold Components Models with Outriggers The function manifold is located in the chassis tray on the ground controls side of the machine Index Schematic No Description Function Torque 1 Check valve 5 psi 0 3 bar AA Platform down circuit 20 ft lbs 27 Nm 2 Diagnostic nipple AB Testing 3 Relief valve 3500 psi 241 3 bar AC System relief 20 ft lbs 27 Nm 4 Proportional solenoid valve AD All functions 35 ft lbs 47 Nm 5 Relief valve 2000 psi 138 bar AE Steering and outrigger circuit 25 ft lbs 34 Nm 6 Diagnostic nipple AF Testing 7 DOS valve 3 position 4 way AG Platform up down 30 35 in Ibs 3 4 Nm 8 Solenoid valve 3 position 4 way AH Steer left right 25 ft lbs 34 Nm 9 Orifice Plug 0 150 inch 3 8 mm Al Platform down circuit 10 Flow regulator 0 1 0 38 L min AJ Bleeds off proportionalvalve to 20 ft lbs 27 Nm tank 11 DO3 valve 3 position 4 way AK Outrigger up down 30 35 3 4 Nm Genie 118 GS 84 GS 90 Part No 162336 April 2015 Service Manual Manifolds
177. gpm 1 ril FO 40 1 L min 34 4 L min 0 to 123 L min 1 3750 psi WELDER T y108 258 6 bar die MANIFOLD 2 020 nen OPTION cuo Ne mm 4 wit di ta Lad 224 bar DRIVE PUMP 270 psi 3 5 gpm FA L L 18 6 bar 13 2 L min gt MES En ee G2 1 Gi WELDER OPTION NOT AVAILABLE 1 ON MACHINES EQUIPPED Tms TT MIRA WITH GENERATOR OPTION mU el 2291 HYDRAULIC me po 1 WELDER OPTION 25 psi 4 137 bar OL gt COOLER t OPTION gt JS Fe N AD 4 gt gt Note alpha callouts refer to components shown In the manifold Illustrations Refer to the Repair Section HYDRAULIC TANK HS7043F Genie BRAND Part No 162336 GS 84 GS 90 195 Service Manual April 2015 Hydraulic Schematic Part 2 of 2
178. guides Lower the railing guides capable of supporting it in the down direction 3 Remove the mounting fasteners from the A WARNING rushing idee The latf tension dack ston brackets at both extension will become a ue s pun unbalanced and fall when RE removed from the machine if Note The platform extension deck stop brackets not properly supported and are located above the platform V roller wheels secured to the forklift 4 platform extension deck to be removed position a fork lift with the forks even with the bottom of the platform extension deck 5 Liftthe platform extension deck lock handle Genie 0 1 Part No 162336 GS 84 GS 90 61 Service Manual April 2015 Scissor Components 99090 9 OE Non steer End 1 Platform centering link 2 Number 3 inner arm 3 4 5 6 7 8 9 1 62 Number 3 center pivot pins Number 3 pivot pins non steer end Number 2 outer arm Number 2 inner arm Number 2 pivot pins non steer end Number 1 inner arm Lift cylinder barrel end pivot pin 0 Number 1 pivot pins non steer end Genie GS 84 05 90 9060 RA Steer End 11 Number 3 outer arm 12 Lift cylinder rod end pivot pin 13 Number 3 pivot pins steer end 14 Number 2 center pivot pins 15 Number 2 pivot pins steer end 16 Number 1 outer arm 17 Number 1 center pivot pins 18 Chassis centering link 19 Number 1 pivot pi
179. he hub until the plugs are located one on top and the other at 90 degrees 1 drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 Ifnecessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Install the plug s into the drive hub 5 Check the torque of the drive hub mounting bolts Refer to Specifications Machine Specifications 6 Repeatthis procedure for each drive hub Genie 32 GS 84 GS 90 Part No 162336 April 2015 Service Manual B 9 Test the Fuel Select Operation Ford Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Start the engine from the platform controls and allow the engine to run at low idle 2 Press high idle button at the platform contro
180. he lower lift cylinder onto the engine cover Remove the cables and hydraulic hoses from the number 3 inner arm index 8 and lay the cables and hoses off to the side Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm index 8 on the hydraulic tank side of the machine Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard Cables can be damaged if they are kinked or pinched Remove the pin retaining fasteners from the hose tray pivot pin at the number 3 inner arm index 11 on the ground controls side of the machine Place a rod through the hose tray pivot pin and twist to remove the pin Lower the hose tray down Component damage hazard Hoses can be damaged if they are kinked or pinched 78 36 37 38 39 40 41 42 43 AWARNING April 2015 Secure both ends of the number 3 inner and outer arms index 8 and 23 together with a strap or other suitable device 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 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 lif
181. he pressure Install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified 6 Repeatsteps 2 through 3 to confirm the relief valve pressure Genie GS 84 GS 90 Part No 162336 April 2015 Service Manual EE EE RAAI Manifolds 7 7 Valve Adjustments Drive Manifold How to Adjust the Charge Pressure Relief Valve Note Refer to Drive Manifold Component list to locate the charge pressure relief valve 1 Connect 0 to 600 psi 0 to 50 bar pressure gauge to test port 2 on the drive manifold 2 the engine from the platform controls 3 Drive the machine 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 the engine off Use a wrench to hold the charge pressure relief valve and remove the cap item EE 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap 7 Repeat steps 2 through to confirm the relief valve pressure Genie BRAND Part No 162336 GS 84 GS 90 129 Service Manual April 2015 TT
182. hooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine e Platform in the stowed position Fault Codes Before Troubleshooting Read understand and 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 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 A DANGER Crushing hazard When testing WARNING AWARNING replacing any hydraulic component always support the structure and secure it from movement Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and
183. ie ir ae BK a i c c c c s FREES 9 S x DE itn I noz BN23 BN9 ELECTRONIC CONTROL MODULE x Ci AUXILIARY DOWN E AUXILIARY DOWN ENABLE 2 89 1 lt lt 8 is ABS 7 7 gt 7 1 812 3 i e as Ig S 8 E 88 8 EE EE 66 30 pommes Lp CR82 Od fea e enaBLe 44 6247 Do 2321825 1 GS 5390 ONL te MAX LOAD 1 2 HEIGHT SENSE Y9 8 ED LIMIT 1184 304 DELAY 4 Y1 m SWITCH 1 4 LIMIT n 1 1 ENABLE 8 el OT lad gt 2 SWITCH ELLY y Hy LA j TA TA TA Y Al GEM 816 ye gt om Y7 i 4 dX BY MIE EPA ERX Y8 C5 SWI1 v2 SW 4700 UF i i i i i i i i i i amp i 2 d 5 86 amp 8 R 2 4 m 7 E ROB m m 3 lt 05 o m m p a 22 9 204 2 B f o2 9 6 m d m zz mm SE z m m EI z 8 4 9 So 6 z E e 3 ME 2 b m ms 2 o m qv 2 9 m m J o 5 o m o m 9 2 j E gt 5 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174H Genie B
184. ifting pressure 7 Remove the pin retaining fasteners from both number 5 pivot pins index 4 at the non steer end of the machine Do not remove the pins 8 Remove the pin retaining fasteners from both number 5 pivot pins index 19 at the steer end of the machine Do not remove the pins 9 Use slide hammer to remove both number 5 pivot pins index 4 from the non steer end of the machine 10 Use a slide hammer to remove both number 5 pivot pins index 19 from the steer end of the machine 11 Carefully remove the number 5 inner and outer arms index 2 and 18 from the machine A WARNING Crushing hazard The number 5 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 12 Remove the pin retaining fasteners from the upper lift cylinder rod end pivot pin index 21 Do not remove the pin 13 Attach a lifting strap from an overhead crane to the lifting eye at the rod end of the upper lift cylinder Genie 76 GS 84 GS 90 Part No 162336 April 2015 VAR Ee ee MH P g 2 14 Use a soft metal drift to remove the upper lift cylinder rod end pivot pin index 21 Lower the rod end of the upper lift cylinder down AWARNING Crushing hazard The upper lift
185. ight to the platform Refer to the chart below GS 3384 and GS 3390 1135 kg GS 4390 most models refer to capacity 680 kg indicator decal GS 4390 some models refer to capacity 816 kg indicator decal 22 Raise the platform to approximately 6 m the hydraulic line will activate the alarm turning the nut or adjustment screw into the hydraulic line will deactivate the alarm Genie BRAND Part No 162336 GS 84 GS 90 145 Service Manual April 2015 C H Un Platform Overload Components 23 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 24 Remove the maximum height limit switch 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 Repeat this procedure beginning with step 7 Tu f 7 7 Limit switch legend 1 load sense delay limit switch 2 down limit switch 3 maximum height limit switch 4 maximum height limit switch cam 27 Install and adjust the maximum height limit Swi
186. iguration performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving Be sure that all fasteners are tight 4 Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect to be sure it is in the engaged position the I 1 brake disengaged position 2 brake engaged position Genie B
187. il to squirt or spray Deutz models 1 manual fuel shutoff lever 2 Connect a 0 to 5000 psi to 350 bar pressure gauge to the high pressure port on 4 the key switch to ground controls and the lift steer pump pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 5 Observe the pressure gauge while cranking the engine Immediately stop if the pressure reaches or exceeds 3500 psi 241 bar Result If the pressure gauge reads 3500 psi 241 bar immediately stop The pump is good R Result If the pressure fails to reach 3500 psi 241 bar the pump or pump coupling is bad pump and will need to be serviced or replaced 2 lif steer pump 6 Remove the pressure gauge and connect the hydraulic hose Genie BRAND Part No 162336 GS 84 GS 90 113 Service Manual April 2015 Hydraulic Pump How to Remove the Lift Steer Pump 1 Locate the three hydraulic tank valves at the hydraulic tank Close the valves open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If 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
188. ine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N 7 no remove from service R 7 repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company April 2015 Service Manual EE EE Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions e Make copies of this report to use for each inspection e Select the appropriate checklist s for the type of inspection s to perform Daily or every 8 hours A Quarterly or every A B 250 hours Semi annually or every 500 hours Annually or 0 1000 hours 0 2000 h
189. ing the area or component affected Genie 154 GS 84 GS 90 Part No 162336 April 2015 Control System Fault Codes Service Manual ID System Ready LED Condition Result Solution 1 INTERNAL ECU Red Internal ECM error System shutdown Replace ECM FAULT 2 PLATFORM ECU Red Platform ECM System shutdown Troubleshoot control cable OR FAULT communication error troubleshoot platform controls 20 CHASSIS START Red Engine start button fault at Engine will not Replace ECM SW FAULT ground controls start 21 CHASSIS Red Starting aid button fault at Starting aid Replace ECM CHOKE SW ground controls disabled FAULT 22 CHASSIS UP SW Red Up switch fault at ground Platform up Replace ECM FAULT controls function inoperable 23 CHASSIS LIFT Red Platform up down enable Platform up down Replace ECM SW FAULT button fault at ground functions disabled controls 24 DOWN SW Red Down switch fault at ground Platform down Replace ECM FAULT controls function disabled 25 LEFT TURN SW Red Left turn switch fault Malfunctioning Troubleshoot steer left FAULT steer left microswitch microswitch 26 RIGHT TURN SW Right turn switch fault Malfunctioning Troubleshoot steer right FAULT steer right microswitch microswitch 27 DRIVE ENABLE Red Function enable switch on Machine functions Release function enable switch SW FLT joystick is activated when disabled on joystick before power up
190. ions 1 the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 2 Startthe engine Raise the platform approximately 18 feet 5 5 m from the ground 4 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 5 Lower the platform onto the safety arm and turn the engine off A WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Attach a lifting strap from an overhead crane to the entry ladder on the hydraulic tank side of the machine 7 gt Remove the entry ladder mounting fasteners and remove the entry ladder from the machine AWARNING Cushing hazard The entry ladder could become unbalanced and fall when removed from the machine if not properly supported 8 Remove the retaining fasteners from the access plate located behind the hydraulic and fuel tank tray and remove the access plate from the machine Genie 52 GS 84 GS 90 Part No 162336 April 2015 Close the two hydraulic shutoff valves located at the hydraulic tank open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the k
191. ir the leak immediately 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 500 hours e Engine oil e Oil filter e Valve clearance Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 Deutz 2011 Series Operation Manual Genie part number 139320 Genie 42 GS 84 GS 90 Part No 162336 April 2015 Service Manual C 6 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install new cap onto the tank Checklist C Procedures C 7 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours e PCV valve e PCV hoses tubes and fittings Required maintenance procedures and additional engine information are available in the Ford MS
192. iring from the oil temperature switch to ECM OR replace the oil temperature switch Genie Part No 162336 GS 84 GS 90 157 Service Manual ie Control System Fault Codes April 2015 ID System Ready LED Condition Result Solution 68 LOW ECU Red Low ECM voltage System shutdown Charge battery VOLTAGE 69 LOW ENGINE Red Low RPM Engine idle RPM Consult Genie Product Support RPM too low 70 HIGH ENGINE Red High RPM Engine RPM too Consult Genie Product Support RPM high 80 LEFT FRONT Red Left front outrigger coil Y35 Left front outrigger Troubleshoot coil OR wiring OTRG COIL FLT fault disabled 81 LEFT REAR Red Left rear outrigger coil Y33 Left rear outrigger Troubleshoot coil OR wiring OTRG COIL FLT fault disabled 82 RIGHT FRONT Red Right front outrigger coil Right front Troubleshoot coil OR wiring OTRG COIL FLT Y36 fault outrigger disabled 83 RIGHT REAR Red Right rear outrigger coil Right rear outrigger Troubleshoot coil OR wiring OTRG COIL FLT Y34 fault disabled 84 OUTRIGGER Red Outrigger extend coil Y40 Outrigger extend Troubleshoot coil OR wiring EXT COIL FLT fault function disabled 85 OUTRIGGER Red Outrigger retract coil Y39 Outrigger retract Troubleshoot coil OR wiring RET COIL FLT fault function disabled 86 OUTRIGGER Red Outrigger slowdown coil Outrigger slow Troubleshoot coil OR wiring SLOW COIL FLT Y44 fault extend function disabled 90 2 S
193. ivery pressure higher than 627 Fpump relay coil open expected 628 FPump motor loop open or high side shorted 1172 Megajector delivery pressure lower than to ground expected 628 Fpump relay control ground short For further engine fault code troubleshooting and apa Pump moter high side shorfed to paar EE information refer to the Ford MSG 425 iagnostic Manual EDI part number 629 Fpump relay coil short to power 1080030 160 Ford MSG 425 EFI Diagnostic Manual Genie part number 162067 Genie GS 84 GS 90 Part No 162336 April 2015 a ss 1 Ford MSG 425 Engine Fault Codes Service Manual Code Description Code Description 1173 Megajector comm lost 1551 AUX DIG1 high 1174 Megajector voltage supply high 1552 AUX DIG1 low 1175 Megajector voltage supply low 1553 AUX 2 high 1176 Megajector internal actuator fault detection 1554 AUX DIG2 low 1177 Megajector internal circuitry fault detection 1555 AUX DIG3 high 1178 Megajector internal comm fault detection 1556 AUX DIG3 low 1311 Misfire detected 1561 AUX analog PD2 high 1312 Misfire detected 1562 AUX analog PD2 low 1313 Misfire detected 1563 AUX analog PD3 high 1314 Misfire detected 1564 AUX analog PD3 low 1315 Misfire detected 1611 5VE 1 2 simultaneous out of range 1316 Misfire detected 1612
194. just A DANGER the lift and or drive speed higher than specified in this procedure Setting drive speed greater than specifications could cause the machine to tip p over resulting in death or serious injury 1 diagnostic display 1 Pull out the red Emergency Stop button to the 2 blue platform up button on position at the platform controls 3 lift function enable button 2 Pushin the red Emergency Stop button to the off position at the ground controls 8 Press the yellow platform down button to decrease the maximum lift speed or press the Turn the key switch to ground control blue platform up button to increase the 4 Press and hold both the blue platform up and maximum lift speed Refer to Specifications yellow platform down buttons Pull out the red Performance Specifications Emergency Stop button to the on position at Note The performance achieved should always be the ground controls within specifications Result TUNE SPEEDS is showing in the lift functi tt diagnostic display window The ECM is now in eno programming mode 10 Push in the red Emergency Stop button to the Press the lift function enable button 11 Check the lift speed of the machine Refer to G Use yellow platform down arrow is serol Specifications Performance Specifications to lift speed Result MAX LIFT SPEED is showing in the diagnostic display window
195. kup manual lowering and manual lowering enable switches will lower the platform when the red Emergency Stop buttons are pulled out to the on position at both the ground and platform controls The auxiliary down switches buttons are located at the ground control panel There is no adjustment required One 12V DC battery is used to start the engine power the auxiliary pump and the ECM The battery is located behind the ground control door assembly Ground Controls 5 2 Controller 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 e Stowed drive speed e High torque drive speed e Raised drive speed e Platform lift speed e Platform lower speed e Steer speed e Platform settling speed For further information or assistance consult the Genie Product Support 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 ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills could result in death or serious injury Note Select a test area that is firm level and free of obst
196. l 11 1 Outrigger Cylinder How to Remove an Outrigger Cylinder if equipped Note When removing a hose assembly or fitting 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 Note Perform this procedure with the platform in the stowed position and the outriggers fully retracted 1 Remove the outrigger footpad 2 Remove the mounting fasteners from the outrigger cover Remove the cover 3 and disconnect the wiring from the outrigger cylinder solenoid valve 4 disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder WARNING 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 strap from an overhead crane to the barrel end of the outrigger cylinder for support Do not apply any lifting pressure Outrigger Components 6 Remove the outrigger cylinder mounting fasteners Remove the outrigger cylinder from the machine CAUTION Crushing hazard The outrigger cylinder may become unbalanced and fall if not properly supported when it is removed from the machine Note If the outrigger cylinder is being replaced remove
197. latform Controls 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 Tagand disconnect the wire connectors from the red Emergency Stop button 6 Tagand disconnect the wire harness connectors from the platform controls circuit board AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Note Depress the locking tab to disconnect the wire harness from the circuit board 7 Carefully remove the platform controls circuit board fasteners 8 Carefully remove the platform controls circuit board from the platform control box Genie 58 GS 84 GS 90 Part No 162336 April 2015 ee 2 1 4 Platform How to Remove the Platform AWARNING Bodily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitab
198. le workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer 7 service is required Note Perform this procedure with the platform in B the stowed position and the platform extension deck s fully retracted and locked in position 9 1 Start the engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 10 2 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 11 Note Be sure that the safety arm is locked in the vertical position 12 3 Lowerthe platform onto the safety arm Turn the machine off 13 WARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Component damage hazard The link set cross tube can be damaged if excessive force is 14 applied Do not continue to lower the platform after the safety arm makes contact with the cross tube Genie Part No 162336 BRAND Service Manual Platform Components 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 Cut the zip ties that secure the platform controls wiring to the bottom of the platform Component damage hazard Be sure not to cut the power to platform wiring Start the engine from the ground controls
199. level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Platform in the stowed position Service Manual April 2015 ee ee Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Gri 1 1 1 14 GS 84 GS 90 Part No 162336 April 2015 Service Manual
200. lowing areas for burnt chafed corroded and loose wires e Ground control panel e Hydraulic power unit module tray e Battery pack module tray e Scissor arms e Platform controls 3 Inspectfor a liberal coating of dielectric grease in the following locations e Between the ECM and platform controls e Engine ECM Ford models e All wire harness connectors e Level sensor 4 the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Genie BRAND GS 84 GS 90 27 Service Manual April 2015 Checklist B Procedures 5 Start the engine from the ground controls raise the platform approximately 18 feet 5 5 m from the ground 6 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 7 Lower the platform onto the safety arm Stop the engine AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Component damage hazard The machine may be damaged if the platform is lowered after the safety arm contacts the link set cross tube Do not continue to lower the platform after the safety arm contacts the link set cross tube 8 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 9 Inspect the following ar
201. ls to allow the engine to run at high idle Result The high idle indicator light should be on and the engine should start promptly and operate smoothly in low and high idle 3 Press high idle button again to return the engine to low idle Result The high idle indicator light should turn off and the engine should return to low idle Checklist B Procedures Press the engine stop button Result The engine should stop Press the LPG operation button Result The LPG indicator light should be on Start the engine and allow it to run at low idle Press high idle button to allow the engine to run at high idle Result The high idle indicator light should be on and the engine should start promptly and operate smoothly in low and high idle Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Genie Part No 162336 GS 84 GS 90 33 Service Manual April 2015 Checklist B Procedures B 10 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation and unusual noise Electrically released individual wheel brakes can appear to operate normally when not fully operational Note Select a test
202. ltage 273 ar Loop Open or Low side short to roun 127 IAT higher than expected 2 274 Injector Coil Shorted 129 BP low pressure 276 Injector Loop Open or Low side short to 134 EGO open lazy pre cat 1 Ground 140 EGO open lazy post cat 1 277 Injector Coil Shorted 154 EGO pre cat 2 post cat 1 279 Injector Loop Open or Low side short to 160 EGO open lazy post cat 2 Ground 171 AL high gasoline bank1 280 Injector Coil Shorted 172 AL low gasoline bank1 282 Injector Loop Open or Low side short to 174 AL high gasoline bank 175 AL low gasoline bank2 283 Coil Shorted 182 Gasoline Low Voltage 285 Injector Loop Open or Low side short to Ground 183 FT Gasoline High Voltage 286 Injector Coil Shorted 187 FT Gaseaous fuel low voltage 288 Injector Loop Open or Low side short to 188 FT Gaseaous fuel high voltage Ground 217 ECT higher than expected 2 289 Injector Coil Shorted 219 Max govern speed override For further engine fault code troubleshooting and 221 TPS1 higher than TPS2 diagnostic information refer to the Ford MSG 425 Diagnostic Manual part number 222 TPS2 low voltage 1080030 223 TPS2 high voltage 236 TIP Active Ford MSG 425 EFI Diagnostic Manual Genie part number 162067 Genie Part No 162336 65 84 GS 90 159 Service Manual ie Ford MSG 425 Engine Fault Codes April 2015
203. m Genie 138 GS 84 GS 90 Part No 162336 April 2015 Service Manual Steer Axle Components 9 2 9 3 Steer Cylinder Oscillating Axle Option How to Remove the Steer Cylinder Note When removing a hose assembly or fitting 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 disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING 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 2 Remove the pin retaining fasteners from the barrel end pivot pin Place a rod through the pin and twist to remove the pin Note Note the location and the amount of the spacers at the barrel end of the steer cylinder 3 Remove the pin retaining fasteners from the rod end pivot pin Place a rod through the pin and twist to remove the 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 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 m
204. m level surface and the platform in the stowed position Use a digital level to confirm 1 Remove the platform controls from the platform If you are not installing a new level sensor proceed to step 9 2 Pushin the red Emergency Stop button to the off position at the platform controls 8 3 Remove the ground control panel retaining 9 fasteners and open the panel 4 Locate the level sensor behind the ground control panel Genie 106 A DANGER GS 84 GS 90 Tag and disconnect the wire harness from the level sensor Remove the level sensor retaining fasteners Remove the level sensor from the machine Install the new level sensor onto the machine with the Y on the level sensor base closest to the steer end of the machine Install and tighten the level sensor retaining fasteners Tip over hazard The tilt level sensor must be installed with the Y on the level sensor base closest to the steer end of the machine Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury O LLLL Level sensor models without outriggers 1 chassis 2 level sensor 3 X indicator 4 Y indicator Connect the wire harness to the level sensor Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and pla
205. m every 800 hours C 7 Engine maintenance Ford models Checklist D 0 1 Scissor arm wear pads D 2 Free wheel configuration D 3 Drive hub oil D 4 Hydraulic filters 0 5 Oscillate axle D 6 Engine maintenance Deutz models Genie BRAND GS 84 GS 90 Comments Part No 162336 April 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sur
206. m railings disconnected from the platform before removal 21 Remove the pin retaining fasteners from each latform slider block pivot pin Do not remove 16 Remove the pin retaining fasteners from the iis pins F D platform centering links located under the platform on both sides of the machine Do not 22 Use slide hammer to remove each platform remove the pins slider block pivot pin 17 Place arod through the platform centering link AWARNING Crushing hazard The platform pin and twist to remove the pin Rest the will fall when the platform slider platform centering link on the scissor arm block pivot pins are removed if not properly supported by the overhead cranes 23 Secure the platform slider blocks to the platform to prevent them from sliding out of the channel when the platform is removed from the machine 24 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Crushing hazard The platform A DANGER will become unbalanced and fall 18 Repeat step 17 for the platform centering link when it is removed from the pivot pin on the other side of the machine machine if not properly 19 Place a lifting strap from an overhead crane supported by the overhead under the platform at the steer end of the machine for support Do not apply any lifting cranes Bodily injury hazard The AWARNING platform slider blocks could fall Component damage hazard out from under the platform if
207. mately 16 feet 5 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning with step 9 Note For reference only the output of the level sensor should be approximately 1 5V DC To confirm connect the positive lead of a multimeter to the blue wire at the level sensor and the negative lead to the black wire 49 Lower the platform to the stowed position 50 Raise the machine slightly 51 Remove the blocks from under both wheels 52 Lower the machine and remove the jack 53 Center a lifting jack under the drive chassis at the non steer end of the machine 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 Ground Controls 5 Raise the platform approximately 16 feet 5 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning
208. ms together at both ends of the machine with a tie down strap or other appropriate device 12 Attach a lifting strap from an overhead crane to the end of the scissor arms that need the slide blocks removed 13 Raise the scissor arms using the overhead crane just enough to take the pressure 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 WARNING Crushing hazard The platform will fall when the platform slide block pivot pins are removed if it is not properly supported by the overhead cranes 16 Remove the retaining fasteners from the wear pads on the slide blocks Remove the wear pads 17 Install the new wear pads onto the scissor arm slide blocks 18 Install the slide blocks onto the chassis 19 Align the holes in the slide blocks with the holes in the scissor arms 20 Install the slide block pivot pins and the pin retaining fasteners 21 Repeat steps 12 through 20 for the remaining scissor arm wear pads 22 Install the top engine cover plate 23 Tighten the engine side cover plate fasteners 24 Close and latch the engine slide out tray 25 Lower the platform to the stowed position 84 April 2015 3 5 Lift Cylinders The lift cylinders are double acting hydraulic cylinders The GS 3384 GS 3390 and
209. mum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties Fluid Properties ISO Grade 46 ISO Grade 15 Viscosity index 192 EE Kinematic Viscosity Viscosity index 300 cSt 149 F 65 C 22 Kinematic Viscosity cSt 104 F 40 C 46 cSt 200 F 100 C 5 5 cSt OF 18 C 1300 cSt 104 F 40 C 15 0 Flashpoint N cSt 40 F 40 C 510 ells Flash point 180 8226 Pour point ad ie Pour point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Genie 4 GS 84 GS 90 Part No 162336 April 2015 Service Manual Specifications Hydraulic Component Specifications Drive Pump Type directional variable displacement piston pump Flow rate 2500 rpm 0 to 32 5 0 to 123 L min Drive pressure maximum 3750 psi 258 6 bar Charge Pump Type Gerotor Flow rate 2500 rpm 9 1 gpm 34 4 L min Charge pump pressure 325 psi 22 4 bar Function pump Type gear pump Displacement 0 98 cu in 16 cc Flow rate 2500 rpm 10 6 gpm 40 1 L min Hydraulic tank return line filter 10 micron with 25 psi Auxiliary power unit Relief valve Part No 162336 Function
210. n are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 Ford MSG 425 Operator Handbook Checklist A Procedures A 5 Test the Oscillate Axle GS90 Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first The oscillate system is designed so that all four tires maintain firm contact to the ground on unlevel terrain improving traction and machine stability Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over Note Perform this procedure with the platform extension s in the retracted position with no additional weight in the platform 1 Start the engine from the platform controls Select the high idle function Test the Oscillate System stowed position 2 the left steer tire up onto a 4 in 10 cm high ramp Result All four tires should maintain firm contact with the ground 3 Drive the right steer tire up onto a 4 in 10 cm high ramp Result All four tires should maintain firm Genie part number 215322 contact with the ground Deutz 2011 Series Operation Manual Genie part number 139320 Genie BRAND
211. n retaining fasteners from the cable tray pivot pin at the number 3 inner arm Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard Cables can be damaged if they are kinked or pinched Secure both ends of the number 3 inner and outer arms index 18 and 16 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 18 and 16 at the steer end of the machine Do not apply any lifting pressure Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 18 and 16 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both number 3 pivot pins index 6 at the non steer end of the machine Do not remove the pins 70 GS 84 GS 90 Part No 162336 April 2015 VAR Ee ee MH P g 2 28 29 30 31 Remove the pin retaining fasteners from both number 3 pivot pins index 19 at the steer end of the machine Do not remove the pins Use a slide hammer to remove both number 3 pivot pins index 6 from the non steer end of the machine Use a slide hammer to remove both number 3 pivot pins index 19 from the steer end of the machine Carefully remove the number 3 inner and outer arms index 18 and 16 from the machine AWARNING Crushing
212. nance Ford Models 21 A 5 Test the Oscillate 21 6 Perform 30 Day Service 22 A 7 Perform Engine Maintenance Ford 23 A 8 Drain the Fuel Filter Water Separator Deutz and Cummins Models 23 9 Replace the Drive Hub 24 A 10 Perform Engine Maintenance Ford Models 25 Genie viii GS 84 GS 90 Part No 162336 April 2015 EE ETE Table of Contents Checklist B Procedures EE REG EE 26 B 1 Inspect the ee ee RA Ee ee 26 B 2 Inspect the Electrical Wiring 02 01 1 00 ee ee etian 27 B 3 Inspect the Engine Air ee esse ee ee ese ee ee Ge ee ee Ee ke ee Ke Ge 28 B 4 Check and Adjust the Engine 29 B 5 Check the Exhaust 31 B 6 Confirm the Proper Brake Configuration 31 B 7 Inspect the Tires Wheels and Lug Nut 32 B 8 Check the Drive Hub Oil Level and Fastener 32 B 9 Test the Fuel Select Operation Ford 33 B 10 Test the Drive Br
213. ng hazard The lift cylinder 38 Attach a lifting strap from an overhead crane could become unbalanced and to the number 2 inner and outer arms index fall when it is removed from the 5 and 6 at the steer end of the machine machine if not properly Do not apply any lifting pressure Supported Dy Me overhead 39 Attach a lifting strap from an overhead crane crane to the number 2 inner and outer arms index 30 Carefully lift the number 1 outer arm index and 6 at the non steer end of the 31 16 approximately 2 inches 5 cm and remove the block Lower the number 1 outer arm index 16 onto the slide blocks AWARNING Crushing hazard Keep hands 40 machine Do not apply any lifting pressure Remove the pin retaining fasteners from both number 1 pivot pins index 10 at the non steer end of the machine Do not remove the pins 41 Remove the retaining fasteners from both clear of moving parts when number 1 pivot pins index 19 at the steer lowering the arms onto the block end of the machine Do not remove the pins 32 Secure the number 1 outer arm index 16 to 42 Use a slide hammer to remove both number the slide blocks 1 pivot pins index 10 from the non steer end of the machine 33 Remove the strap installed in step 19 43 Use slide hammer to remove both number 34 Support the cable tray with an overhead 2 pivot pins index 15 from the steer end of crane the machine 35 Remove the pin retaining f
214. ng installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Loosen the wheel lug nuts Do not remove them 2 Block non steer end wheels and center a lifting jack of ample capacity under the steer end of the drive chassis 3 Raise the machine approximately inches 5 cm Place blocks under the chassis for support A WARNING 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 the yoke 7 Tag disconnect and plug the hoses from the drive motor Cap the fittings on the drive motor AWARNING 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 8 Remove the drive motor mounting fasteners Remove the drive motor Note There is an O ring on the drive motor and drive hub assembly It is installed between the drive motor and drive hub Be sure that the O ring is in place when installing the drive motor onto the machine Mounting bolt torque specifications Drive motor to drive hub dry 75 ft lbs 102 Nm Drive motor to drive hub lubricated 56 ft lbs 76 N
215. ns 1 2 104 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to 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 Push in the red Emergency Stop button to the off position at the ground controls 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 SPEEDS 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 April 2015 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 6568 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 GS 84 models with diesel power Use the yellow platform down arrow to scroll to GS84 DIESEL GS 90 models with gasoline LPG power Use the yellow platform down arrow to scroll to GS90 DUAL FUEL GS 90 models with diesel power Use the yellow platform down arrow to scroll to GS90 DIESEL 7 Pr
216. ns steer end Part No 162336 April 2015 EEE SSS SST ee a ee 3 1 Scissor Assembly GS 3384 and 3390 How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting 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 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the cables from the platform centering link index 1 at the hydraulic tank side of the machine 3 Remove the pin retaining 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 Part No 162336 to the lifting eye at the rod end of the lift cylinder Genie BRAND GS 84 GS 90 63 A CAUTION AWARNING Service Manual Scissor Components 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 li
217. ns to sound 14 Lower the machine onto the blocks 25 Lower the platform to the stowed position 15 Raise the platform approximately 16 feet 26 Push in the red Emergency Stop button to the 5 m off position at both the ground and platform controls Result The tilt sensor alarm should not sound 27 Turn key switch to the off position Result The drive function and the lift function 28 Raise the machine slightly and the tit alarm will sound at 29 Remove the blocks from under both wheels 180 beeps per minute Turn the level sensor adjusting nuts just until the level sensor alarm 30 Lower the machine and remove the jack 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 Genie Part No 162336 GS 84 GS 90 107 Service Manual April 2015 Ground Controls 5 5 Level Sensor Models with Outriggers The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor When the outriggers are stowed the tilt alarm sounds when the incline of the chassis exceeds 2 to the side When the outriggers are deployed the tilt alarm sounds when the incline of the chassis exceeds 0 8 to the side At all times the tilt
218. nspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie BRAND Part No 162336 65 84 GS 90 15 Service Manual April 2015 2 25 EE SSE 4g Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Instructions Use the operator s manual on your mach
219. nstalling the pump Note Before installing the pump verify proper pump coupler spacing Refer to Repair Procedure How to Install Flex Plate Genie BRAND GS 84 GS 90 115 Part No 162336 Service Manual April 2015 Ba EE RE EE EE Hydraulic Pump How to Prime the Pump 4 the engine with the starter motor for 15 seconds wait 15 seconds then crank the Component damage hazard engine an additional 15 seconds or until the Be sure that the hydraulic tank pressure reaches 325 psi 22 4 bar shutoff valves are in the open position before priming the 5 Ford models Connect the hose to the LPG pump The engine must not be tank and open the valve if equipped Move started with the hydraulic tank the fuel select toggle switch at the ground shutoff valves in the closed controls to the gasoline position position or component damage Deutz models Release the manual fuel will occur shutoff lever 1 Connect a 0 to 600 psi 0 to 50 bar pressure 6 Start the engine from the ground controls and gauge to either diagnostic nipple on the drive check for hydraulic leaks manifold 2 key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both 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 Deut
220. ntings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Find a Manual for this Model Go to http www genielift com Use the links to locate Operator s Parts or Service Manuals Copyright 2001 by Terex Corporation 162336 Rev A2 April 2015 Third Edition First Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries GS is a trademark of Terex South Dakota Inc Genie ii GS 84 GS 90 Part No 162336 April 2015 Service Manual Introduction Revision History Revision Date Section Procedure Schematic Page Description A 7 2012 New release 1 2 2014 Maint B 13 A2 4 2015 Repair 12 2 Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Section Diagnostics All charts Click on any content or procedure in the Table of Contents to view the update Section Schematics Legends and schematics Genie BRAND Part No 162336 GS 84 GS 90 iii Service Manual Introduction April 2015 Serial Number Legend Genie A TEREX BRAND Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number 50141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg
221. o 162336 GS 84 GS 90 185 Service Manual April 2015 Electrical Schematic Ford Engine Models CE AS Part 1 of 3 _ FQsaruse c P1EMERGENGY STOP 1 Ee T Bi PLATFORM zx EE saag UM PS2A PLATFORM OVERLOAD PRESSURE SWITCH 4 gs uM d EL i R25 1526 Las DUALPW PS2B PLATFORM OVERLOAD PRESSURE SWITCH MEE GROUND 63 5390 ONLY GONTROL Y i CR77A 86 DOWN ENABLE ED I 85 87 7 CR41 CONTROL CR42 CR1 CR23 CR84 CR85 SYSTEM POWER CR5 ENGINE AUXILIARY OSCILLATE OSCILLATE ESTOP 1 ESTOP 2 HORN IGNITION START DOWN STOWED RAISED TEE 86 3 KI s K2 a 5 304 30 Ka 86 304 KS 304 2 E EEN 5 EMG E EA 24 ETA E
222. operly supported Genie ATIRDI BAD April 2015 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 A WARNING Crushing hazard The number 2 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 see How to Disassemble a Scissor Arm Pair 70 Remove the cables from the number 1 inner arm index 14 71 Secure both ends of the number 1 inner and outer arms index 14 and 16 together with a strap or other suitable device 72 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 14 and 16 at the steer end of the machine Do not apply any lifting pressure 73 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 14 and 16 at the non steer end of the machine Do not apply any lifting pressure 74 Remove the pin retaining fasteners from both chassis centering link pivot pins index 30 at the number 1 inner arm GS 84 GS 90 Part No 162336 April 2015 Service Manual 75 Place rod through each chassis centering link pi
223. ord repair procedures and additional engine information are available in the Ford MSG 425 Operator Handbook EDI part number 1020010 OR the Ford MSG 425 EFI Service Manual EDI part number 1020050 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Ford MSG 425 EFI Service Manual Genie part number 215306 Genie Part No 162336 GS 84 GS 90 89 Service Manual April 2015 Engines 4 4 4 Remove the exhaust pipe located between Flex Plate the exhaust manifold and muffler from the machine The flex plate couples the engine to the pump The 5 Remove the medium pressure filter assembly flex plate is bolted to the engine flywheel and has a from the muffler mount and lay it to the side cutout in the center for the pump coupler 6 Remove the muffler and muffler mount 2 3 4 5 assembly from the machine 7 Center a lifting jack under the engine oil pan 8 Place a wood block between the lifting jack and the engine oil pan W Component damage hazard The engine oil pan can become damaged if the engine is raised with the lifting jack without the 6 wood block between the lifting jack and the engine oil pan 1 pump 2 pump shaft 9 Remove the fasteners securing the bell 3 coupler housing to the slide out tray ers 10 Raise the engine slightly with the lifting jack to B ie T EE take the pressure off the rubber vibration isolators under the bell housing Remove th
224. orm Overload 40 Re Ee RR RR ER RE RA Re Ge ERA RR ER RE Rae Ge ee ee ee 144 12 1 Platform Overload 144 How to Calibrate the Platform Overload 144 12 2 Platform Overload Recovery Message software version B3 and later 152 Section 5 222 22 EE ER EE 153 WTO GUCUION ER EE 153 Control System Fault Codes ee ee ee ee AR ee AR ee AR m ee ee ee ee ee ee 155 Ford MSG 425 Engine Fault 159 Genie xiv GS 84 GS 90 Part No 162336 April 2015 EE EE EE EE er ETE EE EE Table of Contents Section 6 SCHOMALICS 165 EE EE dst 165 Electronic Control Module 166 Electronic Control Module 167 Ground Controls Wiring Panel 168 Ford Engine Relay 169 Wiring Diagram Platform Control 170 Limit Switch 171 Electrical Component Wire Color 172 Electrical Symbols 7 eee 175 Wiring Harness Ford MSG 425
225. ote Be sure that the safety arm is locked in the vertical position Genie 134 GS 84 GS 90 Part No 162336 April 2015 Service Manual 11 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Specifications Machine Specifications ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel 12 Remove the fuel tank hold down strap retaining fasteners Remove the straps from the fuel tank 13 Support and secure the fuel tank to an appropriate lifting device 14 Remove the fuel tank from the machine Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Note Clean the fuel tank and inspect for cracks and other damage before installing Fuel and Hydraulic Tanks 8 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean 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 severe component damage D
226. oth wear pads Measure the thickness of each platform scissor arm wear pad at the non steer end of the machine Result The measurement is 5 16 inch 8 mm or more Result The measurement is less than 5 16 inch 8 mm Replace both wear pads Part No 162336 April 2015 Service Manual D 2 Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Non Steer wheels 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity Checklist D Procedures Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub 1 brake disengaged position 2 brake engaged position Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands
227. ound and the engine continues to run when the platform reaches full height Repeat this procedure beginning with step 7 777 U 7 Limit switch legend 1 load sense delay limit switch 2 down limit switch 3 maximum height limit switch 4 maximum height limit switch cam Genie 148 GS 84 GS 90 Part No 162336 April 2015 Service Manual _ _ _ ___ Platform Overload Components 52 Install and adjust the maximum height limit switch cam until the limit switch activates just before the point reached in step 51 Securely tighten the cam fasteners Do not over tighten 53 Use the auxiliary down function to lower the platform approximately 15 cm 54 Start the engine and fully raise the platform Result The engine continues to run Proceed to step 55 Mm Result An alarm sounds and the engine stops running Repeat this procedure beginning with step 49 55 Lower the platform to approximately 6 m 56 Return the safety arm to the stowed position Confirm the platform stowed pressure switch setting 57 Lower the platform to the stowed position 58 Raise the platform to approximately 4 m in 0 5 m increments Result The engine should continue to run Proceed to step 59 M Result The engine stops running Using a small screwdriver turn the screw of the platform overload pressure switch perpendicular to the cylinder into the hydraulic line in 90
228. ours e Place a check in the appropriate box after each inspection procedure is completed e Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Part No 162336 Checklist A Checklist B R A 1 Inspect the manuals B 1 Batteries and decals 2 2 Electrical wiring A 2 Pre operation EO 3 Engine air filter A 3 Function tests 4 Engine RPM A 4 Engine Maintenance B 5 Exhaust system 5 Oscillate axle B 6 Brake configuration aoe B 7 Tires and wheels Perform after 40 hours B 8 Drive hub oil A 6 30 day service B 9 Fuel select Ford Perform after 100 hours models A 7 Maintenance B 10 Drive brakes monet B 11 Drive speed 8 Filter separator stowed Deve B 12 Drive speed raised Perform after 150 hours ES B 13 Check Up Limit A 9 Drive hub oil Switch Perform after 200 hours B 14 Hydraulic oil analysis A 10 Engine Maintenance Ford models B 15 Tank venting system Perform every 400 hours B 16 Engine air filter Ford models B 17 Engine maintenance Ford models Comments Genie GS 84 GS 90 17 Service Manual April 2015 M
229. ove 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 of the scissor arms AWARNING Crushing hazard The number 4 inner and outer arms could become unbalanced and fall when they are removed from the machine if not properly supported by the overhead crane Component damage hazard The upper lift cylinder may fall if not properly supported when the number 4 inner and outer arms are removed Note If further disassembly of the scissor arm pair is required Refer to Repair Procedure How to Disassemble a Scissor Arm Pair 25 Lower the rod end of the upper lift cylinder onto the cross tube of the number 3 inner arm index 8 26 Tag disconnect and plug the hydraulic hoses from the upper lift cylinder Cap the fittings on the cylinder AWARNING 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 27 Remove the zip ties securing the hydraulic hoses to the upper lift cylinder 28 Remove the pin retaining fasteners from the lower cylinder rod end pivot pin index 24 29 Use a soft metal drift to remove the lower lift cylinder rod end pivot pin Genie BRAND GS 84 GS 90 77 Service Manual is Scissor Components 30 31 32 33 35 Carefully lower the rod end of t
230. ove the pin retaining fasteners from both number 4 pivot pins index 4 at the non steer end of the machine Do not remove the pins 8 Remove the pin retaining fasteners from both number 4 pivot pins index 15 at the steer end of the machine Do not remove the pins 9 Use a slide hammer to remove both number 4 pivot pins index 4 from the non steer end of the machine 10 Use a slide hammer to remove both number 4 pivot pins index 15 from the steer end of the machine 11 Carefully remove the number 4 inner and outer arms index 14 and 2 from the machine A WARNING Crushing hazard The number 4 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 see How to Disassemble a Scissor Arm Pair 12 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 17 Do not remove the pin 13 Attach a lifting strap from an overhead crane to the lifting eye at the rod end of the lift outer arms index 14 and 2 together with a cylinder strap or other 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 Genie 0 1 Part No 162336 65 84 GS 90 69 Service Manual April 2015 Scissor Components
231. parks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure any forklift overhead crane other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time oy Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe e Be sure that your workshop or work area CU is properly ventilated and well lit Genie vi GS 84 GS 90 Part No 162336 April 2015 EE ETE Table of Contents Introduction 0 die AE AR EA ii Important InformatiOr ener leew teense ii Find a Manual for this ee ee ee ee GR AR Re ee ee ee ee ee ee ee ee ee ii Revision iii Serial Number iv Section 1 ind EE EE EE EE ss General Saf
232. peed motor shift circuit 2 speed motor shift circuit Balances fluid flow from flow divider combiner valve BM to flow divider combiner valves BO and BP Controls flow to non steer end drive motors in forward and reverse Controls flow to steer end drive motors in forward and reverse Controls fluid flow to flow divider combiner valves BO and BP in forward and reverse Part No 162336 April 2015 Service Manual a RT Hydraulic Schematics Component Call out Legend Item Function CA Right front outrigger autolevel valve CB Left front outrigger autolevel valve CC Right rear outrigger autolevel valve CD Left rear outrigger autolevel valve DA Oscillate on DB Oscillate system relief valve DC Oscillate float relief valve DD Flow regulator DE Right oscillate cylinder DF Left oscillate cylinder DG Oscillate float EA Flow divider combiner front to rear EB Orifice controls flow side to side at steer end EC Test port 2 ED Orifice controls flow side to side at non steer end EE Charge pressure circuit EF 2 speed motor shift circuit EG Orifice brake circuit EH Orifice 2 speed motor shift circuit El Hot oil relief charge pressure circuit EJ Brake release circuit EK Flow divider combiner balances flow side to side at the non steer end EL Flow divider combiner balances flow side to side at the steer end EM Orifice controls flow front to rear EN Test port 1 FA Diverter valve FB Delays shi
233. pin retaining fasteners from the number 1 inner arm slide blocks index 19 at the steer end of the machine April 2015 52 Use slide hammer to remove the number 1 inner arm slide block pivot pins index 19 53 Use slide hammer to remove the number 1 outer arm slide block pivot pins index 19 at the non steer end of the machine 54 Carefully remove the number 1 inner and outer arms index 8 and 16 from the machine AWARNING 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 Genie 0 GS 84 GS 90 Part No 162336 April 2015 Service Manual EE EE sees Scissor Components How to Disassemble a Scissor 4 Place a 12 inch 30 cm block under the Arm Pair center of the scissor arm pair Lower the scissor arm pair onto the block AWARNING Bodily injury hazard This 5 Remove the external snap rings from both procedure requires specific repair center pivot pins skills lifting equipment and a suitable workshop Attempting 6 Use a soft metal drift to remove both center this procedure without these pins sk and 0 8 could result in 7 Carefully separate the scissor arm pair death or serious injury and significant component damage Crushing hazard The scissor Deale
234. platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal Note To perform this step the system relief valve will need to be adjusted Note To help complete this part of the procedure apply a piece of tape to the underside of the platform at a point which corresponds to the maximum load position of the capacity indicator decal before raising the platform Result The engine continues to run Proceed to step 34 Result The engine has stopped and an alarm is sounding Proceed to step 35 Set the maximum height pressure switch 34 Working on platform overload pressure switch 1 parallel to the cylinder on early models with a small slotted screwdriver turn the adjustment screw out of the hydraulic line just until the overload alarm sounds and the engine stops running Refer to the illustrations below Note Turning the screw out of the hydraulic line will activate the alarm turning the screw into the hydraulic line will deactivate the alarm Gon BRAND GS 84 GS 90 147 Part No 162336 Note The white black wire should be connected to this pressure switch 1 switch 1 2 switch 2 35 Slowly turn the adjustment screw of the platform overload press
235. ppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Petro Canada Environ MV 46 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 Mineral based Biodegradable Fire resistant 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 range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required Specifications Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range a ii 2
236. printed circuit board at platform controls controls 35 LEFT REAR Red Left rear outrigger enable Outriggers Troubleshoot button OR replace OUTRIG SW FLT button fault at platform disabled printed circuit board at platform controls controls 36 RIGHT REAR Red Right rear outrigger enable Outriggers Troubleshoot button OR replace OUTRIG SW FLT button fault at platform disabled printed circuit board at platform controls controls 37 AUTO LEVEL Red Outrigger autolevel enable Outriggers Troubleshoot button OR replace SWITCH FAULT button fault at platform disabled printed circuit board at platform controls controls 49 DRIVE COIL 1 Red Drive 1 1 fault High speed drive Troubleshoot coil OR wiring FAULT function will not operate 50 DRIVE COIL 2 Drive 2 Y1A fault High speed drive Troubleshoot coil OR wiring FAULT function will not operate 51 DRIVE COIL 3 Red Drive 3 Y1B fault High speed drive Troubleshoot coil OR wiring FAULT function will not operate 52 FUNC PROP Red Proportional coil Y9 fault Lift and outrigger Troubleshoot OR wiring COIL FAULT functions are disabled 54 UP COIL FAULT Red Up coil Y8 fault Platform will not Troubleshoot coil OR wiring raise 55 DOWN COIL Red Down coil Y7 fault Platform will not Troubleshoot coil OR wiring FAULT lower Genie 156 GS 84 GS 90 Part No 162336 April 2015 Control System Fault Codes Service Manual
237. r 2139 FPP1 lower than IVS limit 1633 PWM2 Gauge2 open ground short 2140 FPP2 lower than IVS limit 1634 PWM2 Gauge2 short to power 2229 BP high pressure 1635 PWM3 Gauge3 open ground short 2300 Primary Loop Open or Low side Short to 1636 PWM3 Gauge3 short to power Ground 1641 Buzzer control ground short 2301 Primary Coil Shorted 1642 Buzzer open 2303 Loop Open or Low side Short to 1643 Buzzer control short to power 2304 Primary Shorted ground short 2306 Primary Loop Open or Low side Short to 1645 MIL control short to power Ground 2111 Unable to reach lower TPS 2307 Primary Coil Shorted 2112 Unable to reach higher TPS For further engine fault code troubleshooting and 2115 FPP1 higher than IVS limit diagnostic information refer to the Ford MSG 425 2116 FPP2 higher than IVS limit ao Manual EDI part number 2120 FPP1 invalid voltage and FPP2 disagrees with IVS Ford MSG 425 Diagnostic Manual 2121 FPP1 lower than FPP2 Genie part number 162067 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 162 GS 84 GS 90 Genie Part No 162336 April 2015 Service Manual Ford MSG 425 Engine Fault Codes Code Description 2309 Primary Loop Open or Low side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low side Short to Ground 2313 Prim
238. r comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage 1 Selectthe drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 4 Fillthe hub until the oil level is even with the bottom of the lowest plug hole Refer to Specifications Machine Specifications 5 Install the plugs into the drive hub 6 Repeatthis procedure for each drive hub Genie 46 GS 84 GS 90 Part No 162336 April 2015 Service Manual D 4 Replace the Hydraulic Filters Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often A CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off Replace the Medium and High Pressure
239. r service is strongly AWARNING arms could become unbalanced recommended and fall if not properly supported by the overhead cranes 1 Attach a lifting strap from an overhead crane to the end of the outer arm Note Attach the lifting 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 Genie BRAND Part No 162336 GS 84 GS 90 67 Service Manual April 2015 Scissor Components 2 22 9 6 9 900 OO OOO NOO 660 66 Non steer End Steer End 1 Platform centering link 13 Number 1 pivot pins non steer end 2 Number 4 outer arm 14 Number 4 inner arm 3 Number 4 center pivot pins 15 Number 4 pivot pins steer end 4 Number 4 pivot pins non steer end 16 Number 3 outer arm 5 Number 3 center pivot pins 17 Lift cylinder rod end pivot pin 6 Number 3 pivot pins non steer end 18 Number 3 inner arm 7 Number 2 center pivot pins 19 Number 3 pivot pins steer end 8 Number 2 inner arm 20 Number 2 outer arm 9 Number 2 pivot pins non steer end 21 Number 2 pivot pins steer end 10 Number 1 inner arm 22 Number 1 center pivot pins
240. rane to the number 3 inner and outer arms index 2 and 11 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both number 3 pivot pins index 4 at the non steer end of the machine Do not remove the pins Remove the pin retaining fasteners from both number 3 pivot pins index 13 at the steer end of the machine Do not remove the pins Use a slide hammer to remove both number 3 pivot pins index 4 from the non steer end of the machine 64 Genie ATIRDI BAD April 2015 17 Use 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 AWARNING 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 the scissor arm pair is required Refer to Repair Procedure How to Disassemble a Scissor Arm Pair 19 Secure the non steer end of the number 2 inner and outer arms index 5 and 6 and the non steer end of the number 1 inner and outer arms index 8 and 16 together with a strap or other suitable device 20 Attach a lifting strap from an overhead crane to the number 1 outer arm index 16 at the non steer end of the machine Do not apply any lifting pressure 21 Remo
241. ribed below 4 Atthe ground controls turn the key switch to platform controls and pull out the red Emergency Stop button 9 5 out the red Emergency Stop button on the platform controller and start the engine 10 6 Using a volt meter check for voltage by connecting the positive lead to relay K11 terminal 30 and connecting the negative lead to the ground strip terminal Result The volt meter should read 12V DC ms greater Result The volt meter reads OV DC Check the down limit switch LS6 44 12 1 Ground Control Side 2 down limit switch LS6 3 load sense delay LS25 CE models only 4 Hydraulic Tank Side 7 Using a volt meter check for voltage by connecting the positive lead to relay K11 terminal 87 and connecting the negative lead to the ground strip terminal Result The volt meter should read OV DC Result The volt meter reads 12V DC greater Check the green wire on terminal 86 for voltage If yes the drive controller is activated or the ECU needs to be replaced Genie Part No 162336 BRAND Service Manual Checklist D Procedures Press the drive speed button and select high speed drive mode Result The green LED should go off Result The green LED stays on Check the down limit switch LS6 for an open circuit Raise the platform until the green LED comes on Using a volt meter check for voltage by connecting the positive lead to relay K11 terminal 30 and
242. ric callouts refer to corresponding notes on the electrical schematic Genie BRAND Part No 162336 GS 84 GS 90 Manifolds 121 Service Manual April 2015 ca HUI Manifolds 7 3 Drive Manifold Components The drive manifold is located under the function manifold Index n Schematic No Description itam Function Torque 1 Flow divider combiner valve EA Controls flow to front and 50 ft lbs 68 Nm reardrive motors 2 Orifice Plug 0 043 inch 1 1 mm EB Balances flow from flow divider combiner item EL to front drivemotors 3 Diagnostic nipple EC Testing P2 pressure port Orifice Plug 0 046 inch 1 2 mm ED Balances flow from flow 25 ft lbs 34 Nm divider combiner item EK to rear drivemotors 5 Relief valve 280 psi 19 3 bar EE Charge pressure circuit 20 ft lbs 27 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 Charge pressure circuit thatgets 25 ft lbs 34 Nm hot oil out of low pressureside of drive pump and allowslow pressure flow path for brakerelease and 2 speed motor shift 10 Solenoid valve 2 position 3 way EJ Brake release circuit 20 ft lbs 27 Nm 11 Flow divider combin
243. rload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Note Perform this procedure with the machine on a firm level surface 1 Models with outriggers Deploy the outriggers and level the machine 2 Applya thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 3 Disconnect the platform controls from the machine at the platform 4 Open the large ground control panel door and locate connector joining the Electronic Control Module ECM wire harness and the platform controls wire harness Note This connection is just below the ground controls 5 Tagand disconnect the platform controls wire harness from the ECM wire harness 6 Securely connect the platform controls to the ECM wire harness Gon BRAND GS 84 GS 90 39 Part No 162336 Checklist C Procedures 7 Using a suitable lifting device place a test weight corresponding to the maximum load as indicated on the capacity indicator decal in the center
244. rn the key switch to ground control 4 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 SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 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 HIGH SPEED DRIVE is showing in the diagnostic display window Genie 94 GS 84 GS 90 Part No 162336 April 2015 Service Manual 12 Press the lift function enable button 13 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications 14 Press the lift function enable button 15 Push in the red Emergency Stop button to the off position at the ground controls 16 Check the stowed drive speed of the machine Refer to the Maintenance procedure Test the Drive Speed Stowed Position Ground Controls How to Adjust the High Torque Drive Speed A DANGER Tip over hazard Do not adjust the lift
245. rom moving Genie BRAND GS 84 GS 90 23 Part No 162336 Service Manual April 2015 Checklist A Procedures 3 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 1 fuel filter 2 drain plug 4 Clean up any fuel that may have spilled Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks DANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 9 Replace the Drive Hub Oil Drive hub specifications require that this one time procedure be performed after the first 150 hours of usage After this interval refer to the maintenance checklist for continued scheduled maintenance Failure to replace the drive hub oil may cause the machine to perform poorly and continued use may result in component damage 1 Refer to Section D Maintenance Procedure Replace the Drive Hub Oil Genie 24 GS 84 GS 90 Part No 162336 April 2015 Service Manual Checklist A Procedures A 10 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 200 hours e Check and adjust belts e Check Replace fuel filter e Check exhaust and vacuum ho
246. rs after each turn of an adjusting nut Note Be sure there are threads showing through the top of each adjusting nut 20 Disconnect the positive and negative leads 1 chassis 2 Y indicator 21 Apply Sentry Seal to the adjusting nuts 3 level sensor 22 Push the red Emergency Stop button to the 4 X indicator off position at the platform controls 11 Connect the wire harness to the level sensor 23 Press and hold the auto level button and press and hold the left front outrigger button 12 Turn the key switch to platform control and Pull out the red Emergency Stop button to the pull out the red Emergency Stop buttons to on position at the platform controls the on position at both the ground and platform controls Start the engine 24 Continue to hold the auto level button and left front outrigger button for approximately 13 Seta multimeter to read DC voltage 3 seconds or until a beep is heard Adjust the side to side axis 25 Push in the red Emergency Stop button to the 14 Without disconnecting the wire harness from oen ADIRE plan CANTONS the level sensor connect the negative lead of the multimeter to the black wire at the level sensor Genie Part No 162336 65 84 GS 90 109 Service Manual April 2015 Ground Controls Confirm the side to side level sensor setting 26 Center a lifting jack under the drive chassis at the ground control side of the machine 27 Raise the machine approximately 6 inches 15 2
247. ructions Genie Mer Part No 162336 GS 84 GS 90 93 Service Manual April 2015 Ground Controls How to Determine the Revision Level 1 the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both platform and ground controls Result The revision level of the ECM will appear in the LED display window How to Adjust the Stowed Drive Speed 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 Press the lift function enable button 8 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Specifications Performance Specifications Note The performance achieved should always be within specifications DANGER Tip over hazard Do not adjust 9 Press the lift function enable button the lift and or drive speed higher than specified in this Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in procedure Setting drive speed programming mode greater than specifications could cause the machine to tip over resulting in death or serious injury 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Push red Emergency Stop button to the off position at the ground controls Tu
248. s Gon BRAND GS 84 GS 90 101 Part No 162336 Ground Controls 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 see 5 2 How to Determine the Revision Level Machine Option Definitions Descent Delay This option halts descent when the down limit switch is activated All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe Motion Alarm The motion alarm will sound when activating a function Motion Beacons The flashing beacons operate only when activating a function Overload This cuts out all functions when the platform overload pressure switch is tripped The red Emergency Stop button must be cycled before any function can be resumed Required for Europe Sim Operation When enabled this allows some machine functions to be activated simultaneously Required to be disabled for European models Beacons When installed on the machine the flashing beacons operate continuously when the key switch is turned to ground or platform controls and both red Emergency Stop buttons are pulled out to the on position Service Manual April 2015 Ground Controls Outriggers When installed on the machine the outrigger option must be enabled
249. se the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and repeat step 2 low idle adjustment screw low idle lock nut yoke yoke lock nut high idle adjustment lock nuts solenoid boot 6 Press the high idle rabbit symbol button 7 Press and hold the start button and check the engine rpm on the diagnostic display Refer to Section 2 Specifications Skip to step 11 if the high idle rpm is correct If the high idle rpm is not correct and the low idle was just calibrated proceed to step 10 All other machines open the engine tray Proceed to step 8 Release the latches on the engine tray and fully slide the engine tray out 9 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 10 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and confirm the rpm Note Be sure the solenoid fully retracts when activating high idle 11 Close and latch the engine slide out tray Genie 30 GS 84 GS 90 Part No 162336 April 2015 Service Manual Checklist B Procedures B 5 B 6 Check the Exhaust System Confirm the Proper Brake Genie specifications require that this procedure be Conf
250. se a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to maximum forward drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Specifications Performance Specifications 8 Bring the machine to maximum reverse drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 9 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Specifications Performance Specifications Genie 34 GS 84 GS 90 Part No 162336 April 2015 Service Manual B 12 Test the Drive Speed Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apar
251. sential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Note The on board self diagnostics incorporate a built in engine tachometer The first two digits of the engine RPM are displayed on the diagnostic display when the start toggle switch is moved to the start position with the engine running Engine RPM equals the first two digits multiplied by 100 Note Perform this procedure after warming the engine to normal operating temperature Ford models Note The engine rpm is controlled by the ECM and can only be adjusted by reprogramming the ECM If rpm adjustment or service is required please contact the Genie Product Support OR your local Ford dealer Genie BRAND GS 84 GS 90 29 Part No 162336 Service Manual April 2015 Checklist B Procedures Deutz models 1 Start the engine from the ground controls 2 Press and hold the start button and check the engine RPM on the diagnostic display Refer to Section 2 Specifications Skip to step 6 if the low idle rpm is correct 3 Release the latches on the engine tray and fully slide the engine tray out 4 Inserta 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 5 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increa
252. ses pipes for leaks damage or deterioration Required maintenance procedures and additional engine information are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Genie BRAND Part No 162336 GS 84 GS 90 25 Service Manual April 2015 Checklist B Procedures B 1 Inspect the Batteries Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine and machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine and component damage and hazardous conditions AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 2 Be sure that the battery retainers and cable connections are tight 3 sure that the battery separator wire connections are tight if equipped 4 Put
253. spray counterclockwise to decrease the AC voltage Install the flow regulator valve cap AWARNING Electrocution burn hazard Component damage hazard Contact with electrically charged Failure to adjust the generator could result in death as instructed may result in serious injury Remove all rings damage to the generator or watches and other jewelry other electrical equipment Do Note Be sure that the hydraulic oil level is 2 to other between the full and add marks on the oil level indicator 9 Repeat steps 2 through 5 to confirm the 1 Disconnect all electrical tools from the generator AC voltage machine 2 Startthe engine from the platform controls 3 Press the generator select switch Result The generator should activate and the engine should go to high rpm 4 electrical tool which does not draw more than 15 to the electrical outlet at the platform controls and run the tool at full speed Genie Part No 162336 65 84 GS 90 131 Service Manual April 2015 Manifolds 7 10 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases
254. t 2 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine from the platform controls 4 Press and hold a function enable speed select button Raise the platform approximately 12 feet 3 6 m from the ground 5 Choose a point the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Press and hold the function enable switch and slowly move the control handle to the full drive position 7 Bringthe machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Specifications Performance Specifications Checklist B Procedures B 13 Check the Up Limit Switch Drive Cutout and Outriggers GS 5390 Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper limit switch operation is essential to safe machine operation The machine should not drive above the maximum height required to deploy the outriggers Note Select a test area that is firm level and free of obstructions Note Start this procedure with the outriggers fully retracted 1 Remove the platform control box from the platform and connect it at the
255. t and run Proceed to step 15 Result The engine will not start and an alarm is sounding Repeat this procedure beginning with step 12 Genie 144 GS 84 GS 90 Part No 162336 April 2015 Service Manual SS Platform Overload Components Note The red Emergency Stop button must be cycled after each quarter turn of the nut or adjustment screw to allow the platform overload system to reset Note Wait a minimum of 3 seconds between each quarter turn of the nut or adjustment screw to allow the platform overload system to reset 15 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal ADANGER Tip over hazard Raising the platform with maximum load above the maximum load position as shown on the capacity indicator decal on the side of the platform could result in the machine tipping over resulting in death or serious injury Do not raise the platform above the maximum load position of the capacity indicator decal Note To perform this step the system relief valve will need to be adjusted Note To help complete this part of the procedure apply a piece of tape to the underside of the platform at a point which corresponds to the maximum load position of the capacity indicator decal before raising the platform Result The engine continues to run Proceed to step 16 B Result The engine has stopped and an alarm is sounding Proc
256. t may have spilled during the installation procedure Replace the Hydraulic Tank Return Filter 17 Open the function manifold tray door 18 Locate the hydraulic tank return filter located behind the ladder Note The hydraulic filter is mounted on the function manifold next to the hydraulic power unit Genie BRAND GS 84 GS 90 47 Part No 162336 Service Manual April 2015 Checklist D Procedures 19 Remove the filter with an oil filter wrench Clean the area where the hydraulic oil filter meets the filter head AWARNING 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 20 Apply a thin layer of oil to the new oil filter gasket 21 Install the new filter and tighten it securely by hand 22 Use permanent ink marker to write the date and number of hours from the hour meter on the filter 23 Clean up any oil that may have spilled during the replacement procedure 24 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 25 Start the engine from the ground controls 26 Hold the function enable toggle switch in the up direction and activate the platform up function 27 Inspect the filter and related components to be sure that there are no leaks
257. t remove the pins Use a slide hammer to remove both number 2 pivot pins index 9 from the non steer end of the machine AWARNING Clushing hazard The cable tray 56 Use a slide hammer to remove both number may fall if not properly supported 2 pivot pins index 21 from the steer end of by the overhead crane the machine Component damage hazard 57 Carefully remove the number 2 inner and Cables can be damaged if they outer arms index 8 and 20 from the are kinked or pinched machine Crushing hazard The number AWARNING 2 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 see How to Disassemble a Scissor Arm Pair 58 Remove the cables from the number 1 inner arm index 10 50 Secure both ends of the number 2 inner and outer arms index 8 and 20 together with a 59 Secure both ends of the number 1 inner and strap or other suitable device outer arms index 10 and 12 together with a strap or other suitable device 51 Attach a lifting strap from an overhead crane 21 to the number 2 inner and outer arms index 60 Attach a lifting strap from an overhead crane 8 and 20 at the steer end of the machine to the number 1 inner and outer arms index Do not apply any lifting pressure 10 and 12 at the steer end of the machine Do not apply any lifting pressure 52 Attach a
258. tch cam until the limit switch activates just before the point reached in step 26 Securely tighten the cam fasteners Do not over tighten 28 Use the auxiliary down function to lower the platform approximately 15 cm 29 Start the engine and fully raise the platform Result The engine continues to run Proceed to step 30 Result An alarm sounds and the engine stops running Repeat this procedure beginning with step 24 30 Lower the platform to approximately 6 m 31 Return the safety arm to the stowed position Proceed to step 59 GS 5390 models 32 Pull out the red Emergency Stop button to the on position at the ground controls Wait 3 seconds and start the engine Result The alarm doesn t sound and the engine will start and run Proceed to step 33 Result The engine will not start and an alarm is sounding Repeat this procedure beginning with step 12 Note The red Emergency Stop button must be cycled after each quarter turn of the adjustment screw to allow 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 Genie 146 GS 84 GS 90 Part No 162336 April 2015 Service Manual Platform Overload Components 33 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal ADANGER Tip over hazard Raising the
259. tform controls Part No 162336 April 2015 ee er Service Manual Ground Controls 10 Tighten the level sensor adjusting fasteners 21 Raise the machine approximately 4 inches until the bubble in the top of the level sensor 10 cm 22 Models with RT tires Place a 3 x 10 x Note Be sure there are threads showing through 10 inch 7 62 x 25 x 25 cm thick steel block the top of the adjusting fasteners under both wheels at the ground controls side of the machine Result The tilt sensor alarm should not sound Models with flotation tires Place a 3 15 x PEE 10 x 10 inch 8 x 25 x 25 cm thick steel block 11 Center a lifting jack under the drive chassis at under both wheels at the ground controls side the ground controls side of the machine of the machine 12 1 the machine approximately 4 inches 23 Lower the machine onto the blocks cm 24 Raise the platform approximately 16 feet 13 Models with RT tires Place a 2 59 x 10 x 5m 10 inch 6 58 x 25 x 25 cm thick steel block under both wheels at the ground controls side Result The drive function and the lift function of the machine will not operate and the tilt alarm will sound at 180 beeps per minute Models with flotation tires Place a 2 72 x 10 x 10 inch 6 91 x 25 x 25 cm thick steel Result The level sensor alarm does not block under both wheels at the ground sound Adjust the level sensor until the alarm controls side of the machine just begi
260. the shoulder pin from the barrel end of the outrigger cylinder and install it onto the new cylinder 1 valve coil 2 outrigger cylinder Genie BRAND GS 84 GS 90 143 Part No 162336 Service Manual April 2015 Platform Overload Components 12 1 Platform Overload System if equipped How to Calibrate the Platform Overload System if equipped On machines with platform overload systems proper calibration is essential to safe machine operation An improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Be sure the hydraulic oil level is between the full and add marks on the oil level indicator Note Perform this procedure with the machine on a firm level surface that is free of obstructions All models 1 Models with outriggers Deploy the outriggers and level the machine 2 Applya thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 3 Disconnect the platform controls from the machine at the platform 4 Open the large ground control panel door and locate connector joining the Electronic Control Module ECM wire harness and the platform controls wire harness Note This connection is just below the ground controls 5 Tagand disconnect the platform controls wire harness from the ECM wire
261. this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air passes through the breather cap Proceed to step 8 R Result If air does not pass through the cap clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic Perform this procedure in an tank open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Remove the fuel filler cap from the tank 2 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 4 B Result If air does not pass through the cap clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap Genie 1 0 1 Part No 162336 65 84 GS 90 37 Service Manual April 2015 Checklist B Procedures B 16 Replace the Engine Air Filter Element Ford Models Genie specifications require that this procedure be performed every 400 hours or semi annually whichever com
262. ting and tighten the hex nut to the body hex fitting to hand T Replace Hie Ong The ang Musi be tight approximately 30 in Ibs 3 4 Nm replaced anytime the seal has been broken The O ring cannot be re used if the fitting or 2 Using a permanent ink marker make hose end has been tightened beyond finger reference mark on one the flats of the hex nut tight and continue the mark onto the body of the Note The O ring in Parker Seal Lok fittings and mung Refer to lustration 2 hose end are custom size O rings They are not Pd standard size O rings They are available in the L O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation E 4 1 3 Be sure the O ring face seal is seated and retained properly id J 2 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Illustration 1 5 Tighten the nut or fitting to the appropriate 1 hex nut torque Refer to the appropriate torque chart 2 reference mark in this section 3 body hex fitting 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks 1 1 10 GS 84 GS 90 Part No 162336 April 2015 Service Manual ii EE ee es Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Re
263. ting pressure Remove the pin retaining fasteners from both number 3 pivot pins index 10 at the non steer end of the machine Do not remove the pins Remove the pin retaining fasteners from both number 3 pivot pins index 25 at the steer end of the machine Do not remove the pins Use a slide hammer to remove both number 3 pivot pins index 10 from the non steer end of the machine Use a slide hammer to remove both number 3 pivot pins index 25 from the steer end of the machine Carefully remove the number 3 inner and outer arms index 8 and 23 and upper lift cylinder 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 the scissor arm pair is required Refer to Repair Procedure How to Disassemble a Scissor Arm Pair Genie ATIRDI BAD GS 84 GS 90 Part No 162336 April 2015 TEESE SSE SSS a ee ee ee 44 45 46 47 48 49 50 Secure the non steer end of the number 2 inner and outer arms index 26 and 27 and the non steer end of the number 1 inner and outer arms index 14 and 16 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 1 outer arm index 16 at the non steer end of the machine Do not apply any lifting pressure Remove the pin
264. unction Manifold How to Adjust the System Relief Valve Note Perform this procedure with a minimum hydraulic oil temperature of 32 F 0 C anda maximum hydraulic oil temperature of 120 F 48 C Note Be sure that the hydraulic oil level is between the full and add marks on the oil level indicator Note Refer to Function Manifold Component list to 5 Manifolds 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 Ibs 1135 kg GS 4390 1500 Ibs most models refer to capacity indicator 680 kg decal GS 4390 1800 Ibs some models refer to capacity indicator 816 kg decal GS 5390 1500 Ibs 680 kg 6 Using a suitable lifting device place the test weight determined in step 5 at the center of the platform floor Secure the weight to the platform locate the system relief valve 7 the key switch to platform control and 1 Models with Deploy th pull out the red Emergency Stop button to the io hs Oy me on position at both the ground and platform controls Start the engine Models without outriggers Chock both sides of the wheels at the steer end of the 8 Press and hold the lift function enable button machine 9 Activate the platform up function and fully raise the platform while observing the 2 1 system relief valve on the function pressure reading on the pr
265. ure switch into the hydraulic line in 90 increments just until the overload alarm doesn t sound and the engine will start and run Note To allow for the platform 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 Service Manual April 2015 Platform Overload Components 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 position 37 Start the engine Set the platform stowed pressure switch 38 Working on platform overload pressure switch 2 perpendicular to the cylinder on early models remove the retaining ring securing the switch adjustment cover to the pressure switch Refer to the illustrations at step 34 39 Slide the switch adjustment cover away from the tee fitting exposing the slotted switch adjustment screw inside 40 Using a small slotted screwdriver turn the adjustment screw just until the overload alarm sounds and the engine stops running Note Turning the screw out of the hydraulic line will activate the alarm turning the screw into the hydraulic line will deactivate the alarm 41 Slowly turn the adjustment screw of the platform overload pressure switch into the hydraulic line in 9
266. ure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Inserta inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Remove the air intake hose from the engine slide out tray 4 Disconnect the retaining clamp from the air cleaner canister Remove the filter element 6 Clean the inside of the canister and the gasket with a damp cloth 7 Install the new filter element 8 Install the air filter canister end cap and connect the end cap retaining clamp Note Be sure the air cleaner intake hose is inserted in the hole in the front of the engine slide out tray Checklist C Procedures C 4 Replace the Fuel Filter Water Separator Deutz Models Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Regular replacement of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damage Extremely dirty conditions may require this procedure be performed more often A DANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure
267. urs Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation e Check exhaust and vacuum hoses pipes for leaks damage or deterioration Required maintenance procedures and additional engine information are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Checklist A Procedures A 8 Drain the Fuel Filter Water Separator Deutz Models Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damage Extremely dirty conditions may require this procedure be performed more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Insert a6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray f
268. ve the pin retaining fasteners from the number 1 pivot pins index 10 at the non steer end of the machine 22 Use slide hammer to remove both number 1 pivot pins index 10 from the non steer end of the machine 23 Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm 24 Placea6x6x32 inch 15 x 15 80 cm long block across both sides of the chassis under the barrel end of the lift cylinder GS 84 GS 90 Part No 162336 April 2015 Service Manual Scissor Components 25 Lower the number 1 outer arm index 16 onto the block AWARNING Crushing hazard Keep hands 36 Place arod through the cable tray pivot pin and twist to remove the pin Lower the cable tray onto the number 1 inner arm index 8 clear of moving parts when AWARNING Crushing hazard The cable tray lowering the arms onto the block may fall if not properly supported by the overhead crane 26 Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder 27 Remove the lift cylinder barrel end pivot pin Component damage hazard retaining fasteners Cables can be damaged if they 28 Use a soft metal drift to remove the lift are kinked or pinched cylinder Patter end Pivar index 37 Secure both ends of the number 2 inner and 29 Carefully remove the lift cylinder from the machine outer arms index 5 and 6 together with a strap or other suitable device AWARNING Crushi
269. vice Manual Ls AN G9 2 9 5 C9 9 9 9 Non steer End Platform centering link Number 5 inner arm Number 5 center pivot pins Number 5 pivot pins non steer end Number 4 outer arm Number 4 center pivot pins Number 4 pivot pins non steer end Number 3 inner arm Upper lift cylinder barrel end pivot pin 10 Number 3 pivot pins non steer end 11 Number 3 center pivot pins 12 Number 2 center pivot pins 13 Number 2 pivot pins non steer end 14 Number 1 inner arm 15 Lower lift cylinder barrel end pivot pin OAN OAR Genie BRAND Part No 162336 GS 84 GS 90 N7 Scissor Components j 59 NV y S amp OE DANOG Q Steer End 16 Number 1 outer arm 17 Number 1 pivot pins non steer end 18 Number 5 outer arm 19 Number 5 pivot pins steer end 20 Number 4 inner arm 21 Upper lift cylinder rod end pivot pin 22 Number 4 pivot pins steer end 23 Number 3 outer arm 24 Lower lift cylinder rod end pivot pin 25 Number 3 pivot pins steer end 26 Number 2 inner arm 27 Number 2 outer arm 28 Number 2 pivot pins steer end 29 Number 1 center pivot pins 30 Chassis centering link 31 Number 1 pivot pins steer end 75 Service Manual April 2015 Scissor Components 3 3 Scissor Assembly GS 539
270. vot pin and twist to remove the pin Rest the centering links on the chassis 76 Remove the pin retaining fasteners from the number 1 inner arm slide blocks index 31 at the steer end of the machine 77 Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 31 78 Use slide hammer to remove the number 1 outer arm slide block pivot pins index 31 at the non steer end of the machine 79 Carefully remove the number 1 inner and outer arms index 14 and 16 from the machine AWARNING 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 Gen BRAND GS 84 GS 90 81 Part No 162336 Scissor Components How to Disassemble a Scissor Arm Pair AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Attach a lifting strap from an overhead crane to the end of the outer arm Note Attach the lifting strap to the end of the Scissor arm that has the casting pointing upwards 1 outer
271. when lowering the arms onto the block Secure the number 1 outer arm index 16 to the slide blocks Remove the strap installed in step 44 Support the cable tray with an overhead crane Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 26 Service Manual is Scissor Components 61 AWARNING 62 63 65 66 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 14 by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched Secure both ends of the number 2 inner and outer arms index 26 and 27 together with a strap or other suitable device Attach a lifting strap from an overhead crane to the number 2 inner and outer arms index 26 and 27 at the steer end of the machine Do not apply any lifting pressure Attach a lifting strap from an overhead crane to the number 2 inner and outer arms index 26 and 27 at the non steer end of the machine Do not apply any lifting pressure Remove the pin retaining fasteners from both number 2 pivot pins index 13 at the non steer end of the machine Do not remove the pins Remove the pin retaining fasteners from both number 2 pivot pins index 28 at the steer end of the machine Do not remove the pins 80 Crushing hazard The cable tray may fall if not pr
272. with step 9 Note For reference only the output of the level sensor should be approximately 3 4V DC To confirm connect the positive lead of a multimeter to the blue wire at the level sensor and the negative lead to the black wire 58 Lower the platform to the stowed position 59 Raise the machine slightly 60 Remove the blocks from under both wheels 61 Lower the machine and remove the jack 62 Turn the key switch to the off position Genie BRAND GS 84 GS 90 111 Part No 162336 Service Manual April 2015 Ground Controls 5 6 Engine Fault Codes Ford MSG 425 How to Retrieve Engine Fault Codes Ford MSG 425 The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Refer to Fault Codes section and use the Ford Engine ECM Fault Code Chart within the section to aid in identifying the fault 1 Open the ground controls side cover 2 Pull out the red Emergency Stop button to
273. y and significant component damage Dealer service is strongly recommended Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING Note When removing a hose assembly or fitting 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 position Lock the safety arm in position Note Be sure that the safety arm is locked in the vertical position Genie 86 GS 84 GS 90 Part No 162336 April 2015 Service Manual Scissor Components 3 Lower the platform onto the safety arm Turn Attach a lifting strap from an overhead crane the machine off or similar lifting device to the lifting eye at the rod end of the lift cylinder for support AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Component damage hazard The link set cross tube can be eg UMSO damaged if excessive force
274. y window 11 Press the lift function enable button to activate or deactivate the motion alarm option OR use the yellow platform down arrow to scroll to motion beacon Result MOTION BEACON is showing in the diagnostic display window 12 Press the lift function enable button to activate or deactivate the motion beacon option Note For this option to function correctly the machine must be equipped with flashing beacons 13 Models with platform overload option Use the yellow platform down arrow to scroll to overload Result OVERLOAD ON is showing in the diagnostic display window Result OVERLOAD OFF is showing in the diagnostic display window Press the lift function enable button to activate the overload option Ground Controls 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 operation option Note For all models except CE the sim operation option should be activated or in the on 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
275. yoke and drive motor assembly to a lifting jack 9 Remove the cotter pin from the tie rod clevis pin Note Always use a new cotter pin when installing a clevis pin 10 Remove the retaining fastener from the steer cylinder rod end pivot pin Remove the pivot pin 11 Remove the retaining fastener from the lower yoke pivot pin 12 Place arod through the and twist to remove the pin 13 Repeat steps 11 and 12 for the upper yoke pivot pin 14 Remove the yoke and drive motor assembly from the machine clamps Crushing h d Th k d 6 Remove the retaining fasteners from the drive A CAUTION pi 2 1 Be Remove the drive motor guard become unbalanced and fall if rom the yoke not properly supported and secured to the lifting jack when it is removed from the machine Genie BRAND Part No 162336 GS 84 GS 90 137 Service Manual April 2015 Steer Axle Components How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized dealer 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 severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification duri
276. z models Hold the manual fuel shutoff lever clockwise in the closed position 1 manual fuel shutoff valve Gi 1 1 1 116 GS 84 GS 90 Part No 162336 April 2015 Service Manual 44 Hydraulic Pump How to Adjust the Pump Neutral 9 Turn adjustment screw a clockwise direction to a position halfway between the Models with Eaton Pumps positions noted in steps 7 and 8 1 Raise the drive wheels off the ground and set 10 While holding the adjustment screw in the chassis on blocks position tighten the adjustment screw locknut 2 Locate the pump at the rear of the engine Torque to 9 11 ft lbs 12 15 Nm Tag and disconnect the wire harness from the 44 Turn the engine off Remove the blocks and Electronic Displacement Controller EDC lower the machine to the ground coils at the pump 3 Locate the pump neutral adjustment screw at the top of the solenoid valve body at the pump 4 Teea 0 to 1000 psi 0 to 75 bar pressure gauge into the hydraulic line at the smaller filter port at the rear of the pump 5 and run the engine at low idle 6 Loosen the lock nut of the pump neutral 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 adjustment screw in a counter clockwise direction until the reading on the pressure gauge reaches it hi

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