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1. LS12A OIL COOLER LIMIT SWITCH ___ OPTION LS13A 41607 4 NC 42 12 12 E oe OF 16018 o LOWER LS5A esses Er PLAT NC d CB7 T LIMIT SWITCH 20 1 LIMIT PI LS14A switch T fuos tower O LS 4 NC AC F HYDRAULIC BERT LIMIT SWITCH 5 47 eral COOLER DOWN t S LS15A 155 I LEVEL SWITCH LOWER PLAT ran 1 i SENSOR RR ORIG FAN MOTOR 4 LIMIT SWITCH LIMIT MODELS WITHOUT SWITCH BATTERY 12V __QUTRIGGERS 5 BK 6 6 C C C C c c c c c ra OO0F UD gt gt gt gt o gt 9 ERI U5 BN23 E BN91 ELECTRONIC CONTROL MODULE elo AUXILIARY DOWN B AUXILIARY DOWN ENABLE 1s P ABS 1 142 64 1 19 S 2 E 85 8 cRa2 amp Ne N C Mrd ito LIFT 1 CR77 enable 18581 fe 1524 DOWN LS25 S
2. December 2004 Section 6 Schematics Hydraulic Schematic REV D before serial number 40519 Part 2 of 2 1 OUTRIGGERS M STANDARD ON GS 5390 STEER PLATFORM LIFTCYLINDER LIFTCYLINDER OPTION ON GS 3390 AND GS 4390 CYLINDERS OVERLOAD ALL MODELS GS 5390 1 OPTION RIGHT LEFT RIGHT LEFT GS 4390 68 5390 FRONT FRONT REAR REAR HE iP ET HT H ae y Jm 69 69 II ee _ _ amp 1 35 41133 v LLL KNIT 71 eal tia te GS 4390 1800 psi 124 bar GS 5390 1100 psi 76 bar LJ J ie LEVI LEV2 i i D m LEN ca 207 P 207bar 740 Y39 e 2 5 O E 1 D 9 5 L min m une i FUNCTION MANIFOLD 0
3. WH RD c RD WH a BL B B E BK D DH a OR E 822222225524 pd 8 MM bees 1567 Function LS5A NG ENABLE PLAT up OUTRIGGERS EA STANDARD ON 058 5390 i NC 1552 1554 7566 05 5390 OPTION GS 3390 GS 4390 CIRCUIT BOARD ENGINE ENGINE PLATFORM t HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR O RIG MODELS WITHOUT 2 NC LIMIT LIMIT LIMIT LIMIT 2 5 5 OUTRIGGERS 8 GA SWITCH SWITCH SWITCH SWITCH 255 75 T gt gt 155 156 554 NO 4 NOs 2 PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION lt c c lt c gt gt gt gt gt gt w gt gt gt w gt gt gt a a a o a U5 ELECTRONIC CONTROL MODULE SO _ _______ e I 28 c c c S es c c c N c 1 15 m Es N gt gt gt gt 5
4. P2 ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM 2 C c L BK POWER TO PLATFORM EM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 WH BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM M
5. REVA before serial number GiS9003 41523 J1 Connector J2 Connector J3 Connector J4 Connector 36 pin 36 pin 18 pin 18 pin Pin Description Pin Description Pin Description Pin Description A1 Right turn coil A1 Start toggle switch 552 A1 Up limit switch LS5 A1 Fuel select toggle switch A2 Left turn coil Y4 A2 Platform up down toggle A2 Down limit switch LS6 TS53 A3 Up coil Y8 switch TS66 A3 Plug A2 Plug A4 Brake coil Y2 Plug A4 Platform controls data Plug 5 Plug A4 Plug 5 Platform controls data A4 High idle toggle switch A6 Plug Key switch KS1 Left rear outrigger limit TS54 A7 Plug A6 Level sensor S7 white switch LS14 A5 Alternator A8 Plug A7 Platform up down toggle A6 Plug A9 Down coil Y7 switch TS66 B1 Plug A10 2 speed coil Y1 A8 Front left outrigger limit B2 Plug B1 Water oil temperature 11 High speed bypass coil Y49 switch LS12 B3 Plug sender A12 Left front outrigger coil Y35 A9 Plug B4 Platform controls ground B2 Oil pressure sender A10 Front right outrigger limit B5 Right rear outrigger limit B3 Platform overload S5 B1 Flashing beacon switch LS13 switch LS15 B4 High idle solenoid U30 B2 Auxiliary power unit Aii Plug B6 Left rear o
6. REV B ANSI Models with Ford Power from serial number GS9004 41694 to GS9005 42143 Part 2 of 3 28 5890 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V PLAT _ NC 6018 8 1 SWA NJ CB7 po HYDRAULIC r 20A NC 4 OIL TEMP 4 LS AC HA HYDRAULIC CIRCUIT BOARD ABI PLAT LS5 6 ef a oiLcooLeR f PLAT 4 NC SWITCH rae ran 1 57 SENSO SWITCH FANMOTOR MODELS WITHOUT mal m BATTERY 12V L__QUTRIGGERS e L See E U5 l 4 07 BN23 BN91 ELECTRONIC CONTROL MODULE Ep AUXILIARY DOWN AUXILIARY DOWN ENABLE 32 89 S s 5 5 T 5 amp s J2 C4 gt gt 2 gt 8 5 8 Y4 Y1 Y9 Y51 i 1 EDC 1 X E EX dy t i i M5 4 dX ERX D7 Y7 SW1 sw2 S Y2 i i i 5 i 2 d lt 5 6 2 2 48 4 d 5 8 EH 8 DB 55 9 22 2 2 m m 2 m 3 mm 26 43 8 B B g 86 3 9 8 70 6 5 22 202 m 5 5 5 E 5 E D p E m 2 NOTE MACHINE SHOWN IN THE STOWED ES7163C POSITION WITH THE POWER OFF Part No 72863 Genie GS 3
7. P2 ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM a C c L BK POWER PLATFORM SEM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 WH BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM MEMBRANE DECAL POUT2 O g POWER LED L19
8. RIGHT RIGHT FRONT REAR tbt EDAM MIB 1 M3B eg MI rs MIA oe e L di tz Yi te Y2 2 5 0 0451 1 3 5 Limi tmm BL 68 GN in gt Lc 7 1 eui p1 1 1 mm t i t 50 50 1 1 z CSI tt ee Jmm 69 DENT m DRIVE uA rr EDH 6 MANIFOLD 20 7 bar 49 4 EN l M zr T ag Te IMP Mc LEFT LEFT FRONT REAR 1 1 c i B OI L oi 5 1 1 2 n T 7 3625 psi 7 250 bar CES 51 W gt Cm ir 8 10 8 gpm 6 5 0 to 30 gpm W OIL 40 9 Limi 24 6 Limi 010 113 6 Limi i pe COOLER OPTION d L Dui 248 bar DRIVE PUMP gt d d HYDRAULIC TANK HS7036C 6 108 Genie GS 3390 GS 4390 and GS 5390 Part No 72863
9. KS1 1 na EMERGENCY STOP 2 PLATFORM CONTROL 14 1 oe GROUND cer cd l 4 CB2 20a T T PS2 Y PLATFORM OVERLOAD H PRESSURE SWITCH CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 2 86 21 86 9 86 4 86 86 2 30 30 2 85 87 850 e aA D 85 85 e 7 85 7 t 5 n n 12 NCHO T USE G6 1523 O77 C77 1622 Y LEFT RIGHT LINK EAS 1 OSCILLATE OSCILLATE H2 gt LIMIT SWITCH LIMIT SWITCH 1 15 GOV SPEED SELECT OR RD 23 R6 FUELSELECTBKWH 7 5100 L 6 MALFUNCTION LED BL 11 24 KEEP ALIVE POWER WH 662 SW20 9 r 1 gt ENGINE SELF TEST Or 52 j j e 13 SELFTESTSWITCHBKRD 2 m Y54 Yse Y50 j n H FUEL PUMP BL WH tru 15 X X EX 1 1 Los FL ee E i ENGINE HARNESS ELI DNA Sv IE X x aA FUEL PUMP Y57 _ 55 i n n n 9 5 52 22 8 S e D 4 5 S gt FS gt x m gt N o a c c 2 o 2 o lt
10. Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 65 Section 6 Schematics December 2004 Electrical Schematic Deutz Models before serial number 40428 REV Part 1 of 3 IKS1 Kev swircn 1 EMERGENCY STOP PLATFORM CONTROL 18 re GROUND ONTROL 20A CR41 CONTROL CR42 CR5 CR8 CR1 CR58 SYSTEM POWER HORN IGNITION ENGINE START FWD REV 304 K5 30 86 30 86 86 86 A 85 zw D 4 EL 85 at E 87A 2 9 7 U5 ty b J4 A5 ELECTRONIC CONTROL MODULE J4 C3 i J4 B4 d gt gt 5 CR15 5 3 5 Sanne FUNCTION ENABLE m m U30 J a 8 51 D YA MODULE RB d EX 7 032 GLOW 4X T PLUG 1 H2 4 OPTION i NT s 8 90 6 8 55 8 E d 50 2E 2 e
11. J4 J3 Electronic Control Module J1 J2 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 3 Section 6 Schematics December 2004 Electronic Control Module Layout after serial number GS9003 41522 REVA Platform controls Flashing beacons To outriggers Up limit switch KIC To platform overload CE models Electronic Control Module J1 J2 Oscillate manifold Drive manifold Down limit switch Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics m t c U H4 J a an Electronic Control Module Pin Out Legend REVA after serial number GS9003 41522 J1 Connector J2 Connector 36 pin 36 pin Pin Description Pin Description A1 Right turn coil output A1 Up limit switch LS5 input A
12. REV B ANSI Models with Deutz Power from serial number GS9003 41523 to GS9005 42143 Part 2 of 3 3 GS 5390 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V PLAT NC Dis 8 SWA L poeme sion Ga EA N C 4 M 86 30 1 7 1 fuc _ i LEVEL SENSOR Y 15 C HA PLAT LS5 85 87 OIL COOLER DOWN MEE LIMIT PLAT NG LEVEL SWITCH ran 1 57 SENSOR SWITCH FANMOTOR MODELS WITHOUT me BATTERY 12V L__QUTRIGGERS BK 5555555 5 5 s gt gt gt gt gt w gt c 9 pcc U5 l 7 BN23 BN91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIARY DOWN ENABLE J2 C4 4 J2 C10 4 e co e c E CS gt T ar gt I gt gt cox T 4 J2 B9 5 Q gt LS 8 S 8 am m m 2 8 YA Y1 Y9 49 Y51 i i EDC __ 5 1 X 7 X AU AU Y7 sw2 1 1 49 5 2 6 5 Sou 5 gas 2 Bos 7 g 5 FZ E B RB g 89 2 2 2 m o nz ur Q gt 5 3 m 2 m Zug Sum FE j 9 3 96 5 gt 3 E B v m 9 a tC no Dum 3 lt 5 2 NE Nm T 2 2
13. J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK J 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 olx Lew PLATFORM CONTROLS 6 100 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 101 Section 6 Schematics D
14. QD4 WHIRD 4 4 4 4 BK POWER TO PLATFORM RD WH 34 3 p RD POWER ro GROUND 12 31 BL 1 it 1 1 H WH GROUND BK 2 2d va A 2 2 BL DATA LINK HIGH OR 5 5 _5 5 5 OR DATA LINK LOW DECEM OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 J5 PIN2 CDT 6512 CDi2 D7 PLATFORM CONTROLS VOLTAGE zy pc PRINTED CIRCUIT BOARD REGULATOR J2 PIN1 YL 41 HALL EFFECT 58 Wn j GENERATOR 2 AXIS 42 PIN12 1512 1813 1814 1815 TILT LEVEL qus BN CONTROLLER LF RF LR RR SENSOR J2 PINS LUMIT LIMIT J2 SWITCH SWITCH SWITCH SWITCH 8 21125 S Gy 2328 1533 J5 PINS SW5 SW6 2 gt JE BINS OR FUNCTION ENABLE gt 2 STEER A 29 LEFT RIGHT E J2 PING J2 PIN7 BD J2 PINE lt lt c lt c c aaa C toc C um T ppp P p p g 8 8 S288 122 2 POUTI U5 PIN2 HORN BN5 ELECTRONIC CONTROL MODULE PIN3 STARTING AID 2 PIN4 ENGINE START BN2 s 7 7 g g Ill pry 5 o 9 a o N 2 9 HIGH TORQUE BN6 5 e GENERATOR BN7 PE T
15. REVA FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41522 Fault Code LED Condition Result Solution 66 Check the engine oil level OR check wiring from the pressure switch to LOW OIL Red Low oil pressure Engine stops ECM PRESSURE OR replace the oil pressure switch Gasoline LPG models Check the engine radiator coolant level OR check the wiring from the water temperature 67 High engine temperature OR Switch to ECM OR replace the water HIGH COOLANT Red High coolant temperature defective engine coolant or oil temperature switch TEMPERATURE temperature switch Diesel models Check the engine oil level OR check the wiring from the oil temperature switch to ECM OR replace the oil temperature switch LOW ECU Red Low voltage System shutdown Charge battery VOLTAGE 69 T Consult Genie Industries Service LOW ENGINE Red Low RPM Engine idle RPM too low Department RPM 70 Consult Genie Industries Service HIGH ENGINE Red High RPM Engine RPM too high Department RPM 80 Left front outrigger coil Y35 LEFT FRONT Red fault Left front outrigger disabled Troubleshoot coil OR wiring OTRG COIL FLT 81 Left rear outrigger coil Y33 3 1 Red fault Left rear outrigger disabled Troubleshoot coil OR wiring COIL FLT 82 Right front outrigger coil Y36 22 RIGHT FRONT Red fault Right front outrigger disabled Troubleshoot coil OR wiring
16. AB3 71 09 5390 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V by d PLAT NC 2613 UP E laas ub 22552 em LIMIT 4 SWA i SUI HYDRAULIC bon NC 4 OIL TEMP 3 1 9 E ate LS AC HA HYDRAULIC CIRCUIT BOARD iar LS5 85 ef 7 OIL COOLER 7 DOWN 1 i LIMIT PLAT Aem S7 LEVEL SWITCH ran 1 SENSOR SWITCH FANMOTOR MODELS WITHOUT mal m BATTERY 12V L__QUTRIGGERS BK f 6 6 C C C C c 28 c c c c ra o 556o gt gt gt gt o gt e E SO NANI U5 T 7 BN23 BN91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIARY DOWN ENABLE J2 C10 1 J2 B9 s Jos Ed gt gt J2 C4 5 Q 2 N g S 8 am m m ABS lt Y4 Y1 Y9 49 Y51 4 EDC eX 5 X 1 X AL x Y8 2 SW swe 1 1 Y3 Y2 49 5 i 2 5 5 2 m 58 4 8 So a gt gt m m 8 OS d d 8 88 e Biz One 8 22 2 E z Sig 2088 se J 0 m m 8 uZ 8 5 Es 5 n4 guo 5 5 8 Siw 419 v md o o Bou 5 3 0J v m 2 gt m 2 ms m DV n n 2 lt Di o 0 5 4 5 08 5 Y49 AND Y49A WERE REMOVED
17. REV A before serial number GS9003 41523 CR41 CONTROL SYSTEM 86 30 5 Eo fera ELECTRONIC CONTROL MODULE amp lt PS2 v 8 5 5 E PLATFORM LS24 LS25 ESSURE MAXIMUM O LOAD SENSE imr f f 7 CR27 SWITCH SWITCH s E OVERLOAD e 4 3 CR42 C5 T i 4700 uF 85 87 87 4 dX 4 dX Y8 1 Y7 1 1 GROUND lt lt E 5 5 2 S g z 2 MACHINE SHOWN IN THE STOWED ES7167B POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 11 Section 6 Schematics December 2004 Wiring Harness Ford LRG 425 EFI before serial number GS9003 41 369 REV Part 1 of 2 THROTTLE ACTUATOR POSITION SENSOR FUEL INJECTOR VALVES 9999 4 3 2 1 WATER TEMP sa gt n DL SWITCH NO 1 1 o n 8 Bo 8H FE E BS 28 g8 ME 229 5 zz gt sz be 12 5 5
18. a 202 Level sensor models without outriggers a chassis b level sensor X indicator Y indicator GROUND CONTROLS 16 Connect the wire harness to the level sensor 17 Pull out the red Emergency Stop button to the on position at the platform controls 18 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Be sure there are threads showing through the top of the adjusting fasteners Result The tilt sensor alarm should not sound 19 Lower the platform to the stowed position 20 Raise the machine slightly 21 Remove the blocks from under both wheels 22 Lower the machine and remove the jack 23 Remove the blocks from the wheels at the non steer end of the machine 24 Block the wheels at the steer end of the machine 25 Center a lifting jack under the drive chassis at the non steer end of the machine 26 Raise the machine approximately 12 inches 30 cm 27 Place a 10 28 x 10 x 10 inch 26 11 x 25 x 25 cm thick steel block under both wheels at the non steer end of the machine 28 Lower the machine onto the blocks Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS 29 Raise the platform approximately 16 feet 5 m O Result ANSI and CSA models before serial number 40820 The tilt alarm will s
19. 2 L8 NHOH ATALS AAILOWOLNV cH YHOLOW H3 LHVLS H31HVLS EM 10439 99 MOD LSA SIN Q313NION3 593HO 21 1905 PW WHOd Y ld ZA 1331 9954 vA INHOd 1V ld INHVTV SH NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 18 Genie 605 3390 GS 4390 065 5390 72863 Section 6 Schematics Part 2 of 3 Electrical Schematic Ford Models before serial number 40428 December 2004 REVE 73 po MDIBONDOHO m LL 9 M8 A 123135 19154 4 To LLI LL J poy dMHOLMSIS3IJISS 81 M Pn 4 gt gt lt QRER g qus J4 C1 N Y50 LPG abiy S o a LLI 1 SARR 385865 gt E poss qe 2 9 18
20. 3 12 D Checklist B Procedures B 1 Inspect the Batory 3 13 B 2 Inspect the Electrical Wiring ornini neneiia 3 14 B 3 Perform Engine Maintenance Deutz 1011F Models 3 15 B 4 Check the Exhaust System 3 15 B 5 Replace the Engine Air Filter 3 16 B 6 Check and Adjust the Engine 3 17 B 7 Confirm the Proper Brake Configuration 3 19 B 8 Inspect the Tires and Wheels including lug nut torque 3 19 B 9 Check the Oil Level in the Drive Hubs 3 20 10 Test the Key Switches iain ecu ir alae 3 20 11 Test the Emergency riaan anaiei 3 21 B 12 Test the Automotive style 3 21 B 13 the Fuel Select Operation Ford Models 3 22 B 14 Test the Drive Brakes oae tici iie reca Feder i 3 23 B 15 Test the Drive Speed Stowed Position 3 23 B 16 Test the Drive Speed Raised Position 3 24 B 17 Perform Hydraulic Oil Analysis 3 25 B 18 Replace the Medium and High Pressure Hydraulic Filter Elements 3 25 B 19 Inspect the Fuel Tank Cap Venting 3
21. WH RD 4 4 1 RD WH 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRI
22. ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM 2 C c L BK POWER TO PLATFORM EM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 WH BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM MEMBRANE DECAL POUT2 O g POWER LED L19 POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP B
23. X 4 mem Electrical Schematic CE Models with Ford Power REVA after serial number GS9005 42143 Part 1 of 3 FOsaruse stop IKS1 Bi 41 PLATFORM CONTROL gt 31 GROUND CONTROL 4 C CB2 20a y T T PS2 Y PLATFORM OVERLOAD t PRESSURE SWITCH CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 ad D 86 sd 2 86 9 86 4 86 86 sd 86 3o 4 86 ao 2 BAT SE 85 87 85 e aA as 7 a ef Tera 85 ef 7 85 7 851 85 870 Fazal 12 NCHO truse G6 1523 7 7 1522 LINK Y E LEFT RIGHT EAS 1 OSCILLATE OSCILLATE H2 gt LIMIT SWITCH LIMIT SWITCH i 15
24. 198 06 0 18 32 ANA AUX PD1 E dd 150065018 37 ANA AUX PU1 114 LE Y 18 114 LE Y 18 12FPP2 352 BRLG 18 352 BRLG 18 S60 BF PK 18 41 22 359 GY R 18 359 GY R 18 33 ANARTN 351 BR W 18 31 VREF 16 R LG 18 32 R LB 16 E MTRTWR6 MTRSHD6 THROTTLE 13 STARTER CONTROL 355 GY W 18 sss avw 18 FUEL PUMP STARTER 357 YW 18 Zz aszYwi8 RELAY RELAY 151 LB BK 18 151 LB BK 18 317 GY O 18 S 317Gv018 4 D 1 15 STARTER IN INTERUPT 351 BR W 18 32 RB 16 E 3 359 GY R 18 39 STARTER IN AUTOCRANK 2 342 LG P 18 iul 342 LG P 18 359 GY R 18 D 787A PK BK 16 eys 5 FUEL PUMP 351 BR W 18 669 DG W 18 B TX 458 O BK 18 A RX TWR 86 926A LB O 18 52 15 18 361 16 T 253 06 18 OIL PRESSURE 0 OO 511 LG R 18 511 LG R 18 4 BRAKE 253 DG W 18 o 1 1 253 DG W 18 658 PK LG 18 L 2 658 PK LG 18 238 DG Y 18 _ 7101018 _ TEER TS _ 2 148 YR 18 148 Y R 18 10 AUX ANA PU2 1 LM sor BKY 18 23 GOV SELECT 2 l Se 35 ROADSPEED VALERI 172 LE R 18 2 349A 18 IL 30 OVERSPEED 662 DG P 18 28 CAN 459 2018 459 O LG 18 29 620 018 642 06 0 18 11 RS 485 3 RS 485 muera ere 458 O BK 18 18 RS 232 TWR SHD 570 BICW 6 A PLUG GROUND 261A R16 B B
25. SS E T 42 sl EPI ed 22 Es oele Ht Lt 5 7 LL i ptem ROSE NES 84 efg SPs N 5 TM B e 38 5 E _ e ret p UT 1 x Bu BN 1 A claret P i 8 228 gt 4 3 Ecce eee ee Je m EA o l lor Lill 890 He EFE c 45 HN Na AER Ix s Hig f JP Oe ro 38 Aa as IES gel 158 8E wh 28 95 mo 85121 Y 29 i Ime TE ELE 18 ONERE NC Pye RES RR eS SS 1 hat B gel el 5 51 SU NS 9 D dec HE I ra 1 Wis WIR 6 iem TR H N x x AD lt J al P 653 3 HEEL a es y A REV HS7037J 6 113 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 Section 6 Schematics December 2004 poU This page intentionally left blank 6 114 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 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 Genie North Ame
26. a TOI E Y 42 6 saij gp 981 ____ 4 JC1 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM amp OUTRIGGER UP DOWN
27. PLATFORM CONTROL B pu ee GROUND 4 4 CR41 CR1 CONTROL CR42 CR5 CR8 ENGINE CR58 SYSTEM POWER HORN IGNITION START FWD REV 4 86 2 a 304 86 86 T 86 A a 87 85 87A D 4 857 m f 857 87 857 T s E Tes FH oc oe 58 88 298 os D1 G6 E L J4 A5 U5 H2 2 ELECTRONIC CONTROL MODULE J4 B4 J1 C11 C12 gt gt gt N R4 mS N R TS69 15 251 2 AUXILIARY FUNCTION ENABLE STARTING 86 0 Epc 9 AID 45 4 TS70 86 30 85 87 87 AUXILIARY Y4 PIN a PLATFORM DOWN f 85 ef F17 M5 ERN aX 15 FUSE zm 4 032 gt Tas GLOW 4X X FUEL PLUG Q3 t SHUT OFF OPTION HIGH IDLE SOLENOID eee Y7 Y8 n 1 4 4 4 4 n 4 8 0 5 5 55 EO UE gt n gt I T gt v o lt GS 35 5 2 5 5 S E amp H B 3 Der m o I 2 E gt 8 m E um 5 gt 2 2 a m m se gt lt 9 2 2 gt T JE 2 2 2 gt d lt m lt c E4 lt gt 2 go z 4 E c Jy 7 c c gt m 2 v 2 5 X m o lt 2 lt 52 3 Y m z m 5 m 5 5 17 9 8 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF
28. voltage ND Repair charging system OR replace the 361 18 volts for 5 seconds anytime the engine is supply high cranking or running MegaJector Repair VBAT power or ground circuit to 362 MegaJector voltage 95 ECM MegaJector OR replace battery supply low 9 OR repair charging system OR replace the cranking or running MegayJector 5 12 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes REVA FORD ENGINE ECM FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41 368 Code Problem Cause Solution Megajector internal actuator fault detection 363 The MegaJector detects an internal fault Open or short in power ground or CAN circuits s Check Power Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault Contact Ford Power Products for assistance Megajector internal circuitry fault detection 364 The MegaJector detects an internal circuitry failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault Contact Ford Power Products for assistance MegayJector internal communication fault detection 365 The MegaJector detects an internal communications failure Open or short in power ground or CAN circuits Check Power Ground
29. 6 82 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REV Deutz Models from serial number 41066 to GS9003 41350 Part 2 of 3 WH RD c RD WH a BL LS5A ADDED AFTER SERIAL NUMBER 41323 5 27 1 OR E 822222225524 pd 8 Ee Ne TS67 Function LS5A MG ENABLE PLAT up OUTRIGGERS Ed STANDARD ON 058 5390 i NC 1552 1554 7566 05 5390 OPTION GS 3390 GS 4390 CIRCUIT BOARD ENGINE ENGINE PLATFORM t HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR O RIG MODELS WITHOUT NC LIMIT LIMIT LIMIT LIMIT 2 5 9 OUTRIGGERS 5 H A SWITCH SWITCH SWITCH SWITCH 2 5 5 BN 155 156 554 NO 4 NOs NO 2 PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION lt
30. REV D Hydraulic Specifications Hydraulic Oil Specifications Before serial number GS9003 41223 Hydraulic oil type Shell Donax TG Dexron Ill After serial number GS9003 41222 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron Ill oils 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 have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties 3390 Optional fluids PIRUDHIUHD Biodegradable Petro Canada Premium ECO 46 Platform down 29 seconds Statoil Hydra Way Bio Pa 32 BP Biohyd SE S GS 4390 Fire resistant UCON Hydrolube HP 5046 Platform up 45 seconds Quintolubric 822 Platform down 39 seconds Mineral based Shell Tellus T32 Shell Tellus T46 GS 5390 Chevron Aviation A Platform up 55 seconds Platform down 49 seconds Genie specifications require additional equipment and special Airborne noise emissions 80 dB Maximum sound level at normal operation workstations A weighted Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice in
31. i gt e er X kl ol Lx Fy eme em DRIVE 19 3 bar amp 4 MANIFOLD 27 To ______ 1 LEFT LEFT FRONT REAR ZR 1 2 T Y51 71 3750 M 11 258 6 0 10 _______ Toren 4 L min to 8760 COOLER EE pur 2 DRIVE PUMP e L 25 1 7 HYDRAULIC TANK HS7043A 6 112 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 Section 6 Schematics December 2004 Hydraulic Schematic after serial number GS9004 41618 Part 2 of 2 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 AND GS 4390 LIFT CYLINDER ALL MODELS PLATFORM OVERLOAD OSCILLATING AXLE OPTION SF
32. U5 ELECTRONIC CONTROL MODULE SO _ _______ e I 28 c c c S es c c c N c gt a gt 5 5 m E Ai At o Y2 Yi Y29 Y49A H5 Y36 Y34 Y40 S t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt DJ 54 1 g SW2 AEX dX Q AX EXI 51 Lt L4 FB1 9 t 49 35 33 39 5 4 B g i 8 2 9 w 2 2 gt gt o a 2 Dy m 2 9 3 3 R a og 5 2 5 m 5 gt m 2 gt D m x z z a 5 o 2 9 I J3 I d 3 8 5 9 m 2 2 a 2 m 3 gt 5 gt m 2 2 m e m 5 5 8 o m z o o 2 gt lt m 9 o 2 9 gt 2 m 5 p i z 2 2 5 2 5 5 3 8 p 6 2 5 2 gt m 2 m 9 a gt o e o c 4 2 E D c 2 m 3 6 5 2 2 amp 6 m 2 5 Q Q o 5 D 2 c gt 5 o 4 gt 2 2 gt o m m m 9 2 m 2 2 2 2 2 5 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 71 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40428 to 40737 REV D Part 3 of 3 P2
33. red Emergency Stop button P1 b platform up down toggle switch TS66 function enable toggle switch TS67 9 Release the toggle switches push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position REV D DIP Switch Function Definitions If replacing the circuit board note the toggle positions on the DIP switches Set the DIP switches on the new circuit board to the same configuration of the old one Gasoline LPG Indicates that the machine is gasoline LPG powered Diesel Indicates that the machine is diesel powered Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out This cuts out lift and drive functions when the machine exceeds the rating on the serial plate Required for Europe and Australia before serial number 40820 Installed on all machines after serial number 40819 Motion Beacon The motion beacon option flashes only when operating a function Overload This cuts out all functions when the pressure sensor is overloaded The Emergency Stop button must be cycled before any function can be resumed Required for Europe Descent Delay This option halts descent at approximately 12 feet 3 6 All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe No Simultaneous Operation This does not allow the machine lift and drive functions to op
34. 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3
35. a FORD 42 PIN QUICK DISCONNECT i i ENGINE HARNESS 2 SEE ELECTRICAL SCHEMATIC FORD ee a TY TACHLEAD 21 11TY20 R GN KEEP ALIVE PWR 1 earners Y KEEP ALIVE PWR 8 37BY18 R W WATER TEMPERATURE SWITCH 163 39RW20 Y VPWR 91 37Y12 PK BK FUELPUMP OUTPUT 5 787PK BK16 VREF 31 2 351DBR W20 4 BK W BATTERY 34 2 570CBK WI2 BATTERY 42 570EBK W12 P DATALINK 22 107P20 DB BK DRIVE BY WIRE SIGNAL INPUT 14 151LB BK20 AUXILARY INPUT 37 198DG O20 W P SELF TESTINPUT 18 209W P20 GOVERNOR SPEED CONTROL 24 306T LB20 BK Y GOVERNOR SPEED CONTROL 25 307BK Y20 PK LG FAULT LIGHT 6 9 658PK LG20 FUELSELECT 7 674Y BK20 T O CONNECTOR 11 914 20 PK LB CONNECTOR 3 915PK LB20 BL STARTER INPUT 15 1 32ADKBL16 GY R DRIVE BY WIRE SIGNAL RETURN 33 1 2 359LGY Y20 4 R LB STARTER OUTPUT 13 32R LB16 GN W PRESSURE SWITCH 26 253DG W20 NOTE SHOWS USED WIRES 1 J 1 i i a wo ono co Co z Fass 8 55 283 Sg gga 859 205 gt 98 595 55 i MATING FACE 5 xo 29 2g 99 23 SHOWN as E E LI zc
36. d 24 m z E m 9 zi i E 2 2 2 5 2 9 lt 3 2 9 2 gt 2 5 Q Q Q 5 D 2 c gt 2 o m 4 gt D 2 gt o m m m 9 2 m 2 2 A z 2 2 3 1 MACHINE SHOWN IN THE STOWED ES7142C POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 79 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40942 to 41065 REV Part 3 of 3 P2 P2 ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM 2 C c L BK POWER TO PLATFORM EM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITC
37. 250 bar ES 51 W 0 9 amp Ft Teu umm DES poor 250 bar OPTION I d L Dui 248 bar DRIVE PUMP gt ee ee iu HYDRAULIC TANK HS7036C 6 110 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Hydraulic Schematic REVG from serial number 40519 to GS9004 41618 Part 2 of 2 OUTRIGGERS STANDARD 63 5390 OPTION ON 95 3390 AND 95 4390 PLATFORM LIFT CYLINDER LIFT CYLINDER i OVERLOAD ALL MODELS 05 5390 OPTION i E RIGHT LEFT RIGHT LEFT REAR REAR t 11 si 1 1 pl gl e 69 69 226 ur Ml AE _ _ 5 amp 1 aud E al 1 4 4 MEN
38. c c lt c 1 gt gt gt gt gt gt w gt gt gt w gt gt gt a a a RR U5 ELECTRONIC CONTROL MODULE SSS SS e l 28 c c c S c c c N c 1 gt 5 5 m Es N gt gt p x 5 z b gt mrs sii N a 4 At swa Y2 Y1 Y29 Y49A H5 Y36 Y34 40 sg t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt n SENSOR DJ 54 y 1 g SW2 40 AX 1 Y9 Y49 Y35 Y33 Y39 4 4 4 4 n 4 n E g 3 gt dm 2 2 gt m gt 2 m 2 5 m E m c 2 m m 9 9 9 2 gt D o m S 2 2 m 0 5 d y 5 D 2 m E gt Q m J 2 m Q Q m m o m o 2 gt o lt e m 9 o 2 9 gt 2 m 5 m 2 E w gt 2 2 5 gt 2 5 m 5 Q m E o E 2 gt 2 0 x m 3 Q e d 5 4 2 m zi 9 E zi m 2 5 2 o lt wo z E 2 gt a Q 2 5 Q Q o 5 D 2 c 4 S 5 5 0 0 m gt 2 2 2 2 2 c A 2 2 2 5 1 i MACHINE SHOWN IN THE STOWED ES7142D POSITION WITH THE
39. 1 1 1 Lig vate STARTER zi ob 5 1 1 M3 2 d Y8 4 4 4 n n 4 4 5 9 55 Far S 22 az c 8 5 E S gt 5 m og o m 5 5 gt gt gt 3 3 22 gt X E m 5 g mom 2 gt 2 v E o d 9 D I gt 2 m gt m md J m 5 c D Dv 5 5 2 c amp 5 2 lt lt D lt lt D gt 2 E 2 m z Q o MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 30 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics Part 2 of 3 Electrical Schematic December 2004 Ford Models from serial number 40996 to 41065 REVA fo 1 a e LL E M8 A 199195 1304 l D H E 5 d M HOLIMS 1531 414 8L F Se 1 gt mE SE J4 C1 N Y50 LPG SE 5 38 95 CN E 1 Exec T spes i18 8 58 QZW V Ee 9 187 LEVEL SENSOR gt
40. REV MANIFOLDS QO v D BA 1 gt BB 3 a Q X LA Ue C BF 2 6 8 9 Q 9 12 13 Q Cp 59 key O 16 B A 1 Part 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 MANIFOLDS 7 6 REVE Drive Manifold Components after serial number GS9004 41 618 The drive manifold is located under the function manifold Index Schematic No Description Item Function Torque 1 Flow divider combiner valve Controls flow to flow divider combiner valves ED and EL in forward and reverse 50 ft lbs 68 Nm 2 Orifice Plug 0 043 inch 1 1 mm Balances flow from flow divider combiner item EL to front drive motors 3 Diagnostic nipple EG us Testing P2 pressure port 4 Orifice Plug 0 046 inch 1 2 mm ED Balances flow from flow divider combiner item ED to rear drive MOTOTS dee PEE ETE RE HER 25 ft Ibs 34 Nm 5 Relief valve 280 psi 19 3 bar Charge pressure 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
41. FLASHING BEACON OPTION 9 E lt m 4 o 58 id Qi 388 9 1 gy Y49A FLOW CONTROL BYPASS e 5 gt E Oss a gt 4 125562 g 2 gt 2 Sg NMOG 42 2 wE Ji AM 1 Y49 FLOW CONTROL BYPASS 5 55 4 A 5 gt BAT 5 J4B6 Y29 GENERATOR OPTION J 9 N 5 o i uj gt lt lt i5 2 9 PROPORTIONAL FLOW CONTROL 0225 25 Faz gt 9 5 J1 A10 1 TWO SPEED MOTOR STROKE Dua 2 2 52 J4 A1 STEER RIGHT Qu e gt 25 5 ta 1 Y2 BRAKE RELEASE 2 7 4 J2 A1 4 6 27 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40794 to 40995 Part 3 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTION
42. saij gp 981 ____ 4 JC1 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM amp OUTRIGGER UP DOWN TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 728
43. Checklist D Rev D A 9 Filter condition indicator Perform every 125 hours A 10 Engine maintenance Deutz 1011F models Perform every 200 hours A 11 Filter separator Deutz models A 12 Engine maintenance Ford models ChecklistB RevD Y NR Rev D Y N R B 1 Battery B 2 Electrical wiring B 3 Engine maintenance Deutz 1011F models B 4 Exhaust system B 5 Engine air filter B 6 Engine RPM B 7 Brake configuration B 8 Tires and wheels B 9 Drive hub oil level B 10 Key switch B 11 Emergency Stop B 12 Horn B 13 Fuel select Ford models B 14 Drive brakes B 15 Drive speed stowed B 16 Drive speed raised B 17 Hydraulic oil analysis D 1 Scissor arm wear pads D 2 Free wheel configuration 0 3 Drive hub oil D 4 Filter separator Deutz models D 5 Platform overload if equipped D 6 Hydraulic filter Perform every 1000 hours D 7 Engine maintenance Deutz models Checklist E Rev C Y NR E 1 Test or replace hydraulic oil Perform every 2000 hours E 2 Engine maintenance Deutz 1011F models Perform every 2400 hours E 3 Engine maintenance Ford models Perform every 3000 hours E 4 Engine maintenance Deutz models Perform every 12 000 hours E 5 Engine maintenance Deutz 2011F models Perform every 4 years E 6 Engine maintenance Ford models
44. PIN18 2 WH RD 4 POUT2 POUT4 POUTS POUT6 POUT7 POUT8 Oo OUO N PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REV C P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos Ss Ss D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGU
45. PLATFORM amp OUTRIGGER UP DOWN TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics EEE REV D This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 25 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40794 to 40995 REV Part 1 of 3 Ses IKS1 P1 B EMERGENCY STOP 19 15 PLATFORM CONTROL 1 B dm GROUND 12 7 CONROE 7 2 20 CR41 CR1 CR58 contro CR42 CR5 CR8 ENGINE FORWARD SYSTEM POWER HORN IGNITION START REVERSE 4 4 86 2 i 86 304 86 86 gt ii 86 85 87 85 e aA D 85 of 859 87 87 857 i Se Fh OF 9 U5 2 ELECTRONIC CONTROL MODULE e M 1 c A 154 5 gt gt n m ac 8 Y51 5 jane LINK Epc 9 AUXILIARY R6 FUNCTION ENABLE TS70 5 4 AUXILI
46. 1 nes LS12A ME NC m A OIL COOLER OPTION 1657 4 NC J2 C12 BATTERY 12V LS13A N C 8 LSA LIMIT SWITCH UP HYDRAULIC 20A NC 4 cba OIL TEMP _ LS14A N C towen 3 17 1 LS 4 NC AC HYDRAULIC PLAT LIMIT SWITCH 85 OIL COOLER i f DOWN LIMIT LS15A 155 LEVEL SWITCH LOWER PLAT ran 1 87 SENSOR RR ORIG 4 LIMIT SWITCH LIMIT MODELS WITHOUT 6610 SWITCH BATTERY 12V __QUTRIGGERS 26 8 6 C C C C C a c c c c c ra o o o0ooo0 gt gt gt gt 5 ENERO Vo sd OR a i orl Nu EBORE U5 T 4 07 BN23 1 ELECTRONIC CONTROL MODULE AUXILIARY DOWN 5 AUXILIARY DOWN ENABLE 1 J2 C10 ABTA 1 DN S 2 142 9 i ABST ABIS Q 5 gt E 2 9 S g 04 NO N C 82 cA LIFT CR77 enable 18581 LS24 DOWN LS25 S GS 5390 ONLY ENABLE LOAD 8 86 30 HEIGHT SENSE CR82A LIMIT 186 30 DELAY Y4 Y1 Y9 Y49A Y51 t e va switch LIMIT ty Ly 1 EDC ENABLE LA sf ef SWITCH 1 X
47. 17 Duce 804 LS 4 NC AC HA HYDRAULIC ABT PLAT LIMIT SWITCH o a ef Ven COOLER DOWN LS15A 155 LEVEL SWITCH LOWER PLAT 1 87 SENSOR RR ORIG UP FAN MOTOR 4 LIMIT SWITCH LIMIT MODELS WITHOUT 0101 SWITCH BATTERY 12V __QUTRIGGERS eee Sa aa 6 C C C C C c c c c c ra PEP PPP 5 p 5 pP gt gt gt gt 9 PE U5 BN23 BN91 ELECTRONIC CONTROL MODULE V exo AUXILIARY DOWN 5 AUXILIARY DOWN ENABLE 102 9 ran 1s T 505 2 04 6516 1 ABST ABIS Q 5 gt 2 9 g NO N C 10882 A 77 enable 18581 1524 DOWN LS25 S 69 5890 ONLY LOAD 2 5 86 9 HEIGHT SENSE CR82A LIMIT 186 30 DELAY Y4 Y1 Y9 Y49A Y51 l et af Yora switcH po a LIMIT 4 EDC ENABLE 19 sf SWITCH X E X X x 1 Y ABS 12 1 ABS Y7 5 1 Gt 07 4 dX dX j IF GS 5390 YO ___ C5 E SW1 Y49 SW2 4 n 1 h 4 4 4 5 3 4 3 5 Suk 493 RE E rn 8 5 5 Sum as gt gt 2 8 5 5 S9 T a 2 2 8 our 2 gt
48. 24 Carefully lift the platform off of the machine and place it on a structure capable of supporting it ADANGER Crushing hazard The platform will become unbalanced and fall when it is removed from the machine if not properly supported by the overhead cranes AWARNING 2 19 injury hazard The platform slider blocks could fall out from under the platform if they are not secured to the platform Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV C 2 2 Platform Extension Deck How to Remove a Platform Extension Deck Perform this procedure with the platform in the stowed position and the platform extension deck s fully retracted and locked in position If the machine is equipped with the dual extension deck option repeat this procedure for the other platform extension deck 1 Steer end extension deck Remove the platform controls from the platform and lay them off to the side of the machine 2 Remove the retaining pins from the four black plastic railing guides Lower the railing guides in the down direction 3 Remove the mounting fasteners from the platform extension deck stop brackets at both sides of the deck The platform extension deck stop brackets are located above the platform V roller wheels 4 Atthe platform extension deck to be removed position a fork lift with the forks even with the bottom of the platform extension deck 5 Lift
49. 85 AE 510 o o m 2 2 5 Dy m a 4 5 gt 5 9 E g 5 2 85 3 g 8 R 2 8 5 55 a m gt 2 mc c v 2 5 lt lt 2 lt lt 3 2 m mu 0 2 m lt MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142A Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REV Deutz Models before serial number 40428 Part 2 of 3 WH RD c RD WH a BL B E BK D D wa OR E DOEA pd 8 TS67 RON es FUNCTION OUTRIGGERS 775 STANDARD GS 5390 1552 1554 7566 OPTION ON GS 3390 GS 4390 CIRCUIT BOARD ENGINE ENGINE PLATFORM t HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR O RIG O RIG MODELS WITHOUT 4 NO LIMIT LIMIT LIMIT LIMIT 2 5 5 OUTRIGGERS 5 A SWITCH SWITCH SWITCH SWI
50. BH as Charge pressure 20 ft lbs 27 Nm 9 Solenoid valve 2 position way Brake release circuit 20 ft lbs 27 Nm 10 Solenoid valve 2 position 3 way 2 speed motor shift circuit 20 ft lbs 27 Nm 11 Orifice Plug 0 035 inch 0 9 mm BK Brake circuit 12 Orifice Plug 0 045 inch 1 1 mm BL 2 speed motor shift circuit 13 Orifice Plug 0 045 inch 1 1 mm BM 2 speed motor shift circuit 14 Flow regulator valve 2 5 9 5 L MIN BN Balances flow from flow divider combiner item BQ to flow divider combiner valves BO and BP 25 ft lbs 34 Nm 15 Flow divider combiner valve BO is Controls flow to non steer end drive motors in forward and reverse 30 ft lbs 41 Nm 16 Flow divider combiner valve Controls flow to steer end drive motors in forward and reverse 30 ft lbs 41 Nm 17 Flow divider combiner valve Controls flow to flow divider combiner valves BO and BP in forward and reverse 50 ft lbs 68 Nm 4 96 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures
51. Be sure the air cleaner intake hose is inserted in the hole in the front of the engine slide out tray 3 16 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D B 6 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential 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 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 Perform this procedure after warming the engine to normal operating temperature Ford models The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department OR your local Ford dealer CHECKLIST B PROCEDURES Deutz models 1 Start the engine from the ground controls 2 Before serial number GS9004 41523 Move and hold the start toggle switch to the start position and check the engine RPM on the diagnostic display Refer to Section 2 Specifications After serial number GS9004 41522 Press a
52. N C H O 7 N C H O CB2 1523 5 _ LS22 20 LEFT RIGHT OSCILLATE OSCILLATE LIMIT SWITCH LIMIT SWITCH CN 1 lt lt 4 DK A lt 57 55 1 014050 PSA 280 ZSA 280 1481 9SA 878 050 SSA Zt 18 Part 72863 Genie GS 3390 GS 4390 and GS 5390 4 115 Section 4 Repair Procedures December 2004 Non steer Axle Components 10 1 Drive Motor and Brake How to Remove a Drive Motor REV 2 Tag disconnect and plug the hydraulic hoses from the drive motor and brake Cap the fittings on the drive motor and brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and and Brake burn skin Loosen hydraulic Combonentdamaae hazard connections very slowly to allow CAUTION 9 the oil pressure to dissipate Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer gradually Do not allow oil to squirt or spray Component damage hazard The Remove the drive motor mounting fasteners CAUTION work area and surfaces where this 4 Slide the drive motor shaft out of the brake and procedure will be performed must remove the drive motor from the machine 5 Remove the brake from the drive hub could get into the hydraulic system and cause
53. Platform controls before serial number GS9003 41523 Platform controls after serial number GS9003 41522 alarm H1 function enable high speed select button for platform up down function BN12 function enable low speed select button for platform up down function BN13 d platform up down toggle switch TS20 OR platform up down and outrigger up down toggle switch TS21 circuit board DIP switch SW25 joystick controller JC1 potentiometer red Emergency Stop button P2 om 4 2 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Loosen the platform control box lid retaining fasteners Open the control box lid 3 Visually locate the circuit board mounted to the inside of the platform control box lid 4 Secure the control box lid in a level position 5 Tag and disconnect the wire connectors from the red Emergency Stop button 6 Tag and disconnect the wire harness connectors from the platform controls circuit board Electrocution hazard Contact with AWARNING 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
54. Result The alarm does not sound and the engine continues to run Proceed to step 49 W Result The alarm sounds and the engines stops running The load sense delay limit switch needs to be calibrated Proceed to step 42 42 Raise the platform to approximately 6 m 43 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 44 Loosen the fasteners securing the load sense delay limit switch cam just enough to allow movement of the cam 45 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 46 Return the safety arm to the stowed position 47 Raise the platform approximately 1 m 48 Repeat this procedure beginning with step 41 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST D PROCEDURES Enable the descent delay function 49 Push in the red Emergency Stop button to the off position at the ground controls 50 Turn the key switch to ground control 51 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 52 Use the yellow platform down arrow to scroll to
55. 1 Locate and close the three hydraulic shutoff valves located at the hydraulic tank if equipped closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff 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 The hydraulic tank shutoff valves can be accessed from under the hydraulic tank tray 2 Release the latches on the engine tray and fully slide the engine tray out 3 Insert a 6 inch 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving HYDRAULIC PUMPS 4 Tag disconnect and plug the hydraulic hoses from the lift steer pump Cap the fittings on the 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 5 Remove the pump mounting fasteners Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump See 6 2 How to Prime the Pump Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 85 Section 4 Repair Procedures December 2004 HYDRAULIC PUMPS 6 2 Drive Pump T
56. 5 5 OR DATA LINK LOW DECEM OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 J5 PIN2 CDT 6512 CDi2 D7 PLATFORM CONTROLS VOLTAGE zy pc PRINTED CIRCUIT BOARD REGULATOR J2 PIN1 YL 41 HALL EFFECT 58 Wn j GENERATOR 2 AXIS 42 PIN12 1512 1813 1814 1815 TILT LEVEL qus BN CONTROLLER LF RF LR RR SENSOR J2 PINS LUMIT LIMIT J2 SWITCH SWITCH SWITCH SWITCH 8 21125 S Gy 2328 1533 J5 PINS SW5 SW6 2 gt JE BINS OR FUNCTION ENABLE gt 2 STEER A 29 LEFT RIGHT E J2 PING J2 PIN7 BD J2 PINE lt lt c lt c c aaa C toc C um T ppp P p p g 8 8 S288 122 2 POUTI U5 PIN2 HORN BN5 ELECTRONIC CONTROL MODULE PIN3 STARTING AID 2 PIN4 ENGINE START BN2 s 7 7 g g Ill pry 5 o 9 a o N 2 9 HIGH TORQUE BN6 5 e GENERATOR BN7 PE TR LPG SELECT BN14 Y36 Y34 Y40 Y29 oe HIGH IDLE BN4 1 d rS I PIN9 e 7 LF OUTRIGGER ENABLE BN85 Do qi a 277 PIN10 RF OUTRIGGER ENABLE BN86 T d eX Q 1 D PINT 04
57. December 2004 SCISSOR COMPONENTS 50 Secure both ends of the number 2 inner and outer arms index 8 and 20 together with a strap or other suitable device 51 Attach a lifting strap from an overhead crane to the number 2 inner and outer arms index 8 and 20 at the steer end of the machine Do not apply any lifting pressure 52 Attach a 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 53 Remove the pin retaining fasteners from both number 2 pivot pins index 9 at the non steer end of the machine Do not remove the pins 54 Remove the pin retaining fasteners from both number 2 pivot pins index 21 at the steer end of the machine Do not remove the pins 55 Use a slide hammer to remove both number 2 pivot pins index 9 from the non steer end of the machine 56 Use a slide hammer to remove both number 2 pivot pins index 21 from the steer end of the machine 57 Carefully remove the number 2 inner and outer arms index 8 and 20 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair REV D 58 Remove the cables from the number 1 inner arm ind
58. Deutz models a manual fuel shut off lever 4 Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 300 psi 20 7 bar 5 Ford models Connect the hose to the LPG tank and open the valve if equipped Move the fuel select toggle switch at the ground controls to the gasoline position Deutz models Release the manual fuel shut off lever 6 Start the engine from the ground controls and check for hydraulic leaks Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 Manifolds REV 7 1 Function Manifold Components Models with Outriggers before serial number 40519 The function manifold is located in the chassis tray on the ground controls side of the machine Index Schematic No Description Item Function Torque 1 Check valve dtes Steer circuit i tries 25 ft lbs 34 Nm 2 Check valve iere Bau Auxiliary pump 20 ft lbs 27 Nm 3 Priority flow regulator valve 2 5 9 46 L min Steer 25 ft lbs 34 Nm 4 Relief valve 3500 psi 241 3 bar Dices 20 ft lbs 27 Nm 5 Relief valve 2000 psi 138 bar Eas Steer and outrigger 20 ft lbs 27 Nm 6 Diagnostic nipple ae Testing 7 Solenoid valve
59. LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 Lew PLATFORM CONTROLS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 45 Section 6 Schematics December 2004 ET Electrical Schematic ANSI Models with Ford Power REV from serial number GS9004 41694 to GS9005 42143 Part 1 of 3 51 P1 B 212 EMERGENCY STOP PLATFORM CONTROL
60. O a diagnostic display b blue platform up button lift function enable button d yellow platform down button Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Pressthe lift function enable button 6 Use the yellow platform down arrow to scroll to max high speed drive Result HIGH SPEED DRIVE is showing in the diagnostic display window 7 Pressthe 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 Section 2 Specifications The performance achieved should always be within specifications 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground controls 11 Check the stowed drive speed of the machine Refer to the Maintenance procedure B 15 Test the Drive Speed Stowed Position Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D Models with software revision or higher 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 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 Emerg
61. Orifice controls flow side to side at AC System relief BH Charge pressure circuit steer end AD Proportional differential sensing valve Bl BEEN circuit RERE EC Test port 2 AE Steering and outrigger circuit BJ 2 speed motor shift circuit ED Orifice controls flow side to side at AF Testing 99 BK Brake release circuit non steer end AG Platform up down BL 2 speed motor shift circuit EE Charge pressure circuit AH Steer left right 2 speed motor shift circuit EF 2 speed motor shift circuit Al Platform down circuit BN Balances fluid flow from flow EG Orifice brake circuit i divider combiner valve BM to flow EH Orifice 2 speed motor shift circuit Bleeds off proportional valve to tank divider combiner valves BO and BP El H i lief ch Tem AK Outrigger up down BO Controls flow to non steer end drive Hot is ief charge pressure circui AL Generator on motors in forward and reverse J rake release circuit AM Generator relief Controls flow to steer end drive EK 2 nad flow AN Generator flow motors in forward and reverse a s en Accumulator Controls fluid flow to flow EL Flow 44 balances flow AP Platform overload option divider combiner valves BO and BP in side to side at the steer end forward and reverse Testo flow front to rear 6 106 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics REVA lt gt Filter Fixed displac
62. PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REVA P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos E E Loud D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR pare Gill a TOI E Y 42 6 saij gp 981 ____ 4 JC1 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL
63. POUT2 POUT4 POUTS POUT6 POUT7 POUT8 Oo OUO N PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REVA P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos E E Loud D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR pare Gill a TOI E Y 42 6
64. Pressure Switches Temperature switch point 300 Perform this procedure with the 149 C engine off pressure switch specifications 1 Release the latches on the engine tray and fully PPEP orque 10 ft lbs slide the engine tray out JAA Nin 2 Insert a 6 inch 15 cm screwdriver or rod into TE the engine tray lock hole located near the Hex size inches engine tray roller wheels to prevent the engine Oil pressure switch point 7 psi tray from moving 0 48 bar Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 55 Section 4 Repair Procedures December 2004 ENGINES REV 4 4 Coolant Temperature and Oil Pressure Switches Ford Models The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 230 F 110 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes The engine oil pressure switch is a normally closed switch The switch contacts open at approximately 8 psi 0 55 bar If the oil pressure drops below the switch point the switch opens and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens How to Remov
65. RRS 2 S o SAS 5 S SoN T c i OIL PRESSURE ld SWITCH NC e ENGINE HEATED COOLANT N L OXYGEN TEMPERATURE SENSOR 29 COIL SENSOR MANIFOLD 025 2 o5 ECT ABSOLUTE 59 PRESSURE SENSOR 4 1 LOCKOUT ES7144A 6 12 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Wiring Harness Ford LRG 425 EFI before serial number GS9003 41369 REV POWER FUEL PUMP STARTER CR FA CR FB CR FC oS hs hs 5 5 5 8 118 8 Ed 5 5 5 teu 8 8 8 81 AVM8G0ZS 815 1 H89L ZLAYZE 9LMEMdV 282 9LO A1V9zE 215198 914945 9143195 9LT8MQV2E 9 919 1 891 9IgYuee 95TW18 Part 2 of 2 3611918 37BY18 349DB18 350GY18 282DB 018 355GY W18 238ADG Y18 555118 556W18 557BR Y18 558BR LB18 351BR W18 77DB Y18 570BK W18 570ABK W18 570BBK W18 4 e S70HBK W18 107 20 1511 20 198DG O20 209W P20 306T LB20 307BK Y20 658PK LG20 gt 674BR W20 914 20 915PK LB20 926ALB O16 35
66. Schematics Wiring Diagram Platform Control Box after serial number GS9003 41522 REV COIL CORD ASSEMBLY H1 ALARM e BK NC 1 RD e 9 Lt 8 9 2 OR JC1 JOYSTICK CONTROLLER 1l 14 5 t eT le 4 rere x U3 1 PLATFORM CONTROLS CIRCUIT BOARD PP WH BL C 1 8 6 14 Y E J2 OR RD WH 6 ba y TS20 BL OR 15 RD TS21 e 6 TS20 PLATFORM UP DOWN TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS TS21 PLATFORM UP DOWN OUTRIGGER UP DOWN TOGGLE SWITCH MODELS WITH OUTRIGGERS E Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics a Electrical Schematics Abbreviation and Wire Color Legends REVA ABBREVIATION LE
67. lt 4555 56 Toz l J2 A6 WH e s2 5 8 B x tc H ug o 509 1 58 e x J2 B10 RD 09 28 1 25 OQ saro ox 95 J C1 CIO i 458 55 ___ __ ____________ 99 5 a 5 5 THROTTLE 4 4 4 SS 1 T DATA LINK o 5 0 gt hin 8 X 49 1S8 2 AXIS LEVEL SENSOR DATA LINK J3 A4 2 J2 B10 RD go e GND FROM PLAT J3 B4 gt I o N gt Y39 OUTRIGGER RETRACT Q o 2 J3 B5 S WEES 9 gt 88 2 mE 40 OUTRIGGER EXTEND o 1 5 9 o 901 77 J8 A6 2 CAS TOSEF gt wos J3 B6 H1 Y33 LEFT REAR OUTRIGGER 1868 9 8 5 BE J2 A10 gt 9 MESES 6 J4 C2 te 157794 RIGHT REAR OUTRIGGER 5 2 N 52 4 8 J1 A12 gt d EO QYwSEE 6 J2 A8 1 HT Y35 LEFT FRONT OUTRIGGER 5555 9 EXE E 1B gt 21 2 J1 B5 tN Y36 RIGHT FRONT OUTRIGGER i J4 B3 1082655 J1 C7 C8 U5 ECM GROUND 2 E 2255 J4 B2 qj 7 SW2 ENGINE OIL PRESSURE uuoo gt 22 Jaho SW1 ENGINE COOLANT TEMPERATURE m ab e 4 BEFORE SERIAL NUMBER 40043 NU 20 n 5055 J1 B1 FLASHIN
68. 2 lt Di o 0 3 2 Y49 AND Y49A WERE REMOVED AFTER d a A gt oO SERIAL NUMBER 41618 2 A CR UNT L 1 1 MACHINE SHOWN IN THE STOWED ES7164C POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Deutz Power from serial number GS9003 41523 to GS9005 42143 Part 3 of 3 4 4 BK POWER TO PLATFORM 7 RD POWER TO GROUND GROUND REV B P2 EMERGENCY STOP WH RD 4 4 1 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL
69. 32 349 DB 18 CRANK 35 452 GY R 18 ee 34 282 18 CAM 2 VBAT CAM VBAT 5 361 16 361R 14 25 392 R LG 18 EGO2 EGO 1 24 74 GY LB 18 26 EGO O2 SENSOR 29 30 359 GY R 18 4 570 BK W 16 PWR GROUND 242 DG 18 1 850 Y BK 18 2 2 COIL3 43 1 3 COIL4 pd LOCKOFF SOLENOID COIL 5 COIL6 m v 2 342 LG P 18 STARTER LOCKOUT 23 242 DG 18 926A LB O 18 FUEL PUMP RELAY CONTROL 15 18 __ TPS1 355 GY W 18 TPS2 357 Y W 18 DBW 2 29 ____151 ____________ LB BK 18 29 317 GY O 18 DBW 6 511 LG R 18 BRAKE SWITCH r 253 DG W 18 OIL PRESSURE 8 11 T Y 18 TACH 27 658 PK LG 18 FUEL PUMP MON 238 DG Y 18 AUX OUT 1 5 14 72 Y BK 18 FUEL SELECT AUX ANA PU2 15 GOV SELECT 2 see T LG BK 18 ROAD SPEED ROAD SPEED za 33 349A DB 18 Ps OVERSPEED CAN 19 asa 0418 081 CAN 20642 06 018 22 485 21 461018 232 669 DG W 18 1 5 232 TRIM VALVE R 77 DB Y 18 B 361A 16 WPTWR2_GY REVA 361 16 555 T 16 557 BR Y 16 558 BR LB 16 556 W 16 743 GY 18 359 GY R 18 151 LB BK 307 BK Y 18 354 LG R 18 570 BK W 16 570 BK W 16 570 BK W 16 351 BR W 18 16 R LG 18 358 LG BK 18 359 GY R 18 18 O Y 18 198 DG O 18 150 DG W
70. 5 5 7 4 5 S OSCILLATING AXLE 5 B AVAILABLE AFTER SERIAL NUMBER 41618 z 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164E 6 94 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics iS Electrical Schematic REV A ANSI Models with Deutz Power after serial number GS9005 421 43 Part 2 of 3 AB3 GS 5390 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V S PLAT gt 4 NC 2613 o UP da d m1 LIMIT 4 SWA i sic ai hts N C 4 4 i 86 30 1 7 1 fuc Maru LS C HA 1 emeur Boano mE LS5 85 7 OIL COOLER 177 DOWN MEE 3E LIMIT ra 167 LEVEL SWITCH ran 1 SENSOR SWITCH FANMOTOR MODELS WITHOUT mel BATTERY 12V L__QUTRIGGERS BK 6 C C C C C c 28 c c c c ra m m DN N N N N gt gt gt gt gt gt 9 ucc U5 l 7 BN23 BN91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIAR
71. Attempting this procedure without the necessary skills will result in death or serious injury Select a test area that is firm level and free of obstructions PLATFORM CONTROLS How to Determine the Revision Level 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 2 Move and hold the function enable toggle switch and the platform up down toggle switch in the down direction O Result The revision level of the ECM will appear in the LED display window Emergency Stop button 1 b platform up down toggle switch TS66 function enable toggle switch TS67 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 5 Section 4 Repair Procedures December 2004 PLATFORM 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 death or serious injury The GS 5390 will not drive with the platform raised above 33 feet 6 1 m 1 Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel 2 Turn key switch to the off position 3 Models without outriggers Press and hold the horn button and platform extend retract
72. B 18 Pressure filters Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 Checklist A Procedures A 1 Perform Pre operation Inspection 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 shift 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 REVC A 2 Perform Function Tests 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 GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV C A 3 Perform Engine Maintenance Ford Models Engine s
73. COIL AMMETER O 100 9v BATTERY RESISTOR 1 1 1 1 1 1 1 1 1 8 a 1 4111 4 rPe i i jm multimeter diode 9V battery 100 resistor coil OooOooo o0mnm Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe 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 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 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 107 Section 4 Repair Procedures December 2004 Fuel and Hydraulic Tanks 8 1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach ADANGER Explosion and fire hazard Never drain or store f
74. E 5 AUXILIARY 15 E FUNCTION ENABLE i a 51 STARTING U30 AID E Epc 9 TS70 SOLENOID AUXILIARY YA CONTROL 805 PLATFORM DOWN MODULE 4 85 87 acy Lig r0 032 108 GLOW J 4X PLUG ss orta 4 Y8 it 4 1 1 4 4 4 n 4 zog 5 amp E i amp gt gt o gt x v v lt 5 m d 2 5 gt gt 85 lt Rom amp 2 7 2 E 504 22 E 2 d 5 d g 5 9 2 s lt 0 3 A 3 2 2 2 2 m 2 gt 5 J 35 lt c 2 lt c a vo z 2 2 g 8 5 556 25 3 m 1 2 zS S 3 T E 5 2 B 2 2 y amp 5 2 o z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 74 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REVE Deutz Models from serial number 40738 to 40941 Part 2 of 3 WH RD c RD WH a BL B E BK D DH
75. PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LIFT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 69 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40428 to 40737 REV D Part 1 of 3 ees ae eee IKS1 P1 B EMERGENCY STOP i A FE CONTROL 7 pu sei GROUND 7 4
76. STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 Lew PLATFORM CONTROLS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 53 Section 6 Schematics December 2004 a Electrical Schematic CE Models with Ford Power REVA from serial number GS9003 41523 to GS9004 41693 Part 1 of 3
77. T LS12A OIL COOLER LIMIT SWITCH 41607 NC J2 C12 BATTERY 12V 4 LS13A 8 Lowen LSBAf Swa ler ptf LIMIT SWITCH PAT HYDRAULIC 20 41608 OIL TEMP Aog C 4 LS14A luc LIMIT i 4 SWITCH lt LOWER O s 5 17 1 meg LS 4 NC AC F HYDRAULIC ABI pir LIMIT SWITCH oH at eval gt LS15A 185 eee SWITCH LOWER O PLAT ran 1 157 RRO RIG 4 UP SENSOR LIMIT SWITCH LIMIT MODELS WITHOUT 2 1610 SWITCH BATTERY 12V __OQUTRIGGERS 4 AB5 PON RENE PES BK 6 6 C C C C c c c c c ra 55 5 5556 5 gt gt gt gt 5 f NIME SIS ARON cy Sy Pats NU S NARNIA U5 T 7 BN23 91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN 5 AUXILIARY DOWN ENABLE J2 B9 1 c 2 J2 ABO T 1 1 gt 0 EOT 32 04 il 5 i ue T 18 x o Q S 8 86 30 TR peru CR82 a I oJ 84 CR77 enable 18581 1524 DOWN LS25 S 68 5390 ONLY LOAD 2 8 86 9 HEIGHT SENSE CR82A 9 DELAY Y4 Y1 Y9 1 UFT 2 SWITCH ADI LIMIT EDC ENABLE jt 5 siren ii X E X
78. 1 Y ABE ABi2 7 7 7 Y7 i 5 REX D7 C5 SW1 Y yo SW2 1 4700 uF 9 1 Ld 3 Ld 4 0 7575 2728 4 0 2 e ge En 8 33 2 a LZ m m o gt 0 2 98 2 22 2 2 fri gt 2 D m 2 2 gt gt J m m m m br lt o m 2 I Q J 9 o 90 Q m 2 OF 55 5 gt 5 v 506 8 m 3 lt 2 a ms d 2 8 o0 zi m m z 3 2 9 zi m g 2 5 2 c gt ES 7174A NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Pa rt No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic CE Models with Ford Power REVA from serial number GS9004 41694 to GS9005 42143 Part 3 of 3 QD3 QD4 WHIRD 4 4 4 4 1 POWER TO PLATFORM RD WH 34 3 p RD POWER ro GROUND 31 BL 1 it 1 1 H WH GROUND BK 2 2d va A 2 2 BL DATA LINK HIGH OR 5 5 _5
79. 2 ES EA AA 53 9 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 95 Section 4 Repair Procedures December 2004 MANIFOLDS REVE 7 5 Drive Manifold Components before serial number GS9004 41619 The drive manifold is located under the function manifold Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 way High speed bypass 25 ft lbs 34 Nm 2 Solenoid valve 2 position 2 way BB High speed bypass 25 ft lbs 34 Nm 3 Flow regulator valve 2 7 6 L min esse Balances flow from flow divider combiner item BO to rear drive MOTOTS c 25 ft lbs 34 Nm 4 Flow regulator valve 1 5 5 7 L min Balances flow from flow divider combiner item BP to front drive a a 25 ft lbs 34 Nm 5 Shuttle valve 2 position way BE 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 speed motor shift 25 ft lbs 34 Nm 6 Diagnostic nipple Testing P1 pressure port 7 Diagnostic nipple BG sug Testing P2 pressure port 8 Relief valve 300 psi 20 7 bar
80. 2 position 3 way 6 to 8Q 10V DC with diode schematic items EF and EJ 4 106 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its valve coils 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 hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 7 12 How to Test a Coil 2 Connecta 100 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 The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 3 Setamultimeter to read DC amperage The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil MANIFOLDS
81. 4 4 1 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF eek 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR
82. 41 359 GY R 18 33 51 BR W 18 31 Ss 15 STARTER SWITCH 355 GY W 18 Pb 355 GYW 18 FUEL PUMP STARTER 357 Y W18 5 RELAY RELAY 151 LB BK 18 ____ 317 GY 018 S2 R LB 16 D D 1 13 STARTER CONTROL 342 LG P 18 342 LG P 18 359 GY R 18 D 787A PK BK 16 N 5 FUEL PUMP 669 DG W 18 B ev 458 O BK 18 A 7 86 926A LB O 18 25 15 18 361 16 253 DG W 18 OIL PRESSURE 511 LG R 18 511 LG R 18 253 DG W 18 238 DG Y 18 72 306 T LB 18 24 GOV SELECT 1 307 BK Y 18 23 GOV SELECT 2 169 LG BK 18 35 ROADSPEED 172 LB R 18 36 ROADSPEED 662 DG P 18 m CAN ie TOTS nea E DG WTS 1 361AR 16 E1280B Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 15 Section 6 Schematics December 2004 a Wiring Harness Ford LRG 425 EFI after serial number GS9004 41693 Part 1 of 2 6 361 R 16 INJ r 555 T 16 INJ 1 INJ3 8 557 BR Y 16 9 558 BR LB 16 INJ 4 10 556 W 16 INJ 2 11 5 12 6 31 AUX OUT 2 21 EGR 18 18 19 198 DG O 18 AUX PD1 FPP 1 IAT 27 743 GY 18 28 354 LG R 18 ECT I l M ndun FPP2 114 LB Y 18 EGR PWM emita 352 BR LG 18 EGR RECIRC BED POWER GROUND 1 Suu IG POWER GROUND 5 VOLT REF 3 16 R LG 18 VSW 33 350 GY 18 CRANK
83. 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SPECIFICATIONS Seal Lok fittings Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks SAE O ring Boss Port Seal Lok Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 27 ft lbs 36 6 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft lbs 85 4 Nm 12 140 ft lbs 190 Nm 12 90 f
84. 7 2 Sun Z 5c 2 B 218 g 27 55 c 8 4 Es o m 9 4 165 5 o i 9 D gt Aug v mg gt o lt 2 gt m mon mS 5 EI 9 1 o m 1 d e xu g m 1 1 Y49 AND Y49A WERE REMOVED AFTER d a A gt m SERIAL NUMBER 41618 m A Pob slt 2 L Se RR gt c m MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Es7174 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic CE Models with Ford Power REVA from serial number GS9003 41523 to GS9004 41693 Part 3 of 3 eee QD3 QD4 WHIRD 4 4 4 4 4 1 POWER TO PLATFORM RD WH 34 p 8 RD POWER To GROUND 22 31 BL 1 it 1 1 H WH GROUND BK 2 2d va A 2 2 BL DATA LINK HIGH OR 5 5 _5 5 5 OR DATALINK LOW OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 J5 PIN2 5 CDT 6512 CDi2 D7 PLATFORM CONTROLS VOL
85. Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 253 Knock Sensor Open Knock sensor wiring and or connections open or shorted OR sensor is faulty Repair wiring and or connections to knock sensor OR replace knock sensor 254 Excessive Knock Signal Knock sensor wiring and or connections open or shorted OR there is excessive engine vibration OR sensor is faulty Check for excessive engine vibration OR repair wiring and or connections to knock sensor OR replace knock sensor 311 Injector Driver 1 Open Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 312 Injector Driver 1 Shorted Wiring and or connections to fuel injector 1 shorted OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 313 Injector Driver 2 Open Open wiring and or connections to fuel injector 2 OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 2 OR replace fuel injector 2 OR replace the ECM 314 Injector Driv
86. December 2004 SCISSOR COMPONENTS 0 9 2 2 2 2 2 2 2 9 VAN M o y W lt amp aG 2 9 20090909 Non steer End Steer End 1 Platform centering link 16 Number 1 outer arm 2 Number 5 inner arm 17 Number 1 pivot pins non steer end 3 Number 5 center pivot pins 18 Number 5 outer arm 4 Number 5 pivot pins non steer end 19 Number 5 pivot pins steer end 5 Number 4 outer arm 20 Number 4 inner arm 6 Number 4 center pivot pins 21 Upper lift cylinder rod end pivot pin 7 Number 4 pivot pins non steer end 22 Number 4 pivot pins steer end 8 Number 3 inner arm 23 Number 3 outer arm 9 Upper lift cylinder barrel end pivot pin 24 Lower lift cylinder rod end pivot pin 10 Number 3 pivot pins non steer end 25 Number 3 pivot pins steer end 11 Number 3 center pivot pins 26 Number 2 inner arm 12 Number 2 center pivot pins 2 Number 2 outer arm 13 Number 2 pivot pins non steer end 28 Number 2 pivot pins steer end 14 Number 1 inner arm 29 Number 1 center pivot pins 15 Lower lift cylinder barrel end pivot pin 30 Chassis centering link 31 Number 1 pivot pins steer end 4 34 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 3 3 Scissor Asse
87. GS 5390 ONLY LOAD 2 8 86 9 HEIGHT SENSE CR82A 272 90 DELAY Y4 Y1 Y9 Y51 LIFT 2 SWITCH 4152 LIMIT EDC ENABLE 87 2 Yara SWITCH L v 1 LY J X 10 x Y ABS 12 ad BTO BET Y7 j 5 EX EX s 445 63 5390 7 C5 2 t SW1 SW2 i i i i i i i i i lt lt lt lt lt lt lt o 0 lt gt N e 7 g 5 EJ BS 2 a LZ m m 2 98 T o D m eo 8 rog m 9 D m 2 2 gt m m m br 7 2 5 96 c o m o o 5 9 v fe D v lt gt 5 m 2 9 m go 5 gt 5 zi m 3 o lt 2 T m m 9 2 5 i 2 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 63 Section 6 Schematics December 2004 Electrical Schematic CE Models with Ford Power REVA after serial number GS9005 421 43 Part 3 of 3
88. OO steering rocker switch SW6 b function enable high speed select button BN12 horn button BN5 d platform extend retract enable BN16 OR outrigger enable button BN16 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 7 Section 4 Repair Procedures December 2004 PLATFORM CONTROLS How to Adjust the Platform Lower Speed 1 Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel 2 Turn key switch to the off position 3 Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform control Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform control top Genie Genie eo lt 00 Q a steering rocker switch SW6 b function enable low speed select button BN13 horn button BN5 d platform extend retract enable BN16 OR outrigger enable button BN16 REV D The fault code display window at the ground controls will show PS When you see this code release the horn button and the platform extend retract enable button or outrigger enable button The PS in the fault code display window indicates that the ECM is in the programming
89. Schematics Electrical Schematic REV D Deutz Models from serial number 40428 to 40737 Part 2 of 3 WH RD ca i RD WH BL B E BK D D 27 OR E eee pd 8 TS67 RON FUNCTION 1 i OUTRIGGERS I E STANDARD ON GS 5390 OPTION GS 3390 95 4390 CIRCUIT REAR 1 1952 1954 7566 CIRCUIT BOARD ENGINE ENGINE PLATFORM t HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR O RIG O RIG MODELS WITHOUT 4 LIMIT LIMIT LIMIT LIMIT 2 5 5 OUTRIGGERS 8 O SWITCH SWITCH SWITCH SWITCH 2 5 5 BN a 155 156 55 0 4 NO 4 PLAT PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION lt c c lt c Hm EL T eo gt gt gt gt gt gt w gt gt gt w gt gt gt a a a
90. Section 3 Scheduled Maintenance Procedures REV D B 20 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 400 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Genie part number 84792 CHECKLIST B PROCEDURES Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 27 Section 3 Scheduled Maintenance Procedures December 2004 Checklist C Procedures C 1 Test the Platform Overload 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 Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Disconnect the platform controls from the machine at the platform 2 Open the ground control panel and locate the Electronic Control Module ECM 3 Tag and disconnect the platform controls wire
91. af 87 17 AC X EX 15 032 i Q8 U X x PLUG FUEL OPTION Q3 SHUT OFF HIGH IDLE SOLENOID Y57 Y55 L Ed 5 bd Ld 838 9 58 8 S 2 8 0 gt m gt m I gt x gt A 9 c d ud c 0 c 2 o 2 5 g 541 E E 5 P 8 9 7 8 i 2 5 2 2 m 2 gt T ies 2 gt m e gt gt lt c gt gt lt m 9 c s 4 2 O g m d gt m 2 2 lt m m lt 2 5 5 5 OSCILLATING AXLE OPTION 9 AVAILABLE AFTER SERIAL NUMBER 41618 z 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175D 6 102 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics ic Electrical Schematic REV CE Models with Deutz Power after serial number GS9005 421 43 Part 2 of 3 GS 5390 ONLY T 7686
92. e 7 85 7 af 85 Fazal bs t t t 2 N C H O l ae LS23 LS22 04 01 LEFT RIGHT xy 1 OSCILLATE OSCILLATE H2 LIMIT SWITCH LIMIT SWITCH 15 CR4 HIGH IDLE 1602 1603 one 86 30 AID A 4 05 86 85 87 87 54 Y56 t 17 AC X EX 15 032 ci Qs GLOW bo X x FUEL OPTION 103 t t SHUT OFF HIGH IDLE SOLENOID Y57 Y55 n 4 i L n n 5 sS 528 5 S g s E 8 d a 6 gt gt US I gt m N c dc 0 o 2 o 5 gd 5 5 E 9 23 H 8 5 md 2 5 E 2 2 3 E 5 5 2 2 2 2 o e gt gt 2 d o c x o gt 9 o 4 lt o m m a 5 9 2 v m m 2 lt m lt 2 lt o 2 m 5 m 5 S m OSCILLATING AXLE OPTION B AVAILABLE AFTER SERIAL NUMBER 41618 z 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C 6 90 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic
93. enable button then turn the key switch to platform controls Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform controls Genie Q gt 2 06 e9 a JO gt U steering rocker switch SW6 horn button BN5 c platform extend retract enable BN16 OR outrigger enable button BN16 o m REV D Models without outriggers The fault code display window at the ground controls will show PS When you see this code release the horn button and the platform extend retract enable button Models with outriggers The fault code display window at the ground controls will show PS When you see this code release the horn button and the outrigger enable button The PS in the fault code display window indicates that the ECM is in the programming mode Press the horn button to show the maximum raised drive speed percentage To increase or decrease the raised drive speed press and hold the horn button while using the steering rocker switch to adjust the function speed Refer to Section 2 Specifications Release the horn button Turn the key switch to the off position to save the settings Check the raised drive speed of the machine Refer to the Maintenance section B 16 Test the Drive Speed Raised Position 4 6 Genie GS 3390 GS 4390 and GS 5390 Part
94. from serial number GS9003 41523 to GS9005 42143 Part 2 of 3 GS 5390 ONLY T I AB3 LS12A eea OIL COOLER LIMIT SWITCH 4 gt 457 4 NC LS13A 8 LOWER SWA lE esl PLAT micum d CB7 LIMIT SWITCH 20A 1 UP OIL TEMP 1 LS14A LIMIT 4 o NC SWITCH t lt LOWER O 5 87 CR17 804 LS 4 NC AC HA HYDRAULIC ABI BEAT LIMIT SWITCH o at al OIL COOLER IE DOWN LIMIT LS15A 185 LEVEL SWITCH LOWER PLAT 1 87 SENSOR RR ORIG 4 UP FAN MOTOR LIMIT SWITCH LIMIT MODELS WITHOUT 2 1010 SWITCH BATTERY 12V __QUTRIGGERS 26 6 C C C C C a c c c c c ra Pp m PP T o o o o0ooo0 gt gt gt o gt Lecce etre RENNES U5 l 7 BN23 91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN 5 AUXILIARY DOWN ENABLE J2 C10 1 c lt c 4 J2 ABS T 1 gt gt gt 1 2 9 EI Did i Apta 18 B gt Y m 04 NC N C CR82 I oJ 64 CR77 enable 18581 524 DOWN LS25 S 85 5390 ONLY MAX ENABLE LOAD 8 86 30 HEIGHT SENSE CR82A LIMIT 186 30 DELAY Y4 Y1 Y9
95. go d ESQ 2 GENERATOR OPTION 17 min 9 L 4 207 bar i AUXILIARY arate POWER UNIT 93 j HS7037B Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 109 Section 6 Schematics December 2004 Hydraulic Schematic from serial number 40519 to GS9004 41618 REVG Part 1 of 2 RIGHT RIGHT FRONT REAR Sele cen al M B TES M1B M1A M3B M3A ____ LIB E aM 63 G 2 5 52 mm BL psum 0 035 in MI a 69 ME 0 045 in 8M 0 9 1 1 1 t ET 50 4 1 1 pom 1 50 Siri x CS e e 15 gr He 69 29m i 1 5 7 7 6 E 168 i MANIFOLD 20 7 bar CY49 4 i 3 69 TP2 MB mal mB LEFT LEFT FRONT REAR i B OI oi L L J P1 P2 5 T 7 3625 psi
96. harness from the ECM wire harness 4 Securely connect the platform controls to the wire harness 5 Locate the terminal strip behind the ground control panel 6 Tag and disconnect the black wire of the maximum height limit switch wire harness from the A10 terminal of the terminal strip 7 Tagand disconnect the white wire of the maximum height limit switch wire harness from the B9 terminal of the terminal strip REVC 8 Securely connect a jumper wire from terminal A10 of the terminal strip to terminal B9 of the terminal strip 9 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 10 Fully raise the platform Release the joystick O Result The engine should stop and an alarm should sound and fault code 99 PLATFORM OVERLOAD should be present in the diagnostic display window at the ground controls 11 Activate the auxiliary lowering function and lower the platform approximately 4 5 m 12 Turn the key switch to the off position 13 Disconnect the jumper wire from terminal A10 of the terminal strip to terminal B9 of the terminal strip 14 Securely connect the black wire of the maximum height limit switch wire harness to terminal A10 of the terminal strip 15 Securely connect the white wire of the maximum height limit switch wire harness to terminal B9 of the terminal strip 16 Turn the key switch to platform co
97. 18 114 LB Y 18 352 BR LG 18 360 BR PK 18 361 14 355 GY W 18 357 Y W 18 151 LB BK 18 317 GY O 18 342 LG P 18 669 DG W 18 458 O BK 18 926A LB O 18 15 R Y 18 511 LG R 18 253 DG W 18 11 18 658 PK LG 18 238 DG Y 18 7104618 72 Y BK 18 148 Y R 18 306 T LB 18 307 BK Y 18 169 LG BK 18 172 LB R 18 349A DB 18 662 DG P 18 459 O LG 18 642 DG O 18 461 18 669 DG W 18 458 18 361A 16 E1429B 6 16 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics aaa Wiring Harness Ford LRG 425 EFI REV A after serial number GS9004 41693 Part 2 of 2 361 16 361 R 16 361 16 361 R 16 FORD 42 PIN CONNECTOR 16 WATER TEMP 555 T 16 557 BR Y 16 558 BR LB 16 556 W 16 INJECTOR 1 INJECTOR 3 INJECTOR 4 INJECTOR 2 743 GY 18 359 GY R 18 570 BK W 16 39 R W 18 WATER ACT TEMP 151 LB BK 151 LB BK JAFPPI 307 BK Y 18 NS 354 LG R 18 359 GY R 18 1 570 16 570 BK W 16 570 BK W 16 570 BK W 12 34 GROUND 16 R LG 18 16 R LG 18 570 BK W 16 570 BK W 16 MAP CONN 570 BK W 16 351 BR W 18 c 16 R LG 18 358 LG BK 18 358 LG BK 18 359 GY R 18 18 OV 18 __ 38 EGR ANA IN 198 06 0 18 _
98. 20 4 CR41 CONTROL CR42 CR5 CR8 CR1 CR58 SYSTEM POWER HORN IGNITION ENGINE START FWD REV 86 2 A se 304 86 86 lt 86 85 87 7a 85 87A D 857 87 857 87 857 al F16 zoaruse lt lt 65 S 82 66 fe AT SUPPLY 5 To starter 77 87 85 U5 gt H2 D1 ELECTRONIC CONTROL MODULE Iu J4 C3 lt amp J4 B4 gt M gt S 5 5 gt 71969 3 5 5 AUXILIARY 15 FUNCTION ENABLE STARTING a Y51 2 U30 AID NS Epc 9 TS70 SOLENOID AUXILIARY YA CONTROL 85 90 PLATFORM DOWN MODULE vs 85 AX Lig r0 032 c 198 4 FUEL T SHUT OFF OPTION 4 Y8 i 4 1 1 4 1 n n 4 2 8 3 amp 55 45 amp o s 32 2 m a 8 nz 2 P d B 5 gt o 939 5 B amp 2 2 q 2 2 9 5 m gt g 2 2 2 gt 3 g 5 2 56 lt 3 gt c o m 5 v c Day 5 m 2 d gt mc ES zi T lt lt D lt lt gt m 5 5 5 m d v 9 2 pA lt MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 70 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6
99. 26 B 20 Perform Engine Maintenance Ford Models 3 27 Checklist Procedure C 1 Test the Platform Overload System if equipped 3 28 C 2 Perform Engine Maintenance Deutz Models 3 29 C 3 Perform Engine Maintenance Ford Models 3 29 vi Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 ____________________________ TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued D Checklist D Procedures D 1 Check the Scissor Arm Wear Pads 3 30 0 2 Check the Free wheel Configuration 3 31 0 3 Replace the Drive Hub 3 32 0 4 Replace the Fuel Filter Water Separator Deutz models 3 32 D 5 Calibrate the Platform Overload System if equipped 3 33 D 6 Replace the Hydraulic Tank Return Filter 3 40 D 7 Perform Engine Maintenance Deutz Models 3 41 Checklist Procedure E 1 Test or Replace the Hydraulic 3 42 E 2 Perform Engine Maintenance Deutz 1011F Models 3 44 E 3 Perform Engine Maintenance Ford Models 3 45 E 4 Perform Engine Maintenance Deutz Models 3 45 E 5 P
100. 3 IKS1 P1 B EMERGENCY STOP a gt PLATFORM CONTROL B pu ee GROUND 4 4 CR41 CONTROL CR42 CR5 CR8 ENGINE CR58 SYSTEM POWER HORN IGNITION START FWD REV 4 86 2 a 304 86 86 a 86 A a 87 85 87A D 4 857 87 87 857 87 857 FH Fh 3 OF y 92060 G6 9 BEC us d 2 H2 01 ELECTRONIC CONTROL MODULE 44 63 S TS69 AUXILIARY CR15 CR4 a 51 1 FUNCTION ENABLE STARTING HIGH IDLE EDC 9 0 TS70 86 30 86 30 AUXILIARY Y4 PIN KC a PLATFORM DOWN lt f 85 87 85 7 5 aX gt 032 Q8 GLOW 03 4X ran PLUG FUEL HIGH IDLE SHUT OFF OPTION SOLENOID 4 8890 d Y8 n 1 4 n 4 n 4 s amp 58 9 amp 5 5 5 EO UE B 49a E 2 22 3g lt 5 m
101. 3 position 4 way Steer 20 ft lbs 27 Nm 8 Proportional solenoid valve Fees All f nctlOns 30 ft lbs 47 Nm 9 valve 3 position 4 way Platform up down 30 35 in lbs 3 4 Nm 10 003 valve 3 position 4 way Outrigger up down 30 35 in lbs 3 4 Nm 11 Counterbalance valve 3000 psi 207 I eee Outrigger extend 35 ft lbs 47 Nm 12 Counterbalance valve 3000 psi 207 t Outrigger retract circuit 35 ft lbs 47 Nm 4 88 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E MANIFOLDS gt e Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 89 Section 4 Repair Procedures December 2004 MANIFOLDS REVE 7 2 Function Manifold Components Models with Outriggers after serial number 40518 The function manifold is located in the chassis tray on the ground controls side of the machine Index Schematic No Description Item Function Torque 1 Check valve 5 0 3 en AA Platform do
102. 40820 The tilt alarm will sound at 180 beeps per minute O Result ANSI and CSA models after serial number 40819 The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute O Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 49 Lower the platform to the stowed position 50 Push in the red Emergency Stop button to the off position at both the ground and platform controls 51 Turn the key switch to the off position 52 Raise the machine slightly 53 Remove the blocks from under both wheels 54 Lower the machine and remove the jack GROUND CONTROLS 5 5 Level Sensor Models without Outriggers after serial number 41157 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 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 777777177 Tip over hazard Failure to install ADANGER or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious inj
103. 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175D 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2
104. 5 Q Db 2 2 22 2 d 4 m me 2 m 52 gt lt o m A m mr 2 2 2 gt 14 SE lt c 2 lt c 4 m 2 EE d 5 2 2 EX m lt S qm lt 52 3 Y m z m 5 5 E m 279 gt m lt X 2 m 9 8 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 78 Genie 605 3390 GS 4390 065 5390 72863 December 2004 Section 6 Schematics Electrical Schematic REV Deutz Models from serial number 40942 to 41065 Part 2 of 3 i WH RD c RD WH a BL B E BK D DH a OR E pd 8 d E 1 TS67 Function ENABLE beet OUTRIGGERS E STANDARD ON GS 5390 N C TS52 TS54 TS66 OPTION ON GS 3390 GS 4390 EMT Boano ENGINE ENGINE PLATFORM t t t t START HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR MODELS WITHOUT 4 NO LIMIT LIMIT LIMI
105. 5 2 8 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 50138 6 34 Genie 65 3390 65 4390 995 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REV A Ford Models from serial number 41066 to GS9003 41 368 Part 2 of 3 WH RD c RD WH a B E LS5A ADDED AFTER SERIAL NUMBER 41323 5 27 L 22 OR E 2250011 1 8 KEEP ALIVE POWER Y i 9 VPWR Y 14 KEY ON R GN 15 FUEL PUMP PK BK TS67 LS5A L2 CHECK ENGINE LED FUNCTION PLAT N C 5 gt 6 MALFUNCTION LED PK LG ENABLE GOV SPEED CONTROL T LB SWITCH OUTRIGGERS E 65 5200 STANDARD 65 5390 zy 1852 TS53 TS54 OPTION ON GS 3390 GS 4390 FORD ENGINE FUEL ENGINE ENGINE i START SELECT HIGH IDLE TS66 B aa PLATFORM 1512 1813 1814 1815 HARNESS 255 UP DOWN LF RF LR RR Tg s s T ORIG O RIG mo d gt 4 NCG 9 LIMIT LMT LIMIT gt S
106. 5 in Low idle 1600 rpm 12 7 mm 320H2 alternator High idle 2800 rpm Output 55A 14V DC 560 i Fan belt deflection 3 8 to 1 2 inch Governor centrifugal mechanical 9to 12mm Valve clearance cold Battery before serial number 40516 Intake 0 012 in T 12V D 0 3 mm 34 78 Exhaust 0 020 0 5 Quantity 1 Lubrication system Cold cranking ampere 900A Oil pressure 26 to 87 psi Reserve capacity 25A rate 125 minutes 1 8 to 6 0 bar Battery after serial number 40515 Oil capacity 8 5 quarts including filter 8 liters 12V DC Oil viscosity requirements Group 31 Below 60 F 15 5 C 5W 30 Quantity 1 synthetic sy Cold cranking ampere 0 F 1000A 10 to 90 F 23 C to 32 C 10W 40 Reserve capacity 25 rate 200 minutes Above 4 F 20 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF Units ship with 15W 40 CC SG Part No 72863 Genie GS 3390 GS 4390 and GS 5390 2 7 Section 2 Specifications December 2004 SPECIFICATIONS Deutz F3L 2011F Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Low idle High idle Governor Valve clearance cold 142 2 cu in 2 331 liters 3 3 7 x 4 41 inches 94 x 112 mm 48 2800 rpm 35 8 kW 9 2800 rpm j 5 8 19 1 1500 300 Hz 2500 rpm 500 Hz centrifugal mechanical Intake 0 012 to 0 016 in 0
107. 98 a 2 D o 6 52 9 9 2 2 2 FC m m m br s g 1 E E R 5 85 c 3 m 2 25 5 6 gt 3 v 9 m 2 lt 9 m 5 2 8 o0 c m 5 2 9 8 m 9 2 2 e gt 5 MACHINE SHOWN IN THE STOWED ES7163E POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Ford Power after serial number GS9005 421 43 Part 3 of 3 4 4 BK POWER TO PLATFORM q RD POWER TO GROUND GROUND REVA P2 EMERGENCY STOP WH RD 4 4 1 RD WH 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE
108. A 4 05 86 85 87 87A Y54 Y56 t 7 17 AC X EX 15 032 i as ao cott amp ix 44x PLUG FUEL OPTION Q3 SHUT OFF HIGH IDLE SOLENOID Y57 Y55 44 n i L n n g sS 528 5 S g s E 8 d a 6 uri gt gt s x m o a c 3 n 5 2 o 2 f 5 8 X5 xm m x 9 g J 5 2 5 E 2 2 gt gt gt 5 5 d 2 c 5 Q 8 gt lt d c gt 5 2 4 2 O g m d gt m 2 2 lt m m lt 2 k 5 7 B m m 5 5 OSCILLATING AXLE OPTION B AVAILABLE AFTER SERIAL NUMBER 41618 z 4 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175A 6 98 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REV CE Models with Deutz Power
109. AFTER d a A gt oO SERIAL NUMBER 41618 m A Pob slt 2 829 gt 2 MACHINE SHOWN IN THE STOWED ES7163B POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 43 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Ford Power from serial number GS9003 41523 to GS9004 41693 Part 3 of 3 4 4 BK POWER TO PLATFORM 7 RD POWER TO GROUND GROUND REV B P2 EMERGENCY STOP WH RD 4 4 1 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9
110. CONTROLS The fault code display window at the ground controls will show PS When you see this code release the horn button and the platform extend retract enable button or outrigger enable button The PS in the fault code display window indicates that the ECM is in the programming mode Press and hold the platform up down select toggle switch in the down direction to show the platform settling speed percentage in the fault code display window To increase or decrease the platform settling speed press and hold the platform up down select toggle switch in the down direction while using the steering rocker switch to adjust the function speed Refer to Section 2 Specifications Release the platform up down select toggle switch Turn the key switch to the off position to save the settings Component Damage Hazard The CAUTION Platform Settling Speed is intended to slow the rate of platform descent just before the reaching the stowed position Adjust the Platform Settling Speed until the Platform Settling Speed percentage is 3 to 5 points less than the Platform Lowering Speed percentage Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 9 Section 4 Repair Procedures PLATFORM CONTROLS How to Adjust the Steer Speed k e 4 Q The steering speed is not adjustable on machines with software revision B See 1 3 How to Determine the Revision Level Remove the pl
111. E z 2 m a o 2 gt lt 2 o 2 gt gt 2 m m D 5 2 w FO gt 2 2 2 5 gt 5 4 3 m 20 47 5 m 3 m Um g O 6525 3 2 2 5 Xx m 9 52 D d J 8 lt gt 2585 9 J 2 gt 2 2 3 3 3j 8 8 8 2 2 5 2 o o 2 2 g gt 2 3 2 4 MACHINE SHOWN IN THE STOWED ES0138K POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 35 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 41066 to GS9003 41 368 Part 3 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTION PIN18 2 WH RD 4 POUT2 POUT4 POUTS POUT6 POUT7 POUT8 Oo OUO N
112. GE g 8 2 9 w 2 2 2 gt E o a 2 2 m 2 22 9 gt m 2 5 gt o 2 2 m D 20 4 i 4 ES i o fn 2 m z 2 i ES 5 2 o 9 gt 2 m 2 x 5 m 2 2 Q e m m z Q 6 m m 0 0 lt n 9 9 S 4 2 gt m m m o o 5 gt 5 cH 4 m 2 2 m o 2 gt o o c m 2 D m a gt o e o c 4 m 2 E D Im zi r o m 2 T n D 9 lt 3 2 9 2 gt 2 5 Q Q o 5 D 2 c gt 2 o m 4 gt D 2 gt o m m m 9 2 m 2 2 2 2 2 5 1 MACHINE SHOWN IN THE STOWED ES7142B POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 75 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40738 to 40941 REVE Part 3 of 3 P2 P2
113. GOV SPEED SELECT OR RD 23 gt R6 FUEL SELECT BKWH 7 5100 i L 6 MALFUNCTION LED BL 11 24 KEEP ALIVE POWER WH 663 SW20 9 r 1 gt ENGINE SELF TEST Or 52 j j e 118 SELF TESTSWITCHBK RD 54 vs6 50 j n H FUEL PUMP BL WH tru X X EX FORD E ENGINE HARNESS ELI DNA Sv IE X x aA FUEL PUMP Y57 _ 55 i n n n 81 d d gd 5 gt Oo gt gt x m c c c c 2 o 2 m lt dm 2 m x 5 8 o 225 gt 6 gt J O m 26 2 2 2 5 2 9 52 5 v 9 5 2 o gt 2 5 gt lt d T m 5 P 5 m 2 3 g3 7 S B lt f gt m OSCILLATING AXLE OPTION 9 AVAILABLE AFTER SERIAL NUMBER 41618 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B 6 62 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics m S Electrical Schematic REVA after serial number GS9005 42143 Part 2 of 3 GS 5390 ONLY 1606 1 AB3 l
114. In gt J o a o o E m 9 A1 L SW3 Y2 Y1 Y29 Y49A H5 Y36 Y34 40 sg t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt DJ 54 1 g SW2 AEX dX Q 1 Y9 Y49 Y35 Y33 Y39 n 2 n n n 4 4 4 4 n 4 n t 5 4 B g i GE g 8 2 9 w 2 2 2 gt E o a 2 m oc 5 2 z m m 9 gt o z o n gt o o 2 2 A 2 o o 20 d 5 d J J P 9 p P 3J J m 6 m m z Q 6 m m 0 0 lt m 9 o 2 9 gt 2 m 5 m 2 E w gt 2 2 5 gt 2 E m 3 Q 4 o 2 gt o o c m 2 5 m 3 Q e S E 5 m 2 m 9 zi i E 2 2 2 5 2 9 lt 3 2 9 2 gt 2 5 Q Q o 5 D 2 c o gt X o m 4 gt D 2 0 m m m zi m 9 2 m 2 2 2 2 2 5 1 MACHINE SHOWN IN THE STOWED ES7142E POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 87 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number GS9003 41351 to GS9003 41522 REV A Part 3 of 3 P2
115. Lla GROUND CONTRO C CB2 20a CR41 CR1 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN _ IGNITION START DOWN STOWED RAISED 1 86 30 O 86 30 2 86 30 5 86 30 86 30 3 86 30 6 3e 30 86 30 42 AL 85 85 m 85 85 85 t P i p 21 NCHO t 1523 o 27 1522 6 cue H2 LIMIT SWITCH LIMIT SWITCH 1377 2 J GOV SPEED SELECT OR RD 23 85 OIN R6 FUEL SELECT BKWH 7 L 6 MALFUNCTION LED BL 11 KEY ON WH 124 KEEP ALIVE POWER 663 SW20 9 r 1 ROTEN 3 SELF TEST SWITCH BK RD jeep CDS Hi 130 Y50 FUEL PUMP BL WH Ad 1 FORD T eX ENGINE HARNESS ELI DNA Sv IE X x aA FUEL PUMP 1 Y57 Y55 o T gt lt lt lt M M 5 3 55 5 5 h 8 8 g 5 m m 29 gt 5 9 T p S a 2 2 2 5 9 8 8 5 m 5 84 M B 2 gd 8 2 2 x lt 2 v m m m gt m OSCILLATING AXLE 9 AVAILABLE AFTER SERIAL NUMBER 41618 z 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163C Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic
116. MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK J 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH
117. PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 olx Lew PLATFORM CONTROLS 6 104 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 105 Section 6 Schematics Hydraulic Schematics Component Call out Legend Decemb
118. POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP BN1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN29 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LIFT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOU
119. POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 83 Section 6 Schematics Electrical Schematic Deutz Models from serial number 41066 to GS9003 41 350 Part 3 of 3 P2 December 2004 P2 ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM 2 C c L BK POWER TO PLATFORM EM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 W
120. TF Engines dee A Pob eee 2 7 D Deutz 2011F Eng derer tnde tek ed corre 2 8 D Hydraulic Hose and Fitting Torque Specifications 2 9 Section 3 Rev Scheduled Maintenance Procedures IMTFOQUCHION Lm 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection 3 5 C Checklist A Procedures A 1 Perform Pre operation 3 6 2 Perform Tests ek 3 6 Perform Engine Maintenance Ford models 3 7 A 4 Perform Engine Maintenance Deutz models 3 7 A 5 Inspectthe Engine Air Filter 3 8 6 Perform 30 Day 2 3 9 A 7 Perform Engine Maintenance Deutz models 3 9 8 Perform Engine Maintenance Ford models 3 10 A 9 Check the Hydraulic Return Filter Condition Indicator if equipped 3 10 A 10 Perform Engine Maintenance Deutz 1011F Models 3 11 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 December 2004 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued A 5 Drain the Fuel Filter Water Separator Deutz models 3 11 A 12 Perform Engine Maintenance Ford Models
121. TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 Lew PLATFORM CONTROLS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 93 Section 6 Schematics December 2004 ae Electrical Schematic ANSI Models with Deutz Power REVA after serial number GS9005 421 43 Part 1 of 3 FQsaruse P emercency stop KEY SWITCH Zas 2 PLATFORM CONTROL i4 4141 gt 3 GROUND CONTROL asa 4 C CB2 20a i
122. The measurement is less than 5 16 inch 8 mm Replace both wear pads 3 30 Genie 605 3390 65 4390 GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D D 2 Check the Free wheel Configuration Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing 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 CAUTION 1 Chock the wheels the steer end of the machine 2 Center a lifting jack of ample capacity 20 000 16 10 000 kg under the drive chassis between the wheels at the non steer end of the machine 3 Lift the wheels off the ground and place blocks under the drive chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the non steer end 42 disengaged position engaged position CHECKLIST D PROCEDURES 5 Manually rotate each wheel at the non steer end Result Each wheel should rotate with minimum effort 6 Engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for
123. X x 1 Y ABS 12 1 op BET ABE Y7 j 5 1 t Get AC AC 7 EFE 4 59 1608 5390 5 7 SW3 SW2 Bo Becomes aen 8 E Y3 y2 Y49 WHOL ld all NMOG Al 49 AND Y49A WERE REMOVED AFTER SERIAL NUMBER 41618 _ ES7175D SYN LWHAdWAL 3NION3 EMS 1491 8331 PA 82315 A 3XVH8 ZA SSVdA8 6 370815 HOLOW Q33d LA 1VNOlLHOdOHd 6A HOSN3S 13431 ZS SSVdA8 dunssaud 3NION3 ZMS SIN 7109 5 LSA MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 103 Section 6 Schematics December 2004 Electrical Schematic CE Models with Deutz Power after serial number GS9005 421 43 Part 3 of 3 4 4 BK POWER TO PLATFORM q RD POWER TO GROUND GROUND REVA P2 EMERGENCY STOP WH RD 4 4 1 RD WH 3 BL 1 1 4 2 2 OR 5
124. _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 WH BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM MEMBRANE DECAL POUT2 O g POWER LED L19 POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP BN1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN29 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E
125. breaker Hour meter Pressure switch Temperature switch Wve Resistor Solenoid N C N O 4 Limit switch Fusible link Ex e Emergency Stop button Nm Flashing beacon o Solenoid valve e LED Toggle switch pee Je Me i CXE CIRCUIT BOARD 57 n LEVEL SENSOR Level sensor models without outriggers Hii S8 2 AXIS TILT LEVEL SENSOR Level sensor models with outriggers So SSeS Quick disconnect 15 rd JOYSTICK lt 5K CONTROLLER POTENTIOMETER WH BK WH YL STEER SW5 SW6 LEFT RIGHT FUNCTION ENABLE 2 J E 9 9 m 5 5 I i ff HALL EFFECT 9 QX J GENERATOR JC1 JOYSTICK rA CONTROLLER SW5 FUNCTION ENABLE 1531 SW6 2 STEER i LEFT RIGHT Joystick Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics aa Electrical Schematic Platform Overload option
126. 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 CAUTION Depress the locking tab to disconnect the wire harness from the circuit board 7 Remove the platform controls circuit board retaining fasteners 8 Remove the platform controls circuit board from the platform control box lid PLATFORM CONTROLS 1 2 Joystick Controller Maintaining the joystick at the proper setting is essential to safe machine operation The joystick should operate smoothly over its entire range of motion Machines after serial number GS9003 41522 are equipped with Hall effect joysticks which do not require calibration How to Calibrate the Joystick before serial number GS9003 41523 If the joystick is out of calibration fault code 30 will be present on the diagnostic display and the error indicator light will be illuminated at the platform controls 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 3 Section 4 Repair Proc
127. continued A Electrical Schematics Abbreviation and Wire Color Legends 6 9 A Electrical Symbols 6 10 A Electrical Schematic Plattform Overload option before serial number GS9003 41523 6 11 B Wiring Harness Ford LRG 425 EFI before serial number GS9003 41 369 6 12 A Wiring Harness Ford LRG 425 EFI from serial number GS9003 41369 to GS9004 41693 6 14 A Wiring Harness Ford LRG 425 EFI after serial number GS9004 41693 6 16 E Electrical Schematic Ford Models before serial number 40428 6 18 D Electrical Schematic Ford Models from serial number 40428 40793 6 22 C Electrical Schematic Ford Models from serial number 40794 to 40995 6 26 A Electrical Schematic Ford Models from serial number 40996 to 41065 6 30 A Electrical Schematic Ford Models from serial number 41066 to 59003 41368 6 34 A Electrical Schematic Ford Models from serial number GS9003 41369 to GS9003 41522 6 3
128. cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 223 CHT Higher Than Expected 1 Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 224 CHT Higher Than Expected 2 Coolant temperature at the cylinder head is 250 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to Specification 231 MAP High Pressure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 232 MAP Low Voltage Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace
129. faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 538 Throttle Unable to Close Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 545 Governor Interlock Failure Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty Repair wiring and or connections in engine harness OR replace the ECM 551 Max Governor Speed Override ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 552 Fuel Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 553 Spark Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 611 COP Failure Loose wire c
130. force field AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the Coil REV E Valve Coil Resistance Description Specification Solenoid valve 3 position 4 way 8 2 to 10 20 10V DC with diode schematic item G Proportional valve 12V DC 3 1 to 5 10 schematic items H and AD DOS valve 3 position 4 way 10V DC 2 6 to 4 60 schematic items 1 J AG and AK Solenoid valve 3 position 4 way 6 2 to 8 20 10V DC with diode schematic item AH Solenoid valve 2 position 2 way 5 7 to 7 7 10V DC with diode schematic items BA and BB Solenoid valve 2 position 3 way 10V 8 2 to 10 20 schematic items Bl and BJ Solenoid valve 2 position 2 way 10V DC 4 5 to 6 50 schematic items CA CB CC and CD Solenoid valve 2 position 3 way 5 to 70 10V DC schematic item AL Solenoid valve 2 position 2 way 6 5 to 8 50 12V DC with diode schematic item DA Solenoid valve 2 position 3 way 910110 12 DC with diode schematic items DE and DF Solenoid valve 2 position 2 way 9 to 110 12V DC with diode schematic item DG Solenoid valve
131. from the flywheel REV Deutz models 1 Release the latches on the engine tray and fully slide the engine tray out 2 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 3 Remove the hose clamp from the air cleaner hose that connects to the engine 4 Remove the air filter mounting fasteners Remove the air filter from the engine and lay it off to the side 5 Remove the exhaust pipe clamp from the exhaust pipe support bracket 6 Attach a lifting strap from an overhead crane to the pump assembly for support Do not lift it 7 Remove all of the pump mounting plate to engine fasteners 8 Carefully pull the pump assembly away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 9 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump 2 Apply Loctite removable thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 34 ft lbs 46 Nm Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV C 4 3 Oil Temperature and Oil Pressure Switches Deutz Models The engine oil temperature switch is
132. fuel tank if equipped 9 Tag disconnect and plug the fuel supply and return hoses 10 Remove the fuel filler cap from the tank 11 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 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 CAUTION fuel tank is plastic and may become damaged if allowed to fall Clean the fuel tank and inspect for cracks and other damage before installing 4 108 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV C 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 FUEL AND HYDRAULIC TANKS 4 Lowerthe platform onto the safety arm Turn the engine off AWARNING Crushing hazard Keep hands clear of the safety arm when lowering t
133. gg 2858569 2 0 9 E 0 628540 az 5 57 LEVEL SENSOR uz o amou 08526 Toz J2 A6 gt WH 4 4 5g T Li au i ze H 655308 ILE aS SH ui EN I c 25 J2 B10 RD poke 5542 oo We 525 J2 C1 C10 E 430 op 1 1 85 TY ga S 1 c zi I 2 a amp 6 r T THROTTLE J4 B4 J2 B3 YL zi o z DATA LINK J8 A5 0 6 2 BL amp X29 S8 2 AXIS LEVEL SENSOR DATA LINK J3 A4 HM Q 2 GND FROM PLAT 4 J3 B4 gt I o 4 87 I OUTRIGGER RETRACT o 2 J3 B5 gt 28 655 2 E Y40 OUTRIGGER EXTEND i Neos To J8 A6 45556 9 J3 B6 gt fos 5 22 9 H1 Y33 LEFT REAR OUTRIGGER gt 98911 8 erp m o 5 deo J4 C2 TN i Y34 RIGHT REAR OUTRIGGER lt 2 FSF 20 4 200 9 4 2 J1 A12 bel gt 1 J2 A8 Y85 LEFT FRONT OUTRIGGER EZB 2 WM oz gt 21 41 85 36 RIGHT FRONT OUTRIGGER i 4 J4 B3 2 8 5 5 J1 C7 C8 05 ECM GROUND 2 ELE J4 B2 T qj 7 SW2 ENGINE OIL PRESSURE uuoo n ONLUS J3 A2 5 SW1 ENGINE COOLANT TE
134. ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 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 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn The red Emergency Stop button at the ground or platform controls will stop all machine operation without regard to the position of the key switch Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 21 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES B 13 Test the Fuel Select Operation Ford Models 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 while the engine is running or not Fuel 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 Perform this test after checking the gasoline and LPG fuel levels 1 Start the engine from the platform controls and allow the engine to run at low idle 2 Press high idle button a
135. gy 4 FLOW CONTROL BYPASS E 05 5 96 8g gt He 1255569 Eo g gt 2 aa NMOd JA ao E FTT 49 FLOW CONTROL BYPASS 28 4 an 2 gt 4 79 47 N 1Y29 GENERATOR OPTION 5 E gt J1 B4 Y9 PROPORTIONAL FLOW CONTROL lt rol Far gu J4 A4 gt b VE J1 A10 Y1 TWO SPEED MOTOR STROKE 02 uiu l mE gt J4 A1 J1 A1 1 Y3 STEER RIGHT d Qu lt e 2 2 e Sa J1 A4 1Y2 BRAKE RELEASE 8 1 J2 A1 4 6 39 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number GS9003 41369 to GS9003 41522 Part 3 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTION PIN18 2 WH RD 4 POUT2 POUT4 POUTS PO
136. hold the auto level button and press and hold the left front outrigger button Pull out the red Emergency Stop button to the on position at the platform controls 25 Before serial number 41523 Continue to hold the outrigger enable button and the auto level button for approximately 3 seconds or until a beep is heard After serial number 41522 Continue to hold the auto level button and left front outrigger button for approximately 3 seconds or until a beep is heard 26 Push in the red Emergency Stop button to the off position at the platform controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS Confirm the side to side level sensor setting 27 Center a lifting jack under the drive chassis at the ground control side of the machine 28 Raise the machine approximately 6 inches 15 29 Models with tires Place 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 30 Lower the machine onto the blocks 31 Pull out the red Emergency Stop button to the on position at platform controls Start the engine 32 Raise the platform approximately 16 feet 5 m O Result The platform stops raising and the tilt alarm will sou
137. i wo 8 5 ies g PIN13 EN LIFT FUNCTION BN9 3 m 2 m 2 2 gt 9 2 2 258 ORGR AUTOLEVEL ENABLE BN20 d gt 2 29 m 2 2 m Q Q m gt gt 2 m u o o m amp 6 PNIS 4 SYSTEM STATUS 150 2 5 5 8 p s 8 d 2 n 5 mo qu B yL 1 i z 2 DN PLATFORM UP DOWN TS20 2 BL OR o 5 o 9 B S X PLATFORM 8 OUTRIGGER 5 3 UP DOWN J 2 Ji PIN RD BK J1 PINS NOTE H1 MACHINE SHOWN IN THE STOWED Bur bui PLATFORM POSITION WITH THE POWER OFF CONTROLS Es7174 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 57 Section 6 Schematics December 2004 OOOO Electrical Schematic CE Models with Ford Power REVA from serial number GS9004 41694 to GS9005
138. key switch to the off position 5 Turn the key switch to platform controls and start the engine 6 Checkany machine function from the ground controls Result The machine functions should not operate 7 Turn key switch to the off position O Result The engine should stop and no functions should operate 3 20 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D B 11 Test the Emergency Stop A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the ground controls will override the platform controls except the platform red Emergency Stop button 1 Startthe engine from ground controls 2 Pushin the red Emergency Stop button to the off position O Result The engine should shut off and no machine functions should operate 3 Start the engine from platform controls 4 Pushin the red Emergency Stop button to the off position Result The engine should shut off and no machine functions should operate CHECKLIST B PROCEDURES B 12 Test the Automotive style Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to
139. level sensor The tilt alarm sounds when the incline of the chassis exceeds 2 to the side 3 to the front or 5 to the rear How to Install and Calibrate the Level Sensor 771771777 Tip over hazard Failure to install A DANGER or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 1 Perform this procedure with the machine on a firm level surface that is free of obstructions 2 Remove the platform controls from the platform 3 Block the wheels at the non steer end of the machine 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 4 inches 10 cm 6 Place a 1 97 x 10x 10 inch 5 x 25x 25 cm thick steel block under both wheels at the steer end of the machine REV D 7 Lower the machine onto the blocks 8 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 9 Raise the platform approximately 16 feet 5 m Result The tilt sensor alarm should not sound and the bubble in the top of the level sensor is centered in the circles Ww Result ANSI and CSA models before serial number 40820 The tilt alarm will sound at 180 beeps per minute The level sensor must be calibrated Result ANSI and CSA
140. machine if not properly supported by the overhead crane If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS How to Disassemble a Scissor Arm Pair AWARNING 9 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 required 1 Attach a lifting strap from an overhead crane to the end of the outer arm Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards a outer arm b innerarm 2 Attach a lifting strap from a second overhead crane to the end of the inner arm Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards 7 REV D Raise the scissor arms with the overhead cranes approximately 12 inches 30 cm Place a 12 inch 30 cm block under the center of the scissor arm pair Lower the scissor arm pair onto the block Remove the external snap rings from both center pivot pins Use a soft metal drift to remove both center pins Carefully separate the scissor arm pair AWARNING Crushing hazard The scissor arms could become unbalanced and fal
141. mode Press and hold the function enable low speed select button to show the platform lower speed percentage in the fault code display window To increase or decrease the platform lower speed press and hold the function enable low speed select button while using the steering rocker switch to adjust the function speed Refer to Section 2 Specifications Release the function enable low speed select button Turn the key switch to the off position to save the settings Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 REV How to Adjust the Platform Settling Speed 1 I a 5 GO 5 eG Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel Turn the key switch to the off position Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform control Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform control Genie 000 steering rocker switch SW6 platform up down select switch TS20 horn button BN5 platform extend retract enable BN16 OR outrigger enable button BN16 Section 4 Repair Procedures PLATFORM
142. on Machine functi ns di abled replace joystick DRIVE JOYSTICK 29 Lift enable button fault at the Troubleshoot button OR replace printed PLATFORM LIFT platform controls circuit board at platform controls SW FAULT 30 1 Replace up down switch at platform OFF NEUTRAL Red Up down switch off neutral Up down function disabled controls LIFT JOYSTICK 3 Starting aid fault at the TT Troubleshoot button OR replace printed PLATFORM ORE EN platform controls Starting aid disabled circuit board at platform controls FAULT 32 Engine start button fault at 5 Troubleshoot button OR replace printed PLATFORM Red platform controls Engine will not start circuit board at platform controls START SW FAULT 33 Red 177 Outriggers disabled Troubleshoot button OR replace printed LEFT FRONT rault at prado 99 circuit board at platform controls OUTRIG SW FLT controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 5 Fault Codes gt FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41522 December 2004 REVA Fault Code LED Condition Result Solution naw ere re Tr LE d omen ents oe Pos a P e cnn det 1 05 Red Drive coil 1 Y1 fault ie drive function wil not Troubleshoo
143. outer arms index 14 and 16 together with a strap or other suitable device 73 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 74 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 75 Remove the pin retaining fasteners from both chassis centering link pivot pins index 30 at the number 1 inner arm 76 Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis 77 Remove the pin retaining fasteners from the number 1 inner arm slide block pivot pins index 31 at the steer end of the machine 78 Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 31 79 Remove the pin retaining fasteners from the number 1 outer arm slide block pivot pins index 17 at the non steer end of the machine 80 Use a slide hammer to remove the number 1 outer arm slide block pivot pins index 17 81 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 If further disassembly of the
144. outrigger 566 Platform up down BN91 Auxiliary down enable TH or om T 9390 only TS67 Function enable CB2 Circuit breaker LS12 Left front outrigger TS69 Auxiliary function enable CB2 System power 20A LS13 Right front outrigger TS70 Auxiliary down CB7 Oil cooler 20A LS14 Left rear outrigger U Electronic component CR Control relay LS15 Right rear outrigger U3 Platform controls circuit board CR1 Engine start 1522 Right oscillate U5 Electronic control module CR1A Power to starter LS23 Left oscillate U32 Glow plug option CR4 High idle M Motor or pump Y Valve coi CR5 Horn relay M1 Cooling fan Y1 Parallel CR8 Ignition M2 Auxiliary pump Y2 Brake release 15 Starting aid M3 Starter motor Steer right CR17 Oil cooler M4 Fuel pump Y4 Steer left CR23 Auxiliary down 5 Hydraulic power unit Y7 Platform down CR41 Control system NG Normally closed Y8 Platform up CR42 Power NO Normally open Y9 Proportional control CR58 Forward reverse P Powariswit h Y29 Generator on option CR84 Oscillate stowed PILE top buff d Y33 Left rear outrigger CR85 Oscillate raised Emergency stop button ground Y34 Right rear outrigger D Power supply P2 Emergency stop button platfrm Y35 Left front outrigger D1 Alternator a Solenoid ___ Y36 Right front outrigger D7 Voltage regulator Q3 High idle Y39 Outrigger retract FBI Flashing beacons option 98 Fuel shut ott Y
145. 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 Be sure the hydraulic oil level is between the full and add marks on the oil level indicator Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Models with outriggers Deploy the outriggers and level the machine 2 Apply athin 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 Openthe large ground control panel door and locate the Electronic Control Module ECM wire harness to platform controls wire harness connection below the ground controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST D PROCEDURES 5 Tag and disconnect the platform controls wire harness from the ECM wire harness 6 Securely connect the platform controls to the ECM wire harness 7 Using a suitable lifting device place a test weight corresponding to the maximum load as indicated on the capacity indicator decal in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 3390 1878 kg GS 4390 1286 kg most models refer to capacity indicator decal GS 4390 1421 kg some models refer to c
146. 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 47 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS Chassis Scissor Arm Wear Pads If removing the steer end slide blocks the engine top and side covers need to be removed first Proceed to step 1 If removing the non steer end slide blocks proceed to step 11 1 Start the engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 2 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to vertical position Lock the safety arm in position Be sure that the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off Crushing h
147. scissor arm pair is required see How to Disassemble a Scissor Arm Pair REV D After serial number 41072 1 Remove the platform See 2 1 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 CAUTION 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 lifting 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 a slide hammer to remove both number 5 pivot pins index 4 from the non steer end of the machine Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedure
148. serial number 59004 41619 4 96 7 6 Drive Manifold Components after serial number GS9004 41618 4 98 7 7 Oscillate Manifold Components optional after serial number GS9004 41618 4 100 7 8 Valve Adjustments Function Manifold 4 102 7 9 Valve Adjustments Drive Manifold 4 103 7 10 Generator Manifold Components 4 104 7 11 Valve Adjustments Generator Manifold 4 105 12 Nale ed reci eerie Oe 4 106 C Fuel and Hydraulic Tanks 4 108 8 2 Hydraul Tank iiu ere ined aget 4 109 B Steer Axle Components 9 1 Yoke and Drive Motor a 4 111 9 2 Steer Gylinider 4 113 9 3 M 4 114 9 4 Oscillating Axle Option after serial number GS9004 41619 4 115 B Non steer Axle Components 10 1 Drive Motor and Brake 4 116 10 2 Drive due ie 4 117 10 3 Oscillating 4 117 A Outrigger Components 11 1 Outrigger Cylinder iieri 4 118 72863 Genie GS 3390 GS 4390 and GS 5390 ix December 2004 TABLE OF CONTEN
149. severe component damage Dealer service is recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification 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 during installation Refer to Section Two Hydraulic Torque specifications Hose and Fitting Torque Specifications Drive motor mounting bolts dry 75 ft lbs 102 Nm 1 Block the steer wheels Drive motor mounting bolts lubricated 56 ft lbs 76 Nm 4 116 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures E REV B NON STEER AXLE COMPONENTS 10 2 10 3 Drive Hub Oscillating Axle How to Remove a Drive Hub See 9 4 Oscillating Axle Option after serial number GS9004 41618 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 10 1 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 nut
150. 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 6 Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 14 and 2 at the non steer end of the machine Do not apply any lifting pressure 7 Remove the pin retaining fasteners from both 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 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 SCISSOR COMPONENTS 11 Carefully remove the number 4 inner and outer arms index 14 and 2 from the machine 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 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 lift
151. the machine SCISSOR COMPONENTS 43 Carefully remove the number 3 inner and outer arms index 8 and 23 and upper lift cylinder from the machine AWARNING C shing 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 44 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 45 Attach 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 46 Remove the pin retaining fasteners from the number 1 pivot pins index 17 at the non steer end of the machine 47 Use a slide hammer to remove both number 1 pivot pins index 17 from the non steer end of the machine 48 Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm 49 Placea 6x 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 50 Lower the number 1 outer arm index 16 onto t
152. the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance 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 TN disengaged position T org A engaged position Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition 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 result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products 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 and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications Models with air filled tires 4 Check pressure in each air filled tire Add air as necessary Refer to Section 2 Specifications Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Pro
153. the cylinder to a horizontal position Protect the cylinder rod from damage Component damage hazard The CAUTION counterbalance valve on the lift cylinder can be damaged if it is allowed to come in contact with the scissor arm cross tube 10 Remove the lift cylinder barrel end pivot pin retaining fastener Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if it is not properly supported 11 Carefully pull the lift cylinder out the non steer end of the machine through the scissor arms Remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly supported 4 52 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV 4 1 RPM Adjustment Refer to Maintenance Procedure B 6 Check and Adjust the Engine RPM 4 2 Flex Plate The flex plate couples the engine to the pump The flex plate is bolted to the engine flywheel and has a cut out in the center for the pump coupler pump pump shaft coupler flex plate flywheel 1 4inch gap Ford models 3 ainch gap Deutz models we 0 9 How to Remove the Flex Plate Ford models 1 Release the latches on the engine tray and fully slide the engine tray out 2 Insert a 6 inch 15 cm screwdriver or rod into the engi
154. the lift steer pump AWARNING injury hazard Spraying ydraulic 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 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the lift steer pump REV 3 Ford models Close the valve on the LPG tank then disconnect the hose from the tank if equipped Move the fuel select toggle switch at the ground controls to the LPG position Deutz models Hold the manual fuel shut off lever clockwise in the closed position 5 2 M Deutz models a manual fuel shut off lever 4 Turn 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 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 Result If the pressure fails to reach 3500 psi 241 bar the pump or pump coupling is bad and will need to be serviced or replaced 6 Remove the pressure gauge and connect the hydraulic hose Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV How to Remove the Lift Steer Pump
155. the machine Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 58 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 Crushing hazard The cable tray ACAUTION may fall if not properly supported by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched CAUTION 59 Support the hose tray at the ground controls side of the machine with an overhead crane 60 Remove the pin retaining fasteners from the hose tray pivot pin at the cross tube of the number 2 inner arm index 26 on the ground controls side of the machine 61 Place a rod through the hose tray pivot pin and twist to remove the pin Lower the hose tray onto the number 1 inner arm index 14 Crushing hazard The hose tray ACAUTION may fall if not properly supported by the overhead crane Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 62 Remove the hydraulic hoses and cables from the number 2 inner arm index 26 63 Secure both ends of the number 2 inner and outer arms index 26 and 27 together with a strap or other suitable device SCISSOR COMPONENTS 64 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 press
156. the number 3 inner arm index 8 and lay the cables and hoses off to the side CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 32 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 33 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 CAUTION SCISSOR COMPONENTS 34 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 35 Place a rod through the hose tray pivot pin and twist to remove the pin Lower the hose tray down Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 36 Secure both ends of the number 3 inner and outer arms index 48 and 23 together with strap or other suitable device 37 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the steer end of the machine Do not apply any lifting pressure 38 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the non steer end of the machine Do not apply any lifting pressure 39 Remove the pin retaining fasteners from both number 3 pivot pins index 10 a
157. to the stowed position 18 Raise the machine slightly 19 Remove the blocks from under both wheels 20 Lower the machine and remove the jack 21 Center a lifting jack under the drive chassis at the engine side of the machine 22 Raise the machine approximately 4 inches 10 cm 23 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 24 Lower the machine onto the blocks 25 Raise the platform approximately 16 feet 5 m O Result The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result The level sensor alarm does not sound Adjust the level sensor until the alarm just begins to sound 26 Lower the platform to the stowed position 27 Push in the red Emergency Stop button to the off position at both the ground and platform controls 28 Turn the key switch to the off position 29 Raise the machine slightly 30 Remove the blocks from under both wheels 31 Lower the machine and remove the jack GROUND CONTROLS 5 6 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 leve
158. 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 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES 6 Inspect the housing seal and replace it if necessary 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 injury hazard Spraying ydraulic 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 f
159. work surfaces clean and free of debris that could get into machine components and cause damage that your workshop or work area KIJ is properly ventilated and well lit 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 any forklift overhead crane 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 Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe iv Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Table of Contents Introduction Important InfOrmatiOri uu li Section 1 Safety Rules General Safety 2 404 0 000 00 seinen enne ens lii Section 2 Rev Specifications D Machine Specifications cerit tt reete entree 2 1 D Performance Specifications 2 2 D Hydraulic Specificato NS s 2 2 D Manifold Component Specifications see 2 4 D Ford ERG 425 EET Efiglfe aoi teen nre eee ER eerte tien 2 5 D Deutz FAL 1011F 2 6 D Deutz TOA
160. 0 6 97 Section 6 Schematics December 2004 aS Electrical Schematic CE Models with Deutz Power REVB from serial number GS9003 41523 to GS9005 42143 Part 1 of 3 KS1 1 EMERGENCY STOP 1 1 21 S PLATFORM CONTROL 14 1 oe GROUND CONTROL 4 2 CB2 20a 1 ABT TABS PS2 Y PLATFORM OVERLOAD H PRESSURE SWITCH CR41 CR1 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 2 86 30 2 86 5 86 304 4 86 86 2 30 30 2 85 87 85 D 85 v 85 e 7 85 7 e nu 2 N C H O N CH O l FA NT G6 LS23 LS22 gt 01 LEFT RIGHT xy 5 1 OSCILLATE OSCILLATE H2 LIMIT SWITCH LIMIT SWITCH 15 CR4 memes HIGH IDLE 1602 1603 one 86 30 AID
161. 06 oa LR OUTRIGGER ENABLE BN87 5 E Y35 Y33 Y39 PIN12 RR OUTRIGGER ENABLE BN24 i i i i i pure lt lt lt lt lt lt T S onm wo S 8 5 ies g PIN13 EN LIFT FUNCTION BN9 d m 2 FOR rene ene L3 S 3 2 2 258 ORGR AUTOLEVEL ENABLE BN20 A m 8 x E 2 a m 2 2 m Q Q m gt gt 2 gt o o lt 55 5 4 SYSTEM STATUS L50 9 B S s 2 5 x m m 5 J1 Yep 1 3 3 5 HB 2 5 5 9 DN PLATFORM UP DOWN TS20 5 9 B S 2 X PLATFORM amp OUTRIGGER Q m m gt UP DOWN J 2 Ji PIN RD sj J1 PINS NOTE H1 MACHINE SHOWN IN THE STOWED Bur bui PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7174A Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 61 Section 6 Schematics December 2004 i
162. 15 Number 4 pivot pins steer end 3 Number 4 center pivot pins 16 Number 3 outer arm 4 Number 4 pivot pins non steer end 17 Lift cylinder rod end pivot pin 5 Number 3 center pivot pins 18 Number 3 inner arm 6 Number 3 pivot pins non steer end 19 Number 3 pivot pins steer end 7 Number 2 center pivot pins 20 Number 2 outer arm 8 Number 2 inner arm 21 Number 2 pivot pins steer end 9 Number 2 pivot pins non steer end 22 Number 1 center pivot pins 10 Number 1 inner arm 23 Chassis centering link 11 Lift cylinder barrel end pivot pin 24 Number 1 pivot pins steer end 12 Number 1 outer arm 13 Number 1 pivot pins non steer end 4 24 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 3 2 Scissor Assembly GS 4390 How to Disassemble the Scissor Assembly GS 4390 AWARNING 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 required When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Before serial number 41073 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove t
163. 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Slo 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF eer 1 1 WH ER 2 2 BL DATA LINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK J 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE
164. 2 WH RD 4 POUT2 POUT4 POUTS POUT6 POUT7 POUT8 Oo OUO N PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REV E P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos E E Loud D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR pare Gill
165. 2 Left turn coil Y4 output A2 Down limit switch LS6 Upcoil Y8 output input A4 Brake coil Y2 output Aux down power input A5 Plug A4 Aux down relay CR23 A6 Plug terminal 86 output 7 Plug 5 Key switch terminal 3 input A8 Plug Level sensor S7 white A9 Down coil Y7 output input A10 2 speed coil Y1 output A7 Plug A11 Flow control bypass Y49 A8 Fug GS90 OR drive coil Y1A A9 ug GS68 output A10 Platform controls ground A12 Flow control bypass Y49A input GS90 OR drive coil Y1B A11 Platform controls data GS68 output input A12 Platform controls data B1 Generator coil Y29 output input B2 Reverse coil EDC Y51 output B1 Level sensor S8 blue B3 Forward coil EDC Y51 input output B2 Level sensor S8 black B4 Proportional coil Y9 input output B3 Level sensor S8 yellow B5 Right front outrigger coil input Y36 output B4 Plug B6 Outrigger extend coil Y40 B5 Plug output Be Plug B7 Outrigger retract coil Y39 B7 Engine start relay CR1 output terminal 86 output B8 Plug B8 Ignition relay CR8 terminal B9 Left front outrigger coil Y35 86 output output B9 Engine high idle output B10 Left rear outrigger coil Y33 B10 Level sensor S8 red output output B11 Right rear outrigger coil Y34 B11 Horn relay CR5 terminal 86 output output B12 LPG select all OR diesel N B12 Alarm output shut off coil GS68 output 4 C1 System power input C1 Pl
166. 3 to 0 4 mm Exhaust 0 02 to 0 024 in 0 5 to 0 6 mm Lubrication system Oil pressure 20 to 43 psi 1 4 to 3 bar Oil capacity 8 5 quarts including filter 8 liters Oil change capacity 6 35 quarts including filter 6 liters Oil viscosity requirements Above 5 F 15 15W 40 From 22 F to 86 F 30 C to 30 C 5W 30 Engine oil should have properties of API classification CC SE or CC SF Units ship with 15W 40 CC SG REVD Injection system Injection pump make Motorpal Injector pressure minimum 4351 psi 300 bar Fuel requirement Starter motor diesel number 2 D Current draw no load 90A Brush length minimum 0 5 in 12 7 mm Alternator Output 55A 14V DC Fan belt pretension retension 101 79 5 Ibf 450 350 20 Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 0 F 1000A Reserve capacity 25A rate 200 minutes Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 2 Specifications REV D Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok 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 installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm
167. 3390 GS 4390 and GS 5390 6 37 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number GS9003 41369 to GS9003 41522 REV A Part 1 of 3 IKS1 switcn 1 EMERGENCY STOP PLATFORM CONTROL H B GROUND i 4 CONTROL 2 20 CR41 CR1 CR58 contro CR42 CR5 CR8 ENGINE DRIVE SYSTEM POWER HORN IGNITION START FWD REV 4 86 86 304 86 86 a 86 85 87 85 e aA 85 et 859 87 857 a c c tes SR Fh gt U5 A 194 5 ELECTRONIC CONTROL MODULE rios D1 s J1 C11 C12 e J c c c LINK R6 E 5 o gt gt gt 5100 51 2 TS69 gt S 5 AUXILIARY 4 1 FUNCTION ENABLE TS70 AUXILIARY 1 H2 5 LA PLATFORM DOWN L Y4 H5 mh X Lie Al STARTER i Mar e SX FX 3 2 2 d Y8 4 4 4 L 4 n n 4 4 2 7 9 45 g
168. 390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Ford Power from serial number GS9004 41694 to GS9005 42143 Part 3 of 3 4 4 BK POWER TO PLATFORM 7 RD POWER TO GROUND GROUND REV B P2 EMERGENCY STOP WH RD 4 4 1 3 BL 1 1 4 2 2 OR 5 5 OUTRIGGERS STANDARD ON GS 5390 OPTION ON GS 3390 GS 4390 rm con Ta 58 2 AXIS LS12 1813 1514 1815 TILT LEVEL LF RF LR RR SENSOR O RIG O RIG LIMIT LIMIT LIMIT LIMIT SWITCH SWITCH SWITCH SWITCH 8 21125 3 QJ NO 92113 0 04 OF O Sm 5522221 LLLI L c c c c toC C C C gt I T PP PE 8 9 g 5 a U5 l ELECTRONIC CONTROL MODULE s c g g g T 7 D 7 gm N L g Do 5 8 g 8 9 1661 Y36 Y34 Y40 Y29 ACOX i She X AY 5 FB1 Y35 Y33 Y39 lt lt lt lt lt lt lt onm 8 9 8 8 8 515 5 458 m m gt Sl
169. 4 Number 3 pivot pins non steer end 14 Number 2 center pivot pins 5 Number 2 outer arm 15 Number 2 pivot pins steer end 6 Number 2 inner arm 16 Number 1 outer arm 7 Number 2 pivot pins non steer end 17 Number 1 center pivot pins 8 Number 1 inner arm 18 Chassis centering link 9 Lift cylinder barrel end pivot pin 19 Number 1 pivot pins steer end 10 Number 1 pivot pins non steer end 4 18 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 3 1 Scissor Assembly GS 3390 How to Disassemble the Scissor Assembly GS 3390 AWARNING 00 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 required When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 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 to the li
170. 40 Outrigger extend FLI Fusible link battery to alternator QD Quick disconnect Y49 High speed bypass QD3 Control cable to ground Y49A High speed bypass QD4 Control cable to platform Y50 LPG R Resistor Y51 Electronic displacemnt control R6 510 resistor Y54 Oscillate float R15 5K ohm potentiometer Y55 Oscillate enable Y56 Left oscillate Y57 Right oscillate WIRE COLOR WIRE COLOR LEGEND LEGEND FORD WIRING HARNESS Color Description Color Description Color Description Color Description BL Blue BL BLUE GY GREY P PURPLE BK Black BK BLACK LB LIGHT BLUE R RED BN Brown BR BROWN LG LIGHT GREEN T TAN GY Grey DB DARK BLUE N NATURAL WHITE OR Orange DG DARK GREEN YELLOW PP Purple GN GREEN PK PINK RD Red NOTES WH White 1 Wires are labeled with Ford circuit number color and wire gauge YL Yellow Example 74GY LB18 means circuit 74 grey wire with light blue stripe WH BL White Blue 18 gauge wire WH BK White Black WH RD White Red 2 Internal splices are not shown Part No 72863 Genie GS 3390 GS 4390 GS 5390 Section 6 Schematics December 2004 Electrical Symbols Legend REV PLATFORM CONTROL GROUND CONTROL Key switch K5 EX 87A Relay Alternator Spark plug 12V DC Battery e Circuit
171. 40 feet 12 2 m apart 2 Turn key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Startthe engine from the platform controls 4 Lowerthe platform to the stowed position 5 Choose 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 23 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES Models before serial number GS9003 41523 and after serial number GS9003 41522 with software revision B1 or lower 6 Bring the machine to maximum 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 Section 2 Specifications Models after serial number GS9003 41522 with software revision CO or higher 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 Section 2 Specifications 8 Bring the machine to maximum reverse drive speed before reaching the start line Begin timing when your
172. 42143 Part 1 of 3 KS1 1 na EMERGENCY STOP 2 PLATFORM CONTROL 14 1 oe GROUND cer cd l 4 CB2 20a T T PS2 Y PLATFORM OVERLOAD H PRESSURE SWITCH CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 2 86 21 86 9 86 4 86 86 2 30 30 2 85 87 7a 850 87 D 85 85 7 85 7 t 5 n 12 NCHO t G6 LS23 LS22 FUSE LINK E LEFT RIGHT EAS 1 OSCILLATE OSCILLATE H2 gt LIMIT SWITCH LIMIT SWITCH i 1 15 GOV SPEED SELECT OR RD 23 R6 FUELSELECTBKWH 7 5100 i L 6 MALFUNCTION LED BL 11 24 KEEP ALIVE POWER WH 663 SW20 9 r 1 gt ENGINE SELF TEST Or SELF TEST SWITC
173. 5 5 2 o o 2 gt 70 gt 22 255 3 CE m 5 3 B 2 I 29 2 x gt g m J 5 5 m m 2 gt 2 c D D gt 5 2 n 2 gt 2 oo 5 5 op a m o m m Dv 5 gt 2 c 6 5 2 lt lt D lt lt D gt m 2 2 2 m z Q o MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 38 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics Part 2 of 3 Electrical Schematic Ford Models from serial number GS9003 41369 to GS9003 41522 December 2004 REVA 73 1 LL HME 103139 1904 2 o 5 b 1 1831 3135 e A gt 4 5 tug J4 C1 Y50 LPG Po Ho uae BN 2 Pre p OS eye 58 azg F8 E 2 187 LEVEL SENSOR lt 5 Toz J2 A6 WH j 9 898 38 LA
174. 6 85 87 85 87A D 4 857 87 857 87 87 857 2 ooo OD Koa ia T 51 u5 gt 1 4 5 2 ELECTRONIC CONTROL MODULE J4 B4 amp g gt 5 TS69 AUXILIARY CR15 CR4 a 51 E T FUNCTION ENABLE STARTING HIGH IDLE EDC 9 AID TS70 86 30 86 30 AUXILIARY Y4 PIN KC a PLATFORM DOWN f 85 87 85 7 5 RON aX 4 E gt 032 Der Q8 GLOW 03 4X PLUG FUEL HIGH IDLE SHUT OFF OPTION SOLENOID Med _ N7 Y8 n 1 4 4 4 4 8 amp 58 9 amp 5 8 55 BIO XE 5 gt o O m gt T m I gt x 70 lt S rm d e 5 98 S E amp m gt 8 gd 37 5 9 38 E 3 2 2 n 2 2 2 c A De 2 m gt 2 9 5 at lt c 2 lt m c 4 Fo 2 5 S D o Xm m m 3 lt lt v 2 ms 79 2 E m 2 gt 5 m Q 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 86 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REVA Deutz Models from serial number GS9003 41351 to GS9003 41522 Part 2 of 3
175. 6 from the machine AWARNING C ushing 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 32 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 33 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 34 Remove the pin retaining fasteners from the number 1 pivot pins index 13 at the non steer end of the machine 35 Use a slide hammer to remove both number 1 pivot pins index 13 from the non steer end of the machine 36 Carefully lift the number 1 outer arm at the non steer end approximately 15 inches 40 cm 37 a 6 x 6 x 32 inch 15 x 15 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 fro
176. 63 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 33 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 41066 to GS9003 41 368 REV A Part 1 of 3 IKS1 Kev swircn 1 EMERGENCY STOP PLATFORM CONTROL GROUND 1 2 20 CR41 CR58 CONTROL CR42 CR5 CR8 ENGINE DRIVE SYSTEM POWER HORN IGNITION START FWD REV 86 5 86 30 K6 86 30 86 K2 86 30 K1 86 AL A PIN i IE Ed a Rg U5 A J4 AS ELECTRONIC CONTROL MODULE E J1 C11 C12 LINK sa g ys1 k B 8 5 EDC 5 AUXILIARY FUNCTION ENABLE 5 Mi Y4 H5 ULM EU S Tl Q 5 UEM 23 d 12 YT Y8 9s 5 7 8 2 2 22 E 3 d 2 X 8 D 2 5 E 3 2 2 2 8 88 5 55 S gt gg m E 8 8 lt 2 2 15 m v m gt i
177. 7 LEVEL SENSOR 3522640 Toz J2 A6 uZz2 zzudi zdz tc i cre za i ul Bx J2 B10 RD 2238 leo BS E Qgo snunouil ssceg 525 42 1 10 ini att te cac eee 1 1 ee E mmo g I THROTTLE 1 11 DATA LINK E 5 d 5 A5 0 0 BL amp X29 S8 2 AXIS LEVEL SENSOR DATA LINK J3 A4 2 GND FROM PLAT 4 J3 B4 l E V I o OUTRIGGER RETRACT 2 J3 B5 gt p 655 we Y40 OUTRIGGER EXTEND 1 283 93 o 61 SEE J3 A6 9 45556 J3 B6 gt fos 9 H1 Y33 LEFT REAR OUTRIGGER zo 03 18 m o 5 deo J4 C2 TN i Y34 RIGHT REAR OUTRIGGER r2 4 gt amp d 20 22 J1 A12 gt T J2 A8 Y85 LEFT FRONT OUTRIGGER QE amp 555 1 4 5 J1 B5 gt 36 RIGHT FRONT OUTRIGGER t J4 B3 B 083555 J1 C7 C8 U5 GROUND J4 B2 I 1 qj 92 ENGINE OIL PRESSURE uuoo gt ul J8 A2 5 SW1 ENGINE COOLANT TEMPERATURE T ORZES 8 es BEF
178. 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM amp OUTRIGGER UP DOWN TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Sc
179. 794 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 45 Section 3 Scheduled Maintenance Procedures December 2004 E 5 Perform Engine Maintenance Deutz 2011F Models Engine specifications require that this procedure be performed every 12 000 hours Required maintenance procedures and additional engine information is available in the Deutz 2011 Operation Manual Deutz part number 0297 9929 Deutz 2011 Operation Manual Genie part number 84794 REV E 6 Perform Engine Maintenance Ford Models before serial number GS9003 41369 Engine specifications require that this procedure be performed every four years maximum Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Genie part number 84792 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures Observe and Obey 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 Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary to
180. 8 B Electrical Schematic ANSI Models with Ford Power from serial number GS9003 41523 to GS9004 41693 6 42 B Electrical Schematic ANSI Models with Ford Power from serial number GS9003 41694 to GS9005 42143 6 46 A Electrical Schematic ANSI Models with Ford Power after serial number GS9005 42143 6 50 B Electrical Schematic CE Models with Ford Power from serial number GS9003 41523 to GS9004 416993 6 54 B Electrical Schematic CE Models with Ford Power from serial number GS9003 41694 to GS9005 42143 6 58 A Electrical Schematic CE Models with Ford Power after serial number 259005 42143 sss 6 62 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Xi December 2004 TABLE OF CONTENTS Section 6 Rev Schematics continued Electrical Schematic Deutz Models before serial number 40428 6 66 D Electrical Schematic Deutz Models from serial number 404281040737 6 70 E Electrical Schematic Deutz Models from serial number 40738 to 40941 sss 6 74 B Electrical Schematic Deutz Models from serial number 40942 to 41065 6 78 Electrical Schematic Deutz Models from serial number 41066 to 559003 41350 2 24242424 2 6 82 A Electrical Schemati
181. 9 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LIFT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 81 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 41066 to GS9003 41 350 REV A Part 1 of 3 P IKS1 switcn P1 B EMERGENCY STOP
182. 9FGY R20 743GY20 3581 20 354LG R18 342LG P16 264W LB18 225BK Y20 253BDG W20 57BK18 242DG18 96 018 74GY LB18 814 944 81HNL9 eNADWESE OZA MaSee 8 CR4 LOCATED INSIDE THE GROUND CONTROL BOX ES7144A K 81H ADV6SE 810 8Gc8c E HOSN3S 81H ADf 6S OZADEFZ OZd M60c 020 1716 028 9 16 029201 48 0597 4859 DIAGNOSTIC CONNECTOR INTAKE AIR TEMPERATURE SENSOR IAT FORD ENGINE CONTROL MODULE ECM QUICK DISCONNECTS TO ECM IGNITION COIL 1 NOT USED VPWR KEEP ALIVE PWR NOT USED NOT USED CRANKSHAFT SENSOR RETURN CRANKSHAFT SENSOR RETURN CAMSHAFT SENSOR FEED 3 THROTTLE POSITION SENSOR INPUT FUEL PUMP MONITOR NOT USED NOT USED NOT USED FUEL INJECTOR 1 FUEL INJECTOR 2 FUEL INJECTOR 3 FUEL INJECTOR 4 VREF DRY FUEL MODULATOR NOT USED NOT USED POWER GROUND POWER GROUND POWER GROUND POWER GROUND NOT USED NOT USED NOT USED NOT USED DATA LINK DRIVE BY WIRE AUXILLARY INPUT SELF TEST INPUT GOVERNOR SELECT 1 GOVERNOR SELECT 2 MALFUNCTION INDICATOR LAMP FUEL SELECT DATA LINK CONNECTOR DATA LINK CONNECTOR 9 FUEL PUMP RELAY CONTROL NOT USED NOT USED SINGLE RETURN NOT USED NOT USED NOT USED INTAKE AIR TEMP SENSOR MAP SENSOR INPU
183. AL NUMBER GS9003 41523 December 2004 REV Fault Code Dot Problem Possible Causes Solution 60 Flash LPG coil Y50 fault Malfunctioning coil OR wire Troubleshoot coil OR inspect wire disconnected from coil connection Malfunctioning coil OR wire Troubleshoot coil OR inspect wire 61 Masi shuroll coll disconnected from coil connection Check the engine oil level OR check Low engine oil pressure OR wiring at the oil pressure switch OR 66 Flash Lowoilipressure defective oil pressure switch check the wiring at the ECM OR replace the oil pressure switch Ford models Check the engine radiator coolant level OR check the wiring at the water temperature switch High engine temperature 67 Flash High temperature 2 Deutz models Check the engine oil level OR check the wiring at the oil temperature switch OR check the wiring at the ECM OR replace the oil temperature switch 68 Solid Low ECM voltage Battery discharged Charge battery 69 Flash Low RPM Engine idle RPM too low Consult SENICE Department 70 Flash High RPM Engine RPM too high Consult Genie Industries Service Department Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes REVA after serial number GS9003 41522 Fault Code LE
184. ARY YA H5 2 ES PLATFORM DOWN pe e 1 1 vate 1 STARTER 1 a F M3 5 i e d Y8 4 n 4 4 4 55 2 9 2 as 5 x 5 a D gt o 0 gt TIE gt gt lt 9 gt 65 m m E Rom gt g 3 5 32 3 g 3 204 z 5 55 5 T p 2 amp 2 2 z 2 8 86 5 ms d s 4 amp m m 3 5 2 mg f S 26 2 lt lt 2 lt 2 m m m gt zi B Um m m 2 B z Q Q MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138H 6 26 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics Part 2 of 3 Electrical Schematic December 2004 Ford Models from serial number 40794 to 40995 REV fo 1 e LL 5 E M8 A 123735 1304 l D H Se 5 d MHOLIMS 1531 414 8L me 1 gt Z 3 i Y50 LPG Bx TEZ N 7 5 386 o 235 LN BRB E
185. AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED 86 86 86 86 86 86 30 30 42 85 87 85 87 aA D 87 857 e 85 e 7 85 7 i ae N CHO NCHO em 1523 07 07 1622 LINK LEFT RIGHT EAN 1 OSCILLATE OSCILLATE H2 gt LIMIT SWITCH LIMIT SWITCH 1 15 GOV SPEED SELECT OR RD 23 gt R6 FUEL SELECT BKWH 7 5100 i L 6 MALFUNCTION LED BL 11 24 KEEP ALIVE POWER WH A 663 SW20 9 gt ENGINE SELF TEST at cog 25 118 SELFTESTSWITCHBK RD Y54 Y56 Y50 n FUEL PUMP BL WH X X EX FORD x E i ENGINE HARNESS f M 7 X FUEL PUMP Y57 Y55 1 i n n n 5 5 52 22 8 5 2 9 a amp M gt o 0 a gt x m gt 2 e c GA c c r o 2 T lt dm 2 m x gt 3 e 3 G26 ie 5 t ul g m 22 lt f d 2 3 gt 5 g gt lt lt c 5 lt 04 Q gt amp m n 9 5 e 5 m f gt m OSCILLATING AXLE z OPTION 9 AVAILABLE AFTER SERIAL NUMBER 41618 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163E 6 50 Genie 605 3390 GS 4390 065 5390 72863 December 2004 Section 6
186. AUXILIARY Y4 H5 2 PLATFORM DOWN 4 S EE on r3 E FR STARTER A se s x I EN ica 1 N7 Y8 n L 4 4 4 1 n n 4 4 55 5 Q S S 3 5 8 s gz gt 45 rc gt E 39 4 E 5 9 5 5 9 m x 5 m 3 m x g lt 2 gt T 2 D 3 2 z 5 E Be 2 3 2 2 h 2 3 z 2 5 lt E m c Dv gt d 5 g S m gt D mc amp 9 2 lt lt 2 gt lt d 3 m ms 5 5 m 2 gt z m p NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 22 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 Section 6 Schematics Part 2 of 3 Electrical Schematic December 2004 Ford Models from serial number 40428 to 40793 REV D 73 po 1 1 1 Le i M8 A 123135 1904 4 gt 55 d MHOLIMS 1831 4135 BL gt gt lt ZTN E zt g J4 C1 N 1750 LPG oe a B 68288 o
187. CHECKLIST D PROCEDURES Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 41 Section 3 Scheduled Maintenance Procedures December 2004 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers 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 frequently Component damage hazard The CAUTION work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to th
188. CIRCUIT BOARD REGULATOR pare Gill a TOI E Y 42 6 saij gp 981 ____ 4 JC1 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13
189. Checkthe battery acid level of each battery cell If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the battery vent caps Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 13 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring 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 hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit module tray Battery pack module tray Scissor arms Platform controls 3 Inspect for a liberal coating of dielectric grease in the following locations Between the ECM and platform controls Engine Ford models All wire harness connectors Level sensor 4 Turn 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 REV D 5 Startthe engine from the grou
190. D Condition Result Solution SYSTEM READY Green Normal operation INTERNAL ECU Red Internal ECM error System shutdown Replace ECM FAULT 02 Platform ECM communication Troubleshoot control cable OR PLATFORM ECU mee error System shutdown troubleshoot platform controls FAULT 20 Engine start button fault at CHASSIS START Red ground controls Engine will not start Replace ECM SW FAULT 21 Starting aid button fault at TN CHASSIS CHOKE Red ground controls Starting aid disabled Replace ECM SW FAULT 22 Up switch fault at ground 922 CHASSIS UP SW Red controls Platform up function inoperable Replace ECM FAULT 23 Platform up down enable Platform up down functions CHASSIS LIFT SW Ped button fault at ground controls disabled Replace ECM FAULT 24 Red Down fault at ground Platform down function disabled Replace ECM DOWN SW FAULT controls 25 Red Left turn switch fault Malfunctioning steer left Troubleshoot steer left microswitch LEFT TURN SW H Ut microswitch FAULT 26 Red Right turn switch fault Malfunctioning steer right Troubleshoot steer right microswitch RIGHT TURN SW g microswitch 9 FAULT 27 Function enable switch on Release function enable switch on DRIVE ENABLE Red joystick is activated when Machine functions disabled joystick before power up OR replace SW FLT machine is turned on joystick 28 Drive joystick off neutral when Release joystick before power OR OFF NEUTRAL Red machine is turned
191. DC Ref Higher than Expected Engine harness wiring and or connections open or shorted to ground OR there is a engine sensor OR is faulty Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM Loose wire connections to ECM OR ECM is Locate and repair any engine harness wiring 655 RTI 2 Loss BU damage or shorts to ECM to be sure they y are secure OR replace ECM Locate repair any engine harness wiring 656 3 Loss connections 10 damage or shorts to ECM to be sure they aulty are secure OR replace ECM 5 14 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Observe and Obey M Troubleshooting 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 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 Schematics About This Section There are two groups of schematics in this section An illustration legen
192. EED GASEOUS TRIM 33 349A DB 18 349A 18 CAN 18 662 DG P 18 9098 CAN 19 459 O LG 18 Doo 20 642 06 0 18 2060 18 45 ____ 581018 se RS 232 TX 1 35 458 O BK 18 Doo d 258 OK 18 RS 232 RX 4 TRIM VALVE R 77 DB Y 18 361 16 l 361AR 16 WPTWR2 GY E1280B 6 14 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics a Wiring Harness Ford LRG 425 EFI REVA from serial number GS9003 41369 to GS9004 41693 Part 2 of 2 361 16 361 R 16 361 16 361 R 16 FORD 42 PIN CONNECTOR 16 WATER TEMP 555 T 16 557 BR Y 16 558 BR LB 16 556 W 16 INJECTOR 1 INJECTOR 3 INJECTOR 4 INJECTOR 2 743 GY 18 359 GY R 18 570 BK W 16 39 R W 18 WATER ACT TEMP 151 LB BK 151LB BK JAFPPI 307 BK Y 18 25 NS 354 LG R 18 359 GY R 18 1 570 16 570 BK W 16 570 BK W 16 570 BK W 12 34 GROUND 16 R LG 18 570 BK W 16 570 BK W 16 CONN 570 BK W 16 351 BR W 18 16 R LG 18 358 LG BK 18 359 GY R 18 18 O Y 18 EE 38 EGR ANA IN ____ 150 GW 18 oe 352 BRIG weenie DU 360 1
193. EMBRANE DECAL POUT2 O g POWER LED L19 POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP BN1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN29 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LIFT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11
194. FE Lt zl GS 4390 1800 psi 124 bar STEER CYLINDERS 65 5390 1100 psi 76 bar LEFT RIGHT 4 1 ro L m le 7 A 17 0150 1 3 8 Y7 Y8 x Y4 Y40 ij IL IE p E i 69 mae pe L 138 bor 5 nn E L AJ X 0 1 0 38 L min FUNCTION L 241 3 bar MANIFOLD Plo GENERATOR OPTION E AUXILIARY 2000 psi 137 9 bar POWER UNIT T4 OK HS7037J Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 111 Section 6 Schematics December 2004 Hydraulic Schematic after serial number GS9004 41618 REV Part 1 of 2 INL RIGHT RIGHT FRONT REAR EE 1 EN I tz 82 0 090 in 0 085 in lt 23mm Ar N Es 0 9 s mam 4 Su a so EN TP1
195. FT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 85 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number GS9003 41351 to GS9003 41522 REV A Part 1 of 3 KS1 P1 Bt 2 EMERGENCY STOP PLATFORM CONTROL 3 els GROUND CONTROL 4 4 CR41 CONTROL CR42 CR5 CR8 ENGINE CR58 SYSTEM POWER HORN IGNITION START FWD REV 4 86 a a se 304 86 86 O 8
196. Fuel Pump High Side Shorted To Power Wiring and or connections to fuel pump shorted to power OR fuel pump is faulty Repair wiring and or connections to fue pump OR replace fuel pump 353 delivery pressure higher than expected Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked restricted or is leaking OR engine cooling system is not operating properly OR Megavector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector 354 Megajector delivery pressure lower than expected Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked restricted or is leaking OR engine cooling system is not operating properly OR Megavector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector 355 MegaJector communication lost The doesn t get any response from the MegaJector or an incorrect response for 500ms period or longer Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the Megavector MegaJector detects voltage greater than
197. G REV D Injection system Injection pump make OMAP Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Starter motor Current draw no load 90A Brush length minimum 0 5 in 12 7 mm Alternator Output 55A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Battery before serial number 40516 Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Battery after serial number 40515 Type 12V DC Group 31 Quantity 1 Cold cranking ampere 0 1000A Reserve capacity O 25A rate 200 minutes Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 REV Deutz F3L 1011F Engine Displacement Number of cylinders Bore and stroke 125 cu in 2 05 liters 3 3 58 x 4 13 inches 91 x 105 mm Section 2 Specifications 22227 SPECIFICATIONS Injection system Injection pump make OMAP Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Horsepower 42 2800 rpm 31 3 kW 2800 rpm Starter motor Firing order Legs Current draw no load 90A Compression ratio 18 511 Brush length new 0 748 in Compression pressure 362 to 435 psi 19 mm 25 to 30 bar Brush length minimum 0
198. G BEACON 5 MA OPTION Ihi m 9 5 gt ZO ZER 1 gy Y49 FLOW CONTROL BYPASS Y 28 2 8 gt LHe x c 2 3 NMOG JA ao E 1 FLOW CONTROL BYPASS 28 A o dn 2 gt 5 J4 B6 1Y29 GENERATOR OPTION J 9 me gt Obs 605 84 Y9 PROPORTIONAL FLOW CONTROL 0225 Fea F r T VE J1 A10 1 TWO SPEED MOTOR STROKE 02 uj EX 2 J4 A1 J1 A1 STEER RIGHT x Qu e 95 gt 5 Co oe J1 A4 rh 1Y2 BRAKE RELEASE E 1 4 6 31 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40996 to 41065 Part 3 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTION PIN18 2 WH RD 4
199. G ILE t ui bd I lo BS J2 B10 Rb Le 82 522 T lt eof 525 J2 C1 C10 8E Qo gt MES gt 95 lt a 1 1 oz 5 1 6E gt THROTTLE J4 B4 J2 B3 YL zi 77 z s DATA LINK J8 A5 0 6 2 BL amp X29 S8 2 AXIS LEVEL SENSOR 4 25 158 GND FROM PLAT J3 B4 pov V I o 1 87 I OUTRIGGER RETRACT o S DETE 6 J3 B5 28 E E Y40 OUTRIGGER EXTEND Uu 1 q 96 J3 A6 2 SGSES 6 J3 B6 gt 5 mog 20 2 H1 Y33 LEFT REAR OUTRIGGER ozg 0 o sz 5 Bag J2 A10 gt bs g 25 MES ES 6 i J4 C2 rta 7734 RIGHT REAR OUTRIGGER r 4 5 1546 655 ZO 4 2 1922 4 J1 A12 gt a J2 A8 Y85 LEFT FRONT OUTRIGGER OF g A S 0 9555 gt J1 B5 Y36 RIGHT FRONT OUTRIGGER i 4 i t J4 B3 1 7 05 GROUND 055506 E2925 J4 B2 I 1 qj 92 ENGINE OIL PRESSURE i oe ore SW1 ENGINE COOLANT TEMPERATURE 5 J4 B1 c BEFORE SERIAL NUMBER 40043 a 9 20 a0 J1 B1 FLASHING BEACON 2 a oN TA OPTION t L lt m o 58 20 ZES Q
200. GEND ABBREVIATION LEGEND ABBREVIATION LEGEND Item Description Item Description Item Description B1 Battery G Gauge S Sensor BN Button G1 Volt meter S5 Platform overload pressure BN1 Engine stop G6 Hour meter Switch option BN2 Engine start G8 Diagnostic display S7 Level sensor BN3 Starting aid GND Ground models without outriggers BN4 High idle H Horn or alarm S8 Level sensor Horn H1 Alarm models with outriggers BN6 High torque H2 Automotive style horn Sw Switch BN7 Generator H5 Alarm SW1 Engine coolant temperature 9 Platform up JC1 Joystick controller SW Engine oil pressure BN12 High speed lift enable KS1 Key switch SWS Engine oil temperature BN13 Low speed lift enable L LED or light SW4 Hydraulic oil temperature BN14 LPG select L2 Check engine light SW5 Function enable BN15 Horn left rear outrigger L19 Power SW6 Steer left right BN16 Outrigger function enable L21 High torque SW25 DIP switch BN17 High torque left front outriggr 122 LPG 5 Toggle switch 18 Generator right front outriggr L23 High idle TS20 Platform up down BN20 Auto level L25 Faul TS21 Platform outrigger up down BN23 Auxiliary down L27 Generator TS52 Engine start BN24 Right rear outrigger L39 Auxiliary power lift disable TS53 Fuel select BN85 Left front outrigger L50 System status TS54 Engine high idle BNOS po front 2 LS Limit switch TS56 Starting aid Lett rear
201. Genie Service Manual GS 3390 GS 4390 GS 5390 Introduction December 2004 Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance or repair 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 Technical Publications Genie Industries 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 printings of this and all other manuals Contact Us PO Box 97030 Redmond WA 98073 9730 USA www genieindustries com e mail techsup genieind com Copyright 2001 by Genie Industries 72863 RevE December 2004 F
202. Green Purple 86 Yellow 12 Gauge 30 Yellow 30 Red Light Blue 30 Red 12 Gauge 87 Pink Black 87 Dark Blue 87A After serial number GS9003 41368 7 5 15 Power J FA Relay 4 15 20 F2 5A F1 30A pes a4 Starter Fuel Pump Relay Relay Note For detailed wire color information refer to the Ford engine wiring harness diagrams 6 6 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Wiring Diagram Platform Control Box REV before serial number GS9003 41523 EMERGENCY STOP a BUTTON Uo RD RD JC1 JOYSTICK CONTROLLER U3 PLATFORM CONTROLS CIRCUIT BOARD PP OR Q Q Pie pue Q REGULATOR WH TO BN12 BN13 TS20 PLATFORM UP DOWN COIL mE FUNCTION TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS CORD ENABLE ENABLE OR ASSEMBLY HIGHSPEED LOW SPEED TS21 PLATFORM UP DOWN OUTRIGGER UP DOWN ol TOGGLE SWITCH MODELS WITH OUTRIGGERS LER Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 7 December 2004 Section 6
203. H BK RD 54 Y56 Y50 4 FUEL PUMP BL WH tru 15 X X EX 1 Los FLU E ENGINE HARNESS ELI DNA Sv IE X x aA FUEL PUMP Y57 _ 55 i n n n 9 5 52 22 8 S e D 4 5 gt o gt gt x m 2 9 e c c 2 o 2 o lt gt gt dm 2 m x gt o o o 8 3 020 5 ul 5 d m 20 lt 2 9 2 SZ gt 5 m 20 lt 2 d I o 8 gt gt 5 lt gt o 4 lt E v o m m 9 5 Dm D m 2 3 7 S B lt f gt m OSCILLATING AXLE OPTION 9 AVAILABLE AFTER SERIAL NUMBER 41618 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174A 6 58 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics ic S Electrical Schematic REV CE Models with Ford Power from serial number GS9004 41694 to GS9005 42143 Part 2 of 3 GS 5390 ONLY 1656
204. H BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM MEMBRANE DECAL POUT2 O g POWER LED L19 POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP BN1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN29 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LI
205. H PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl _____ JC1 R 6 4 BN gt 15 JOYSTICK 5 o BN 5 15 JOYSTICK 5K CONTROLLER 5K CONTROLLER 47 POTENTIOMETER 8 WH BK WH YL WH BK WH YL STEER STEER WH BL FUNCTION se End SWG LETT ior vui FUNCTION SW5 RIGHT PIN18 4 2 PIN18 4 Rm 2 3 WH RD i WH RD i BK PLATFORM CONTROLS BK PLATFORM CONTROLS o q t MEMBRANE DECAL S uM MEMBRANE DECAL POUT2 O g POWER LED L19 POUT2 O 44 4 POWER LED 119 POUT3 POUT3 E 4 LIFT ERROR INDICATOR LED L57 POUT4 FAULT LED L25 POUT4 FAULT LED 125 zu GENERATOR LED L27 POUTS lt GENERATOR LED 127 by ES HIGH TORQUE LED 121 POUTe O HIGH TORQUE LED 121 4 4 HIGH IDLE LED 123 POUT8 1 4 HIGH IDLE LED 123 PINS gt ENGINE STOP BN1 PINS 22 ENGINE STOP BN1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN2
206. L 6 MALFUNCTION LED BL 11 24 KEEP ALIVE POWER WH 663 SW20 9 r 1 gt ENGINE SELF TEST cog 3 SELFTESTSWITCHBKRD 2 m Y54 Yse Y50 j n H FUEL PUMP BL WH tru 15 X X EX 1 Los FL ee E i ENGINE HARNESS ELI DNA Sv IE X x aA FUEL PUMP Y57 _ 55 i n n n 9 5 52 22 8 S e D 4 5 gt o 0 gt 5 gt 2 e e mo c c c r z o 2 o lt dm 2 m x gt 8 3 020 5 ul 5 d m 20 lt 2 9 2 SZ gt 5 m 14 3 20 2 d T o gt gt 2 95 5 0 8 9 Gm c m m 9 5 Dm D m 2 3 7 S B lt f gt m OSCILLATING AXLE 5 9 AVAILABLE AFTER SERIAL NUMBER 41618 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163B 6 42 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa Electrical Schematic REV ANSI Models with Ford Power from serial number GS9003 41523 to GS9004 41693 Part 2 of 3
207. LATOR pare Gill a TOI E Y 42 6 saij gp 981 ____ 4 JC1 7516 BN gt 15 JOYSTICK 5546 5 CONTROLLER POTENTIOMETER 48 WH BK WH YL SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM am
208. LOAD orr is showing in the diagnostic display window Press the lift function enable button to activate the overload option 11 Use the yellow platform down arrow to scroll to sim operation Result sim OPERATION ON is showing in the diagnostic display window Result OPERATION OFF is Showing in the diagnostic display window Press the lift function enable button to activate the sim operation option For all models except CE the sim operation option should be activated or in the position 12 Use the yellow platform down arrow to scroll to return to the main menu O Result RETURN TO MAIN MENU is showing in the diagnostic display window GROUND CONTROLS 13 Press the lift function enable button Result sELEcT options is showing in the diagnostic display window 14 Push in the red Emergency Stop button to the off position at the ground controls CE models 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 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 et diagnostic display blue platform up button lift functi
209. MANIFOLDS 7 4 REVE Function Manifold Components Models without Outriggers after serial number 40518 The function manifold is located in the chassis tray on the ground controls side of the machine Index Schematic No Description Item Function 1 Check valve 5 psi 0 9 Dar sie re AA Platform down circuit 2 Diagnostic nipple AB Testing 3 Relief valve 3500 psi 241 3 bar AC System relief 4 Proportional solenoid valve AD All functions 5 Relief valve 2000 psi 138 bar AB Steer circuit 6 Diagnostic nipple Testing 7 valve 3 position 4 way AG sete Platform up down 8 Solenoid valve 3 position 4 way AH Steer left right 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 proportional valve to tank 25 ft lbs 34 Nm Torque 20 ft lbs 27 Nm 20 ft lbs 27 35 ft lbs 47 Nm mE 25 ft lbs 34 Nm 30 35 in lbs 3 4 Nm 20 ft lbs 27 4 94 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV MANIFOLDS
210. MAP sensor 234 BP High Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 235 BP Low Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 242 Crank Sync Noise Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is aulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 243 Never Crank Synced At Start Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is aulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 244 Camshaft Sensor Loss Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is aulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor Continued on next page 28 Part 72863 Genie GS 3390 GS 4390 065 5390 5 11 Section 5 Fault Codes FORD ENGINE ECM FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41368 December 2004 REVA Code Problem Cause Solution 245 Camshaft Sensor Noise
211. MPERATURE T 9 Jb i BEFORE SERIAL NUMBER 40043 gt 20 Gas 5g FLASHING BEACON a Mh lut lt OPTION o IQESESS o LL 2 368 9 1 gy 4 FLOW CONTROL BYPASS t 9595 5 2 LO z p NMOG J2 A2 JAM 49 FLOW CONTROL BYPASS a5 4 55 e gt l J2 A7 J4 B6 N 1Y29 GENERATOR OPTION twa gt 2 J1 B4 Y9 PROPORTIONAL FLOW CONTROL J4 A4 gt b 9 5 J1 A10 Y1 TWO SPEED MOTOR STROKE Qua Fra J4 A1 J1 A1 gt STEER RIGHT N jmd 9x J1 A4 th Y2 BRAKE RELEASE e 1 2 1 4 6 23 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40428 to 40793 Part 3 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTIO
212. N PIN18 2 WH RD 4 POUT2 POUT4 POUTS POUT6 POUT7 POUT8 Oo OUO N PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REV D P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos E E Loud D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED
213. N1 PING ENGINE START BN2 PING ENGINE START BN2 PIN10 O HIGH IDLE PIN10 a4 AUTO LEVEL BN20 ES p PIN19 O HORN BN5 PIN19 O HIGH TORQUE LF OUTRIGGER BN171 PIN23 O HIGH TORQUE BN6 PIN23 O SA HIGH IDLE BN4 PIN24 7 PIN24 O RR OUTRIGGER BN24 T PIN25 O 47 PLATFORM EXT RET ENABLE 16 PIN13 O E 4 HORN LR OUTRIGGER BN15 i E PIN29 t STARTING AID PIN25 0 E OUTRIGGER ENABLE BN16 a Sp PIN25 O 4 GENERATOR RF OUTRIGGER BN18 E PIN29 O STARTING i LIFT ENABLE HIGH BN12 WH E PIN1 LIFT ENABLE HIGH BN12 PIN2 LIFT ENABLE LOW BN13 BL e PIN2 4 LIFT ENABLE LOW BN13 PINS RD vi PLATFORM UP DOWN TS20 O UP PIN4 YL PLATFORM amp OUTRIGGER UP DOWN 521 POUTI POUTI O HD H1 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 77 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40942 to 41065 REV Part 1 of
214. NTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLEVEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 Lew PLATFORM CONTROLS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 539
215. No 72863 December 2004 Section 4 Repair Procedures E REV D PLATFORM CONTROLS How to 4 The fault code display window at the ground controls will show PS When you see this Adjust the Lift Speed code release the horn button and the platform extend retract enable button or outrigger enable 1 Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel The PS in the fault code display window indicates that the ECM is in the programming mode button 2 Turn key switch to the off position 3 Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform controls 5 Press and hold the function enable high speed select button to show the fast platform lift speed percentage in the fault code display window 6 Toincrease or decrease the fast platform lift speed press and hold the function enable high speed select button while using the steering rocker switch to adjust the function speed Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform controls Genie Refer to Section 2 Specifications 7 Release the function enable high speed select button 8 Turn the key switch to the off position to save ae the settings 99 i Genie
216. ORE SERIAL NUMBER 40043 m 20 Qz8 5g FLASHING BEACON 2 in OPTION 5 LL 20 033 288 28 Y49A FLOW CONTROL BYPASS o Osos d 0 gt 4 OFS 5 gt 059 NMOG J2 A2 JAM 1 Y49 FLOW CONTROL BYPASS Fas 4 e 2 gt 222 J2 A7 J4 B6 N Y29 GENERATOR OPTION O5 twa l gt 0 2 J1 B4 9 PROPORTIONAL FLOW CONTROL Fea 096 J4 A4 gt b 9 5 JAT0 1 TWO SPEED MOTOR STROKE ow 4 J4 M J1 A1 STEER RIGHT g e Ze 5 Hae gt 5 J1 A4 tu 2 BRAKE RELEASE 8 Eat 2 1 4 in LLIILILII 6 19 Genie GS 3390 GS 4390 GS 5390 Part No 72863 Section 6 Schematics December 2004 Electrical Schematic Ford Models before serial number 40428 Part 1 of 3 P2 EMERGENCY QD3 C c L BK POWER PLATFORM A J A RD POWER TO GROUND B GROUND D D BL DATALINK HIGH E YL DATALINK LOW DIP SWITCH PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR OR JC1 BN R15 JOYSTICK gt gt CONTROLLER WH BK WH YL STEER WH BL FUNCTION PIN18
217. OTRG COIL FLT 83 Right rear outrigger coil Y34 T RIGHT REAR Red faut 99 Right rear outrigger disabled Troubleshoot coil OR wiring OTRG COIL FLT 84 Outrigger extend coil Y40 OUTRIGGER EXT Red fault Outrigger extend function disabled Troubleshoot coil OR wiring COIL FLT 85 Outrigger retract coil Y39 T OUTRIGGER RET Red fault Outrigger retract function disabled Troubleshoot coil OR wiring COIL FLT 86 Outrigger slowdown coil Y44 Outrigger slow extend function 7 OUTRIGGER Red fault disabled Troubleshoot coil OR wiring SLOW COIL FLT 2 SPEED COIL Red 2 speed coil Y1 fault High torque drive function disabled Troubleshoot coil OR wiring FAULT 92 Drive pump forward 4 lt DRIVE FWD PROP Red proportional coil Y51 fault Drive forward function disabled Troubleshoot coil OR wiring COIL FAULT 93 Drive pump reverse DRIVE REV PROP Red proportional coil Y51 fault Drive reverse function disabled Troubleshoot coil OR wiring COIL FAULT MACHINE TYPE Red Wrong machine type selected Machine will not operate Correct selection FAULT Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 5 Fault Codes December 2004 Ford Engine ECM Fault Code Chart before serial number GS9003 41369 REVA Code Problem Cause Solution 11 Normal operation 12 Throttle Position TP sensor low voltage Faulty TP sens
218. PLATFORM THE PRESSURE SWITCH ALARM CONTINUES TO SOUND SYSTEM NEEDS TO BE RESET TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM PROPERLY OVERLOAD SYSTEM NOT ADJUSTED TURN THE PRESSURE SWITCH NUT 1 4 TURN INTO THE HYDRAULIC LINE OR REPEAT CALIBRATION PROCEDURE Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 39 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST D PROCEDURES D 6 Replace the Hydraulic Tank Return Filter 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 Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns The hydraulic filter is mounted on the function manifold next to the hydraulic power unit 1 Open the function manifold tray door 2 Locate the hydraulic tank return filter located behind the ladder 3 Remove the filter with an oil filter wrench Clean REV D the area where the hydraulic oil filter meets the filter head AWARNING injury hazard Spraying ydraulic oil can penetra
219. PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 73 Section 6 Schematics December 2004 Electrical Schematic Deutz Models from serial number 40738 to 40941 REVE Part 1 of 3 ees ae eee IKS1 P1 B EMERGENCY STOP CONTROL ole GROUND 4 4 20 4 CR41 CONTROL CR42 CR5 CR8 ENGINE CR58 SYSTEM POWER HORN IGNITION START FWD REV 86 2 A se 304 86 86 O 86 SW 85 87 85 87A D 857 m f 857 87 87 857 3 gt D amp N 5 98 88 REI 9265 1 G6 9 A U5 2 ty su 2 Jang ELECTRONIC CONTROL MODULE t amp J4 B4 gt i gt 5 gt 569 lt
220. PLUG RELAY POWER 361A 16 CIL CR MER c PLUG CAN MEGAJECTOR D D PLUG CAN E1429B MTRTWR4 MTRSHD4 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 17 Section 6 Schematics December 2004 Electrical Schematic Ford Models before serial number 40428 REVE Part 1 of 3 IKS1 P1 EMERGENCY STOP CONTROL 1 A GROUND ONTROL 20A CR41 CONTROL CR42 CR5 CR8 CR1 CR58 SYSTEM POWER HORN IGNITION ENGINE START FWD REV 86 a a 304 86 86 86 A 85 87 85 st 87A D 857 87 857 87 87 857 gt 9 17 FOLO 68 er Sg vr LLa er ELECTRONIC CONTROL MODULE T 12 E ev le eia er ruse D1 5 LINK TS69 Sion AUXILIARY FUNCTION ENABLE 6 w N E D 3H lt TS70 45 umm EX ES n XJ ES 54 lt lt
221. Platform Lowering esee 4 57 5 2 Controller Adjustments after serial number GS9003 41522 4 57 5 3 Software Configuration after serial number GS9003 41522 4 68 5 4 Level Sensor Models without Outriggers before serial number 41158 4 72 5 5 Level Sensor Models without Outriggers after serial number 41157 4 75 5 6 Level Sensor Models with 4 77 5 7 Engine Fault Codes Ford 4 82 C Hydraulic Pumps 6 1 Lif Steer iui rci eee re eer iet 4 84 6 2 Divo PUMP 4 86 Manifolds 7 1 Function Manifold Components Models with Outriggers before serial number 40519 4 88 7 2 Function Manifold Components Models with Outriggers after serial number 40518 4 90 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 EOU TABLE OF CONTENTS Section 4 Rev Repair Procedures continued 7 3 Function Manifold Components Models without Outriggers before serial number 40519 sse 4 92 7 4 Function Manifold Components Models without Outriggers after serial 40518 4 94 7 5 Drive Manifold Components before
222. Plug 0 045 inch 1 1 mm EH 2 speed motor shift circuit 9 Shuttle valve 2 position way 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 speed motor shift 25 ft lbs 34 Nm 10 Solenoid valve 2 position way EJ 3i Brake release circuit 20 ft lbs 27 Nm 11 Flow divider combiner valve EK Controls flow to non steer end drive motors in forward and reverse 30 ft lbs 41 Nm 12 Flow divider combiner valve EL us Controls flow to steer end drive motors in forward and reverse 30 ft lbs 41 Nm 13 Orifice Plug 0 090 inch 2 3 mm EM Balances flow from flow divider combiner item EA to flow divider combiner valves ED and EL 25 ft lbs 34 Nm 14 Diagnostic nipple EN uu Testing P1 pressure port 4 98 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E MANIFOLDS Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 99 Section 4 Repair Procedures December 2004 MANIFOLDS REVE 7 7 Oscillate Manifold Components optional after serial number GS9004 41618 The oscillate manifold is located under the functi
223. Q o 5 D 2 c gt 2 o m 4 gt D 2 gt o m m m 9 o o m m 2 A z o 2 2 3 1 MACHINE SHOWN IN THE STOWED ES7142A POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 67 Section 6 Schematics December 2004 Electrical Schematic Deutz Models before serial number 40428 REV Part 3 of 3 P2 P2 ALARM QD3 EMERGENCY 003 EMERGENCY STOP STOP C c L BK POWER PLATFORM 2 C c L BK POWER TO PLATFORM EM ER d A 5 RD POWER TO GROUND RD POWER TO GROUND B B wH GROUND E WH GROUND NL 0 D BL DATA LINK HIGH gt YL DATA LINK LOW eye SW25 U3 D7 DIP PLATFORM CONTROLS VOLTAGE DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR SWITCH PRINTED CIRCUIT BOARD REGULATOR REVO UG 6 1 a4 2 OR JC1 6 Rl
224. R LPG SELECT BN14 Y36 Y34 Y40 Y29 oe HIGH IDLE BN4 1 d rS I PIN9 e 7 LF OUTRIGGER ENABLE BN85 Do qi a 277 PIN10 RF OUTRIGGER ENABLE BN86 T d eX Q 1 D PINT 04 06 oa LR OUTRIGGER ENABLE BN87 5 E Y35 Y33 Y39 PIN12 RR OUTRIGGER ENABLE BN24 i i i i i pure lt lt lt lt lt lt T S onm wo S 8 5 ies g PIN13 EN LIFT FUNCTION BN9 d m 2 FOR rene ene L3 S 3 2 2 258 ORGR AUTOLEVEL ENABLE BN20 A m 8 x E 2 a m 2 2 m Q Q m gt gt 2 gt o o lt 55 5 4 SYSTEM STATUS L50 9 B S s 2 5 x m m 5 J1 Yep 1 3 3 5 HB 2 5 5 9 DN PLATFORM UP DOWN TS20 5 9 B S 2 X PLATFORM amp OUTRIGGER Q m m gt UP DOWN J 2 Ji PIN RD sj J1 PINS NOTE H1 MACHINE SHOWN IN THE STOWED Bur bui PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7174B
225. ROLS Machine Option Definitions Descent Delay This option halts descent at approximately 12 feet 3 6 m All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe Lift Drive Cut Out Lift and drive functions are disabled when the down limit switch is activated and the machine is on a slope exceeding the rating on the serial plate Activated for all machines 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 to ground or platform controls and both red Emergency Stop buttons are in the on position Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 71 Section 4 Repair Procedures December 2004 GROUND CONTROLS 5 4 Level Sensor Models without Outriggers before serial number 41158 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
226. 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 29 Use a slide hammer to remove both number 3 pivot pins index 6 from the non steer end of the machine 30 Use a slide hammer to remove both number 3 pivot pins index 19 from the steer end of the machine 31 Carefully remove the number 3 inner and outer arms index 18 and 16 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 32 Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder 33 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin index 11 34 Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 11 35 Carefully remove the lift cylinder from the machine AWARNING 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 36 Remove the cables from the number 2 inner arm index 8 37 Support the cable tray with an overhead c
227. Repair Procedures December 2004 MANIFOLDS REVE 7 10 Generator Manifold Components The generator manifold is located below the ground controls Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position way AE crea Generator 25 ft lbs 34 Nm 2 Flow regulator 4 3 16 3 L min Generator speed 20 ft lbs 27 Nm 3 Relief valve 3000 psi 206 8 bar Generator 20 ft los 27 Nm 4 104 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E 7 11 Valve Adjustments Generator Manifold How to Adjust the Generator Voltage AWARNING ird injury hazard Spraying ydraulic 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 AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Be sure that the hydraulic oil level is within the top 2 inches 5 cm of the sight gauge Perform this procedure with the machine on a firm level surface 1 Disconnect all electrical tools from the machine Start the engine from the platform controls Press the generator sele
228. SW5 SWE STEER WH BL FUNCTION ENABLE lt CERI RIGHT PIN18 eer 2 WH RD 4 i LIFT ENABLE HIGH BN12 BK PLATFORM CONTROLS Be MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 O 4 LIFT ERROR INDICATOR LED 157 POUT4 FAULT LED 125 POUTS O 1 GENERATOR LED 127 POUT6 24 4 HIGH TORQUE LED 121 POUT7 LPG LED 122 POUT8 HIGH IDLE LED 123 a PINS 2 ENGINE STOP BN1 ME PING ENGINE START BN2 T PIN10 O AUTO LEVEL BN20 T PIN19 O HIGH TORQUE LF OUTRIGGER BN17 PIN23 s HIGH IDLE PIN24 es LPG SELECT RR OUTRIGGER BN22 PIN13 lt OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 ccs PIN25 O GENERATOR RF OUTRIGGER BN18 25 PIN29 O STARTING AID I PINs oP uP pina O L ______ POUTI H1 BK ALARM PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM amp OUTRIGGER UP DOWN TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS
229. Schematics m Electrical Schematic REVA ANSI Models with Ford Power after serial number GS9005 42143 Part 2 of 3 GS 5390 OIL COOLER OPTION LS5A J2 C12 BATTERY 12V PLAT NC 5 5 4 2 CB7 Sch HYDRAULIC 20K NC 4 OIL TEMP i ia 4 4 O 17 o LS C HA HvDRAULIC emeur oanp PLAT LS5 85 87 OIL COOLER DOWN 1 i LIMIT PLAT LEVEL SWITCH UP 1 1 eas MODELS WITHOUT m BATTERY 12V L__QUTRIGGERS BK 9QO0F DDD gt gt gt gt D gt e NIE Mu AA O E Be No SUNRISE U5 T 7 BN23 BN91 ELECTRONIC CONTROL MODULE AUXILIARY DOWN AUXILIARY DOWN ENABLE J2 C10 J2 B9 ow T s J2 C4 gt Q gt gt gt p 8 m g am m m 5 Y4 Y1 Y9 Y51 i i EDC 5 44 ew E E 4 Y8 1 Y7 1 SW1 yo SW2 lt lt lt lt lt lt x o 0 lt N 5 2 4 4 4 9 3 ES 25 2 2 p m m 6 2
230. Stop button to the off position at the ground controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS REV D How to 773 5 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 death or serious injury 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 See 5 2 How to Determine the Revision Level The GS 5390 will not drive with the platform raised above 33 feet 6 1 m Models with software revision B1 or lower 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 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 wi
231. T LIMIT 2 5 5 OUTRIGGERS 2 8 GA SWITCH SWITCH SWITCH SWITCH 255 75 T gt gt 155 156 554 NO 4 NOs 2 PLAT PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION c c lt c eo 1 gt gt gt gt gt jee gt gt gt 92 gt gt gt a a a U5 ELECTRONIC CONTROL MODULE SES e c ds c c c mode ep si B R R 8 8 Ss 58 M L SW3 Y2 Y1 9 49 H5 Y36 Y34 Y40 58 t t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt DJ 54 g SW2 AEX dX Q AX EXI 51 1 Y9 Y49 Y35 Y33 Y39 n n n n n 4 4 4 4 n 4 n 2 5 4 B g g lt 8 2 9 m 2 2 2 gt 2 a id 5 5 2 m 22 9 gt m 2 5 gt o 2 2 5 d 20 4 4 ES i o 2 amp 2 2 z 2 2 9 2 2 ni 2 gt m 2 2 m Q m m m z Q m m 0 0 lt o e D gt m m m m 3 2 2 5 2 w 2 2 2 m 2 5 5 gt 2 E m 5 4 o o 2 gt o c m 2 m m 5 2 9 s 9 9 8
232. T ECT SENSOR NO USAGE STARTER LOCKOUT NOT USED IDLE AIR CONTROL DRY FUEL SENSOR OIL PRESSURE GROUND DRYFUEL LOCKOFF IGNITION COIL 2 HO2S SENSOR SIDE MATING FACE SHOWN gt i xcu t X ou e D lt x S40 MATING FACE SHOWN Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 13 Section 6 Schematics December 2004 Wiring Harness Ford LRG 425 EFI from serial number GS9003 41369 to GS9004 41693 REVA Part 1 of 2 6 361 16 361 16 7 555 T 16 555 T 16 INJ1 Ms 8 557 BR Y 16 557 BR Y 16 INJA 9 558 BR LB 16 558 BR LB 16 10 556 16 556 W 16 INJ2 m 1445 743 GY 18 6 359 GY R 18 AUX OUT 2 7 EGA 18 0 18 19 198 DG O 18 AUX PD1 MAE 20 358 LG BK 18 FPP 1 151 LB BK js 27 743 GY 18 307 BK Y 18 28 354 LG R 18 F ECT 354 LG R 18 17 307 18 114 LB Y 18 EGRPWH emita 352 BR LG 18 EGR RECIRC EIL 1 570 BK W 16 570 BK W 16 POWER GROUND 2 570 BK W 16 570 BK W 16 POWER GROUND 13 359 GY R 18 570 BK W 16 14 351 BR W 18 351 BR W 18 5
233. T OUTRIGGERS PLATFORM CONTROLS DIESEL MODELS WITH OUTRIGGERS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 89 Section 6 Schematics December 2004 aS Electrical Schematic ANSI Models with Deutz Power REVB from serial number GS9003 41523 to GS9005 42143 Part 1 of 3 KS1 1 gt EMERGENCY STOP ETATS PLATFORM CONTROL 244 1 oe GROUND 3 l 2 CB2 20a ABS CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 ad D 86 sd 2 86 9 86 304 4 86 86 sd 86 so 4 86 ao 2 aM Ww Eu EN Em 85 87 85 87 aA asf a7 857 e Tera 85
234. TABS AB CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 2 86 21 86 9 86 304 4 86 86 30 30 2 85 87 85 e aA D 85 v 85 e 7 85 7 e nu 1 t 2 N C H O l ae LS23 LS22 04 01 LEFT RIGHT xy 1 OSCILLATE OSCILLATE H2 LIMIT SWITCH LIMIT SWITCH 15 CR4 ee HIGH IDLE CR15 109 gt STARTING 86 30 ES eet OP ces AID A ba 655 86 85 87 87A 54 Y56 t 17 AC X X 15 1 032 Ta Q8 GLOW LEE X x PLUG FUEL OPTION Q3 SHUT OFF HIGH IDLE SOLENOID Y57 Y55 n i L n n S amp 28 9 6 8 gt gt 55 gt m bu N c 3 3 o c r lt o 2 m o 8 X5 xm m x 2 9 J 2 5 5 3 a 3 pg gH 2 w D 2 gt 5 70 aS 2 5 lt gt Bo 3 9 225 Q 5 o d gt m D lt m D E
235. TAGE Tey pc PRINTED CIRCUIT BOARD REGULATOR J2 YL 41 HALL EFFECT 58 Wn j GENERATOR 2 AXIS 42 PIN12 1512 1813 1814 1815 TILT LEVEL qus BN CONTROLLER LF RF LR RR SENSOR ORIG O RIG O RIG O RIG J2 LIMIT Limit LIMIT o J2 SWITCH SWITCH SWITCH SWITCH 8 21125 S Gy 2328 1533 J5 PINS SW5 SW6 2 NO4 BOE FREE OR FUNCTIONENABLE p 2 STEER Zum 4 5 LEFT RIGHT l l RD OF J2 PIN7 J2 PINS lt lt c lt c c aaa C toc C x T T PP ep ley 15 l g 8 8 2288 i E 2 POUTI U5 PIN2 HORN BNS ELECTRONIC CONTROL MODULE PIN3 STARTING AID amp M 5 ENGINE START BN2 5 T g 95 S 9 2 wo 0 a o N 2 9 HIGH TORQUE BN6 5 e GENERATOR BN7 LPG SELECT BN14 Y36 Y34 Y40 29 o ooa HIGH IDLE 4 1 d rS I iX PIN9 Co om LF OUTRIGGER ENABLE 85 Do qi a 277 PIN10 RF OUTRIGGER ENABLE BN86 T d AD PX H5 FB1 PINT 04 06 a 4 LR OUTRIGGER ENABLE BN87 a m Y35 Y33 Y39 PIN12 147 14 RR OUTRIGGER ENABLE BN24 4 as ji lt lt x lt lt lt e T 5 oam
236. TCH 2 5 5 BN 155 156 554 gt NOs NO 2 PLAT PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION lt c c lt c Hm EL T eo gt gt gt gt gt gt w gt gt gt w gt gt gt a a a U5 ELECTRONIC CONTROL MODULE SO _ _______ e I 28 c c c S es c c c N c 5 957 A1 L SW3 Y2 Y1 9 49 5 Y36 Y34 Y40 58 t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt DJ 54 y 1 g SW2 EX FX EX 40 AX FB1 Y3 Y9 Y49 Y35 Y33 Y39 4 4 4 2 n n n 4 4 4 4 n 4 n t 5 gg gg g gg e 2 9 7 gt 2 a 2 5 m m gt da 2 2 gt 9 2 m 5 25 D m D m x 2 2 m D 2 5 A 9 e g P 2 d d 9 5 gt 2 m 2 x 5 m 2 2 Q e m m m z Q m m 0 0 lt D I 2 m 2 gt 2 gt gt 2 ni z 2 2 C 5 5 2 F gt m m 9 E 2 a gt o e o c X m 2 E D e c E 2 zi m 3 6 5 2 2 amp 6 m 2 5 Q
237. TS Section 5 Rev Fault Codes 5 1 Fault Code Chart before serial number 59003 41 523 5 3 A Fault Code Chart after serial number GS9003 41522 sse 5 5 A Ford Engine ECM Fault Code Chart before serial number GS9003 41 369 5 8 A Ford Engine ECM Fault Code Chart after serial number GS9003 41368 5 10 Section 6 Rev Schematics 6 1 Electronic Control Module Layout before serial number 459003 41523 6 2 A Electronic Control Module Pin Out Legend before serial number 41523 6 3 A Electronic Control Module Layout after serial number 59003 41522 6 4 A Electronic Control Module Pin Out Legend after serial number 59003 41522 6 5 B Ford Engine Relay Layout iret dot dt ne ees 6 6 Wiring Diagram Platform Control Box before serial number GS9003 41523 6 7 A Wiring Diagram Platform Control Box after serial number GS9003 41522 sees 6 8 x Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 TABLE OF CONTENTS Section 6 Rev Schematics
238. TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 21 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40428 to 40793 REV D Part 1 of 3 PC i IKS1 key switcn 1 EMERGENCY STOP 15 CONTROL Bo de GROUND CONTROL 4 20A 4 CR41 CONTROL CR42 CR5 CR8 CR1 CR58 SYSTEM POWER HORN IGNITION ENGINE START FWD REV 86 a R 304 86 86 86 a 85 87 85 87A D 4 857 87 857 87 857 4 CRIA F POWER SUPPLY 18 989 F16 TO STARTER wy d 2 A L2 ok 20A 4 U5 gt FUSE ne ELECTRONIC CONTROL MODULE A J4 A5 e R amp amp 8 FUSE 2 2 d S LINK R6 m Y51 8 TS69 7 4 EDO AUXILIARY 5100 FUNCTION ENABLE M4 TS70 nm
239. UT6 POUT7 POUT8 Oo OUO N PINS e 4 PING i 10 27 PIN19 Fa 4 PIN23O 2 PIN24 O 2 Eod PIN13 O PIN25 O 2 4 PIN29 O PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED L21 LPG LED L22 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 a gt PINs 9 YL O DOWN RD POUT1 O H1 PIN11 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 REVA P2 QD3 EMERGENCY STOP C POWER TO PLATFORM RD POWER GROUND _ B Lwu aroun opos E E Loud D D BL DATA LINK HIGH YE DATA LINK LOW SW25 U3 DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR pare Gill a TOI E Y 42 6 saij gp 981 ____ 4 JC1
240. VEL ENABLE BN20 SYSTEM STATUS 150 E PIN15 lt ax PLATFORM UP DOWN TS20 Ji PINS X OR PLATFORM amp OUTRIGGER 0 80 J1 PINS O lt 1 H1 Lew PLATFORM CONTROLS Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 49 Section 6 Schematics December 2004 su Electrical Schematic ANSI Models with Ford Power REVA after serial number GS9005 421 43 Part 1 of 3 F9 c stop IKS1 Bi 5 41 PLATFORM CONTROL 2 3 GROUND CONTROL j C CB2 20a T AB3 T CR41 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE
241. VOLT REF 3 16 R LG 18 16 R LG 18 33 350 GY 18 358 LG BK 18 32 349 DB 18 359 GY R 18 CRANK 35 452 GY R 18 18 O Y 18 ds 34 282 DB O 18 198 DG O 18 Mop 4 150 DG W 18 5 AE 361 14 V kT l 114 LB Y 18 EGO 2 ud 352 BR LG 18 EGO 1 360 BR PK 18 361 14 29 KNK 30 KNK J1 BLACK 4 __ 570 Bk w 16 X SENSOR QU 74 GY LB 18 151 LB BK 18 _ 359 SPF 317 GY O 18 342 LG P 18 4 570 BK W 16 PWR GROUND 242 0016 1 850 18 m COLS Se 361AR 16 a 15 ____ 2 24 LOCKOFF SOLENOID 669 DG W 18 COILS 458 18 2 342 LG P 18 STARTER LOCKOUT FUEL LOCKOFF FUEL 9 926A LB O 18 926A LB O 18 _ __32 seyg oo d 15 R Y 18 ici e 1 355 GY W 18 aes I 357 18 _ 28 ____15 29 317 GY O 18 6 511 LG R 18 511 LG R 18 7 253 DG W 18 _ 25306 18 8 11 TY 18 11 T Y 18 TACH Mi 27 658 PK LG 18 658 18 238 DG Y 18 FUEL PUMP MON LE AUX OUT 1 2 e 04618 71046 18 FUEL SELECT 1 72v 72 Y BK 18 AUX ANA BUS 15 148 Y R18 148 Y R 18 e Seve __________ ___________________________________ GOV SELECT 2 307 BK Y 18 307 BK Y 18 ROAD SPEED _ 1 ROAD SP
242. WITCH SWITCH switcH SWITCH 2 E 5 p 155 156 554 gt NOs 2 Beg PLAT PLATFORM zA Ah G8 TS64 DOWN OVERLOAD aes DIAGNOSTIC FAULT CODE LIMIT LIMIT PRESSURE gt DISPLAY DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION c c i c c C oC C C Eo q gt gt gt gt gt gt gt gt gt gt a 3 a a RRO U5 d ELECTRONIC CONTROL MODULE 4 a lt f s amp 4 s 55 cI E 55 bo p 6 amp E g ET ee Ea 27 lt 4710141 49 Y2 Y1 29 Swi Y36 Y34 Y40 58 I 1 n 1 1 2 AXIS 804 X A M U X 2 TILT CIRCUIT BOARD n m 1 SENSOR E 50 1 1 LEVEL EX LY EEX dX S7 sson cay L1 MODELS WITHOUT 1 SW2 L_OUTmIGGERS Y3 Y9 49 Y35 Y33 Y39 BN i i 2 i i i i lt lt lt lt lt lt lt ong lt lt lt lt lt lt lt S 9 4 8 2 S983 29 8 8 9 B8 8 8 po S m dn m A m Q Q 2 2 gt 22 ZZ S8 m o 2 9 20 mo i 4 I i i 2 m E m 0 2 2 02 22 1 2 5 5 m m
243. Y DOWN ENABLE J2 C4 i gt a gt T gt 1 T km 4 J2 B9 5 Q gt g S 8 am m m 2 8 YA Y1 Y9 49 Y51 i i EDC MES 5 X 7 X AU AU Y8 Y7 1 sw2 1 1 49 5 2 6 5 2 95 d 4 98 gd B az E RH BH g 99 2 2 m 8 our 22 9 9 r 7 6 Zin e z m m fF 012 0960 5 gt 3 E B v m 9 a tC no Dum 3 lt 5 2 m NE Nm mS T 9 Toa 2 2 lt Di o 0 3 2 Y49 AND Y49A WERE REMOVED AFTER 5 8 9 oO SERIAL NUMBER 41618 5 gr Noo s7 Dr MACHINE SHOWN IN THE STOWED ES7164E POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Deutz Power after serial number GS9005 42143 Part 3 of 3 4 4 POWER TO PLATFORM q RD POWER TO GROUND GROUND REVA P2 EMERGENCY STOP
244. Y49A Y51 UFT 2 switcH S LIMIT n i i EDC ENABLE 4 4 ge a SWITCH Al X X ABE 12 Y7 i 5 EX Dj C5 t SW3 Y2 YA SW2 4700 uF 9 Ld 3 Ld 9 5 i 82 d S Su 2 95 z d 9 Bun m m gt 3 2 m m gt 9b a a 2 m m ous zz 7 2 Sun Z 5c J 2 2 d um m Quz c o 012 0960 4210 Dw gt mc 5 9 m C Bir 3 lt z m nr m mu 5 n 1 Sus zu 28 m gt 2 49 AND Y49A WERE REMOVED AFTER 5 9 0 m 8 SERIAL NUMBER 41618 2 ES7175A MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 6 Schematics December 2004 Electrical Schematic CE Models with Deutz Power from serial number GS9003 41523 to GS9005 42143 Part 3 of 3 4 4 BK POWER TO PLATFORM q RD POWER TO GROUND GROUND REV B P2 EMERGENCY STOP WH RD
245. a OR E DOEA pd 8 IUE TS67 ENABLE OUTRIGGERS e STANDARD GS 5390 TS52 TS54 TS66 OPTION ON GS 3390 GS 4390 ENGINE ENGINE PLATFORM t HIGH IDLE UP DOWN 1512 1813 1814 1815 67 LEVEL LF RF LR RR SENSOR O RIG O RIG MODELS WITHOUT 4 NO LIMIT LIMIT LIMIT LIMIT 2 5 5 OUTRIGGERS SWITCH SWITCH SWITCH SWITCH Be 9 A 5 5 gt BN LS5 LS6 55 0 4 NO 4 556 PLAT PLATFORM G8 DOWN OVERLOAD 1 gto DIAGNOSTIC LIMIT LIMIT PRESSURE gt DISPLAY SWITCH SWITCH SWITCH GS 5390 OPTION lt c c lt c Hm EL T eo gt gt gt gt gt gt w gt gt gt w gt gt gt a a a U5 ELECTRONIC CONTROL MODULE SO _ _______ e I 5 oe 5 B NET oT t 5 t Sg S I gt gt gt gt 5 In gt J o a o o E m 9 M L SW3 Y2 Y1 Y29 Y49A H5 Y36 Y34 40 sg t 2 AXIS Al 2 X X X 2 TILT LEVEL Lt DJ 54 1 g SW2 AEX dX Q 1 Y9 Y49 Y35 Y33 Y39 4 4 4 n n n n 4 4 4 4 n 4 n t 5 4 B g i
246. a normally open switch The switch contacts close at approximately 300 F 149 the oil temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes The engine oil pressure switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the switch point the switch opens and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens ENGINES 3 Oil temperature switch Remove the fasteners from the engine side cover and remove the cover pressure switch Locate the oil pressure Switch near the oil filter 4 Tagand disconnect the wiring from the switch Remove the switch from the engine Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns 5 Install and tighten the new switch Torque to specification Always use pipe thread sealant when installing a switch 6 Connect the wires to the new switch 7 Oil temperature switch Install the engine side cover Oil temperature switch specifications Torque 8 10 ft lbs How to Remove the Oil Temperature and Hex size 11 16 inches
247. achine slightly 52 Remove the blocks from under both wheels 53 Lower the machine and remove the jack Section 4 Repair Procedures GROUND CONTROLS 54 Center a lifting jack under the drive chassis at the non steer end of the machine 55 Raise the machine approximately 6 inches 15 cm 56 Models with RT tires Place a 4 36 x 10 x 10 inch 11 07 x 25 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 57 Lower the machine onto the blocks 58 Raise the platform approximately 16 feet 5 m O 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 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 59 Lower the platform to the stowed position 60 Raise the machine slightly 61 Remove the blocks from under both wheels 62 Lower the machine and remove the jack 63 Turn the key switch to the off position Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedur
248. agnostic 8 5 8 5 2 8 e so Ss io lgSs Diagnostic a 3 818 65 Display Switch lt gt 5 3 9 8 Code 2 lt 85151 Cod 5 2018 89 9 8 0 981 5 2165 oge 5 6 418 25 oO gt 0 gt 0209 6 12 97 00010000 00010001 100 00010011 101 00010100 103 00010110 104 00010111 106 00011001 107 01111010 109 00101000 110 00011101 112 00011111 113 00000000 115 00000010 116 00000011 118 00000101 119 00000110 121 00001000 122 00001001 124 00001011 125 00001100 127 00001110 128 00001111 130 00100001 131 00100010 133 00100110 134 00100111 136 00101011 137 00101110 139 00110010 140 00110100 142 00110110 143 00111001 145 00111110 146 01000000 148 01000010 149 01000011 151 01000101 152 01000110 154 01001000 155 01001001 157 01001011 158 01001100 160 01001110 161 01001111 163 01010101 164 01010110 166 01011101 167 01011110 169 01100001 170 01100010 172 01100110 173 01100111 175 01101110 176 10100000 178 10100010 179 10100011 181 10101010 182 10101011 184 10110000 185 10110001 187 10110011 188 10110100 190 10110110 191 10110111 Tet et _ IN 14 Genie GS 3390 GS 4390 and GS 5390 Part N
249. alve coil Y5 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 Y5 is de energized Oscillate Raised Relay CR85 Terminal 30 of the Oscillate Raised relay CR85 receives power from the Power relay CR42 When power is cut to terminal 86 of CR42 via key switch or either Emergency Stop button power to terminal 30 of CR85 will be lost Terminal 86 of CR85 receives continuous power from pin J2 C6 when the ECM is powered until an outrigger is lowered to the ground at which point the power from J2 C6 is cut STEER AXLE COMPONENTS Oscillate Limit Switches LS22 LS23 The right and left oscillating limit switches LS22 and LS23 respectively are normally closed limit switches held in the open position when the machine is on a level surface When the left rear or right rear wheel drops the limit switch will relax and close its circuit sending power to the appropriate oscillating valve coil r FROM PLATFORM CONTROLS EMERGENCY STOP J2 C1 C3 LS6 PLAT pown LMT SWITCH J2 C5 CR84 CR85 CR42 OSCILLATE OSCILLATE POWER STOWED RAISED J2 C6 86 2 s l 30 42 U5 SAN IN pce C pcs ELECTRONIC CONTROL 85 87 87A 85 87 87 85 87 87 MODULE
250. and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault Contact Ford Power Products for assistance 411 Coil Driver 1 Open Open wiring and or connections to ignition coil 1 OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 412 Coil Driver 1 Shorted Wiring and or connections to ignition coil 1 shorted OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 413 Coil Driver 2 Open Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 414 Coil Driver 42 Shorted Wiring and or connections to ignition coil 2 shorted OR ignition coil 22 is faulty Repair wiring and or connections to ignition coil 2 OR replace ignition coil 2 If this fault appears on your machine 511 FPP1 High Voltage Not used contact Genie Industries Service Department If this fault appears on your machine 512 FPP1 Low Voltage Not used contact Genie Industries Service Department If this fault appears on your machine 513 dad Higher than IVS Not used contact Genie Industries Service imit Department If this fault appears on your machine 514 ded Mains Not used contact Genie Industries Service imit Depa
251. apacity indicator decal GS 5390 1410 kg 8 Turn the 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 Remove the cover from the pressure switch The pressure switch is located on the lift cylinder REV D 12 Slowly turn the nut of the platform overload pressure switch one quarter turn into the hydraulic line 13 Push in the red Emergency Stop button to the off position at the ground controls 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 start and run Proceed to step 15 Result The engine will not start and an alarm is sounding Repeat this procedure beginning with step 12 The red Emergency Stop button must be cycled after each quarter turn of the nut to allow the platform overload system to reset Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D 15 Raise the platform until the position indicator corresponds to t
252. ard 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 When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 2 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Be sure that the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 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 ve
253. atform controls from the platform and place the controls near the diagnostic display at the ground control panel Turn the key switch to the off position Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform control Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform control Genie 066 y steering rocker switch SW6 b horn button BN5 machine on incline button BN6 OR machine on incline LF outrigger button BN17 d platform extend retract enable BN16 OR outrigger enable button BN16 December 2004 REV D The fault code display window at the ground controls will show PS When you see this code release the horn button and the platform extend retract enable button or outrigger enable button The PS in the fault code display window indicates that the ECM is in the programming mode Press and hold the machine on incline button to show the steering speed percentage in the fault code display window To increase or decrease the steering speed press and hold the machine on incline button while using the steering rocker switch to adjust the function speed Refer to Section 2 Specifications Release the machine on incline button Turn the key switch to the off position to save t
254. ations 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 B 15 Test the Drive Speed Stowed Position Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS How to Adjust the High Torque 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 death or serious injury 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 See 5 2 How to Determine the Revision Level Models with software revision B1 or lower 1 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 REV D diagnostic display blue platform up button lift function enable b
255. azard Keep hands AWARNING clear of the safety arm when lowering the platform 4 Release the latches on the engine tray and fully slide the engine tray out 5 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 REV D 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 Start the engine from the ground controls 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 arms 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 Crushing hazard The platform will AWARNING fall when the platform slide block pivot pins are removed if it is not proper
256. blem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction Identify gt Troubleshoot discovered symptoms problem still exists 4 Return to 0 0 Perform service problem repair solved REV B 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 pinpointing the area or component affected 5 2 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes REV B before serial number GS9003 41523 Fault Code Dot Problem Possible Causes Solution Flash Normal operation 01 Solid Internal ECM error EPROM not programmed Replace ECM 02 Solid ECM Platform communication Malfunctioning control cable OR Troubleshoot control cable OR error malfunctioning platform controls troubleshoot platform controls 03 Solid See platform DIP switch DIP switch settings incorrect Correct DIP switch settings Ground control function enable Malfunctioning g
257. bs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft Ibs 102 Nm REV D Valve Coil Resistance Description Specification Solenoid valve 3 position 4 way 8 2 to 10 20 10V DC with diode schematic item G Proportional valve 12V DC 3 1 to 5 10 schematic items H AD DOS valve 3 position 4 way 10V DC 2 6 to 4 60 schematic items 1 J AG and Solenoid valve 3 position 4 way 6 2 to 8 20 10V DC with diode schematic item AH Solenoid valve 2 position 2 way 5 7 to 7 7 10V DC with diode schematic items BA and BB Solenoid valve 2 position 3 way 10V 8 2 to 10 20 schematic items Bl and BJ Solenoid valve 2 position 2 way 10V DC 4 5 to 6 50 schematic items CA CB CC and CD Solenoid valve 2 position 3 way 5 to 70 10V DC schematic item AL Solenoid valve 2 position 2 way 6 5 to 8 50 12V DC with diode schematic item DA Solenoid valve 2 position 3 way 910110 12 DC with diode schematic items DE and DF Solenoid valve 2 position 2 way 9 to 110 12V DC with diode schematic item DG Solenoid valve 2 position 3 way 6 to 80 10V DC with diode schematic items EF and EJ Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 2 Speci
258. c Deutz Models from serial number GS9003 41351 to GS9003 41522 6 86 B Electrical Schematic ANSI Models with Deutz Power from serial number GS9003 41523 to GS9005 42143 6 90 A Electrical Schematic ANSI Models with Deutz Power after serial number GS9005 42143 6 94 Electrical Schematic CE Models with Deutz Power from serial number GS9003 41523 to GS9005 42143 6 98 A Electrical Schematic CE Models with Deutz Power after serial number GS9005 42143 6 102 A Hydraulic Schematics Component Call out Legend 6 106 A Hydraulic Symbols 2 6 107 D Hydraulic Schematic before serial number 40519 6 108 G Hydraulic Schematic from serial number 40519 to 289004 41618 6 110 B Hydraulic Schematic after serial number 259004 41618 6 112 Xii Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 2 Specifications REV D Machine Specifications Specifications High Flotation foam filled Fluid capacities Tire size 33 16LL500 Hydraulic tank 32 gallons FONT 121 liters Tire contact area 48 sqi
259. cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 dearees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs Install the plugs Refer to Section 2 Specifications 5 Repeat steps 1 through 4 for all the other drive hubs REV D D 4 Replace the Diesel Fuel Filter Water Separator Deutz Models Replacing the diesel fuel filter water separator is essential to good engine performance and service life A dirty or clogged filter water separator may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter water separator be replaced more often ADANGER Explosion and fire hazard Engine fuels are combustible Replace the fuel filter water separator in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 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 eng
260. cedures December 2004 CHECKLIST B PROCEDURES B 9 Check the Oil Level in the Drive Hubs 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 the hub until the plugs are located one on top and the other at 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 side plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 4 Apply pipe thread sealant to the plug s and then install the plug s in the drive hub 5 Repeat this procedure for each drive hub REV D B 10 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground controls and start the engine 3 Checkany machine function from the platform controls Result The machine functions should not operate 4 Turn the
261. check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch 52 Crankshaft Position CKP sensor senses extra or missing pulses The CKP and CMP sensors work together if one is bad the other one won t work correctly and causes the ECM to detect a fault The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor 53 Camshaft Position CMP sensor senses unknown pattern The CMP and CKP sensors work together if one is bad the other one won t work correctly and causes the ECM to detect a fault The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection Check for shorted wires or poor terminal connections from the CKP and sensors to the ECM OR replace the CKP or CMP sensor 54 ECM Fault Illegal Operation The ECM received an illegal instruction signal from one or more of the sensors and has gone into a default program and then return to normal operation Replace the ECM 55 Illegal Interruption The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation Replace the ECM 56 ECM Computer Operating P
262. chine 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 CAUTION If further disassembly of the scissor arm pair is required see 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 injury hazard Spraying ydraulic 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 GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 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 30 Carefully lower the rod end of the lower lift cylinder onto the engine cover 31 Remove the cables and hydraulic hoses from
263. condition indicator gauge Result The needle on the gauge should be operating in the green area If the needle is in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See B 18 Replace the Hydraulic Tank Return Filter Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV A 10 Perform Engine Maintenance Deutz 1011F Models Engine specifications require that this procedure be performed every 125 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 CHECKLIST A PROCEDURES A 11 Drain the Fuel Filter Water Separator Deutz Models Genie specifications require that this procedure be performed every 200 hours or monthly 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 component damage A DANGER 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 Perform this procedur
264. contamination from fuel OR use of improper thread sealant on sensor threads OR sensor wires shorted to ground or poor terminal connections OR HO2 sensor is bad Test for a leaking or malfunctioning fuel injector misfiring cylinder or bad TP sensor Remove sensor and check condition of sensor for contamination OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes _ 2 uH REVA FORD ENGINE ECM FAULT CODE CHART BEFORE SERIAL NUMBER GS9003 41369 Code Problem Cause Solution 43 Engine Coolant Temperature ECT sensor low voltage ECM detects a excessively low signal voltage from the ECT sensor Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor 45 Intake Air Temperature IAT sensor low voltage ECM detects a excessively low signal voltage from the IAT sensor The IAT sensor shares the same ground wire as the ECT and MAP sensors Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor 51 Low oil pressure Bad oil pressure switch wires shorted to ground or not enough engine oil Check engine oil level OR
265. could fall when the upper lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 15 Remove the cables from the number 4 inner arm index 20 and lay the cables off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 16 Secure both ends of the number 4 inner and outer arms index 20 and 5 together with a strap or other suitable device 17 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 18 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 19 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 20 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 21 Use a slide hammer to remove both number 4 pivot pins index 7 from the non steer end of the machine REV D 22 Use a slide hammer to remove both number 4 pivot pins index 22 from the steer end of the machine 23 Support the rod end of the upper lift cylinder with a suitable lifting device 24 Carefully remove the number 4 inner and outer arms index 20 and 5 from the ma
266. ct switch o m Result The generator should activate and the engine should go to high rpm 4 Connect an appropriate electrical tool to the electrical outlet at the platform controls and run the tool at full speed MANIFOLDS Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical outlet at the generator Result The reading on the multimeter should be 112 to 118V AC Result If the reading on the multimeter is not 112 to 118V AC proceed to step 6 Turn the key switch to the off position 7 Usea wrench to hold the generator flow regulator valve item AM and remove the cap a generator manifold b flow regulator Adjust the internal hex socket Turn it clockwise to increase the AC voltage or counterclockwise to decrease the AC voltage Install the flow regulator valve cap Component damage hazard CAUTION Failure to adjust the generator as instructed may result in damage to the generator or other electrical equipment Do not adjust the generator to other than specified Repeat steps 2 through 5 to confirm the generator AC voltage Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 105 Section 4 Repair Procedures December 2004 MANIFOLDS 7 12 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this
267. ction 4 Repair Procedures December 2004 MANIFOLDS 7 3 Function Manifold Components Models without Outriggers before serial number 40519 The function manifold is located in the chassis tray on the ground controls side of the machine Index Schematic No Description Item Function Torque 1 Check valve dtes Steer circuit i 25 ft lbs 34 Nm 2 Check valve iere Bau Auxiliary pump circuit sssrinin 20 ft lbs 27 Nm 3 Priority flow regulator valve 2 5 9 46 L min C uuu Steer circuit esee 25 ft lbs 34 Nm 4 Relief valve 3500 psi 241 3 bar Des System relief 20 ft lbs 27 Nm 5 Relief valve 2000 psi 138 bar Steer 2 20 ft lbs 27 Nm 6 Diagnostic nipple Eau Testing 7 Solenoid valve 3 position 4 way 20 ft lbs 27 Nm 8 Proportional solenoid valve Flo All f nctlons 30 ft lbs 47 Nm 9 valve 3 position 4 Platform up down 30 35 in Ibs 3 4 Nm 4 92 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E MANIFOLDS E Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 93 Section 4 Repair Procedures December 2004
268. ction strainers from the tank and clean them using a mild solvent 18 Rinse out the inside of the tank using a mild solvent 19 If equipped install the suction strainers using Loctite 567 on the pipe threads Always use Loctite 567 on all pipe threads 20 Install the drain plug using Loctite 567 on the pipe threads Always use Loctite 567 on all pipe threads 21 Install the hydraulic tank onto the machine 22 Install the hydraulic tank strap 23 Install the two suction hoses Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST E PROCEDURES 24 Install the tank return hose 25 Install the T fitting with the 2 hoses connected to it 26 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 Section 2 Specifications 27 Clean up any oil that may have spilled during the procedure 28 If equipped open the hydraulic tank shutoff valves Component damage hazard CAUTION Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Refer to Repair procedure 6 2 How to Prime the Pump 29 Install the access plate and install the access plate retaining fasteners 30 Install the entry ladder and install the entry ladder mounting fasteners 31 Clean up any fuel that may have spilled du
269. d precedes each group of drawings Electrical Schematics AWARNING Electrocution 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 AWARNING 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 General Repair Process Malfunction _ Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 1 Section 6 Schematics December 2004 Electronic Control Module Layout before serial number GS9003 41523 REV Engine Platform controls Down limit switch Up limit switch To outriggers J4 J3 Electronic Control Module J2 Level sensor Function manifold Drive manifold Ground controls 6 2 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics m ssss HM J ng Electronic Control Module Pin Out Legend
270. drive motor Bodily injury hazard Spraying AWARNING 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 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 Torque specifications Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm 9 2 Steer Cylinder How to Remove the Steer Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 the location and the amount of the spacers at the barrel end of the ste
271. e on position at both the ground and platform controls REVC 2 Startthe engine 3 Raise the platform approximately 18 feet 5 5 m from the ground 4 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 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 AWARNING 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 Remove the entry ladder mounting fasteners and remove the entry ladder from the machine AWARNING Crushing 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 3 42 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV 9 If equipped close the two hydraulic shutoff valves located at the hydraulic tank Component damage hazard The CAUTION engine must not be started with the hydraul
272. e outside of the machine rotate the down limit switch cam in a clockwise direction until the cam lobe is approximately 1 mm lower Tighten the fasteners Do not over tighten When adjusting the down limit switch cam do not move cam which activates the load sense delay limit switch Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D 64 Raise the platform approximately 1 m 65 Return the safety arm to the stowed position 66 Repeat this procedure beginning with step 59 67 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 72 Result The platform stops lowering The down limit switch needs to be calibrated Proceed to step 68 68 Raise the platform to approximately 6 m 69 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 70 Loosen the fasteners securing the down limit switch cam just enough to allow movement of the cam TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM CHECKLIST D PROCEDURES 71 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 When adjusting the down limit switch cam do not move cam which activates
273. e stowed position 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 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 personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of ADANGER 5 an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performi
274. e test port item F or AB on the function manifold 2 Start the engine from the ground controls 3 Simultaneously move and hold the function enable and the platform up down toggle switch in the Down direction with the platform fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item D or AC 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 3 to confirm the relief valve pressure REVE How to Adjust the Steer Relief Valve Perform this procedure with the platform in the stowed position 1 Connect a 0 to 3000 psi 0 to 250 bar pressure gauge to the test port item F or AB on the function manifold 2 Startthe engine from the platform controls 3 Press and 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 Section 2 Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item E or AE 5 Adjust the internal hex socket Turn i
275. e the Coolant Temperature and Oil Pressure Switches Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns 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 on the tank side of the engine tray to prevent the engine tray from moving 3 Locate the oil pressure or coolant temperature switch a oil pressure switch b coolant temperature switch hidden from view 4 Tag and disconnect the wiring from the desired switch Remove the switch from the engine block 5 Install and tighten the new switch Torque to specification 6 Connect the wires to the new switch Always use pipe thread sealant when installing a sending unit Coolant temperature switch specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 13 16 inch Temperature switch point 230 110 C Oil pressure switch specifications Torque 8 10 ft lbs 11 14 Nm Hex size 11 16 inches Oil pressure switch point 8 psi 0 55 bar Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures bem Ground Controls 5 1 5 2 Auxiliary Platform Lowering In the event of an engine failure activating the back up manual lowering and manual lowering enable switches will lower the platform when the red Emergency Stop butto
276. e the retaining fasteners from the drive motor guard Remove the drive motor guard from the yoke drive motor Cap the fittings on the drive motor AWARNING xri injury hazard Spraying ydraulic 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 yoke and drive motor assembly to a lifting jack 9 Remove the cotter pin from the tie rod clevis pin 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 a rod through the pin and twist to remove the pin 13 Repeat steps 11 and 12 for the upper yoke pivot pin Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 111 Section 4 Repair Procedures December 2004 STEER AXLE COMPONENTS REV 14 Remove the yoke and drive motor assembly How to Remove a Drive Motor from the machine Component damage hazard ACAUTION Crushing hazard The yoke and CAUTION Repairs to the motor should only drive motor assembly may be performed by an authorized become unbalanced and fall if not dealer properly supported and secured to the lifting jack when it is removed CAUTION Component damage hazard The from the machine work area and surfaces where this procedure wil
277. e to a vertical position Lock the safety arm in position Be sure that the safety arm is locked in the vertical position open closed CAUTION Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 109 Section 4 Repair Procedures December 2004 p FUEL AND HYDRAULIC TANKS REV 9 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 11 Tag disconnect and plug the tank return hose at the tank 12 Disconnect and plug the T fitting located at the tank with the 2 hoses connected to it 13 Remove the hydraulic tank strap retaining fasteners and remove the hydraulic tank strap from the machine 14 Support and secure the hydraulic tank to a suitable lifting device 15 Remove the hydraul
278. e with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Insert a 6 inch 15 cm screwdriver rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST A PROCEDURES 3 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug a fuel filter b drain plug 4 Clean up any fuel that may have spilled 5 Start the engine from the ground controls and check the fuel filter water separator for leaks ADANGER 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 REV A 12 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 200 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Genie part number 84792 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Mai
279. ecember 2004 a OOOO Electrical Schematic CE Models with Deutz Power REVA after serial number GS9005 421 43 Part 1 of 3 F9saruse stop KEY SWITCH Zas 2 Bt PLATFORM CONTROL i4 4141 EE 3 GROUND CONTROL fell asi estat aes ok 4 CB2 20a ABT 52 Y PLATFORM OVERLOAD H PRESSURE SWITCH 4 CR41 CR1 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED ABT 86 2 86 30 2 86 5 86 304 4 86 86 2 30 30 2 85 87 85 D 85 v 85 e 7 85 7 e nu 2 N C H O N CH O l FA NT G6 LS23 LS22 gt 01 LEFT RIGHT xy 5 1 OSCILLATE OSCILLATE H2 LIMIT SWITCH LIMIT SWITCH 15 CR4 e HIGH IDLE one 86 30 ERES AID A 4 05 86 85 87 87A Y54 Y56 E
280. ecure 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 Remove the pin retaining fasteners from the number 1 pivot pins index 10 at the non steer end of the machine 22 Use a 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 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 25 Lower the number 1 outer arm index 16 onto the block AWARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the block 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 retaining fasteners 28 Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 9 29 Carefully remove the lift cylinder from the machine AWARNING Crushing hazard The lift cylinde
281. ed of the machine Refer to 7 Press the lift function enable button Section 2 Specifications 4 64 Genie GS 3390 65 4390 GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D How to Adjust the Platform Lower Speed 1 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 3 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 DESCENT sPEED is showing in the diagnostic display window GROUND CONTROLS FN b T diagnostic display blue platform up button lift function enable button yellow platform down button Qo om Press the lift function enable button 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 Section 2 Specifications The performance achieved should always be within specifications 9 Press the lift function enable button 10 Push in
282. edures December 2004 PLATFORM CONTROLS 3 Locate the potentiometer on the base of the joystick JC1 JOYSTICK CONTROLLER U3 PLATFORM CONTROLS CIRCUIT BOARD _ 00000000 joystick controller JC1 potentiometer shaft slot potentiometer shaft set screw platform controls circuit board U3 potentiometer brown wire purple wire 4 Using a volt meter to read DC voltage place the voltmeter negative lead on the purple wire Place the volt meter positive lead on the brown wire AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry o immi H D 6 e 5 5 REV D Loosen the set screw on the potentiometer shaft just enough to allow the shaft to rotate With the joystick in the center or neutral position adjust the potentiometer shaft until 2 05V DC is displayed on the voltmeter Tighten the set screw Move the joystick full stroke in both directions several times Return the joystick to the center position Result The voltmeter should read 2 05V DC Result If the voltmeter does not read 2 05V DC repeat steps 5 through 8 Do not activate the function enable switch Turn
283. eer end of the machine 46 Use a slide hammer to remove both number 2 pivot pins index 21 from the steer end of the machine 47 Carefully remove the number 2 inner and outer arms index 8 and 20 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 48 Remove the cables and hydraulic hoses from the number 1 inner arm index 10 and lay them off to the side Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 49 Secure both ends of the number 1 inner and outer arms index 10 and 12 together with a strap or other suitable device 50 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 10 and 12 at the steer end of the machine Do not apply any lifting pressure 51 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 REV D 52 Remove the pin retaining fasteners from both chassis centering link pivot pins index 23 at the number 1 inner arm 53 Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on
284. el injectors 143 Adaptive Learn High LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components 144 Adaptive Learn Low LPG Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty Repair short in engine wire harness OR test and repair the fuel system components Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 pm H r Section 5 Fault Codes REVA FORD ENGINE ECM FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41 368 Code Problem Cause Solution 161 System Voltage Low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted Replace battery OR repair alternator OR repair battery supply wiring to ECM 162 System Voltage High Alternator is overcharging the battery when engine RPM is greater than 1500 rpm Repair or replace the alternator 211 IAT High Voltage 1 sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold Repair wir
285. ement pump Bi directional variable speed motor Counterbalance valve Flow regulator valve Flow divider combiner valve Relief valve Priority flow regulator Accumulator gt Orifice M Shut off valve Dual acting cylinder ME Solenoid operated 2 position 2 way valve normally closed with manual over ride Y27 M Y2 Solenoid operated 2 position 3 way YZ VA Y4 Hydraulic Symbols Legend fog Brake Check valve eh Hot oil shuttle valve Proportional solenoid valve Y8 NI M M Solenoid operated 3 position 4 way directional valve directional valve Solenoid operated 3 position 4 way directional valve W Y49A Solenoid operated 2 position 2 way directional valve Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 107 Section 6 Schematics December 2004 Hydraulic Schematic before serial number 40519 REV D Part 1 of 2
286. ency Stop button to the on position at the ground controls Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to max fwd high speed drive Result 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 Section 2 Specifications 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 GROUND CONTROLS G a diagnostic display b blue platform up button c liftfunction enable button d 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 REV HIGH SPEED 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 Section 2 Specifications The performance achieved should always be within specific
287. engagement Raise the machine and remove the blocks Lower the machine AWARNING Collision hazard Failure to engage the drive hubs could result in death or serious injury and property damage 7 Chock the wheels at the non steer end of the machine 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the wheels at the steer end 9 Lift the wheels off the ground and place blocks under the drive chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the steer end 11 Manually rotate each wheel at the steer end Result Each wheel should rotate with minimum effort 12 Engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine and remove the blocks Lower the machine AWARNING Collision hazard Failure to engage the drive hubs could result in death or serious injury and property damage Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST D PROCEDURES D 3 Replace the Drive Hub Oil 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
288. engine tray out 2 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 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 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust 8 Install the filter element 9 Install the air filler canister end cap and the end cap retaining ring REVC Deutz models 1 Release the latches on the engine tray and fully slide the engine tray out 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 Remove the air intake hose from the engine slide out tray Disconnect the retaining clamp from the air cleaner canister Remove the filter element Clean the inside of the canister and the gasket with a damp cloth Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Install the filter element Install the air filter canister end cap and connect the end cap retaining clamp Be sure the air clea
289. ent just before the reaching the stowed position Adjust the Platform Settling Speed until the Platform Settling Speed percentage is 3 to 5 points less than the Platform Lowering Speed percentage 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground controls Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D GROUND CONTROLS How to ZA 4 Adjust the Steer Speed 1 Pull out the red Emergency Stop button to the Y on position at the platform controls d 2 Push the red Emergency Stop button to the J off position the ground controls E diagnostic display 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 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to steering speed Result STEERING SPEED is showing the diagnostic display window lift function enable button a b blue platform up button d yellow platform down button 7 Pressthe lift function enable button Press the yellow platform down button to decrease the steering speed or
290. ent of our products is a Genie policy Product specifications are subject to change without notice System relief valve pressure 3500 psi 241 bar Steer relief valve pressure 2000 psi before serial number 40519 138 bar Steer flow regulator 2 5 gpm before serial number 40519 9 5 L min Lift relief valve pressure 2000 psi after serial number 40518 138 bar Proportional valve flow regulator 0 1 gpm after serial number 40518 0 38 L min Oscillate manifold System relief valve pressure 3500 psi 241 bar Float relief valve pressure 900 psi 62 bar Oscillate flow regulator 1 gpm 3 8 L min Drive manifold Hot oil relief pressure 300 psi before serial number GS9004 41619 20 7 bar Hot oil relief pressure 280 psi after serial number GS9004 41618 19 3 bar Drive motors Displacement 2 speed motor 0 6 to 1 5 cu in before serial number GS9004 41619 9 8 to 24 6 cc Displacement 2 speed motor 0 54 to 1 52 cu in after serial number GS9004 41618 8 8 to 25 cc Drive hubs Fluid capacity 17 fl oz before serial number GS9004 41619 0 5 liters Fluid capacity 26 fl oz after serial number GS9004 41618 0 77 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 2 Specifications December 2004 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in l
291. er 2 Shorted Wiring and or connections to fuel injector 2 shorted OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 2 OR replace fuel injector 2 OR replace the ECM 315 Injector Driver 3 Open Open wiring and or connections to fuel injector 3 OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 3 OR replace fuel injector 3 OR replace the ECM 316 Injector Driver 3 Shorted Wiring and or connections to fuel injector 3 shorted OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 3 OR replace fuel injector 3 OR replace the ECM 321 njector Driver 4 Open Open wiring and or connections to fuel injector 4 OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 4 OR replace fuel injector 4 OR replace the ECM 322 Injector Driver 4 Shorted Wiring and or connections to fuel injector 4 shorted OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 4 OR replace fuel injector 4 OR replace the ECM 351 Fuel Pump Loop Open or High Side Short To Ground Open wiring and or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty Repair wiring and or connections to fue pump OR replace fuel pump 352
292. er 2004 REVA HYDRAULIC COMPONENT HYDRAULIC COMPONENT HYDRAULIC COMPONENT LEGEND LEGEND LEGEND Item Function Item Function Item Function A Steer circuit BA High speed bypass CA Right front outrigger autolevel valve B Auxiliary pump circuit BB High speed bypass CB Left front outrigger autolevel valve Steer circuit BC Balances fluid flow from flow Right rear outrigger autolevel valve D System relief divider combiner BO to non steer end CD Left rear outrigger autolevel valve E Steer outrigger circuit drive motors F Test port BD Balances fluid flow from flow DA Oscillate on G Steer left right divider combiner BP to steer end drive DB Oscillate system relief valve H All functions motors DC Oscillate float relief valve Platform up down BE Charge pressure circuit that gets hot DD Flow regulator J Outrigger up down out of low pressure side of drive DE Right oscillate cylinder K Outrigger extend circuit pump and allows low pressure flow DF Leftoscillate cylinder L Outrigger retract circuit Em for brake release and 2 motor DG Oscillate float AA Platform down circuit Testing ux pressure Flow divider combiner front to rear Testing G Testing pressure
293. er 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 the location and the amount of the spacers at the barrel end of the steer cylinder 4 Remove the steer cylinder from the machine Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 113 Section 4 Repair Procedures December 2004 STEER AXLE COMPONENTS 9 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pin from each tie rod clevis pin Remove the clevis pins Always use a new cotter pin when installing a clevis pin Note the location and the amount of the spacers at both ends of the tie rod 2 Remove the tie rod How to Adjust the Toe in before serial number 40030 Always perform this procedure on a firm level surface Block the non steering tires and be sure that the platform is in the stowed position 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture 3 Center a lifting jack under the front of the chassis and raise the machine until the steer tires are off of the ground REV B 4 Loosen the jam nut on the adjustable end of the tie rod 5 Remove the cotter pin from the clevis pin at the adjustable end of the tie rod Always use a new cotter pin when installing a clevis pin 6 Slide the tie rod off of the yoke and adjust it by turning the end One half turn on
294. erate at the same time Required for Europe Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D DIP Switch Codes Chart A inthe column indicate that the machine configuration includes this option Diagnostic Display Code Overload Sensor 5 els 5 8 g 0 2 9 2 Gasoline LPG Descent Delay S lt 5 5 01 02 04 05 07 01011010 00111010 01010001 10100110 01011011 00111011 01010000 10100111 01010100 00110000 00100100 10100100 01011000 00111000 00101100 10101100 01010011 00110011 00100101 10100101 01010111 00110111 00101001 10101001 01011100 00111100 00101101 10101101 01011111 00111111 00101111 10101111 10 11 13 14 16 17 19 20 22 23 25 26 28 29 31 32 34 35 37 38 40 41 43 44 46 47 et Tet _ ELE et Tet _____ No Simultaneous Operation Diagnostic Display Code PLATFORM CONTROLS 9 o No Simultaneous Overload Sensor Operation 2 5 5 Motion Beacon Descent Delay S lt 9 5 gt Continued to the next page Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 1 Section 4 Repair Procedures December 2004 PLATFORM CONTROLS REV D 5 5 5 5 o Di
295. erform Engine Maintenance Deutz 2011F Models 3 46 E 6 Perform Engine Maintenance Ford Models before serial number 59003 41369 3 46 Section 4 Rev Repair Procedures E 4 1 D Platform Controls 1 1 CIRCUIT BOGEGS oa acit tee 4 3 1 2 Joystick 1 4 3 1 3 Controller Adjustments before serial number GS9003 41 523 4 5 1 4 Software Configuration before serial number GS9003 41523 4 11 Platform Components 251 4 15 2 2 Platform Extension 4 17 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 vil December 2004 27 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued D Scissor Componenis 3 1 Scissor Assembly 55 3390 22000 4 18 3 2 Scissor Assembly 55 4390 00 4 24 3 3 Scissor Assembly 55 5390 0000 4 34 3 4 Wear Pads usui i ee 4 47 3 5 JLift Oylinder S eds 4 49 Engines 41 BPNIAdjuSImeht A 4 53 4 2 Flex Plate cite duce edet osuere 4 53 4 3 Oil Temperature and Oil Pressure Switches Deutz Models 4 55 4 4 Coolant Temperature and Oil Pressure Switches Ford Models 4 56 D Ground Controls 5 1 Auxiliary
296. es December 2004 GROUND CONTROLS 5 7 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes When a engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will illuminate at the ground controls Use the following procedure to retrieve the engine fault code to determine the engine malfunction Perform this procedure with the key switch in the off position 1 Open the ground controls side cover 2 Pull out the red Emergency Stop button to 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 REV D 5 Continue to hold the run test toggle switch in the test position and count the blinks 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 6 Refer to Section Five for definition of eng
297. ex 10 59 Secure both ends of the number 1 inner and outer arms index 10 and 12 together with a strap or other suitable device 60 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms index 10 and 12 at the steer end of the machine Do not apply any lifting pressure 61 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 62 Remove the pin retaining fasteners from both chassis centering link pivot pins index 23 at the number 1 inner arm 63 Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis 64 Remove the pin retaining fasteners from the number 1 inner arm slide blocks index 24 at the steer end of the machine 65 Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 24 66 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 67 Carefully remove the number 1 inner and outer arms index 10 and 12 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Sc
298. f a multimeter to the yellow wire at the level sensor and the negative lead to the black wire 41 Lower the platform to the stowed position 42 Raise the machine slightly 43 Remove the blocks from under both wheels 44 Lower the machine and remove the jack Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 REV D Confirm the front to back level sensor setting 45 Center a lifting jack under the drive chassis at the steer end of the machine 46 Raise the machine approximately 6 inches 15 47 Models with RT tires Place 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 48 Lower the machine onto the blocks 49 Raise the platform approximately 16 feet 5 m O 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 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 50 Lower the platform to the stowed position 51 Raise the m
299. ff to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 22 Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm 23 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched REV D 24 Secure both ends of the number 3 inner and outer arms index 18 and 16 together with a strap or other suitable device 25 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 26 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 27 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 28 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 29 Use a slide hammer to remove both number 3 pivot pins index 6 from the non steer end of the machine 30 Use a slide hammer to remove both number 3 pivot pins index 19 from the steer end of the machine 31 Carefully remove the number 3 inner and outer arms index 18 and 1
300. fications REV D Ford LRG 425 EFI Engine Displacement 153 cu in 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke SPECIFICATIONS Engine coolant Capacity 11 5 quarts 10 9 liters Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Horsepower 70 2500 rpm 52 kw 2500 rpm Current draw maximum load 800A m Circuit voltage drop 0 5V DC Firing order while starting maximum normal temperature Low idle computer controlled 1600 rom Brush length minimum 0 25 in 320 Hz 6 35 mm High idle computer controlled 2500 rpm Commutator run out maximum 0 005 inches S00 bie 0 127 mm Compression ratio 9 4 1 Electronic fuel pump Compression pressure approx Fuel pressure static 63 psi Pressure psi or bar of lowest cylinder must be 4 3 at least 75 of highest cylinder Fuel flow 0 58 Valve clearances 0 035 to 0 055 inches Seat ate collapsed tappet 0 889 to 1 397 mm RFP Alternator Lubrication system Output 95A 14 5V D Oil pressure 40 to 60 psi DEK des operating temperature 2500 rpm 2 75 to 4 1 bar gt Battery before serial number 40516 capacity 4 5 quarts 12V DC including filter 4 3 liters Group 34 78 Oil viscosity requirements Quantity 1 Above 15 F 26 C 10W 40 Cold cranking ampere 900A Abo
301. fting eye at the rod end of the lift cylinder SCISSOR COMPONENTS 5 Use 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 AWARNING Crushing hazard The lift cylinder could fall when the lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 6 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 7 Cut the zip ties attaching the hydraulic hoses to the lift cylinder Lay the hoses out of the way Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 8 Remove the cables from the number 2 inner arm index 6 and lay the cables off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 9 Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm index 2 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 19 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 10 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down C
302. ged if they are kinked or pinched Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 34 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 35 Place a rod through the hose tray pivot pin and twist to remove the pin Lower the hose tray down Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 36 Secure both ends of the number 3 inner and outer arms index 48 and 23 together with a strap or other suitable device 37 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the steer end of the machine Do not apply any lifting pressure 38 Attach a lifting strap from an overhead crane to the number 3 inner and outer arms index 8 and 23 at the non steer end of the machine Do not apply any lifting pressure 39 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 40 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 41 Use a slide hammer to remove both number 3 pivot pins index 10 from the non steer end of the machine 42 Use a slide hammer to remove both number 3 pivot pins index 25 from the steer end of
303. ged if they are kinked or pinched CAUTION 62 Secure both ends of the number 2 inner and outer arms index 26 and 27 together with a strap or other suitable device 63 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 64 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 65 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 66 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 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 428 from the steer end of the machine 69 Carefully remove the number 2 inner and outer arms index 26 and 27 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 If further disassembly of the sci
304. gt ET 3 9 tz 187 LEVEL SENSOR o moui i 358 58 692 J2 A6 5 12 IR i Lr 9 8 308 LAG 5 aS SH t ui EN I lo BS J2 B10 Rb Le 82 246 T lt 1 NOS 525 J2 C1 C10 8E Qo gt 1 55 M9 E 9 z I 1 Q a zc THROTTLE J4 B4 J2 B3 ae o Min 2598 1S8 2 AXIS LEVEL SENSOR DATA LINK J3 A4 mein E 2 GND FROM PLAT j J3 B4 V I o Y39 OUTRIGGER RETRACT o 5 a 195 3 zt 28 655 2 E qs Y40 OUTRIGGER EXTEND 8a 21 o 0 To J8 A6 0 45255 9 J3 B6 gt Hog 7226 H1 Y33 LEFT REAR OUTRIGGER os 4 e ern J2 A10 gt gt lt gol J4 C2 ta 01794 RIGHT REAR OUTRIGGER c 4 0 022 J1 A12 gt lt 6 J2 A8 Y35 LEFT FRONT OUTRIGGER W59ES TB 50 2 lt 4 9 J1 B5 gt 2 2 the Y36 RIGHT FRONT OUTRIGGER 4 i J4 B3 28 52 1 C7 U5 ECM GROUND lt 99552 CAES E2925 J4 B2 I 1 qj 92 ENGINE OIL PRESSURE uuoo gt Jaho SW1 ENGINE COOLANT TEMPERATURE T OZER J4 B1 E BEFORE SERIAL NUMBER 40043 4 a 9 20 a0 J1 B1
305. gt gt dm 2 m x gt o o o 8 3 020 5 ul 5 d m 20 lt 2 9 2 SZ gt 5 m 20 lt 2 d I o 8 gt gt 5 lt gt o 4 lt E v o m m 9 5 Dm D m 2 3 7 S B lt f gt m OSCILLATING AXLE OPTION 9 AVAILABLE AFTER SERIAL NUMBER 41618 1 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Es7174 6 54 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics Electrical Schematic REVA from serial number GS9003 41523 to GS9004 41693 Part 2 of 3 GS 5390 ONLY T 7686 1 AB3 t T LS12A LOWER OIL COOLER LF O RIG OPTION LIMIT SWITCH 1657 4 NC J2 C12 BATTERY 12V LS13A iuc OF 6013 8 LOWER LS5A esses Er BAT SW4 i LIMIT SWITCH HYDRAULIC 20 i NC 4 jew Ur OIL TEMP 2 o LS14A 4 SWITCH 8 1 1 lt LOWER O 3
306. ham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA Instructions Use the operator s manual on your machine 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 completed no unable to complete R 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 Section 3 Scheduled Maintenance Procedures December 2004 This page intentionally left blank 3 4 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions copies of t
307. he diagnostic display window 10 Press the lift function enable button to activate or deactivate the motion beacons option OR use the yellow platform down arrow to scroll to overload For this option to function correctly the machine must be equipped with flashing beacons Result ovERLOAD ON is showing in the diagnostic display window Result ovERLOAD is showing in the diagnostic display window Press the lift function enable button to activate the overload option For CE models the overload option should be activated or in the position 11 Use the yellow platform down arrow to scroll to sim operation Result OPERATION OFF is showing in the diagnostic display window Result OPERATION ON is showing in the diagnostic display window Press the lift function enable button to deactivate the sim operation option For CE models the sim operation option should be deactivated or in the orr position 4 70 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 12 Use the yellow platform down arrow to scroll to return to the main menu O Result RETURN TO MAIN MENU is showing in the diagnostic display window 13 Press the lift function enable button Result SELECT is showing in the diagnostic display window 14 Push in the red Emergency Stop button to the off position at the ground controls GROUND CONT
308. he block AWARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the block 51 Attach a lifting strap from an overhead crane to the lifting eyes on the lift cylinder 52 Remove the lift cylinder barrel end pivot pin retaining fasteners 53 Use a soft metal drift to remove the lift cylinder barrel end pivot pin index 15 54 Carefully remove the lift cylinder from the machine AWARNING 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 55 Carefully lift the number 1 outer arm index 16 approximately 2 inches 5 cm and remove the block 56 Lower the number 1 outer arm index 16 onto the slide blocks AWARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the blocks 57 Secure the number 1 outer arm index 16 to the slide blocks 58 Remove the strap installed in step 44 59 Support the cable tray with an overhead crane REV D 60 Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 26 61 Place a rod through the cable tray pivot and twist to remove the pin Lower the cable tray onto the number 1 inner arm index 14 AWARNING Crushing hazard The cable tray may fall if not properly supported by the overhead crane Component damage hazard Cables can be dama
309. he 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 13 and lay the cables off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 4 Secure both ends of the number 4 inner and outer arms index 14 and 2 together with a strap or other suitable device SCISSOR COMPONENTS 5 Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 14 and 2 at the steer end of the machine Do not apply any lifting pressure 6 Attach a lifting strap from an overhead crane to the number 4 inner and outer arms index 14 and 2 at the non steer end of the machine Do not apply any lifting pressure 7 Remove the pin retaining fasteners from both 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 AWARNING Crushing hazard The number 4 inner and outer arms could become unbalanced and fa
310. he 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 Industries Service Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The CAUTION 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the lift steer pump See 6 1 How to Remove the Lift Steer Pump REV Disconnect the electrical connections at the EDC located on the drive pump Tag disconnect and plug the hydraulic hoses from the drive pump Cap the fittings on the pump Bodily injury hazard Spraying CAUTION 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 Support the drive p
311. he 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 To perform this step the system relief valve will need to be adjusted Before raising the platform applying a piece of tape onto the underside of the platform ata point which corresponds to the maximum load position of the capacity indicator decal may help complete this part of the procedure Result The engine continues to run Proceed to step 16 Result The engine has stopped and an alarm 15 sounding Proceed to step 17 CHECKLIST D PROCEDURES Set the pressure switch 16 Using a wrench turn the nut of the platform overload pressure switch out of the hydraulic line until the overload alarm sounds and the engine stops running Turning the nut out of the hydraulic line will activate the alarm turning the nut into the hydraulic line will deactivate the alarm 17 Slowly turn the nut 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 a
312. he platform 5 Attach a lifting strap from an overhead crane to the entry ladder on the hydraulic tank side of How to Remove the Hydraulic Tank CAUTION 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification the machine 6 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder AWARNING could become unbalanced and fall when it is removed from the machine if it is not properly supported 7 Remove the retaining fasteners from the access plate located behind the hydraulic and fuel tank tray 8 Close the two hydraulic shutoff valves located at the hydraulic tank if equipped during installation Refer to Section Two 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 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotat
313. he settings Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 1 4 Software Configuration before serial number GS9003 41523 How to Configure the Software The Electronic Control Module ECM contains programming for all configurations of the GS90 Models before serial number GS9003 41523 can be adjusted to a different configuration by changing the combination of the DIP switch settings located on the circuit board inside the platform control box DIP switches have two positions on or off When reading the DIP switch code in the D P Switch Codes Chart on the next page the on and off are represented by the numbers 1 on and O off 7177177 hazard Do not adjust the DIP switch settings to other than what is specified in this procedure Exceeding specifications will cause death or serious injury If replacing the circuit board note the toggle positions on the DIP switch Set the DIP switch on the new circuit board to the same configuration as the old one 1 Pushin red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Remove the fasteners securing the lid of the platform controls and open the platform control box PLATFORM CONTROLS Rotate the platform controller box in the position shown to correctly identify the configuration of the DIP s
314. hematics Sa This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 41 Section 6 Schematics December 2004 Electrical Schematic ANSI Models with Ford Power REV from serial number GS9003 41523 to GS9004 41693 Part 1 of 3 re KS1 key 1 na EMERGENCY STOP 2 Ut PLATFORM CONTROL 21 4 1 oe GROUND CONTRO l 2 CB2 20a CR41 CR1 CR23 CR84 CR85 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE SYSTEM POWER HORN IGNITION START DOWN STOWED RAISED 86 86 21 86 9 86 A 86 86 30 86 30 42 85 87 85 87 aA D a e 85 7 85 7 i 5 N CHO NCHO 1523 07 0 1622 m LEFT RIGHT EAS 1 OSCILLATE OSCILLATE H2 gt LIMIT SWITCH LIMIT SWITCH 1 15 GOV SPEED SELECT OR RD 23 R6 FUELSELECTBKWH 7 5100 i
315. hing hazard The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly supported 4 50 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D GS 5390 Bodily injury hazard The counterbalance valves in the lift AWARNING cylinders are factory set Do not attempt to adjust the counterbalance valves Attempting to adjust the counterbalance valves will 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 When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two 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 SCISSOR COMPONENTS 2 Before serial number 40263 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40262 Release the safety arm latch lift the safety arm and rotate to a vertical pos
316. his report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection Semi annually 500 hour Inspection A B C Annually or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures 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 remove from service R repaired Comments Checklist A Rev C YNR Checklist B continued YNR A 1 Pre operation inspect A 2 Function tests B 19 Fuel tank cap venting Perform every 400 hours A 3 Engine maintenance Ford models B 20 Engine maintenance Ford models A 4 Engine maintenance Deutz models Perform after 40 hours Checklist C Rev C C 1 Platform overload if equipped 5 Engine air filter A 6 30 day service Perform after 50 hours 7 Engine maintenance Deutz models Perform every 100 hours A 8 Engine maintenance Ford models C 2 Engine maintenance Deutz models Perform every 800 hours C 3 Engine maintenance Ford models
317. ic tank from the machine Crushing hazard The hydraulic AWARNING 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 CAUTION sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank See 6 2 How to Prime the Pump Always use pipe thread sealant when installing the drain plug and strainers 4 110 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures Steer Axle Components 9 1 7 Tag disconnect and plug the hoses from the Yoke and Drive Motor How to Remove the Yoke and Drive Motor When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two 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 Crushing hazard The chassis will AWARNING fall if it is 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 Remov
318. ic tank shutoff 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 open closed 10 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Bodily injury hazard Spraying AWARNING 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 Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot oil and or hot engine parts may cause severe burns 11 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves or tank CHECKLIST E PROCEDURES 12 Tag disconnect and plug the tank return hose at the tank 13 Tag disconnect and plug the T fitting located at the tank with the 2 hoses connected to it 14 Remove the hydraulic tank strap retaining fasteners and remove the hydraulic tank strap from the machine 15 Support and secure the hydraulic tank to a suitable lifting device 16 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING 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 17 If equippd remove the su
319. ie GS 3390 GS 4390 and GS 5390 3 9 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST A PROCEDURES A 8 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 100 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Genie part number 84792 REV A 9 Check the Hydraulic Return Filter Condition Indicator if equipped Genie specifications require that this procedure be performed every 100 hours of operation Maintaining the hydraulic return filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage In extreme cold conditions 20 F 6 and below warm the engine for 5 minutes before operating to prevent hydraulic system damage 1 Start the engine from the platform controls 2 Press the high idle button at the platform controls to allow the engine to run at high idle 3 Open the function manifold tray door and locate the hydraulic tank return filter behind the entry ladder 4 Inspect the filter
320. in programming mode 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 OR use the yellow platform down arrow to scroll to lift drive cutout Result curour is showing in the diagnostic display window Result CUTOUT OFF is showing in the diagnostic display window Press the lift function enable button to activate the lift drive cutout option The lift drive cutout option should be activated or in the on position Use the yellow platform down arrow to scroll to motion alarm Result MOTION ALARM is showing in the diagnostic display window 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 beacons Result MOTION BEACONS is showing in the diagnostic display window Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 9 Press the lift function enable button to activate or deactivate the motion beacons option For this option to function correctly the machine must be equipped with flashing beacons 10 Models with platform overload option Use the yellow platform down arrow to scroll to overload Result ovERLOAD is showing in the diagnostic display window Result ovER
321. ine fault codes 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 See How to Clear Engine Fault Codes from the ECM Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D GROUND CONTROLS How to Clear Engine Fault Codes from the ECM 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 AWARNING Electrocution 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 Start the engine and allow it to idle for approximately ten minutes Result The check engine light should not turn on Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 83 Section 4 Repair Procedures December 2004 Hydraulic Pumps 6 1 Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications How to Test the Lift Steer Pump 1 disconnect and plug the high pressure hydraulic hose from
322. ine tray roller wheels to prevent the engine tray from moving 3 Turn the manual fuel shutoff valves located at the fuel tank to the closed position Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D 4 Remove the fuel separator with filter wrench a oil filter b separator 5 Fill the new filter with fresh diesel fuel and apply athin 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 Usea permanent ink marker to write the date and number of hours from the hour meter on the filter 8 Turn the manual fuel shutoff valves located at the fuel tank to the open position 9 Start the engine from the ground controls and inspect the fuel filter for leaks ADANGER 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 CHECKLIST D PROCEDURES D 5 Calibrate the Platform Overload System if equipped Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first On machines with platform overload systems proper calibration is essential to safe machine operation An improperly calibrated
323. information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 CHECKLIST B PROCEDURES B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust System can cause component damage and unsafe operating conditions AWARNING 91 injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Release the latches on the engine tray and fully slide the engine tray out 2 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 3 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES B 5 Replace the Engine Air Filter Element Genie requires 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 go
324. ing and or connections OR replace sensor OR direct warmer air into air intake 212 IAT Low Voltage IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot Repair wiring and or connections OR replace sensor OR direct cooler air into air intake 213 IAT Higher Than Expected 1 Air intake temperature is greater than 200 with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor 214 IAT Higher Than Expected 2 Air intake temperature is greater than 210 F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor 215 Oil Pressure Low Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Replace oil pressure sensor OR repair sensor wiring and or connections OR fill engine oil level to specification 221 CHT ECT High Voltage Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor 222 CHT ECT Low Voltage Engine
325. ing eye at the rod end of the lift cylinder 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 19 Tag disconnect and plug the hydraulic hoses from the lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 CAUTION Hoses can be damaged if they are kinked or pinched 21 Remove the cables from the number 3 inner arm index 18 and lay the cables o
326. inspect wire disconnected from coil connection Malfunctioning coil OR wire Troubleshoot coil OR inspect wire 41 Left turn coil Ya disconnected from coil connection 42 Flash Up coil Y8 fault Ma functioning coi OR wire Troub eshoot coil OR inspect wire disconnected from coil connection Malfunctioning coil OR wire Troubleshoot coil OR inspect wire 43 disconnected from coil connection 44 Flash Down coil Y7 fault Ma functioning coi OR wire Troub eshoot coil OR inspect wire disconnected from coil connection 45 Flash High speed bypass coil Y49 Malfunctioning coil OR wire Troubleshoot coil OR inspect wire ER and Y49A fault disconnected from coil connection 47 Flash Function proportional coil Y9 Malfunctioning coil OR wire Troubleshoot coil OR inspect wire fault disconnected from coil connection 48 Flash Drive pump proportional coil Malfunctioning coil OR wire Troubleshoot coil OR inspect wire Y51 fault disconnected from coil connection 55 Flash Two speed coil Y1 fault Ma functioning coi OR wire Troub eshoot coil OR inspect wire disconnected from coil connection 56 Flash Generator coil fault Malfunctioning coil OR wire Troubleshoot coil OR inspect wire disconnected from coil connection Continued on next page Part No 72863 Genie GS 3390 GS 4390 and GS 5390 5 3 Section 5 Fault Codes _ FAULT CODE CHART BEFORE SERI
327. ire harness If you are not installing a new level sensor proceed to step 13 REV D Install the level sensor 9 Tag and disconnect the wire harness from the level sensor 10 Remove the three level sensor retaining fasteners Remove the level sensor from the machine 11 Install the new level sensor onto the machine with the X on the level sensor base closest to the steer end of the machine Install and tighten the level sensor retaining fasteners ADANGER Tip over hazard The tilt level 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 MODELS WITH OUTRIGGERS ON ANN LPT y Lll d d Level sensor models without outriggers a chassis b level sensor Y indicator d indicator 4 78 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 12 Connect the wire harness to the level sensor 13 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Start the engine 14 Set a multimeter to read DC voltage Adjust the side to side axis 15 Without disconnecting the wire harness from the level sen
328. irst Edition Fifth Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries 69 Printed on recycled paper Printed in U S A li Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 1 Safety Rules 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 M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 72863 Genie GS 3390 GS 4390 and GS 5390 lii Section 1 Safety Rules December 2004 SAFETY 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 Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert
329. issor Arm Pair Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D How to Disassemble a Scissor Arm Pair AWARNING 9 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 required 1 Attach a lifting strap from an overhead crane to the end of the outer arm Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards a outer arm b innerarm 2 Attach a lifting strap from a second overhead crane to the end of the inner arm 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 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 AWARNING Crushing hazard The scissor arms could become unbalanced and fall if not properly supported by the overhead cranes Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures
330. ithout these skills and tools could result in death or serious injury and significant component damage Dealer Service is required 1 Attach a lifting strap from an overhead crane to the end of the outer arm Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards a outer arm b innerarm 2 Attach a lifting strap from a second overhead crane to the end of the inner arm 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 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 AWARNING Crushing hazard The scissor arms could become unbalanced and fall if not properly supported by the overhead cranes Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS ORE 2 9 9 9 CO Non steer End REV D 22 2 C amp 2 Steer End 1 Platform centering link 14 Number 4 inner arm 2 Number 4 outer arm
331. ition Lock the safety arm in position Be sure that the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 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 5 Lower lift cylinder Cut the zip ties attaching the hydraulic hoses to the lift cylinder Lay the hoses out of the way Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 6 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 51 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS REV D 7 Attach a lifting strap from a second overhead crane or similar lifting device to the lifting eye at the barrel end of the lift cylinder for support 8 Remove the lift cylinder rod end pivot pin retaining fastener Use a soft metal drift to remove the pin Crushing hazard The lift cylinder AWARNING will fall if it is not properly supported 9 Carefully lower
332. k nut and confirm the rom Models with throttle linkage 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 Deutz models with throttle cable Be sure the solenoid fully retracts a low idle adjustment lock nut when activating high idle b idle adjustment lock nuts c cable sheath 6 Before serial number 59004 41523 Move the rpm select toggle switch to the high idle rabbit symbol position After serial number GS9004 41522 Press the high idle rabbit symbol button 7 Before serial number GS9004 41523 Move and hold the start toggle switch to the start b position and check the engine rpm on the diagnostic display Refer to Section 2 Specifications After serial number GS9004 41522 Press and hold the start button and check the engine rpm on the diagnostic display Refer to Section 2 Specifications Deutz models with throttle cable a high idle solenoid b adjustment nut C lock nut d sheath 11 Close and latch the engine slide out tray Skip to step 11 if the high idle rpm is correct 3 18 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REVD CHECKLIST B PROCEDURES B 7 B 8 Confirm
333. l be performed must Torque specifications be clean and free of debris that could get into the hydraulic system Drive hub mounting bolts dry 120 ft lbs and cause severe component 163 Nm ge damage Dealer service is Drive hub mounting bolts lubricated 90 ft lbs recommended m When removing a hose assembly Drive motor mounting bolts dry 75 ft lbs or fitting the O ring on the fitting 102 Nm and or hose must be replaced and 7 then torqued to specification Drive motor mounting bolts lubricated during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe 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 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis will AWARNING fall if it is not properly supported 4 Remove the wheel lug nuts Remove the tire and wheel assembly 4 112 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV B STEER AXLE COMPONENTS Remove the hose clamps retaining fasteners from the drive motor guard Remove the hose clamps Remove the retaining fasteners from the drive motor guard Remove the drive motor guard from the yoke Tag disconnect and plug the hoses from the drive motor Cap the fittings on the
334. l if not properly supported by the overhead cranes 4 46 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 REV 3 4 Wear Pads How to Replace the Scissor Arm Wear Pads Platform Scissor Arm Wear Pads 1 Place a lifting strap from an overhead crane under the platform at the steer end of the machine for support Do not attach the lifting straps from the overhead crane to the platform railings Place a lifting strap from a second overhead crane under the platform at the non steer end of the machine for support Do not attach the lifting straps from the overhead crane to the platform railings Lift the platform slightly using the overhead cranes just enough to take the pressure off the platform slide block pivot pins Remove the pin retaining fasteners from each platform centering link pivot pin at the platform Place a rod through each platform centering link pivot pin and twist to remove the pin Rest the centering links on the scissor arms Section 4 Repair Procedures SCISSOR COMPONENTS 6 Remove the pin retaining fasteners from each platform slide block pivot pin Do not remove the pins 7 Useaslide hammer to remove each platform slide block pivot pin Crushing hazard The platform will AWARNING 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
335. l or partial free wheel configuration Refer to B 7 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions Be sure the platform is fully retracted and lowered to the stowed position 1 Mark a test line on the ground for reference 2 Startthe engine from the platform controls 3 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 Section 2 Specifications The brakes must be able to hold the machine on any slope it is able to climb CHECKLIST B PROCEDURES B 15 Test the Drive Speed Stowed Position Proper drive function movement is 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 Select a test area that is firm level and free of obstructions 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
336. l 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 alarm sounds when the incline of the chassis exceeds 3 to the front or rear How to Install and Calibrate the Level Sensor hazard Failure to install ADANGER or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 1 Perform this procedure with the machine on a firm level surface that is free of obstructions 2 Remove the platform controls from the platform 3 Remove the ground control panel retaining fasteners and open the panel Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS 4 Locate the level sensor behind the ground control panel 5 Disconnect the platform controls from the machine at the platform 6 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 7 Tag and disconnect the platform controls wire harness from the ECM wire harness 8 Securely connect the platform controls to the ECM w
337. ll when they are removed from the machine if not properly supported by the overhead crane 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 13 Attach a lifting strap from an overhead crane to the lifting eye at the rod end of the lift cylinder 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 Crushing hazard The lift cylinder AWARNING could fall when the lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 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 P injury hazard Spraying ydraulic oil can penetra
338. lower lift cylinder Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic 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 REV D 49 Cut the zip ties securing the hydraulic hoses to the lower lift cylinder Lay the hoses out of the way Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 50 Attach a lifting strap from an overhead crane to the lifting eyes at the rod end of the lower lift cylinder for support Do not lift it 51 Raise the lower lift cylinder to a vertical position using the overhead crane 52 Remove the pin retaining fasteners from the lower lift cylinder barrel end pivot pin index 15 53 Use a soft metal drift to remove the lower lift cylinder barrel end pivot pin index 15 54 Carefully remove the lower lift cylinder from the machine Crushing hazard The lower lift AWARNING cylinder could become unbalanced and fall when it is removed from the machine if not properly supported by the overhead crane 55 Remove the cables and hydraulic hoses from the number 2 inner arm index 26 56 Support the cable tray at the hydraulic tank side of the machine with an overhead crane 57 Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 26 on the hydraulic tank side of
339. ly supported by the overhead cranes Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 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 SCISSOR COMPONENTS 3 5 Lift Cylinder s The lift cylinders are double acting hydraulic cylinders The GS 3390 and 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 3390 and GS 4390 AWARNING 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 AWARNING 991 injury haz
340. m an overhead crane to the lifting eyes on the lift cylinder 40 Remove the lift cylinder 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 AWARNING 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 SCISSOR COMPONENTS 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 AWARNING Crushing hazard Keep hands clear of moving parts when lowering the arms onto the blocks 45 Secure the number 1 outer arm index 12 to the slide blocks 46 Remove the strap installed in step 32 47 Support the cable tray with an overhead crane 48 Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 8 49 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 AWARNING Crushing hazard The cable tray may fall if not properly supported by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched CAUTION Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures
341. m centering links located under the platform on both sides of the machine Do not remove the pins 17 Place a rod through the platform centering link pin and twist to remove the pin Rest the platform centering link on the scissor arm 18 Repeat step 17 for the platform centering link pivot pin on the other side of the machine 19 Place a lifting strap from an overhead crane under the platform at the steer end of the machine for support Do not apply any lifting pressure CAUTION Component damage hazard The platform railings can be damaged if used to lift the platform Do not attach the lifting straps to the platform railings REV 20 Place a lifting strap from a second overhead crane under the platform at the non steer end of the machine for support Do not apply any lifting pressure CAUTION Component damage hazard The platform railings can be damaged if used to lift the platform Do not attach the lifting straps to the platform railings 21 Remove the pin retaining fasteners from each platform slider block pivot pin Do not remove the pins 22 Use a slide hammer to remove each platform slider block pivot pin Crushing hazard The platform will AWARNING fall when the platform slider 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
342. m the outrigger cylinder solenoid valve 4 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 REVA 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 6 Remove the outrigger cylinder mounting fasteners Remove the outrigger cylinder from the machine Crushing hazard The outrigger ACAUTION cylinder may become unbalanced and fall if not properly supported when it is removed from the machine If the outrigger cylinder is being replaced remove the shoulder pin from the barrel end of the outrigger cylinder and install it onto the new cylinder 4 118 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes Observe and Obey Troubleshooting 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 repair procedure with the machine in the following configura
343. mage hazard Be CAUTION sure not to cut the platform controls wiring 6 Start the engine from the ground controls 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 10 Tag and disconnect the platform controls from the control cable at the steer end of the machine 11 Remove the platform control box from the platform and lay it off to the side 12 Remove the mounting fasteners that hold the platform controls quick disconnect plug to the platform 13 Lay the platform controls wiring off to the side Component damage hazard The CAUTION platform controls wiring can be damaged if it is kinked or pinched 14 Remove the AC power to platform outlet bracket mounting fasteners Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 15 Section 4 Repair Procedures December 2004 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 CAUTION AC power to platform wiring can be damaged if it is kinked or pinched If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 16 Remove the pin retaining fasteners from the platfor
344. mbly GS 5390 How to Disassemble the Scissor Assembly GS 5390 AWARNING P09 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 required When removing a hose assembly or fitting the O ring on the fitting and or hose must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Before serial number 41073 1 Remove the platform See 2 1 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 CAUTION 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 SCISSOR COMPONENTS 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 appl
345. models after serial number 40819 The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute The level sensor must be calibrated Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute The level sensor must be calibrated If you are not installing a new level sensor proceed to step 18 10 Push in the red Emergency Stop button to the off position at the platform controls 11 Remove the ground control panel retaining fasteners and open the panel 12 Locate the level sensor behind the ground control panel 13 Tag and disconnect the wire harness from the level sensor 14 Remove the level sensor retaining fasteners Remove the level sensor from the machine Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 15 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 the level sensor retaining fasteners Tip over hazard The tilt level sensor must be installed with the 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 MODELS WITHOUT OUTRIGGERS 4
346. n 309 7 cm Hydraulic system 35 gallons including tank 132 5 liters Tire diameter 33 in 83 8 cm Fuel tank 1 Tire width 16 in 41 Tire and wheels Wheel diameter 19 5 in Wheel lugs 9 5 8 18 49 5 cm Lug nut torque dry 125 ftlbs Wheel width 14 in 169 5 Nm 35 6 cm Lug nut torque lubricated 94 ft lbs Weight 419 Ibs 10 165 Rough Terrain foam filled High Flotation air filled Tire size LSW 305 546 NHS size 393 161900 Tire ply rating 10 Tire ply rating 10 Tire contact area 48 sq in Tire contact area 36 in 309 7 cm 232 3 cm Tire diameter 33 in Tire diameter 33 in 83 8 cm 83 8 cm Tire width 16 in Tire width 12 41 30 em Wheel diameter 19 5 in Wheel diameter 21 5in 49 5 55 Wheel width 14 in Wheel width 10 in disi 25 4 cm Weight 157 lbs 71 2 kg Weight 257 lbs 10 1 5 116 6 kg 4 5 Pressure 38 psi 2 6 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 72863 Genie GS 3390 GS 4390 and GS 5390 2 1 Section 2 Specifications December 2004 SPECIFICATIONS Performance Specifications Drive speed maximum Platform stowed 5 mph 40 ft 5 5 sec 8 km h 12 2 5 5 sec Platform raised 0 7 mph 40 ft 39 sec 1 13 km h 12 2 m 39 sec Gradeability GS 3390 and GS 4390 50 GS 5390 40 Function speed maximum from platform controls with 1 person in platform
347. n the machine reference point passes over the finish line Refer to Section 2 Specifications Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D B 17 Perform Hydraulic Oil Analysis 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 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 See E 1 Test or Replace the Hydraulic Oil CHECKLIST B PROCEDURES B 18 Replace the Medium and High Pressure Hydraulic Filter Elements Replacing the medium pressure hydraulic filter element is essential to good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Perform this procedure
348. nd 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 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 REV D 33 Raise the machine slightly 34 Remove the blocks from under both wheels 35 Lower the machine and remove the jack 36 Center a lifting jack under the drive chassis at the tank side of the machine 37 Raise the machine approximately 6 inches 15 cm 38 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 39 Lower the machine onto the blocks 40 Raise the platform approximately 16 feet 5 m O 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 For reference only the output of the level sensor should be approximately 3 3V DC To confirm connect the positive lead o
349. nd controls and raise the platform approximately 18 feet 5 5 m from the ground 6 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 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 8 Inspect the center chassis area and scissor arms for burnt chafed and pinched cables 9 Inspect the following areas for burnt chafed corroded pinched and loose wires Scissor arms ECM to platform controls Power to platform wiring 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D B 3 Perform Engine Maintenance Deutz 1011F Models Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional engine
350. nd 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 Insert a 6 inch 15 cm screwdriver 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 increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and repeat step 2 Deutz models with throttle linkage low idle adjustment screw low idle lock nut yoke yoke lock nut high idle adjustment lock nuts solenoid boot Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST B PROCEDURES REV D ori JP 8 Release the latches on the engine tray and fully slide the engine tray out 9 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 10 Models with throttle cable Loosen the lock nut on the high idle solenoid Turn the adjustment nut clockwise to increase the rpm or counter clockwise to decrease the rpm Tighten the loc
351. ndow The ECM is now in programming mode O a diagnostic display b blue platform up button lift function enable button d yellow platform down button 5 Pressthe lift function enable button 6 Use the yellow platform down arrow to scroll to raised drive speed Result MAX RAISED DRIVE SPEED is showing in the diagnostic display window 7 Pressthe lift function enable button 8 Press the yellow platform down button to decrease the raised drive speed or press the blue platform up button to increase the raised drive speed Refer to Section 2 Specifications The performance achieved should always be within specifications 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground controls 11 Check the raised drive speed of the machine Refer to the Maintenance procedure B 16 Test the Drive Speed Raised Position Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D Models with software revision or higher 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 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 co
352. ne tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving 3 Remove the hose clamp from the air cleaner hose that connects to the throttle body 4 Disconnect the valve cover vent hose from the air cleaner Engines 5 Remove the air filter mounting fasteners Remove the air filter from the engine and lay it off to the side 6 Close the shutoff valve on the Liquid Petroleum Gas LPG tank by turning it clockwise if equipped 7 Remove the LPG supply hose from the LPG solenoid TaT Explosion and fire hazard Engine A DANGER fuels are combustible Replace the fuel hoses in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard Liquid A DANGER Petroleum Gas LPG is kept at a very high pressure Fuel may be expelled under pressure if the hose is removed too quickly Loosen the LPG supply hose very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around LPG supply hose to absorb leaking fuel before disconnecting them Bodily injury hazard Beware of ACAUTION Liquid Petroleum Gas LPG Contact with LPG may cause severe burns 8 Remove the ground wire for the LPG solenoid from the ECM mounting fastener 9 Remove the engine ECM mounting bracket fasteners Remove the engine ECM from the engine slide out tray and carefully la
353. ner intake hose is inserted in the hole in the front of the engine slide out tray 3 8 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV C CHECKLIST A PROCEDURES A 6 A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Perform the following maintenance procedures Ford models 7 Inspect the Tires and Wheels including lug nut torque B 20 Perform Engine Maintenance Ford Models D 6 Replace the Hydraulic Tank Return Filter Deutz models Perform Engine Maintenance Deutz Models Engine specifications require that this one time procedure be performed after 50 hours of operation Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0297 9929 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 84794 7 Inspect the Tires and Wheels including lug nut torque C2 Perform Engine Maintenance Deutz Models 0 4 Replace the Fuel Filter Water Separator Deutz Models D 6 Replace the Hydraulic Tank Return Filter Part No 72863 Gen
354. ng a series of steps Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 1 Section 3 Scheduled Maintenance Procedures December 2004 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend 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 a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service will be required to perform this procedure E EE Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to pe
355. ns 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 Controller Adjustments after serial number GS9003 41522 All machine function speeds are determined by the percentage of total ECM voltage output The speeds of the following machine functions may be adjusted to compensate for wear in the hydraulic pump and drive motors Stowed drive speed High torque drive speed Raised drive speed Platform lift speed Platform lower speed Steer speed Platform settling speed For further information or assistance consult the Genie Industries Service Department An Tip over hazard Do not adjust the ADANGER 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 TJ hazard This procedure ADANGER must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Select a test area that is firm level and free of obstructions How to Determine the Revision Level 1 Turn the key switch to gro
356. ntenance Procedures REV D B 1 Checklist B Procedures Inspect the Battery Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the battery For a more accurate determination of battery condition fully charge the battery and allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Put on protective clothing and eye wear 2 Besure that the battery cable connections are free of corrosion Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight Models without maintenance free or sealed batteries 4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer O Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced 5
357. ntrol 17 Fully raise the platform Release the joystick Result The platform should stop raising at maximum height The engine should continue to run and an alarm should not sound 18 Lower the platform to the stowed position 19 Disconnect the platform controls from the ECM wire harness 20 Securely connect the platform controls wire harness to the ECM wire harness 21 Securely connect the platform controls to the platform controls wire harness at the platform Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV 2 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0297 9929 CHECKLIST PROCEDURES C 3 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Deutz 1011F Operation Manual Genie part number 84792 Genie pa
358. ntrols Result TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to max fwd high torque drive Result FWD RAISED DRIVE SPEED 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 Section 2 Specifications 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 GROUND CONTROLS G a diagnostic display b blue platform up button c lift function enable button d 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 REV RAISED DRIVE sPEED is showing in the diagnostic display window 12 Press the lift function enable button 13 Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed Refer to Section 2 Specifications The performance achieved should always be within specifications 14 Press the lift function enable but
359. o 5 5 4 5 amp 5 85 I d I d 2 2 o 0 0 D 2 ic m 2 2 Q m gt zz a m gt 5 d 65 2 4 2 2 3 m 2 2 2 8 6 c 2 2 5 5 6 2 zm D o o 5 5 2 o m 4 2 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163C 1 1 WH ER 2 2 BL DATALINK HIGH I 5 5 OR DATA LINK LOW J5 PIN2 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 VOLTAGE REGULATOR J2 PIN1 YL J2 PIN2 7 ERATOR JC1 J2 PIN12 WH JOYSTICK m CONTROLLER J2 PIN13 J2 PIN3 42 SW5 SW6 EX BINS OR FUNCTION ENABLE 7 Fl 2 STEER BK J 2 LEFT RIGHT J2 PING 42 PIN7 45 42 PINS J2 PIN14 1 PIN2 HORN BN5 PIN3 STARTING AID BN3 PIN4 ENGINE START BN2 HIGH TORQUE BN6 GENERATOR BN7 LPG SELECT BN14 HIGH IDLE LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 LR OUTRIGGER ENABLE BN87 RR OUTRIGGER ENABLE BN24 LIFT FUNCTION BN9 PIN14 ORGR AUTOLE
360. o 72863 December 2004 Section 4 Repair Procedures REV C 2 1 Platform How to Remove the Platform AWARNING 20 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 required Perform this procedure with the platform in the stowed position and the platform extension deck s fully retracted and locked in position 1 Startthe engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 2 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Be sure that the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Platform Components Cut the zip ties that secure the power to platform wiring to the bottom of the platform Component damage hazard Be CAUTION sure not to cut the power to platform wiring 5 Outthe zip ties that secure the platform controls wiring to the bottom of the platform Component da
361. o fuel pump OR replace the fuel pump 32 Heated Oxygen HO2 sensor low voltage Water in the fuel misfiring cylinder plugged fuel filter OR the HO2 sensor wiring is shorted to ground OR there is a poor terminal connection OR the HO2 sensor is bad Check for water in the fuel misfiring cylinder or plugged fuel filter OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor 33 Engine Coolant Temperature ECT sensor high voltage Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is bad Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor 35 Intake Air Temperature IAT sensor high voltage IAT sensor signal is greater than or equal to 4 93V DC for at least 3 seconds Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor 41 Fuel pump high voltage Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON Test the fuel pump relay see the Repair Section OR check for poor terminal connections from the fuel pump relay to fuel pump OR replace the ECM 42 Heated Oxygen HO2 sensor high voltage A leaking or malfunctioning fuel injector misfiring cylinder faulty TP sensor or
362. od condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage 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 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 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 Install the new filter element 8 Install the air filter canister end cap and the end cap retaining ring REV D Deutz models 1 Release the latches on the engine tray and fully slide the engine tray out 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 Remove the air intake hose from the engine slide out tray Disconnect the retaining clamp from the air cleaner canister Remove the filter element Clean the inside of the canister and the gasket with a damp cloth Install the new filter element Install the air filter canister end cap and connect the end cap retaining clamp
363. ols and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed 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 Repair Procedures About This Section Most of the procedures in this section should only be performed by a 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 To re assemble perform the disassembly steps in reverse order 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 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With
364. omponent damage hazard CAUTION Cables can be damaged if they are kinked or pinched 11 Secure both ends of the number 3 inner and outer arms index 2 and 11 together with a strap or other suitable device 12 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 13 Attach a lifting strap from an overhead crane 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 14 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 15 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 16 Use a slide hammer to remove both number 3 pivot pins index 4 from the non steer end of the machine REV D 17 Use a slide hammer to remove both number 3 pivot pins index 13 from the steer end of the machine 18 Carefully remove the number 3 inner and outer arms index 2 and 11 from the machine 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 19 S
365. on enable button yellow platform down button 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS 5 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 6 Press the lift function enable button Result DESCENT DELAY ON is showing in the diagnostic display window Result DESCENT DELAY orr is showing in the diagnostic display window Press the lift function enable button to activate the descent delay option For CE models the descent delay option should be activated or in the position 7 Usethe yellow platform down arrow to scroll to lift drive cutout Result CUTOUT is showing in the diagnostic display window Wi Result cutout orr is showing in the diagnostic display window Press the lift function enable button to activate the lift drive cutout option The lift drive cutout option should be activated or in the position 8 Use the yellow platform down arrow to scroll to motion alarm Result MOTION ALARM is showing in the diagnostic display window REV D 9 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 beacons O Result vorioN BEACONS is showing in t
366. on manifold Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 way DA 25 ft lbs 34 Nm 2 Relief valve 3500 psi 241 3 bar DB System relief esses 20 ft lbs 27 Nm 3 Relief valve 900 psi 62 bar Float circuit 20 ft lbs 27 Nm 4 Priority flow regulator 1 gpm 3 8 L MIN DD Oscillate 25 ft los 34 Nm 5 Solenoid valve 2 position way DE Right oscillate circuit 20 ft lbs 27 Nm 6 Solenoid valve 2 position way Left oscillate 20 ft lbs 27 Nm Solenoid valve 2 position 2 way DG Oscillate 25 ft lbs 34 Nm 4 100 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E MANIFOLDS o Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 101 Section 4 Repair Procedures December 2004 MANIFOLDS 7 8 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the platform in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to th
367. on to the off position at the ground controls 33 Turn the key switch to ground control 34 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 euo diagnostic display blue platform up button lift function enable button yellow platform down button 35 Use the yellow platform down arrow to scroll to SELECT OPTIONS Result seLEcr OPTIONS is showing in the diagnostic display window The ECM is now in programming mode 36 Press the lift function enable button Result DESCENT DELAY ON is showing in the diagnostic display window 37 Press the lift function enable button to deactivate the descent delay option Result DESCENT DELAY OFF is Showing in the diagnostic display window 38 Push in the red Emergency Stop button to the off position at the ground controls 39 Pull out the red Emergency Stop button to the on position at the ground controls For more information on programming refer to Section 4 Repair CHECKLIST D PROCEDURES Calibrate the load sense delay limit switch 40 Turn the key switch to platform control Start the engine 41 Lower the platform until the load sense delay limit switch activates and the platform stops lowering Release the joystick
368. onnections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 612 Invalid Interrupt Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Loose wire connections to ECM OR ECM is Locate and repair any engine harness wiring 61 3 A D Loss damage shorts to ECM to be sure they are secure OR replace ECM Locate and repair any engine harness wiring 614 RTI 1 Loss Wits connections EGM ig damage or shorts to ECM to be sure they aulty are secure OR replace ECM 615 Flash Checksum Invalid Loose wire connections to OR is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 616 RAM Failure Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 631 External 5V DC Ref Lower than Expected Engine harness wiring and or connections open or shorted to ground OR there is a engine sensor OR is faulty Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM 632 External 5V
369. or OR sensor wires shorted to ground or poor terminal connection Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor 14 Manifold Absolute Pressure MAP sensor low voltage Faulty MAP sensor OR sensor wires shorted to ground or poor terminal connection Check for poor terminal connections OR wires shorted to ground OR replace MAP sensor 21 Engine speed exceeded 4000 RPM Obstruction in throttle body OR faulty ECM Check for obstructions in the throttle body that could cause binding of the throttle assembly OR replace ECM 22 Throttle Position TP sensor high voltage The ECM senses a signal from the TP sensor that is greater than 4 9V DC OR the TP sensor wiring is shorted to ground OR there is a poor terminal connection OR the TP sensor is bad Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor 24 Manifold Absolute Pressure MAP sensor high voltage Faulty MAP sensor OR sensor wires shorted to ground or poor terminal connection Check for poor terminal connections or shorted wires from the MAP sensor to the ECM to ground OR replace MAP sensor 31 Fuel pump low voltage Voltage to fuel pump is greater than or equal to 2V DC below ignition voltage Test the fuel pump relay see the Repair Section OR check for poor terminal connection from the fuel pump relay t
370. ound at 180 beeps per minute Result ANSI and CSA models after serial number 40819 The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute O Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result The tilt sensor alarm does not sound Turn the level sensor adjusting nuts just until the level sensor alarm begins to sound 30 Lower the platform to the stowed position 31 Raise the machine slightly 32 Remove the blocks from under both wheels 33 Lower the machine and remove the jack 34 Remove the blocks from the wheels at the steer end of the machine 35 Center a lifting jack under the drive chassis at the ground controls side of the machine 36 Raise the machine approximately 4 inches 10 cm 37 Models with RT tires Place a 2 59 x 10 x 10 inch 6 58 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 2 72 x 10 x 10 inch 6 91 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine REV D 38 Lower the machine onto the blocks 39 Raise the platform approximately 16 feet 5 m Result The tilt sensor alarm should not sound Result ANSI and CSA models before serial number 40820 The tilt alarm will sound at 180 beeps per minute T
371. p OUTRIGGER UP DOWN TS21 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 6 Schematics pe T REV This page intentionally left blank Part No 72863 Genie GS 3390 GS 4390 and GS 5390 6 29 Section 6 Schematics December 2004 Electrical Schematic Ford Models from serial number 40996 to 41065 REV A Part 1 of 3 meum ee IKS1 key switcn 1 EMERGENCY STOP PLATFORM CONTROL 1 B GROUND Pr LL 2 20 CR41 CR58 contro CR42 CR5 CR8 ENGINE DRIVE SYSTEM POWER HORN IGNITION START FWD REV 4 86 a se 304 86 CUN 86 gt i 86 an 85 87 85 e aA D Sf 85 et 859 87 85 af 87 a c c SR Fh a A 194 5 ELECTRONIC CONTROL MODULE ase Dl 3 1 c LINK R6 z E 9 5102 S 5 S B 51 TS69 lt JS AUXILIARY FUNCTION ENABLE TS70 AUXILIARY H2 5 PLATFORM DOWN Y4 H5 D i
372. p 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 49 Remove the pin retaining fasteners from both chassis centering link pivot pins index 18 at the number 1 inner arm REV D 50 Place a rod through each chassis centering link pivot pin and twist to remove the pin Rest the centering links on the chassis 51 Remove the pin retaining fasteners from the number 1 inner arm slide blocks index 19 at the steer end of the machine 52 Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 19 53 Use a 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D How to Disassemble a Scissor Arm Pair AWARNING 0 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure w
373. pecifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook CHECKLIST A PROCEDURES 4 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0297 9929 Genie part number 84792 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 84794 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 7 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST A PROCEDURES A 5 Inspect the Engine Air Filter Genie specifications require that this procedure be performed every 40 hours or weekly whichever comes first 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 Perform this procedure with the engine off Ford models 1 Release the latches on the engine tray and fully slide the
374. 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 controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 67 Section 4 Repair Procedures December 2004 GROUND CONTROLS 5 3 Software Configuration after serial number GS9003 41522 How to Configure the Software The Electronic Control Module ECM contains programming for all configurations of the GS 90 Models after serial number GS9003 41522 can be adjusted to a different configuration using the buttons at the ground controls ANSI and CSA models 1 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 3 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 3 51252 J a diagnostic display b blue platform up button c lift function enable button d yellow platform down button REV D 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
375. r X indicator Y indicator REV 9 Connect the wire harness to the level sensor 10 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 11 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Be sure there are threads showing through the top of the adjusting fasteners Result The tilt sensor alarm should not sound 12 Center a lifting jack under the drive chassis at the ground controls side of the machine 13 Raise the machine approximately 4 inches 10 cm 14 Models with RT tires Place a 2 59 x 10 x 10 inch 6 58 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 2 72 x 10 x 10 inch 6 91 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 15 Lower the machine onto the blocks 16 Raise the platform approximately 16 feet 5 m O Result The tilt sensor alarm should not sound Result The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Turn the level sensor adjusting nuts just until the level sensor alarm does not sound Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 17 Lower the platform
376. r could become unbalanced and fall when it is removed from the machine if not properly supported by the overhead crane 30 Carefully lift the number 1 outer arm index 16 approximately 2 inches 5 cm and remove the block 31 Lower the number 1 outer arm index 16 onto the slide blocks Crushing hazard Keep hands AWARNING clear of moving parts when lowering the arms onto the blocks 32 Secure the number 1 outer arm index 16 to the slide blocks 33 Remove the strap installed in step 19 34 Support the cable tray with an overhead crane SCISSOR COMPONENTS 35 Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 6 36 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray onto the number 1 inner arm index 8 AWARNING Crushing hazard The cable tray may fall if not properly supported by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched CAUTION 37 Secure both ends of the number 2 inner and outer arms index 5 and 6 together with a strap or other suitable device 38 Attach a lifting strap from an overhead crane to the number 2 inner and outer arms index 5 and 6 at the steer end of the machine Do not apply any lifting pressure 39 Attach lifting strap from an overhead crane to the number 2 inner and outer arms index 5 and 6 at the non
377. r and outer arms index 20 and 5 at the steer end of the machine Do not apply any lifting pressure 18 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 19 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 20 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 21 Use a slide hammer to remove both number 4 pivot pins index 7 from the non steer end of the machine 22 Use a slide hammer to remove both number 4 pivot pins index 422 from the steer end of the machine 23 Support the rod end of the upper lift cylinder with a suitable lifting device Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 24 Carefully remove the number 4 inner and outer arms index 20 and 5 from the machine while guiding the rod end of the upper lift cylinder out 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 o
378. rane SCISSOR COMPONENTS 38 Remove the pin retaining fasteners from the cable tray pivot pin at the cross tube of the number 2 inner arm index 8 39 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 Crushing hazard The cable tray ACAUTION may fall if not properly supported by the overhead crane Component damage hazard Cables can be damaged if they are kinked or pinched CAUTION 40 Secure both ends of the number 2 inner and outer arms index 8 and 20 together with a strap or other suitable device 41 Attach a lifting strap from an overhead crane to the number 2 inner and outer arms index 8 and 20 at the steer end of the machine Do not apply any lifting pressure 42 Attach a 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 43 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 44 Remove the pin retaining fasteners from both number 2 pivot pins index 21 at the steer end of the machine Do not remove the pins Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 45 Use a slide hammer to remove both number 2 pivot pins index 9 from the non st
379. 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 Section 2 Specifications REV D B 16 Test the Drive Speed Raised Position Proper drive function movement is 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 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 apart 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 a function enable speed select button Raise the platform approximately 12 feet 3 6 m from the ground 5 Choose 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 Press and hold the function enable switch and slowly move the control handle to the full drive position 7 Bring the 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 whe
380. rform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours Semi annually every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 3 2 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 Pre Delivery Preparation 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 Genie Industries USA 18340 NE 76th Street PO Box 97030 Genie UK The Maltings Wharf Road Grant
381. rica Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 3493 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 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 Service Manual GS 3390 amp GS 4390 amp GS 5390 Part No 72863 Rev
382. ring this procedure REVC E 2 Perform Engine Maintenance Deutz 1011F Models Engine specifications require that this procedure be performed every 2000 hours or two years whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 Deutz 1011F Operation Manual Genie part number 52883 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV C E 3 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 2400 hours or every two years whichever comes first Required maintenance procedures and additional engine information is available in the Ford LRG425 Operator Handbook Ford part number FPP 194 302 Ford LRG 425 Operator Handbook Genie part number 84792 CHECKLIST E PROCEDURES E 4 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 3000 hours or two years whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0297 9929 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 84
383. rom the ground controls 15 Inspect the filter assembly to be sure that there are no leaks 16 Clean up any oil that may have spilled during the installation procedure REV D B 19 Inspect the Fuel Tank Cap Venting System Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist A free breathing fuel tank cap is essential for good engine performance and service life A dirty or clogged fuel tank cap may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap be inspected more often 777771171 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 Perform this procedure with the engine off 1 Remove the cap from the fuel tank 2 Check for proper venting When checking for positive fuel tank cap venting air should pass freely through the cap Result Air should pass through the fuel tank cap Clean or replace the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air 4 Repeat step 2 Install the fuel tank cap onto the fuel tank Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004
384. roperly COP failure Under normal operation the ECM will store numbers into memory If this does not happen it will reset itself and set fault code 56 Replace the ECM 61 System voltage low Battery supply voltage to the is 8V DC or less Check battery and or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM 62 System voltage high Battery supply voltage to the ECM is 18V DC or more Check battery and or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 5 Fault Codes December 2004 Ford Engine ECM Fault Code Chart after serial number GS9003 41368 REVA Code Problem Cause Solution 111 Closed Loop Multiplier High LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks Repair wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks Heated Oxygen Sensor wiring and or HO2S Open Inactive Repair wiring and or connections OR 1 1 2 Bank 1 open or shorted OR sensor is replace sensor Heated Oxygen Sensor wiring and or EET HO2S Open Inactive Repair wiring and or connections OR 113 S Bank 2 connections open or shorted OR sensor is faul
385. round control 1 4 Solid toggle switch closed at start up function enable switch Troubleshoot function enable switch Starting aid button fault at Faulty switch circuit board in Replace switch circuit board in 20 Flash platform controls platform control box platform control box 21 Flash Engine start button fault at Faulty switch circuit board in Replace switch circuit board in as platform controls platform control box platform control box 22 Flash Left turn switch fault functioning steer left Troubleshoot steer left microswitch microswitch Malfunctioning steer right 23 Flash Right turn switch fault microswitch Troubleshoot steer right microswitch 26 Flash Platform up down switch fault ctioning platform up down Troubleshoot platform up down switch 27 Solid Platform lift high speed enable Malfunctioning high speed enable Troubleshoot platform high speed on fault Switch enable switch OR replace switch 28 Solid Platform lift low speed enable Malfunctioning low speed enable Troubleshoot platform low speed fault Switch enable switch OR replace switch 29 Solid Platform drive enable switch Malfunctioning platform drive Troubleshoot platform drive enable e fault enable switch switch OR replace switch Joystick not centered on start Joystick potentiometer not 30 Solid up centered Verify potentiometer setting 40 Flash Right tum coil fault Ma functioning coi OR wire Troub eshoot coil OR
386. rs 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 REV D E GS 3384 NS K GS 3390 GS 4390 GS 5390 Limit switch legend a load sense delay limit switch b down limit switch c maximum height limit switch d maximum height limit switch cam 27 Install and adjust the maximum height limit Switch 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 W 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D Disable the descent delay function 32 Push in the red Emergency Stop butt
387. rt number 52883 Deutz 2011 Operation Manual Genie part number 84794 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 3 29 Section 3 Scheduled Maintenance Procedures December 2004 Checklist D Procedures D 1 Check the Scissor Arm Wear Pads Maintaining the scissor arm wear pads in good condition is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions 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 W 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 O Result The measurement is 5 16 inch 8 mm or more Proceed to step 3 W Result The measurement is less than 5 16 inch 8 mm Replace both wear pads REV D 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 6 inch 8 mm Replace both 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
388. rtment If this fault appears on your machine 521 FPP2 High Voltage Not used contact Genie Industries Service Department If this fault appears on your machine 522 FPP2 Low Voltage Not used contact Genie Industries Service Department The 1 throttle position sensor wiring and or Be sure system ground connections are in 533 High 531 TPS1 Signal Voltage connections open or shorted OR there is a place and secure OR repair wiring and or High poor system ground connection OR throttle connections to sensor OR replace throttle position sensor 1 is faulty position sensor 1 The 1 throttle position sensor wiring and or Be sure system ground connections are in 532 TPS1 Signal Voltage connections open or shorted OR there is a place and secure OR repair wiring and or Low poor system ground connection OR throttle connections to sensor OR replace throttle position sensor 1 is faulty position sensor 1 The 2 throttle position sensor wiring and or Be sure system ground connections are in TPS2 Signal Voltage connections open or shorted OR there is a place and secure OR repair wiring and or poor system ground connection OR throttle position sensor 2 is faulty o onnections to sensor OR replace throttle osition sensor 2 o TPS2 Signal Voltage Low 534 The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position
389. ry slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Cut the zip ties attaching the hydraulic hoses to the lift cylinder Lay the hoses out of the way Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 6 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 REV D 7 Attach a lifting strap from a second overhead crane or similar lifting device to the lifting eye at the barrel end of the lift cylinder for support Remove the lift cylinder rod end pivot pin retaining fastener Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if it is not properly supported 9 Carefully lower the cylinder onto the cross tube of the number 2 inner arm Protect the cylinder rod from damage Component damage hazard The CAUTION counterbalance valve on the lift cylinder can be damaged if it is allowed to come in contact with the scissor arm cross tube 10 Remove the lift cylinder barrel end pivot pin retaining fastener Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if it is not properly supported 11 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 AWARNING Crus
390. s REV D 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 Crushing hazard The number 5 AWARNING inner and outer arms could become unbalanced and fall when they are removed from the machine if not properly supported by the overhead crane 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 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 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 Crushing hazard The upper lift AWARNING cylinder could fall when the upper lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 15 Remove the cables from the number 4 inner arm index 20 and lay the cables off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched SCISSOR COMPONENTS 16 Secure both ends of the number 4 inner and outer arms index 20 and 5 together with a strap or other suitable device 17 Attach a lifting strap from an overhead crane to the number 4 inne
391. s Do not remove them 4 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis will fall if it is 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 ACAUTION C vshino hazard The drive hub may become unbalanced and fall if itis not properly supported and secured to the lifting jack Torque specifications Drive hub mounting bolts dry 120 ft lbs 163 Nm Drive hub mounting bolts lubricated 90 ft lbs 122 Nm Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 117 Section 4 Repair Procedures December 2004 Outrigger Components 11 1 Outrigger Cylinder How to Remove an Outrigger Cylinder if equipped Perform this procedure with the platform in the stowed position and the outriggers fully retracted When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the outrigger footpad 2 Remove the mounting fasteners from the outrigger cover Remove the cover 3 Tag and disconnect the wiring fro
392. safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information 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 72863 Genie GS 3390 GS 4390 and GS 5390 4 1 Section 4 Repair Procedures December 2004 Platform Controls REV D The joystick controller is controlled by an ECM Electronic Control Module located behind the ground control panel The ECM aids in troubleshooting by recognizing machine malfunctions and displaying fault codes LED display window at the ground controls See the Troubleshooting section of this manual for a list of fault codes and additional information The ECM is not user serviceable The joystick controller is calibrated at the factory and does not need to be adjusted For further information or assistance consult the Genie Industries Service Department
393. select options Result seLEcr options is showing in the diagnostic display window The ECM is now in programming mode 53 Press the lift function enable button Result DESCENT DELAY OFF is showing in the diagnostic display window 54 Press the lift function enable button to activate the descent delay option Result DESCENT DELAY ON is showing in the diagnostic display window 55 Push in the red Emergency Stop button to the off position at the ground controls 56 Pull out the red Emergency Stop button to the on position at the ground controls REV D Calibrate the down limit switch 57 Turn the key switch to platform control Start the engine 58 Raise the platform approximately 1 59 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 six seconds Release the joystick and proceed to step 67 Result The platform stops and then will immediately begin to lower again The down limit switch needs to be calibrated Proceed to step 60 60 Raise the platform to approximately 6 m 61 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 62 Loosen the fasteners securing the down limit Switch cam just enough to allow movement of the cam 63 Working from th
394. sensor 2 is faulty 00 sure system ground connections place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 535 TPS1 Higher than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors Continued on next page 28 Part 72863 Genie GS 3390 GS 4390 065 5390 5 13 Section 5 Fault Codes SS 2 FORD ENGINE ECM FAULT CODE CHART AFTER SERIAL NUMBER GS9003 41368 December 2004 REVA Code Problem Cause Solution 536 TPS1 Lower than TPS2 The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors 537 Throttle Unable to Open Governor actuator is stuck closed OR wiring and or connections open or shorted OR governor actuator is
395. sor connect the negative lead of the multimeter to the black wire at the level sensor 16 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the yellow wire at the level sensor 17 Adjust the side to side axis of the level sensor until the multimeter reads 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut Be sure there are threads showing through the top of each adjusting nut 18 Disconnect the positive lead of the multimeter from the level sensor wire harness GROUND CONTROLS Adjust the front to back axis 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 20 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 fingers after each turn of an adjusting nut Be sure there are threads showing through the top of each adjusting nut 21 Disconnect the positive and negative leads 22 Apply Sentry Seal to the adjusting nuts 23 Push in the red Emergency Stop button to the off position at the platform controls 24 Before serial number 41523 Press and hold the outrigger enable button and press and hold the auto level button and pull out the red Emergency Stop button to the on position at the platform controls After serial number 41522 Press and
396. ssor 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 SCISSOR COMPONENTS 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 75 Place a rod through each chassis centering link pivot 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 a 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
397. stallation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 2 Specifications REV D Drive pump SPECIFICATIONS Function manifold Type Bi directional variable displacement piston pump Flow rate 2500 rpm 0 to 30 gpm before serial number GS9004 41619 0 113 6 L min Flow rate 2500 rpm 0 to 32 5 gpm after serial number GS9004 41618 0 to 123 L min Drive pressure maximum 3500 psi before serial number GS9004 41619 241 bar Drive pressure maximum 3750 psi after serial number GS9004 41618 258 6 bar Charge pump Type Gerotor Flow rate 2500 rpm 6 5 gpm before serial number GS9004 41619 24 6 L min Flow rate 2500 rpm 9 1 gpm after serial number GS9004 41618 34 4 L min Charge pump pressure 360 psi before serial number GS9004 41619 24 8 bar Charge pump pressure 325 psi after serial number GS9004 41618 22 4 bar Function pump Type Gear Displacement 1 025 cu in before serial number GS9004 41619 16 8 cc Displacement 0 98 cu in after serial number GS9004 41618 16 cc Flow rate 2500 rpm 10 8 gpm before serial number GS9004 41619 40 9 L min Flow rate 2500 rpm 10 6 gpm after serial number GS9004 41618 40 1 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return line filter Continuous improvem
398. steer end of the machine Do not apply any lifting pressure 40 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 pin retaining fasteners from both number 1 pivot pins index 19 at the steer end of the machine Do not remove the pins 42 Use a slide hammer to remove both number 1 pivot pins index 10 from the non steer end of the machine Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 43 Use a slide hammer to remove both number 2 pivot pins index 15 from the steer end of the machine 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 45 Remove the cables from the number 1 inner arm index 8 46 Secure both ends of the number 1 inner and outer arms index 8 and 16 together with a strap or other suitable device 47 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 48 Attach a lifting stra
399. symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death J Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation Be aware of potential crushing hazards such as moving parts free swinging or warrants it 3l s unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W 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
400. t TUNE SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Press the lift function enable button 6 Use the yellow platform down arrow to scroll to max fwd high torque drive Result FWD HIGH TORQUE DRIVE is showing in the diagnostic display window 7 Pressthe 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 Section 2 Specifications 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 GROUND CONTROLS diagnostic display blue platform up button lift function enable button yellow platform down button oo 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 Section 2 Specifications The performance achieved should always be within specifications 14 Press the lift function enable button 15 Push in the red Emergency
401. t clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat steps 2 through 3 to confirm the relief valve pressure 4 102 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REVE MANIFOLDS 7 9 Valve Adjustments Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to either test port item BG or EC on the drive manifold 2 Start 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 Section 2 Specifications Component damage hazard CAUTION 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 4 Turn the engine off Use a wrench to hold the charge pressure relief valve and remove the cap item BH or EE 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap 6 Repeat steps 2 through 3 to confirm the relief valve pressure Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 103 Section 4
402. t coil OR wiring FAULT E 2 Red Drive 2 fault 2 drive function will not Troubleshoot OR wiring FAULT T UN Red Drive coil 3 1 fault 4 drive function will not Troubleshoot OR wiring FAULT F N Red Proportional coil Y9 fault Troubleshoot coil OR wiring FAULT Na mm Red Up coil Y8 fault Platform will not raise Troubleshoot coil OR wiring E LM Red Down coil Y7 fault Platform will not lower Troubleshoot coil OR wiring FAULT RIGHT COIL Red Right turn coil fault Machine will not turn right Troubleshoot coil OR wiring FAULT LEFT COIL Red Left turn coil Y4 fault Machine will not turn left Troubleshoot coil OR wiring FAULT BR 28 COIL Red Brake release coil Y2 fault Brakes will not release Troubleshoot coil OR wiring FAULT aa Hed Forward 1 coil Y6 fault 2 or not Troubleshoot coil OR wiring FAULT icoi Reverse 1 coil Y5 fault 2277 Troubleshoot OR wiring FAULT 2 Forward 2 coil Y6A fault Troubleshoot OR wiring FAULT meee Red Reverse 2 coil fault ee Troubleshoot coil OR wiring FAULT Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 5 Fault Codes _ 2
403. t lbs 122 Nm 16 210 ft lbs 284 7 Nm 16 120 ft lbs 162 7 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Part No 72863 Genie GS 3390 GS 4390 and GS 5390 2 9 Section 2 Specifications December 2004 9 This page intentionally left blank 2 10 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey 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 on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Platform in th
404. t 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 W Result The engine will not start and an alarm is sounding Repeat this procedure beginning with step 17 The red Emergency Stop button must be cycled after each quarter turn of the nut to allow the platform overload system to reset Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset 20 Return the safety arm to the stowed position Lower the platform to the stowed position After returning the safety arm to the stowed position use the auxiliary down function to lower the platform Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 3 Scheduled Maintenance Procedures December 2004 CHECKLIST D PROCEDURES 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 weight to the platform Refer to the chart below GS 3390 1135 kg GS 4390 680 kg most models refer to capacity indicator decal GS 4390 816 kg some models refer to capacity indicator decal GS 5390 680 kg 22 Raise the platform to approximately 6 m 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 fastene
405. t the non steer end of the machine Do not remove the pins 40 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 41 Use a slide hammer to remove both number 3 pivot pins index 10 from the non steer end of the machine 42 Use a slide hammer to remove both number 3 pivot pins index 25 from the steer end of the machine Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 43 Carefully remove the number 3 inner and outer arms index 8 and 23 and upper lift cylinder 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 44 Block the steer end wheels and center a lifting jack of ample capacity under the non steer end of the drive chassis 45 Loosen the wheel lug nuts on one of the non steer wheels Do not remove them 46 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 47 Remove the wheel lug nuts Remove the tire and wheel assembly 48 Tag disconnect and plug the hydraulic hoses from the
406. t the platform controls to allow the engine to run at high idle O 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 O Result The high idle indicator light should turn off and the engine should return to low idle 4 Press the engine stop button O Result The engine should stop o o REV D 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 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 3 22 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D B 14 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free whee
407. te 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 CAUTION Hoses can be damaged if they are kinked or pinched REV D 21 Remove the cables from the number 3 inner arm index 18 and lay the cables off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 22 Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm 23 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 24 Secure both ends of the number 3 inner and outer arms index 18 and 16 together with a strap or other suitable device 25 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 26 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 27 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 28
408. te 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 Apply athin layer of oil to the new oil filter gasket 5 Install the new filter and tighten it securely by hand 6 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 7 Clean up any oil that may have spilled during the replacement procedure 8 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 9 Start the engine from the ground controls 10 Hold the function enable toggle switch in the up direction and activate the platform up function 11 Inspect the filter and related components to be sure that there are no leaks Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 3 Scheduled Maintenance Procedures REV D D 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0297 9929 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 84794
409. the adjustable end equals approximately 1 4 inch 6 4 mm change in the front and rear measurements 7 Slide the tie rod onto the yoke Install the clevis pin 8 Lower the machine 9 Repeat step 2 If further adjustment is needed repeat steps 3 through 7 10 Install a new cotter pin in the tie rod clevis pin 11 Tighten the jam nut on the adjustable end of the tie rod Toe in specification 0 0 125 inch 0 3 2 mm Measurement 4 114 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV B 9 4 Oscillating Axle Option after serial number GS9004 41618 How the Oscillating Axle Functions When driving the GS 90 with the platform in the stowed position the oscillating axle function ensures that all four wheels maintain solid 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 v
410. the chassis 54 Remove the pin retaining fasteners from the number 1 inner arm slide block pivot pins index 24 at the steer end of the machine 55 Use a slide hammer to remove the number 1 inner arm slide block pivot pins index 24 56 Remove the pin retaining fasteners from the number 1 outer arm slide block pivot pins index 13 at the non steer end of the machine 57 Use a slide hammer to remove the number 1 outer arm slide block pivot pins index 13 58 Carefully remove the number 1 inner and outer arms index 10 and 12 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D After serial number 41072 1 Remove the platform See 2 1 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 CAUTION Cables can be damaged if they are kinked or pinched 4 Secure both ends of the number 4 inner and outer arms index 14 and 2 together with a
411. the key switch to the off position Wait a few seconds and then turn the key switch to platform control Result The error indicator light on the top of the platform control box should not be illuminated and code 30 should not be present on the diagnostic display Result If the error indicator light is illuminated or if code 30 is present on the diagnostic display repeat this procedure beginning with step 5 10 Turn the key switch to the off position 11 Close the lid and install the fasteners Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 1 3 Controller Adjustments before serial number GS9003 41523 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 Raised drive speed Fast platform lift speed Platform lower speed Steer speed Platform settling speed For further information or assistance consult the Genie Industries Service Department Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional
412. the load sense delay limit switch 72 Raise the platform to approximately 6 m 73 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position 74 Install the cover onto the platform overload pressure switch box and securely tighten the cover retaining fasteners Do not over tighten 75 Apply Sentry Seal to one of the cover retaining fasteners where it contacts the platform overload pressure switch box 76 Return the safety arm to the stowed position 77 Lower the platform to the stowed position 78 Calibrate the system relief valve CONDITION POSSIBLE CAUSE SOLUTION CANNOT LIFT RATED LOAD AT MAXIMUM HEIGHT WITH RATED LOAD IN PLATFORM THE PRESSURE SWITCH ALARM CONTINUES TO SOUND RELIEF VALVE SET TOO LOW SYSTEM NEEDS TO BE RESET INCREASE RELIEF VALVE PRESSURE TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON MAXIMUM HEIGHT LIMIT SWITCH OUT OF ADJUSTMENT OR FAULTY LOWER THE UP LIMIT SWITCH SLIGHTLY OR REPLACE CONTACTS TOO MUCH WEIGHT IN PLATFORM PRESSURE SWITCH OUT OF ADJUSTMENT PUT CORRECT RATED LOAD IN PLATFORM TURN THE PRESSURE SWITCH NUT 1 4 TURN INTO THE HYDRAULIC LINE BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIES PROPERLY OVERLOAD SYSTEM NOT ADJUSTED REPEAT CALIBRATION PROCEDURE SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS AT DOWN LIMIT WITH RATED LOAD IN
413. the platform extension deck lock handle 8 PLATFORM COMPONENTS Carefully slide the platform extension deck out until the platform extension deck makes contact with the carriage on the forklift Attach a strap from the platform extension deck railings to the carriage on the forklift to help support the platform extension deck Remove the three V roller and extension deck lock bracket mounting fasteners from the extension deck at the tank side of the machine Carefully pull the V roller and extension deck lock assembly out of the extension deck 10 Remove the fasteners from the roller wheels located under the platform extension deck Remove the roller wheels 11 Carefully slide the platform extension deck out of the platform and place it on a structure capable of supporting it AWARNING Crushing hazard The platform extension deck could become unbalanced and fall when removed from the machine if not properly supported and secured to the forklift Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 17 Section 4 Repair Procedures December 2004 Scissor Components REV D 9 o o 9 GGG 9 Non steer End Steer End 1 Platform centering link 11 Number 3 outer arm 2 Number 3 inner arm 12 Lift cylinder rod end pivot pin 3 Number 3 center pivot pins 13 Number 3 pivot pins steer end
414. the red Emergency Stop button to the off position at the ground controls 11 Check the lower speed of the machine Refer to Section 2 Specifications Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS REV D How to Adjust the Platform Settling Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Push in 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 5 Pressthe lift function enable button 6 Use the yellow platform down arrow to scroll to settling speed Result SETTLING SPEED is showing in the diagnostic display window a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 7 Pressthe lift function enable button 8 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 CAUTION Platform Settling Speed is intended to slow the rate of platform desc
415. tion Machine parked on a firm level surface Platform in the stowed position 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 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 Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 5 1 Section 5 Fault Codes December 2004 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 pro
416. ton 15 Push in the red Emergency Stop button to the off position at the ground controls Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS REV D How to Adjust the Lift Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Push in the red Emergency Stop button to the off position at the ground controls diagnostic display blue platform up button lift function enable button yellow platform down button 3 Turn the key switch to ground control oo 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 8 Press the yellow platform down button to ground controls decrease the maximum lift speed or press the blue platform up button to increase the Result TUNE SPEEDS is Showing in the diagnostic maximum lift speed Refer to Section 2 display window The ECM is now in Specifications programming mode The performance achieved should 5 Press the lift function enable button always be within specifications 6 Use the yellow platform down arrow to scroll to 9 Press the lift function enable button lift speed 10 Push in the red Emergency Stop button to the Result LIFT SPEED is showing in the off position at the ground controls diagnostic display window 11 Check the lift spe
417. ty 114 Post cat oxygen sensor open The post cat Heated Oxygen Sensor wiring and or connections are open or shorted OR sensor is cold non responsive or inactive for 60 seconds or longer Repair wiring and or connections OR replace the post cat oxygen sensor 121 Closed Loop Multiplier High Gasoline Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors 122 Closed Loop Multiplier Low Gasoline MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Adjust or replace sensors OR clean or repair fuel injectors 124 Closed Loop Multiplier Low LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty Repair wiring and or connections OR replace sensor OR replace fuel OR test and repair the fuel system components 133 Gasoline cat monitor There are exhaust leaks OR the catalyst s
418. uel in an open container due to the possibility of fire ADANGER Explosion and fire hazard When transferring fuel connect a grounding strip between the machine and pump or container 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 Startthe engine and raise the platform approximately 18 feet 5 5 m from the ground 3 Before serial number 40351 Release the safety arm latch lift the safety arm and rotate down to a vertical position After serial number 40350 Release the safety arm latch lift the safety arm and rotate to vertical position Lock the safety arm in position Be sure that the safety arm is locked in the vertical position 4 Lower the platform onto the safety arm Turn the engine off AWARNING Cushing hazard Keep hands clear of the safety arm when lowering the platform REV 5 Attach a lifting strap from an overhead crane to the entry ladder on the hydraulic tank side of the machine 6 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder AWARNING could become unbalanced and fall when it is removed from the machine if it is not properly supported 7 Remove the retaining fasteners from the access plate located behind the hydraulic and fuel tank tray 8 Locate and close the 2 fuel tank shutoff valves located at the
419. ug aX XY enne C2 System power input C2 Platform overload input wees 0000011 System power input C3 Right front outrigger limit OOO 12 C4 Engine starting aid output switch LS13 input aX X X X Xt SV WAKE 5723 5 stowed relay CR84 4 Right rear outrigger limit S CUTE terminal 86 output switch LS15 input C6 Oscillate raised relay CR85 C5 Left front outrigger limit terminal 86 output switch LS12 input C7 Ground output C6 Left rear outrigger limit C8 Plug Switch LS14 input C9 Plug C7 Alternator input C10 Auxiliary down relay CR23 C8 Engine oil pressure SW2 terminal 87 output input C11 Flashing beacons FS1 c9 Engine water temp SW1 OR output oil temp SWS input C12 ECM power input C10 Plug C11 Fuel coil GS68 output C12 Plug Electronic Control Module J1 J2 Part 72863 Genie GS 3390 GS 4390 GS 5390 Section 6 Schematics December 2004 Ford Engine Relay Layout REV Before serial number GS9003 41369 Control Relays Ford Models before serial number GS9003 41369 CR FA CR FB CR FC Power to Engine ECM Relay Fuel Pump Relay Engine Starter Relay Wire Color Terminal Wire Color Terminal Wire Color Terminal Brown Light Green 85 Red 85 Red Light Green 85 Black White 86 Light Blue Orange 86 Light
420. ump with a suitable lifting device and remove the two drive pump mounting fasteners Carefully pull the drive pump out until the pump coupler separates from the flex plate Remove the drive pump from the machine Component damage hazard CAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Before installing the pump verify proper pump coupler spacing See 4 2 Flex Plate 4 86 Genie GS 3390 GS 4390 GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV How to Prime the Pump Component damage hazard Be CAUTION sure that the hydraulic tank shutoff valves are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to either diagnostic nipple on the drive manifold 2 Turn 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 HYDRAULIC PUMPS 3 Ford models Close the valve on the LPG tank then disconnect the hose from the tank if equipped Move the fuel select toggle switch at the ground controls to the LPG position Deutz models Hold the manual fuel shut off lever clockwise in the closed position Ae AE Y
421. und 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 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 57 Section 4 Repair Procedures December 2004 GROUND CONTROLS REV D How to 773 Adjust the Stowed 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 death or serious injury On machines with software revision B1 or lower stowed 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 stowed forward drive speed and the stowed reverse drive speed may be adjusted independent of one another See 5 2 How to Determine the Revision Level Models with software revision B1 or lower 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 3 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
422. ure 65 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 66 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 67 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 68 Use a slide hammer to remove both number 2 pivot pins index 13 from the non steer end of the machine 69 Use a slide hammer to remove both number 2 pivot pins index 428 from the steer end of the machine 70 Carefully remove the number 2 inner and outer arms index 26 and 27 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 If further disassembly of the scissor arm pair is required see How to Disassemble a Scissor Arm Pair 71 Remove the cables and hydraulic hoses from the number 1 inner arm index 14 and lay them off to the side CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 72 Secure both ends of the number 1 inner and
423. urn the level sensor adjusting nuts just until the level sensor alarm does not sound W Result ANSI and CSA models after serial number 40819 The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Turn the level sensor adjusting nuts just until the level sensor alarm does not sound Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Turn the level sensor adjusting nuts just until the level sensor alarm does not sound 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 44 Center a lifting jack under the drive chassis at the engine side of the machine 45 Raise the machine approximately 4 inches 10 cm 46 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 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D 47 Lower the machine onto the blocks 48 Raise the platform approximately 16 feet 5 m Result ANSI and CSA models before serial number
424. ury Do not install or calibrate the level sensor other than specified in this procedure 1 Perform this procedure with the machine on a firm level surface that is free of obstructions 2 Remove the platform controls from the platform If you are not installing a new level sensor proceed to step 10 3 Pushin the red Emergency Stop button to the off position at the platform controls 4 Remove the ground control panel retaining fasteners and open the panel Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 GROUND CONTROLS 5 Locate the level sensor behind the ground control panel 6 Tag and disconnect the wire harness from the level sensor 7 Remove the level sensor retaining fasteners Remove the level sensor from the machine 8 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 ADANGER 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 MODELS WITHOUT OUTRIGGERS Z 9 2727 Level sensor models without outriggers a chassis b level senso
425. uter arms are removed CAUTION If further disassembly of the scissor arm pair is required see 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 injury hazard Spraying ydraulic 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 REV D 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 30 Carefully lower the rod end of the lower lift cylinder onto the engine cover 31 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 CAUTION Cables and hoses can be damaged if they are kinked or pinched 32 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 33 Place a rod through the cable tray pivot pin and twist to remove the pin Lower the cable tray down Component damage hazard CAUTION Cables can be dama
426. utrigger coil Y33 B5 Start relay CR1 terminal 86 B3 Forward reverse relay CR58 A12 Plug B6 Generator coil Y29 terminal 30 C1 Plug B4 Proportional Y9 Bi Level sensor 58 blue C2 Plug C1 LPGcoil Y50 B5 Right front outrigger coil B2 Plug Plug C2 Right rear outrigger coil Y34 Y36 B3 Level sensor S8 yellow C4 Plug Plug B6 Outrigger extend coil Y40 B4 Plug C5 Plug C4 Ignition relay CR8 terminal B7 Outrigger retract coil Y39 B5 Plug C6 Plug 86 B8 Plug B6 Plug C5 Plug B9 Plug B7 Plug C6 Plug B10 Plug B8 Plug B11 Plug B9 Forward reverse relay CR58 B12 Plug terminal86 3 B10 Level sensor red C1 Power to terminal 30 on B11 Horn relay CR5 terminal 86 relays CR1 CR5 and 8 12 Alarm H5 C2 Power to terminal 30 on relays CR1 CR5 and CR8 C1 Diagnostic display G8 000000 C3 Power to terminal 30 on C2 Diagnostic display G8 B OO X65 relays CR1 CR5 and CR8 Diagnostic display G8 aN aN aN C4 Power to terminal 30 on C4 Diagnostic disp ay G8 A 1000006 0 relays CR1 5 ands CR8 C5 Diagnostic display G8 5 Plug Diagnostic display G8 6 Plug C7 Diagnostic display G8 EM C7 Ground strip C8 Diagnostic display G8 C8 Proportional coil Y9 C9 Diagnostic disp G8 18 pin connector J3 and J4 cg Plug C10 Diagnostic display G8 C10 Plug C11 Plug C11 Emergency Stop relay C12 Plug CR41 terminal 87 C12 Plug
427. utton yellow platform down button 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 max high torque drive Result HIGH TORQUE DRIVE 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 speed Refer to Section 2 Specifications The performance achieved should always be within specifications 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground controls Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV D Models with software revision or higher 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 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 Resul
428. ve 22 F 30 C 5W 30 Reserve capacity 25A rate 125 minutes Use oils meeting API classification SJ or SH Units ship with 15W 40 SJ Battery after serial number 40515 Ignition system Type 12V DC Spark plug type Motorcraft AWSF 52 C Group 31 before serial number GS9004 41694 Quantity 1 Spark plug type Motorcraft AGSF 32 FM after serial number GS9004 41693 Role crating ampere EDA Spark plug gap 0 042 to 0 046 inches Reserve capacity 25A rate 200 minutes 1 07 to 1 17 mm Part No 72863 Genie GS 3390 GS 4390 and GS 5390 2 5 Section 2 Specifications December 2004 SPECIFICATIONS Deutz FAL 1011F Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold 166 7 cu in 2 732 liters 4 3 58 x 4 13 inches 91 x 105 mm 56 3000 rpm 42 kw 3000 rpm 1 3 4 2 18 5 1 362 to 435 psi 25 to 30 bar 1600 rpm 320 Hz 2500 rpm 500 Hz centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 26 to 87 psi 1 8 to 6 bar Oil capacity 11 quarts including filter 10 4 liters Oil viscosity requirements Below 60 F 15 5 C 5W 30 synthetic 10 F to 90 F 23 C to 32 C 10W 40 Above 4 F 20 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF Units ship with 15W 40 CC S
429. witch settings 4 Open the controller box lid and locate the DIP switch on the circuit board Move the DIP Switch settings to correspond with the configuration of the machine options indicated in the chart See 1 4 DIP Switch Codes Chart nnnm red Emergency Stop button P2 DIP switch SW25 platform control box enlarged view of DIP switch SW25 circuit board joystick controller JC1 5 Apply dielectric grease to the DIP switch after setting the configuration 6 Close the lid and install the platform control box lid fasteners Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 PLATFORM CONTROLS 7 Toconfirm the settings pull out the red Emergency Stop button to the on position at both the ground and platform controls and turn the key switch to ground control Do not start the engine 8 Move and hold the platform up down toggle switch in the up direction and activate the function enable toggle switch from the ground controls Result The LED diagnostic readout window located on the ground control panel will display a configuration number without the dot illuminated This configuration number indicates the current configuration of the machine A Q HOUR METER
430. wn 20 ft lbs 27 Nm 2 Diagnostic nipple AB Testing 3 Relief valve 3500 psi 241 3 bar AC cines 20 ft lbs 27 Nm 4 Proportional solenoid valve AD amp 35 ft lbs 47 Nm 5 Relief valve 2000 psi 138 bar AE uen Steering and outrigger circuit 25 ft lbs 34 Nm 6 Diagnostic nipple aes Testing 7 valve 3 position 4 way AG uus Platform up down 30 35 in lbs 3 4 Nm 8 Solenoid valve 3 position 4 way AH Steer 2 4 222 222 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 Ad Bleeds off proportional valve to tank esses 20 ft lbs 27 Nm 11 valve 3 position 4 way Outrigger up down 30 35 in lbs 3 4 Nm 4 90 Genie GS 3390 GS 4390 and GS 5390 Part No 72863 December 2004 Section 4 Repair Procedures REV E MANIFOLDS OW A OW Z Q QD 5 W 96 0 Part No 72863 Genie GS 3390 GS 4390 and GS 5390 4 91 Se
431. y any lifting 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 a 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 AWARNING 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 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 upper lift cylinder rod end pivot pin index 21 Do not remove the pin Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 SCISSOR COMPONENTS 13 Attach a lifting strap from an overhead crane to the lifting eye at the rod end of the upper lift cylinder 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 Crushing hazard The upper lift AWARNING cylinder
432. y it off to the side CAUTION Component damage hazard The engine ECM is a sensitive instrument It can be damaged internally if the ECM is dropped or sustains any physical shock even if the damage is not visible Part No 72863 Genie GS 3390 GS 4390 and GS 5390 Section 4 Repair Procedures December 2004 ENGINES 10 Remove the exhaust pipe clamp from the exhaust pipe support bracket 11 Center a lifting jack under the engine oil pan 12 Place a wood block between the lifting jack and the engine oil pan Component damage hazard The CAUTION engine oil pan can become damaged if the engine is raised with the lifting jack without the wood block between the lifting jack and the engine oil pan 13 Remove the 2 engine mounting fasteners from the bell housing that attach the engine to the slide out tray 14 Raise the engine slightly with the lifting jack to take the pressure off the rubber vibration isolators under the bell housing Remove the rubber vibration isolators 15 Attach a lifting strap from an overhead crane to the pump and bell housing assembly for support Do not apply any lifting pressure 16 Remove all of the bell housing to engine fasteners 17 Carefully pull the pump and bell housing away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 18 Remove the flex plate mounting fasteners Remove the flex plate
433. ystem efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 141 Adaptive Lean Fault High Limit Gasoline Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low Repair heated oxygen sensor wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors 142 Adaptive Rich Fault Low Limit Gasoline IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Adjust or replace sensors OR clean or repair fu

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