Genie 5394

Par ts Manual
Service Manual
Serial Number
Serial Range
Number Range
GS-3384 from GS8406-40833
GS-3390 from GS9006-42686
GS-4390 from GS9006-42686
GS-5390 from GS9006-42686
Part No. 84793

Rev E
June 2007
Introduction June 2007
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the appropriate Operator's Manuals for these models:
Manual on your machine before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled Genie GS-3390, GS-4390 and GS-5390 Service
maintenance information for the machine owner Manual, First Edition
and user. It also provides troubleshooting and (from serial number 40001 to GS9005-42685) ..... 72863
repair procedures for qualified service Genie GS-3384 Service Manual,
professionals. First Edition
Basic mechanical, hydraulic and electrical (from serial number 40001 to GS8405-40832) ..... 82259
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.
Copyright © 2001 by Genie Industries

Contact Us:
84793 Rev E June 2007
PO Box 97030 Second Edition, Fifth Printing
Redmond, WA 98073-9730 USA
"Genie" is a registered trademark of Genie
www.genieindustries.com Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.
e-mail: techsup@genieind.com
Printed on recycled paper
Printed in U.S.A.
ii GS-84 • GS-90 Part No. 84793

June 2007
INTRODUCTION
Serial Number Legend
Model: GS-1930
Serial number: GS3005A-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: ES0141
Machine unladen weight: 2,714 lb / 1,231 kg
Rated work load (including occupants): 500 lb / 227 kg GS30 05 A - 12345

Maximum allowable inclination of the chassis:
N/A
Model Sequence
Gradeability: N/A number
Model year
Maximum allowable side force : 100 lb / 445 N
Maximum number of platform occupants: 2
Facility code
(used only for model manufactured
Country of manufacture: USA in multiple facilities )
This machine complies with:
ANSI A92.6-1999
B354.2-01
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Serial label
(inside cover)
Serial number Serial number

(stamped on chassis) (stamped on chassis)
Part No. 84793 GS-84 • GS-90 iii

June 2007
This page intentionally left blank.
iv GS-84 • GS-90 Part No. 84793

June 2007 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:
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. 84793 GS-84 • GS-90 v

Section 1 • Safety Rules June 2007
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for
use. Keep work surfaces clean and free of
Safety alert symbol—used to alert debris that could get into machine components and
personnel to potential personal cause damage.
injury hazards. Obey all safety
messages that follow this symbol Be sure any forklift, overhead crane or
to avoid possible injury or death. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates an imminently hazardous
weight to be lifted. Use only chains or straps that
situation which, if not avoided, will
are in good condition and of ample capacity.
result in death or serious injury.
Be sure that fasteners intended for one
Indicates a potentially hazardous
situation which, if not avoided, time use (i.e., cotter pins and self-locking
could result in death or serious nuts) are not reused. These components
injury. may fail if they are used a second time.
Indicates a potentially hazardous Be sure to properly dispose of old oil or

situation which, if not avoided, other fluids. Use an approved container.
may cause minor or moderate Please be environmentally safe.
injury. Be sure that your workshop or work area
Indicates a potentially hazardous is properly ventilated and well lit.
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi GS-84 • GS-90 Part No. 84793

June 2007
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules

General Safety Rules ........................................................................................ v
Section 2 Rev Specifications

F Machine Specifications ................................................................................ 2 - 1
Performance Specifications ......................................................................... 2 - 2
Hydraulic Specifications ............................................................................... 2 - 3
Hydraulic Component Specifications ........................................................... 2 - 4
Manifold Component Specifications ............................................................. 2 - 5
Valve Coil Specifications .............................................................................. 2 - 5
Ford LRG-425 EFI Engine ........................................................................... 2 - 6
Ford DSG-423 EFI Engine ........................................................................... 2 - 7
Deutz F3L 2011 Engine / Deutz D2011L03i Engine ..................................... 2 - 8
Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 9
SAE and Metric Fasteners Torque Charts ................................................. 2 - 10
Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
E Checklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 7
A-2 Perform Pre-operation Inspection ....................................................... 3 - 8
A-3 Perform Function Tests ...................................................................... 3 - 8
A-4 Perform Engine Maintenance - Ford models ...................................... 3 - 9
A-5 Perform Engine Maintenance - Deutz models .................................... 3 - 9
A-6 Perform 30 Day Service ..................................................................... 3 - 9
Part No. 84793 GS-84 • GS-90 vii

June 2007
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A-7 Perform Engine Maintenance - Deutz Models .................................. 3 - 10
A-8 Perform Engine Maintenance - Ford Models .................................... 3 - 10
A-9 Replace the Drive Hub Oil ................................................................ 3 - 11
A-10 Drain the Fuel Filter/ Water Separator - Deutz Models ..................... 3 - 11
A-11 Perform Engine Maintenance - Ford Models .................................... 3 - 12
E Checklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 13
B-2 Inspect the Electrical Wiring ............................................................. 3 - 14
B-3 Check the Exhaust System .............................................................. 3 - 15
B-4 Inspect the Engine Air Filter .............................................................. 3 - 16
B-5 Check and Adjust the Engine RPM .................................................. 3 - 17
B-6 Confirm the Proper Brake Configuration ........................................... 3 - 18
B-7 Inspect the Tires, Wheels and Lug Nut Torque ................................. 3 - 19
B-8 Check the Drive Hub Oil Level and Fastener Torque ....................... 3 - 19
B-9 Test the Key Switch .......................................................................... 3 - 20
B-10 Test the Emergency Stop ................................................................. 3 - 20
B-11 Test the Automotive-style Horn ........................................................ 3 - 21
B-12 Test the Fuel Select Operation - Ford Models .................................. 3 - 21
B-13 Test the Drive Brakes ....................................................................... 3 - 22
B-14 Test the Drive Speed - Stowed Position ........................................... 3 - 23
B-15 Test the Drive Speed - Raised Position ............................................ 3 - 24
B-16 Perform Hydraulic Oil Analysis ......................................................... 3 - 24
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 25
B-18 Replace the Engine Air Filter Element - Ford Models ....................... 3 - 26
B-19 Perform Engine Maintenance - Ford Models .................................... 3 - 26
viii GS-84 • GS-90 Part No. 84793

June 2007
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

C Checklist C Procedures
C-1 Test the Platform Overload System (if equipped) ............................. 3 - 27
C-2 Replace the Engine Air Filter Element - Duetz Models ..................... 3 - 28
C-3 Perform Engine Maintenance - Deutz Models .................................. 3 - 29
C-4 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 29
C-5 Perform Engine Maintenance - Ford Models .................................... 3 - 30
B Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 31
D-2 Check the Free-wheel Configuration ................................................ 3 - 32
D-3 Replace the Drive Hub Oil ................................................................ 3 - 33
D-4 Replace the Fuel Filter/Water Separator - Deutz Models .................. 3 - 33
D-5 Replace the Hydraulic Filters ............................................................ 3 - 34
D-6 Perform Engine Maintenance - Deutz Models .................................. 3 - 36
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 37
E-2 Perform Engine Maintenance - Ford Models .................................... 3 - 39
E-3 Perform Engine Maintenance - Deutz Models .................................. 3 - 40
E-4 Perform Engine Maintenance - Deutz Models .................................. 3 - 40
Part No. 84793 GS-84 • GS-90 ix

June 2007
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1
A Platform Controls
1-1 Circuit Boards .................................................................................... 4 - 2
B Platform Components
2-1 Platform ............................................................................................. 4 - 3
2-2 Platform Extension Deck .................................................................... 4 - 5
B Scissor Components
3-1 Scissor Assembly, GS-3384 and GS-3390 ........................................ 4 - 6
3-2 Scissor Assembly, GS-4390 ............................................................ 4 - 12
3-3 Scissor Assembly, GS-5390 ............................................................ 4 - 20
3-4 Wear Pads ....................................................................................... 4 - 28
3-5 Lift Cylinder(s) .................................................................................. 4 - 30
C Engines
4-1 RPM Adjustment .............................................................................. 4 - 34
4-2 Engine Fault Codes - Ford Models ................................................... 4 - 34
4-3 Engine Repair .................................................................................. 4 - 34
4-4 Flex Plate ......................................................................................... 4 - 35
C Ground Controls
5-1 Auxiliary Platform Lowering .............................................................. 4 - 40
5-2 Controller Adjustments ..................................................................... 4 - 40
5-3 Software Configuration ..................................................................... 4 - 51
5-4 Level Sensor - Models without Outriggers ........................................ 4 - 57
5-5 Level Sensor - Models with Outriggers ............................................. 4 - 59
5-6 Engine Fault Codes - Ford Models ................................................... 4 - 64
x GS-84 • GS-90 Part No. 84793

June 2007
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

C Hydraulic Pumps
6-1 Lift/Steer Pump ................................................................................ 4 - 66
6-2 Drive Pump ...................................................................................... 4 - 68
A Manifolds
7-1 Function Manifold Components - Models with Outriggers ................ 4 - 72
7-2 Function Manifold Components - Models without Outriggers ........... 4 - 74
7-3 Drive Manifold Components ............................................................. 4 - 76
7-4 Oscillate Manifold Components, GS-90 Models (option) .................. 4 - 78
7-5 Valve Adjustments - Function Manifold ............................................ 4 - 80
7-6 Valve Adjustments - Drive Manifold ................................................. 4 - 82
7-7 Generator Manifold Components ..................................................... 4 - 83
7-8 Valve Adjustments - Generator Manifold .......................................... 4 - 84
7-9 Valve Coils ....................................................................................... 4 - 85
A Fuel and Hydraulic Tanks
8-1 Fuel Tank ......................................................................................... 4 - 87
8-2 Hydraulic Tank ................................................................................. 4 - 88
B Steer Axle Components
9-1 Yoke and Drive Motor ...................................................................... 4 - 90
9-2 Steer Cylinder .................................................................................. 4 - 92
9-3 Oscillating Axle Option (GS-90 models) ........................................... 4 - 93
B Non-steer Axle Components
10-1 Drive Motor and Brake ..................................................................... 4 - 94
10-2 Drive Hub ......................................................................................... 4 - 95
10-3 Oscillating Axle ................................................................................ 4 - 95
A Outrigger Components
11-1 Outrigger Cylinder ............................................................................ 4 - 96
B Platform Overload Components
12-1 Platform Overload System ............................................................... 4 - 97
Part No. 84793 GS-84 • GS-90 xi

June 2007
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction .................................................................................................. 5 - 1
B Machine Fault Code Chart ........................................................................... 5 - 3
A Ford LRG-425 ECM Fault Code Chart ......................................................... 5 - 6
A Ford DSG-423 ECM Fault Code Chart ...................................................... 5 - 11
Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1
A Electronic Control Module Layout ................................................................ 6 - 2
A Electronic Control Module Pin-Out Legend .................................................. 6 - 3
B Ford Engine Relay Layout ........................................................................... 6 - 4
A Wiring Diagram - Platform Control Box ........................................................ 6 - 5
B Limit Switch Legend ..................................................................................... 6 - 6
A Electrical Schematics Abbreviation and Wire Color Legends ....................... 6 - 8
A Electrical Symbols Legend ........................................................................... 6 - 9
A Wiring Harness - Ford LRG-425 EFI
(GS-84 models before serial number GS8406-41197)
(GS-90 models before serial number GS9006-43481) ............................... 6 - 10
B Wiring Harness - Ford DSG-423 EFI
(GS-84 models from serial number GS8406-41197 to GS8407-41311)
(GS-90 models from serial number GS9006-43481 to GS9007-43786) ..... 6 - 12
A Wiring Harness - Ford DSG-423 EFI
(GS-84 models after serial number GS8407-41311)
(GS-90 models after serial number GS9007-43786) .................................. 6 - 14
xii GS-84 • GS-90 Part No. 84793

June 2007
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

B Electrical Schematic - ANSI Models with Ford Power
C Electrical Schematic - CE Models with Ford Power
C ANSI Models with Deutz Power ................................................................. 6 - 40
D CE Models with Deutz Power .................................................................... 6 - 44
A Hydraulic Schematics Component Call-out Legend ................................... 6 - 48
A Hydraulic Schematics Symbols Legend ..................................................... 6 - 49
C Hydraulic Schematic .................................................................................. 6 - 50
Part No. 84793 GS-84 • GS-90 xiii

June 2007
GS-84 • GS-90 Part No. 84793

June 2007 Section 2 • Specifications
REV F
Specifications
Machine Specifications Rough Terrain, foam-filled (GS-90)
Fluid capacities Tire size LSW 305-546 NHS
Hydraulic tank 32 gallons Tire ply rating 10

121 liters Tire diameter 33 in
Hydraulic system with outriggers 37.5 gallons 83.8 cm
(including tank), GS-3384 and GS-3390 142 liters Tire width 12 in
Hydraulic system with outriggers 38.25 gallons 30 cm
(including tank), GS-4390 144.8 liters Wheel diameter 21.5 in
Hydraulic system with outriggers 38.75 gallons 55 cm
(including tank), GS-5390 146.7 liters Wheel width 10 in
Hydraulic system without outriggers 34.25 gallons 25.4 cm
(including tank), GS-3384 and GS-3390 129.6 liters Weight 257 lbs (+/- 10 lbs)
Hydraulic system without outriggers 35 gallons 116.6 kg (+/- 4.5 kg)
(including tank), GS-4390 132.5 liters Rough terrain, foam-filled (GS-84)
Fuel tank 30 gallons Tire size 10-16.5 NHS
114 liters
Tire ply rating, minimum 6
Tire and wheels
Tire diameter 31 in
High Flotation, air-filled and foam-filled (all models) 79 cm
Tire size 33/16LL500 Tire width 10 in
Tire ply rating 10 25.4 cm
Tire diameter 33 in Wheel diameter 16.5 in

83.8 cm 41.9 cm
Tire width 16 in Wheel width 8.25 in
41 cm 21 cm
Wheel diameter 19.5 in
Weight 239 lbs (+/- 10 lbs)
49.5 cm
108.4 kg (+/- 4.5 kg)
Wheel width 14 in
Tire and wheels
35.6 cm
Weight, foam-filled 419 lbs (+/- 10 lbs) Wheel lugs 9 @ 5/8-18
190 kg (+/- 4.5 kg) Lug nut torque, dry 125 ft-lbs
Weight, air-filled 157 lbs 169.5 Nm
71.2 kg Lug nut torque, lubricated 94 ft-lbs
Pressure, air-filled 38 psi 127.4 Nm
2.6 bar
Continuous improvement of our products is a

For operational specifications, refer to the Genie policy. Product specifications are
Operator's Manual. subject to change without notice.
Part No. 84793 GS-84 • GS-90 2-1

Section 2 • Specifications June 2007
SPECIFICATIONS REV F
Performance Specifications Function speed, maximum from platform controls

(with maximum rated load in platform)
Drive speed, maximum (GS-90)
GS-3384 and GS-3390
Platform stowed 5 mph
40 ft / 5.5 sec Platform up 42 to 52 seconds
8 km/h Platform down 25 to 35 seconds
12.2 m / 5.5 sec GS-4390
Platform raised 0.7 mph Platform up 50 to 60 seconds
40 ft / 39 sec Platform down 32 to 42 seconds
1.1 km/h
12.2 m / 39 sec GS-5390
Drive speed, maximum (GS-84) Platform up 70 to 90 seconds
Platform down 42 to 52 seconds
Platform stowed 4 mph
40 ft / 6.8 sec Airborne noise emissions 80 dB
6.4 km/h Maximum sound level at normal operation workstations
12.2 m / 6.8 sec (A-weighted)
Platform raised 0.7 mph
40 ft / 39 sec
1.1 km/h
12.2 m / 39 sec Continuous improvement of our products is a
Braking distance, maximum Genie policy. Product specifications are
high range on paved surface 60 inches
152.4 cm
Gradeability
GS-3384, GS-3390 and GS-4390 50%

GS-5390 40%
Rated work load at full height, maximum
GS-3384 and GS-3390 2500 lbs

1135 kg
GS-4390 1500 lbs

(most models - refer to capacity indicator decal) 680 kg
GS-4390 1800 lbs

(some models - refer to capacity indicator decal) 816 kg
GS-5390 1500 lbs

680 kg
2-2 GS-84 • GS-90 Part No. 84793

REV F SPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent

Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) 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 the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV 46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046

Quintolubric 822
Mineral based Shell Tellus T32

Shell Tellus T46
Chevron Aviation A
Continued use of Chevron

Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Part No. 84793 GS-84 • GS-90 2-3

Hydraulic Components Function manifold

Specifications System relief valve pressure, 2700 to 2900 psi
GS-3384 and GS-3390 186 to 200 bar
Drive pump
System relief valve pressure, 2900 to 3100 psi
Type: Bi-directional, variable displacement piston pump GS-43390 and GS-5390 200 to 214 bar
Flow rate @ 2500 rpm 0 to 32.5 gpm Steer relief valve pressure 2000 psi
0 to 123 L/min 138 bar
Drive pressure, maximum 3750 psi Proportional valve flow regulator 0.1 gpm
258.6 bar 0.38 L/min
Charge pump Drive manifold
Type: Gerotor Hot oil relief pressure 280 psi

19.3 bar
Flow rate @ 2500 rpm 9.1 gpm
34.4 L/min Drive motors
Charge pump pressure 325 psi Displacement (2 speed motor) 0.54 to 1.52 cu in
22.4 bar 8.8 to 25 cc
Function pump Drive hubs
Type: Gear Fluid capacity 26 fl oz

0.77 liters
Displacement 0.98 cu in
16 cc Fluid type: SAE 90 multipurpose hypoid gear oil
API service classification GL5
Flow rate @ 2500 rpm 10.6 gpm
40.1 L/min Installation torque, lubricated 180 ft-lbs
244 Nm
Hydraulic tank 10 micron with
return line filter 25 psi / 1.7 bar bypass
Auxiliary power unit Oscillate manifold (GS-90) (option)
Relief valve 2000 psi System relief valve pressure 3500 psi
137.9 bar 241 bar
Float relief valve pressure 900 psi

62 bar
Continuous improvement of our products is a Oscillate flow regulator 1 gpm

3.8 L/min
Genie policy. Product specifications are
subject to change without notice. Generator manifold (option)
Relief valve 3000 psi

207 bar
Flow rate, maximum 4.5 gpm

17 L/min
2-4 GS-84 • GS-90 Part No. 84793

Manifold Component Valve Coil Resistance

Specifications Specifications
Plug torque Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
SAE No. 2 50 in-lbs / 6 Nm valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
SAE No. 4 13 ft-lbs / 18 Nm
increase or decrease by 4% for each 18°F / 20°C
SAE No. 6 18 ft-lbs / 24 Nm that your air temperature increases or decreases
from 68°F / 20°C.
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm Description Specification
SAE No. 12 75 ft-lbs / 102 Nm Proportional valve, 12V DC 4.1Ω

(schematic item AD)
DO3 valve, 3 position 4 way, 10V DC 3.6Ω

(schematic items AG and AK)
Solenoid valve, 3 position 4 way 7.2Ω

10V DC with diode (schematic item AH)
Solenoid valve, 2 position 2 way 10V DC 5.5Ω

(schematic items CA, CB, CC and CD)
Solenoid valve, 2 position 3 way 6Ω

10V DC (schematic item AL)
Solenoid valve, 2 position 2 way 7.5Ω

12V DC with diode (schematic item DA)

12V DC with diode (schematic items DE and DF)

12V DC with diode (schematic item DG)

10V DC with diode (schematic items EF and EJ)

Part No. 84793 GS-84 • GS-90 2-5

Ford LRG-425 EFI Engine Electronic fuel pump
Displacement 153 cu in Fuel pressure, static 63 psi

2.5 liters 4.3 bar
Number of cylinders 4 Fuel flow rate 0.58 gpm

2.2 L/min
Bore & stroke 3.78 x 3.4 inches
96.01 x 86.36 mm Fuel requirement
Horsepower 70 @ 2500 rpm For fuel requirements, refer to the engine Operator's
52 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Ignition system
Low idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FM
Frequency 320 Hz Spark plug gap 0.042 to 0.046 inches
High idle (computer controlled) 2500 rpm 1.07 to 1.17 mm
Frequency 500 Hz Engine coolant
Compression ratio 9.4:1 Capacity 11.5 quarts
Compression pressure (approx.) 10.9 liters
Pressure (psi or bar) of lowest cylinder must be Coolant temperature sending unit
at least 75% of highest cylinder
Engine shut-down temperature 300°F
Valve clearances - 0.035 to 0.055 inches 149°C
collapsed tappet 0.889 to 1.397 mm
Starter motor
Lubrication system
Normal engine cranking speed 200 to 250 rpm
Oil pressure 40 to 60 psi
(operating temperature @ 2500 rpm) 2.75 to 4.1 bar Current draw, normal load 140-200A
Oil capacity 4.5 quarts Current draw, maximum load 800A
(including filter) 4.3 liters
Alternator
Oil pressure switch
Output 95A, 14.5V DC
Oil pressure switch point 7.5 psi
0.51 bar Battery
Oil viscosity requirements Type 12V DC
Units ship with 15W-40. Group 31

Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the Quantity 1
Engine Operator Handbook on your machine. Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes

2-6 GS-84 • GS-90 Part No. 84793

Ford DSG-423 EFI Engine Electronic fuel pump
Displacement 140.4 cu in Fuel pressure, static 64 psi

2.3 liters 4.4 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm Fuel requirement
Firing order 1-3-4-2 Ignition system
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FEC
Frequency 320 Hz Spark plug gap 0.044 to 0.045 inches
High function idle (computer controlled) 2500 rpm 1.125 to 1.135 mm
Frequency 500 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 4 quarts Starter motor
(including filter) 3.8 liters
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Current draw, normal load 140-200A
Oil pressure switch point 7.5 psi
0.51 bar Current draw, maximum load 800A
Oil viscosity requirements Alternator
Units ship with 15W-40. Output 95A, 13.8V DC
alternative engine oils. For oil requirements, refer to the Battery
Engine Operator Handbook on your machine.
Type 12V DC
Group 31
Quantity 1
Genie policy. Product specifications are Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes
Part No. 84793 GS-84 • GS-90 2-7

Deutz F3L 2011 Engine Injection system

Deutz D2011L03i Engine Injection pump make Bosch
Displacement 142 cu in Injector pressure, maximum 15000 psi

2.33 liters 1034 bar
Number of cylinders 3 Injector opening pressure 3046 psi

210 bar
Bore and stroke 3.7 x 4.41 inches
94 x 112 mm Fuel requirement
Firing order 1-2-3 Starter motor
Compression ratio 19:1 Current draw, no load 90A
Low idle 1500 Brush length, minimum 0.5 in

Frequency 300 Hz 12.7 mm
High idle 2500 Alternator

Frequency 500 Hz
Output 60A, 14V DC
Governor centrifugal mechanical 3/8 to 1/2 in
Fan belt (pretension / retension)
Valve clearance, cold 9 to 12 mm
Intake 0.012 to 0.016 in Battery

0.3 to 0.4 mm
Type 12V DC
Exhaust 0.020 to 0.024 in
0.5 to 0.6 mm Group 31
Lubrication system Quantity 1
Oil pressure 20 to 44 psi Cold cranking ampere @ 0°F 1000A

1.4 to 3 bar Reserve capacity @ 25A rate 200 minutes
Oil capacity 8.5 quarts
(including filter) 8 liters
Oil change capacity 6.35 quarts

(including filter) 6 liters Continuous improvement of our products is a
Oil viscosity requirements subject to change without notice.
Units ship with 15W-40.
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
2-8 GS-84 • GS-90 Part No. 84793

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
SAE O-ring Boss Port available in the O-ring field service kit (Genie part
(tube fitting - installed into Aluminum) number 49612).
SAE Dash size Torque
2 Lubricate the O-ring before installation.
-4 11 ft-lbs / 14.9 Nm 3 Be sure that the face seal O-ring is seated and
-6 23 ft-lbs / 31.2 Nm retained properly.
-8 40 ft-lbs / 54.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-10 69 ft-lbs / 93.6 Nm tight.
-12 93 ft-lbs / 126.1 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm
6 Operate all machine functions and inspect the
-20 172 ft-lbs / 233.2 Nm hoses and fittings and related components to
-24 208 ft-lbs / 282 Nm 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 / 25 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm
-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm
-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm
-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm
Part No. 84793 GS-84 • GS-90 2-9

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2 - 10 GS-84 • GS-90 Part No. 84793

June 2007 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
annually and every 2 years as specified on the Indicates an imminently hazardous
Maintenance Inspection Report. situation which, if not avoided, will
Failure to perform each procedure
as presented and scheduled could Indicates a potentially hazardous
result in death, serious injury or situation which, if not avoided,
substantial damage. could result in death or serious
injury.
Immediately tag and remove from service a
damaged or malfunctioning machine. Indicates a potentially hazardous
Repair any machine damage or malfunction may cause minor or moderate
before operating the machine. injury.
Use only Genie approved replacement parts. Indicates a potentially hazardous
Machines that have been out of service for a may result in property damage.
period longer than 3 months must complete the
quarterly inspection. Indicates that a specific result is expected after
performing a series of steps.
Unless otherwise specified, perform each
maintenance procedure with the machine in the Indicates that an incorrect result has occurred
following configuration: after performing a series of steps.
· 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
Part No. 84793 GS-84 • GS-90 3-1

Section 3 • Scheduled Maintenance Procedures June 2007
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. 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
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
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
Indicates that a cold engine will be perform a scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service will be
required to perform this procedure. 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 GS-84 • GS-90 Part No. 84793

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
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
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, 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. Rev B
3-4 GS-84 • GS-90 Part No. 84793

Maintenance Inspection Report

Model Checklist A - Rev E Y N R Checklist B - Rev E Y N R
A-1 Manuals and decals B-1 Battery
Serial number
A-2 Pre-operation inspect B-2 Electrical wiring
Date A-3 Function tests B-3 Exhaust system
A-4 Engine maintenance - B-4 Engine air filter
Hour meter Ford models B-5 Engine RPM
A-5 Engine maintenance - B-6 Brake configuration
Machine owner Deutz models
B-7 Tires and wheels
Inspected by (print) Perform after 40 hours:
B-8 Drive hub oil level
A-6 30 day service
B-9 Key switch
Inspector signature Perform after 50 hours:
B-10 Emergency Stop
A-7 Engine maintenance -
Inspector title B-11 Horn
Deutz models
B-12 Fuel select -
Inspector company Perform every 100 hours:
Ford models
A-8 Engine maintenance -
B-13 Drive brakes
Instructions Ford models
B-14 Drive speed - stowed
· Make copies of this report to use for Perform after 150 hours:
each inspection. B-15 Drive speed - raised
A-9 Drive hub oil
· Select the appropriate checklist(s) for B-16 Hydraulic oil analysis
Perform every 200 hours:
the type of inspection to be B-17 Tank venting systems
A-10 Filter/separator -
performed. Perform every 400 hours:
Deutz models
Daily or 8 hour A-11 Engine maintenance - B-18 Engine air filter -
Inspection: A Ford models Ford models
Quarterly or 250 hour B-19 Engine maintenance -

Inspection: A+B Ford models
Semi-annually or 500 hour

Inspection: A+B+C Comments
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 in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 84793 GS-84 • GS-90 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C - Rev C Y N R Checklist E - Rev B Y N R

C-1 Platform overload E-1 Test or replace
Serial number (if equipped) hydraulic oil
Date C-2 Engine air filter - Perform every 2400 hours:

Deutz models E-2 Engine maintenance -
Hour meter C-3 Engine maintenance - Ford models
Deutz models Perform every 3000 hours:
Machine owner C-4 Breather cap - models E-3 Engine maintenance -
with optional oil Deutz models
Inspected by (print) Perform every 800 hours: Perform every 12,000 hours:
Inspector signature C-5 Engine maintenance - E-4 Engine maintenance -
Ford models Deutz models
Inspector title
Checklist D - Rev B Y N R
Inspector company D-1 Scissor arm wear pads
Instructions D-2 Free-wheel

configuration
· Make copies of this report to use for
each inspection. D-3 Drive hub oil
· Select the appropriate checklist(s) for D-4 Filter/separator -
the type of inspection to be performed. Deutz models
D-5 Hydraulic filters
Daily or 8 hour
D-6 Engine maintenance -
Inspection: A
Deutz models
Quarterly or 250 hour
Inspection: A+B
Comments
Semi-annually or 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 in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 GS-84 • GS-90 Part No. 84793

REV E
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed every 8 hours or daily, whichever Result: The machine is equipped with all
comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie Industries if replacement manuals or decals
and personnel to the many possible hazards are needed.
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 84793 GS-84 • GS-90 3-7

CHECKLIST A PROCEDURES REV E
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever
comes first. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
3-8 GS-84 • GS-90 Part No. 84793

REV E CHECKLIST A PROCEDURES
A-4 A-6
Perform Engine Maintenance - Perform 30 Day Service
Ford Models
The 30 day maintenance procedure is a one-time

Engine specifications require that this procedure sequence of procedures to be performed after the
be performed every 8 hours or daily, whichever first 30 days or 40 hours of usage. After this
comes first. interval, refer to the maintenance checklists for
continued scheduled maintenance.
Required maintenance procedures and additional
engine information is available in the 1 Perform the following maintenance procedures:
Ford LRG-425 EFI Operator Handbook Ford models:
(Ford part number FPP 194-302) OR the
· A-8 Perform Engine Maintenance -
Ford DSG-423 EFI Operator Handbook
Ford Models
(EDI part number 1060020).
· B-7 Inspect the Tires, Wheels and
Lug Nut Torque
Ford LRG-425 EFI Operator Handbook
Genie part number 84792 · D-5 Replace the Hydraulic Filters
Deutz models:
Genie part number 119488 · B-5 Check and Adjust the Engine RPM
· B-7 Inspect the Tires, Wheels and
Lug Nut Torque
· D-4 Replace the Fuel Filter/Water
Separator - Deutz Models
A-5
· D-5 Replace the Hydraulic Filters
Perform Engine Maintenance -
Deutz Models
Engine specifications require that this procedure

be performed every 10 hours or daily, whichever
comes first.

engine information is available in the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).

Genie part number 84794
Part No. 84793 GS-84 • GS-90 3-9

A-7 A-8
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Ford Models
Engine specifications require that this one-time Engine specifications require that this procedure
procedure be performed after 50 hours of be performed every 100 hours or quarterly,
operation. whichever comes first.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information is available in the engine information is available in the
Deutz 2011 Operation Manual Ford LRG-425 EFI Operator Handbook
(Deutz part number 0297 9929). (Ford part number FPP 194-302) OR the
Deutz 2011 Operation Manual (EDI part number 1060020).

3 - 10 GS-84 • GS-90 Part No. 84793

REV E CHECKLIST A PROCEDURES
A-9 A-10
Replace the Drive Hub Oil Drain the Fuel Filter/ Water
Separator - Deutz Models
Drive hub specifications require that this one-time

procedure be performed after the first 150 hours of Engine specifications require that this procedure
usage. After this interval, refer to the maintenance be performed every 200 hours or quarterly,
checklists for continued scheduled maintenance. whichever comes first.
Replacing the drive hub oil is essential for good Proper maintenance of the fuel filter/water
machine performance and service life. Failure to separator is essential for good engine
replace the drive hub oil at yearly intervals may performance. Failure to perform this procedure can
cause the machine to perform poorly and lead to poor engine performance and component
continued use may cause component damage. damage.
See D-5, Replace the Drive Hub Oil. Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Release the latches on the engine tray and fully

slide the engine tray out.
2 Insert 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.
Part No. 84793 GS-84 • GS-90 3 - 11

3 Loosen the drain plug located at the bottom of A-11

the filter. Allow the water to drain into a suitable
container until fuel starts to come out. Perform Engine Maintenance -
Immediately tighten the drain plug. Ford Models

be performed every 200 hours or quarterly,
whichever comes first.

a Ford LRG-425 EFI Operator Handbook
b Ford LRG-425 EFI Operator Handbook


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.
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.
3 - 12 GS-84 • GS-90 Part No. 84793

REV E
Checklist B Procedures
B-1 6 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Inspect the Battery follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Genie requires that this procedure be performed • Subtract 0.004 from the reading of each cell for
every 250 hours or quarterly, whichever comes every 10° / 5.5° C below 80° F / 26.7° C.
first.
Result: All battery cells display an adjusted
Proper battery condition is essential to good specific gravity of 1.277 or higher. The battery
machine performance and operational safety. is fully charged. Proceed to step 12.
Improper fluid levels or damaged cables and
Result: One or more battery cells display a
connections can result in component damage and
specific gravity of 1.217 or below. Proceed to
hazardous conditions.
step 9.
Electrocution hazard. Contact with 7 Perform an equalizing charge OR fully charge
electrically charged circuits could the batteries and allow the battery to rest at
result in death or serious injury. least 6 hours.
Remove all rings, watches and
other jewelry. 8 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Bodily injury hazard. Batteries hydrometer. Note the results.
contain acid. Avoid spilling or
contacting battery acid. Neutralize 9 Check the ambient air temperature and adjust
battery acid spills with baking soda the specific gravity reading for each cell as
and water. follows:
1 Put on protective clothing and eye wear. • Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
2 Be sure that the battery cable connections are
free of corrosion. • Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion Result: All battery cells display a specific gravity
on the battery terminals and cables. of 1.277 or greater. The battery is fully charged.
Proceed to step 10.
3 Be sure that the battery retainers and cable
connections are tight. Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
4 Fully charge the battery. Allow the battery to the specific gravity of one or more cells is less
rest 24 hours before performing this procedure than 1.217. Replace the battery.
to allow the battery cells to equalize.
10 Check the battery acid level. If needed,
5 Remove the battery vent caps and check the replenish with distilled water to 1/8 inch / 3 mm
specific gravity of each battery cell with a below the bottom of the battery fill tube. Do not
hydrometer. Note the results. overfill.
11 Install the vent caps and neutralize any
electrolyte that may have spilled.
Part No. 84793 GS-84 • GS-90 3 - 13

CHECKLIST B PROCEDURES REV E
B-2 5 Start the engine from the ground controls and

raise the platform approximately 18 feet / 5.5 m
Inspect the Electrical Wiring from the ground.
6 Release the safety arm latch, lift the safety arm
and rotate to a vertical position. Lock the safety
arm in position.
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes Note: Be sure that the safety arm is locked in the
first. vertical position.
Maintaining electrical wiring in good condition is 7 Lower the platform onto the safety arm. Stop
essential to safe operation and good machine the engine.
performance. Failure to find and replace burnt,
Crushing hazard. Keep hands
chafed, corroded or pinched wires could result in
clear of the safety arm when
unsafe operating conditions and may cause
lowering the platform.
component damage.
Component damage hazard. The
Electrocution hazard. Contact with
machine may be damaged if the
hot or live circuits could result in
platform is lowered after the safety
death or serious injury. Remove all
arm contacts the link set cross
rings, watches and other jewelry.
tube. Do not continue to lower the
1 Inspect the underside of the chassis for platform after the safety arm
damaged or missing ground strap(s). contacts the link set cross tube.
2 Inspect the following areas for burnt, chafed, 8 Inspect the center chassis area and scissor
corroded and loose wires: arms for burnt, chafed and pinched cables.
· Ground control panel 9 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Hydraulic power unit module tray
· Battery pack module tray · Scissor arms
· Scissor arms · ECM to platform controls
· Platform controls · Power to platform wiring
3 Inspect for a liberal coating of dielectric grease · Engine
in the following locations: 10 Inspect for a liberal coating of dielectric grease
in all connections between the ECM and the
· Between the ECM and platform controls
platform controls.
· Engine ECM (Ford models)
11 Raise the platform and return the safety arm to
· All wire harness connectors the stowed position.
· Level sensor
12 Lower the platform to the stowed position and
4 Turn the key switch to ground control and pull turn the machine off.
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
3 - 14 GS-84 • GS-90 Part No. 84793

REV E CHECKLIST B PROCEDURES
B-3
Check the Exhaust System

every 250 hours or quarterly, whichever comes
first.
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.
Bodily injury hazard. Do not

inspect while the engine is
running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
tray from moving.
3 Be sure that all fasteners are tight.
4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
Part No. 84793 GS-84 • GS-90 3 - 15

B-4 Deutz models:

Inspect the Engine Air Filter 1 Release the latches on the engine tray and fully
Genie requires that this procedure be performed the engine tray lock hole located near the
every 250 hours or quarterly, whichever comes engine tray roller wheels to prevent the engine
first. Perform this procedure more often if dusty tray from moving.
conditions exist. 3 Remove the air intake hose from the engine
slide out tray.
Maintaining the engine air filter in good condition is
essential to good engine performance and service 4 Disconnect the retaining clamp from the air
life. Failure to perform this procedure can lead to cleaner canister.
poor engine performance and component damage.
5 Remove the filter element.
6 Clean the inside of the canister and the gasket
Ford models: with a damp cloth.
1 Release the latches on the engine tray and fully 7 Inspect the air filter element. If needed, blow
slide the engine tray out. from the inside out using low pressure dry
compressed air, or carefully tap out dust.
2 Insert a 6 inch / 15 cm screwdriver or rod into Replace the filter if needed.
engine tray roller wheels to prevent the engine 8 Install the filter element.
tray from moving. 9 Install the air filter canister end cap and connect
3 Remove the retaining ring from the end cap of the end cap retaining clamp.
the air filter canister. Note: Be sure the air cleaner intake hose is
4 Remove the end cap from the air cleaner inserted in the hole in the front of the engine slide
canister. out tray.
5 Remove the air filter retaining fastener. Remove

the air filter element.
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.
Replace the filter if needed.
8 Install the filter element.
9 Install the air filter canister end cap and the end
cap retaining ring.
3 - 16 GS-84 • GS-90 Part No. 84793

B-5 Deutz models:

Check and Adjust the 1 Start the engine from the ground controls.
Engine RPM 2 Press and hold the start button and check the
engine RPM on the diagnostic display. Refer to
Section 2, Specifications.
Skip to step 6 if the low idle rpm is correct.
every 250 hours or quarterly, whichever comes 3 Release the latches on the engine tray and fully
first. slide the engine tray out.
Maintaining the engine rpm at the proper setting for 4 Insert a 6 inch / 15 cm screwdriver or rod into
both low and high idle is essential to good engine the engine tray lock hole located near the
performance and service life. The machine will not engine tray roller wheels to prevent the engine
operate properly if the rpm is incorrect and tray from moving.
continued use may cause component damage. 5 Loosen the low idle lock nut and turn the low
idle adjustment screw clockwise to increase the
Note: The on-board self diagnostics incorporate a
rpm, or counterclockwise to decrease the rpm.
built-in engine tachometer. The first two digits of
Tighten the low idle lock nut and repeat step 2.
the engine RPM are displayed on the diagnostic
display when the start toggle switch is moved to
a b
the START position with the engine running. Engine
RPM equals the first two digits multiplied by 100.
Note: Perform this procedure after warming the
engine to normal operating temperature.
Ford models:
Note: The engine rpm is controlled by the ECM

and can only be adjusted by re-programming the
ECM. If rpm adjustment or service is required,
please contact the Genie Industries Service
Department OR your local Ford dealer.
f e d c
Deutz models with throttle linkage
a low idle adjustment screw

b low idle lock nut
c yoke
d yoke lock nut
e high idle adjustment lock nuts
f solenoid boot
Part No. 84793 GS-84 • GS-90 3 - 17

6 Press the high idle (rabbit symbol) button. B-6

7 Press and hold the start button and check the Confirm the Proper
engine rpm on the diagnostic display. Refer to
Brake Configuration
Skip to step 11 if the high idle rpm is correct.
If the high idle rpm is not correct and the low

idle was just calibrated, proceed to step 10. All Genie requires that this procedure be performed
other machines, open the engine tray. Proceed every 250 hours or quarterly, whichever comes
to step 8. first.
8 Release the latches on the engine tray and fully Proper brake configuration is essential to safe
slide the engine tray out. operation and good machine performance.
Hydraulically-released, spring-applied individual
9 Insert a 6 inch / 15 cm screwdriver or rod into wheel brakes can appear to operate normally when
the engine tray lock hole located near the they are actually not fully operational.
tray from moving. 1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
10 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
disengaged position
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and confirm the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
11 Close and latch the engine slide out tray.
engaged position
3 - 18 GS-84 • GS-90 Part No. 84793

B-7 B-8
Inspect the Tires, Wheels and Check the Drive Hub Oil Level
Lug Nut Torque and Fastener Torque
Genie requires that this procedure be performed Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes
first. first.
Maintaining the tires and wheels in good Failure to maintain proper drive hub oil levels may
condition is essential to safe operation and good cause the machine to perform poorly and
performance. Tire and/or wheel failure could result continued use may cause component damage.
in a machine tip-over. Component damage may
also result if problems are not discovered and 1 Drive the machine to rotate the hub until the
repaired in a timely fashion. plugs are located one on top and the other at
90 degrees.
Bodily injury hazard. An over-
inflated tire can explode and could
Tip over hazard. Do not use a
temporary flat tire repair products.
Note: The tires on some machines are foam filled
a
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.
a drive hub plugs
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications. 2 Remove the plug located at 90 degrees and
check the oil level.
Models with air-filled tires:
Result: The oil level should be even with the
4 Check pressure in each air-filled tire. Add air as bottom of the side plug hole.
necessary. Refer to Section 2, Specifications.
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.
6 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
Part No. 84793 GS-84 • GS-90 3 - 19

B-9 B-10
Test the Key Switch Test the Emergency Stop
Genie requires that this procedure be performed Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes
first. first.
Proper key switch action and response is essential A properly functioning Emergency Stop is essential
to safe machine operation. The machine can be for safe machine operation. An improperly
operated from the ground or platform controls and operating red Emergency Stop button
the activation of one or the other is accomplished will fail to shut off power and stop all machine
with the key switch. Failure of the key switch to functions, resulting in a hazardous situation.
activate the appropriate control panel could cause
a hazardous operating situation. Note: As a safety feature, selecting and operating
the ground controls will override the platform
1 Pull out the red Emergency Stop button to the controls, except the platform red Emergency Stop
on position at both the ground and platform button.
controls.
1 Start the engine from ground controls.
2 Turn the key switch to ground controls and start
the engine. 2 Push in the red Emergency Stop button to the
off position.
3 Check any machine function from the platform
controls. Result: The engine should shut off and no
machine functions should operate.
Result: The machine functions should not
operate. 3 Start the engine from platform controls.
4 Turn the key switch to the off position. 4 Push in the red Emergency Stop button to the
off position.
5 Turn the key switch to platform controls and
start the engine. Result: The engine should shut off and no
machine functions should operate.
6 Check any machine function from the ground
controls. Note: The red Emergency Stop button at the
ground or platform controls will stop all machine
Result: The machine functions should not operation without regard to the position of the key
operate. switch.
7 Turn the key switch to the off position.
Result: The engine should stop and no
functions should operate.
3 - 20 GS-84 • GS-90 Part No. 84793

B-11 B-12
Test the Automotive-style Horn Test the Fuel Select Operation -
Genie requires that this procedure be performed Ford Models
first.
A functional horn is essential to safe machine

operation. The horn is activated at the platform Genie requires that this procedure be performed
controls and sounds at the ground as a warning to every 250 hours or quarterly, whichever comes
ground personnel. An improperly functioning horn first.
will prevent the operator from alerting ground The ability to select and switch between
personnel of hazards or unsafe conditions. gasoline and LPG fuels as needed is essential to
1 Turn the key switch to platform controls and safe machine operation. A fuel selection can be
pull out the red Emergency Stop button to the made while the engine is running or not.
on position at both the ground and Fuel switching malfunctions and/or the failure of
platform controls. the engine to start and run properly in both fuel
modes and through all idle speeds can indicate
2 Push down the horn button at the platform fuel system problems that could develop into a
controls. hazardous situation.
Result: The horn should sound. Note: Perform this test after checking the gasoline
Note: If necessary, the horn can be adjusted to and LPG fuel levels.
obtain the loudest volume by turning the 1 Start the engine from the platform controls and
adjustment screw near the wire terminals on the allow the engine to run at low idle.
horn.
2 Press high idle button at the platform controls to
allow the engine to run at high idle.
Result: The high idle indicator light should be on
and the engine should start promptly and
operate smoothly in low and high idle.
3 Press high idle button again to return the engine
to low idle.
Result: The high idle indicator light should turn
off and the engine should return to low idle.
Part No. 84793 GS-84 • GS-90 3 - 21

4 Press the engine stop button. B-13

Result: The engine should stop. Test the Drive Brakes
5 Press the LPG operation button.
Result: The LPG indicator light should be on.
6 Start the engine and allow it to run at low idle. Genie requires that this procedure be performed
7 Press high idle button to allow the engine to run
first.
at high idle.
Result: The high idle indicator light should be on Proper brake action is essential to safe machine
and the engine should start promptly and operation. The drive brake function should operate
operate smoothly in low and high idle. smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
Note: The engine may hesitate momentarily and brakes can appear to operate normally when they
then continue to run on the selected fuel if the fuel are actually not fully operational.
source is switched while the engine is running.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
Refer to B-7, Confirm the Proper
Brake Configuration.
Note: Select a test area that is firm, level and free
of obstructions.
Note: Be sure the platform is fully retracted and

lowered to the stowed position.
1 Mark a test line on the ground for reference.
2 Start the 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.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
3 - 22 GS-84 • GS-90 Part No. 84793

B-14 6 Bring the machine to maximum forward drive

speed before reaching the start line. Begin
Test the Drive Speed - timing when your reference point on the
Stowed Position 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
first.
timing when your reference point on the
Proper drive function movement is essential to machine crosses the start line.
safe machine operation. The drive function should 9 Continue at full speed and note the time when
respond quickly and smoothly to operator control. the machine reference point passes over the
Drive performance should also be free of finish line. Refer to Section 2, Specifications.
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

of obstructions.
Note: Be sure the platform is fully retracted and
lowered to the stowed position.
1 Create start and finish lines by marking two

lines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform controls and pull
controls.
4 Lower the platform to the stowed position.
when crossing the start and finish lines.
Part No. 84793 GS-84 • GS-90 3 - 23

B-15 B-16
Test the Drive Speed - Perform Hydraulic Oil Analysis
Raised Position

Genie requires that this procedure be performed first.
first. Replacement or testing of the hydraulic oil is
essential for good machine performance and
Proper drive function movement is essential to service life. Dirty oil and a clogged suction strainer
safe machine operation. The drive function should may cause the machine to perform poorly and
respond quickly and smoothly to operator control. continued use may cause component damage.
Drive performance should also be free of Extremely dirty conditions may require oil changes
hesitation, jerking and unusual noise over the to be performed more often. Refer to Section 2,
entire proportionally controlled speed range. Specifications.
Note: Select a test area that is firm, level and free Note: Before replacing the hydraulic oil, the oil may
of obstructions. be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
1 Create start and finish lines by marking two necessary. If the hydraulic oil is not replaced at
lines on the ground 40 feet / 12.2 m apart. the two year inspection, test the oil quarterly.
2 Turn the key switch to platform controls and pull Replace the oil when it fails the test. See E-1,
out the red Emergency Stop button to the on Test or Replace the Hydraulic Oil.
controls.
4 Press and hold a function enable/speed select
button. Raise the platform approximately
12 feet / 3.6 m from the ground.
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 when
the machine reference point passes over the
finish line. Refer to Section 2, Specifications.
3 - 24 GS-84 • GS-90 Part No. 84793

B-17 2 Check for proper venting.

Inspect the Fuel and Hydraulic Result: Air passes through the fuel tank cap.
Proceed to step 4.
Tank Cap Venting Systems
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
Genie requires that this procedure be performed air should pass freely through the cap.
first. Perform this procedure more often if dusty 3 Using a mild solvent, carefully wash the cap
conditions exist. venting system. Dry using low pressure
compressed air. Repeat this procedure
Free-breathing fuel and hydraulic tank caps are beginning with step 2.
essential for good machine performance and
service life. A dirty or clogged tank cap may cause 4 Install the fuel tank cap onto the fuel tank.
the machine to perform poorly and continued use 5 Remove the breather cap from the hydraulic
may cause component damage. Extremely dirty tank.
conditions may require that the caps be inspected
more often. 6 Check for proper venting.
Explosion and fire hazard. Engine Result: Air passes through the fuel tank cap.
fuels are combustible. Perform this Proceed to step 8.
procedure in an open, well- Result: If air does not pass through the cap,
ventilated area away from heaters, clean or replace the cap. Proceed to step 7.
sparks, flames and lighted
tobacco. Always have an Note: When checking for positive tank cap venting,
approved fire extinguisher within air should pass freely through the cap.
easy reach. 7 Using a mild solvent, carefully wash the cap
Note: Perform this procedure with the engine off. venting system. Dry using low pressure
compressed air. Repeat this procedure
1 Remove the cap from the fuel tank. beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
Part No. 84793 GS-84 • GS-90 3 - 25

B-18 B-19
Replace the Engine Air Filter Perform Engine Maintenance -
Element - Ford Models Ford Models

be performed every 400 hours or semi-annually,
whichever comes first. Perform this procedure
more often if dusty conditions exist. Required maintenance procedures and additional
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
1 Release the latches on the engine tray and fully Genie part number 84792
2 Insert a 6 inch / 15 cm screwdriver or rod into Ford DSG-423 EFI Operator Handbook
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.
with a damp cloth.
7 Install the new filter element.
8 Install the air filter canister end cap and the end
cap retaining ring.
3 - 26 GS-84 • GS-90 Part No. 84793

REV C
Checklist C Procedures
C-1 6 Tag and disconnect the black wire of the
maximum height limit switch wire harness from
Test the Platform Overload the A10 terminal of the terminal strip.
System (if equipped) 7 Tag and disconnect the white wire of the
maximum height limit switch wire harness from
the B9 terminal of the terminal strip.
8 Securely connect a jumper wire from terminal
Genie specifications require that this procedure be
A10 of the terminal strip to terminal B9 of the
performed every 500 hours or six months,
terminal strip.
whichever comes first OR when the machine fails
to lift the maximum rated load. 9 Turn the key switch to platform control and pull
Testing the platform overload system regularly is position at both the ground and platform
essential to safe machine operation. Continued controls.
use of an improperly operating platform overload
system could result in the system not sensing an 10 Fully raise the platform. Release the joystick.
overloaded platform condition. Machine stability
Result: The engine should stop and an alarm
could be compromised resulting in the machine
should sound and fault code 99 PLATFORM
tipping over.
OVERLOAD should be present in the ECM
Note: Perform this procedure with the machine on diagnostic display window at the ground
a firm, level surface that is free of obstructions. controls.
1 Disconnect the platform controls from the Result: The engine does not stop OR an alarm
machine at the platform. doesn't sound OR fault code 99 is not present
in the ECM diagnostic display window at the
2 Open the ground control panel and locate the ground controls. Refer to Repair Procedure
Electronic Control Module (ECM). 12-1, Calibrate the Platform Overload System
(if equipped).
3 Tag and disconnect the platform controls wire
harness from the ECM wire harness. 11 Activate the auxiliary lowering function and
lower the platform approximately 4.5 m.
4 Securely connect the platform controls to the
ECM wire harness. 12 Turn the key switch to the off position.
5 Locate the terminal strip behind the ground 13 Disconnect the jumper wire from terminal A10
control panel. of the terminal strip to terminal B9 of the
terminal strip.
Part No. 84793 GS-84 • GS-90 3 - 27

CHECKLIST C PROCEDURES REV C
14 Securely connect the black wire of the C-2

maximum height limit switch wire harness to
terminal A10 of the terminal strip. Replace the Engine Air Filter
15 Securely connect the white wire of the
Element - Deutz Models
maximum height limit switch wire harness to
terminal B9 of the terminal strip.
16 Turn the key switch to platform control. Note: Engine specifications require that this
17 Fully raise the platform. Release the joystick. procedure be performed every 500 hours or semi-
annually, whichever comes first. Perform this
Result: The platform should stop raising at procedure more often if dusty conditions exist.
maximum height. The engine should continue
to run and an alarm should not sound. Maintaining the engine air filter in good condition is
essential to good engine performance and service
Result: The engine stops OR an alarm sounds. life. Failure to perform this procedure can lead to
Refer to Repair Procedure 12-1, Calibrate the
Platform Overload System (if equipped).
19 Disconnect the platform controls from the ECM 1 Release the latches on the engine tray and fully
wire harness. slide the engine tray out.
20 Securely connect the platform controls wire 2 Insert a 6 inch / 15 cm screwdriver or rod into
harness to the ECM wire harness. the engine tray lock hole located near the
21 Securely connect the platform controls to the tray from moving.
platform controls wire harness at the platform.
3 Remove the air intake hose from the engine
slide out tray.
4 Disconnect the retaining clamp from the air
cleaner canister.
5 Remove the filter element.
with a damp cloth.
7 Install the new filter element.
8 Install the air filter canister end cap and connect
the end cap retaining clamp.
Note: Be sure the air cleaner intake hose is
inserted in the hole in the front of the engine slide
out tray.
3 - 28 GS-84 • GS-90 Part No. 84793

REV C CHECKLIST C PROCEDURES
C-3 C-4
Perform Engine Maintenance - Replace the Hydraulic Tank
Deutz Models Breather Cap - Models with
Optional Hydraulic Oil

whichever comes first. Genie requires that this procedure be performed
every 500 hours or semi-annually, whichever
Required maintenance procedures and additional comes first.
Deutz 2011 Operation Manual The hydraulic tank is a vented-type tank. The
(Deutz part number 0297 9929). breather cap has an internal air filter that can
become clogged or, over time, can deteriorate. If
Deutz 2011 Operation Manual the breather cap is faulty or improperly installed,
Genie part number 84794 impurities can enter the hydraulic system which
may cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.
1 Remove and discard the hydraulic tank breather

cap.
2 Install and new cap onto the tank.
Part No. 84793 GS-84 • GS-90 3 - 29

CHECKLIST C PROCEDURES REV C
C-5
Ford Models




3 - 30 GS-84 • GS-90 Part No. 84793

REV B
Checklist D Procedures
D-1 3 Measure the thickness of each platform scissor
arm wear pad at the steer end of the machine.
Check the Scissor Arm Wear
Result: The measurement is 5/16 inch / 8 mm or
Pads
more. Proceed to step 4.
Result: The measurement is less than
5/16 inch / 8 mm. Replace both wear pads.
Genie requires that this procedure be performed 4 Measure the thickness of each platform scissor
every 1000 hours or annually, whichever comes arm wear pad at the non-steer end of the
first. machine.
Maintaining the scissor arm wear pads in good Result: The measurement is 5/16 inch / 8 mm or
condition is essential to safe machine operation. more.
Continued use of worn out wear pads may result in
component damage and unsafe operating Result: The measurement is less than
conditions.
Note: Perform this procedure on a firm, level

surface with the platform in the stowed position.
1 Measure the thickness of each chassis wear

pad at the steer end of the machine.
2 Measure the thickness of each chassis wear

pad at the non-steer end of the machine.
Part No. 84793 GS-84 • GS-90 3 - 31

CHECKLIST D PROCEDURES REV B
D-2 4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each wheel hub
Check the Free-wheel at the non-steer end.
Configuration
5 Manually rotate each wheel at the non-steer
end.
Result: Each wheel should rotate with minimum
Genie requires that this procedure be performed effort.
every 1000 hours or annually, whichever comes 6 Engage the drive hubs by turning over
first. the hub disconnect caps. Rotate each wheel to
Proper use of the free-wheel configuration is check for engagement. Raise the machine and
essential to safe machine operation. The remove the blocks. Lower the machine.
free-wheel configuration is used primarily for Collision hazard. Failure to engage
towing. A machine configured to free-wheel without the drive hubs could result in
operator knowledge may cause death or serious death or serious injury and
injury and property damage. property damage.
Collision hazard. Select a work 7 Chock the wheels at the non-steer end of the
site that is firm and level. machine.
Component damage hazard. If the 8 Center a lifting jack of ample capacity
machine must be towed, do not (20,000 lbs / 10,000 kg) under the drive chassis
exceed 2 mph / 3.2 km/h. between the wheels at the steer end.
1 Chock the wheels at the steer end of the 9 Lift the wheels off the ground and place blocks
machine. under the drive chassis for support.
2 Center a lifting jack of ample capacity Crushing hazard. The chassis
(20,000 lbs / 10,000 kg) under the drive chassis could fall if not properly supported.
between the wheels at the non-steer end of the
10 Disengage the drive hubs by turning over the
machine.
drive hub disconnect caps on each wheel hub
3 Lift the wheels off the ground and place blocks at the steer end.
under the drive chassis for support.
11 Manually rotate each wheel at the steer end.
Crushing hazard. The chassis
Result: Each wheel should rotate with minimum
could fall if not properly supported.
effort.
disengaged position 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.
Collision hazard. Failure to engage
the drive hubs could result in
death or serious injury and
property damage.
engaged position
3 - 32 GS-84 • GS-90 Part No. 84793

REV B CHECKLIST D PROCEDURES
D-3 D-4
Replace the Drive Hub Oil Replace the Diesel Fuel
Filter/Water Separator -
Deutz Models
every 1000 hours or annually, whichever comes
first.
Replacing the drive hub oil is essential for good every 1000 hours or annually, whichever comes
machine performance and service life. Failure to first.
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and Replacing the diesel fuel filter/water separator is
continued use may cause component damage. essential to good engine performance and service
life. A dirty or clogged filter/water separator may
1 Select the drive hub to be serviced. Drive the cause the engine to perform poorly and continued
machine until one of the two plugs is at the use may cause component damage. Extremely
lowest point. dirty conditions may require that the filter/water
2 Remove both plugs and drain the oil into a separator be replaced more often.
suitable container. Explosion and fire hazard. Engine
3 Drive the machine until one plug is at the top fuels are combustible. Replace the
and the other is at 90 degrees. fuel filter/water separator in an
open, well-ventilated area away
from heaters, sparks, flames and
lighted tobacco. Always have an
a approved fire extinguisher within
easy reach.
a
a drive hub plugs tray from moving.
4 Fill the hub with oil from the top hole until the oil 3 Turn the manual fuel shutoff valves, located at
level is even with the bottom of the side hole. the fuel tank, to the closed position.
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.
Part No. 84793 GS-84 • GS-90 3 - 33

4 Remove the fuel filter/water separator with a D-5

filter wrench.
Replace the Hydraulic Filters

every 1000 hours or annually, whichever comes
first.
Replacing the hydraulic filters is essential to good

a 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 elements be replaced
more often.
b
hot oil. Contact with hot oil may
a oil filter cause severe burns.
b fuel filter/water separator
5 Fill the new filter with fresh diesel fuel and apply
a thin layer of diesel fuel to the new fuel filter Replace the Medium and High Pressure
gasket. Hydraulic Filter Elements
6 Install the new filter and tighten it securely by 1 Release the latches on the engine tray and fully
hand. Clean up any diesel fuel that might have slide the engine tray out.
spilled during the procedure.
7 Use a permanent ink marker to write the date the engine tray lock hole located near the
and number of hours from the hour meter on engine tray roller wheels to prevent the engine
the filter. tray from moving.
8 Turn the manual fuel shutoff valves, located at 3 Locate the medium pressure hydraulic filter
the fuel tank, to the open position. mounted on the side of the engine near the
pump.
inspect the fuel filter for leaks. 4 Remove the filter housing using a wrench on
the nut provided on the bottom of the housing.
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.
3 - 34 GS-84 • GS-90 Part No. 84793

REV B CHECKLIST D PROCEDURES
5 Remove the filter element from the housing. Replace the Hydraulic Tank Return Filter
6 Inspect the housing seal and replace it if 1 Open the function manifold tray door.
necessary.
2 Locate the hydraulic tank return filter located
7 Install the new filter and hand tighten the behind the ladder.
housing onto the filter head.
Note: The hydraulic filter is mounted on the
8 Locate the high pressure hydraulic filter function manifold next to the hydraulic power unit.
mounted next to the function manifold.
3 Remove the filter with an oil filter wrench. Clean
9 Remove the filter housing using a filter wrench.
the area where the hydraulic oil filter meets the
Bodily injury hazard. Spraying filter head.
hydraulic oil can penetrate and
Bodily injury hazard. Spraying
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. or spray.
11 Inspect the housing seal and replace it if 4 Apply a thin layer of oil to the new oil filter
necessary. gasket.
12 Install the new filter element and hand tighten 5 Install the new filter and tighten it securely by
the housing onto the filter head. hand.
13 Use a permanent ink marker to write the date 6 Use a permanent ink marker to write the date
and number of hours from the hour meter on and number of hours from the hour meter on
the filters. the filter.
14 Start the engine from the ground controls. 7 Clean up any oil that may have spilled during
the replacement procedure.
15 Inspect the filter assembly to be sure that there
are no leaks. 8 Turn the key switch to ground controls and pull
16 Clean up any oil that may have spilled during
the installation procedure.
controls.
9 Start the engine from the ground controls.
Part No. 84793 GS-84 • GS-90 3 - 35

10 Hold the function enable toggle switch in the up D-6

direction and activate the platform up function.
11 Inspect the filter and related components to
be sure that there are no leaks.4 Apply a
Deutz Models
thin layer of oil to the new oil filter gasket.
5 Install the new filter and tighten it securely by
hand. Engine specifications require that this procedure
be performed every 1000 hours or annually,
6 Use a permanent ink marker to write the date whichever comes first.
and number of hours from the hour meter on
the filter. Required maintenance procedures and additional
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 Deutz 2011 Operation Manual
position at both the ground and platform Genie part number 84794
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.
3 - 36 GS-84 • GS-90 Part No. 84793

REV B
Checklist E Procedures
E-1 1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
Test or Replace the Hydraulic Oil position at both the ground and platform
controls.
2 Start the engine.
Genie requires that this procedure be performed 3 Raise the platform approximately 18 feet / 5.5 m
every 2000 hours or every two years, whichever from the ground.
comes first. 4 Release the safety arm latch, lift the safety arm
Replacement or testing of the hydraulic oil is and rotate to a vertical position. Lock the safety
essential for good machine performance and arm in position.
service life. Dirty oil and suction strainers may Note: Be sure that the safety arm is locked in the
cause the machine to perform poorly and vertical position.
continued use may cause component damage.
Extremely dirty conditions may require oil changes 5 Lower the platform onto the safety arm and turn
to be performed more frequently. Refer to Section the engine off.
2, Specifications.
Component damage hazard. The clear of the safety arm when
work area and surfaces where this lowering the platform.
procedure will be performed must 6 Attach a lifting strap from an overhead crane to
be clean and free of debris that the entry ladder on the hydraulic tank side of
could get into the hydraulic the machine.
system.
7 Remove the entry ladder mounting fasteners
Note: Before replacing the hydraulic oil, the oil may and remove the entry ladder from the machine.
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is Crushing hazard. The entry ladder
necessary. If the hydraulic oil is not replaced at could become unbalanced and fall
the two year inspection, test the oil quarterly. when removed from the machine if
Replace the oil when it fails the test. not properly supported.
Note: When removing a hose assembly or fitting, 8 Remove the retaining fasteners from the access
the O-ring on the fitting and/or hose end must be plate located behind the hydraulic and fuel tank
replaced and then torqued to specification during tray and remove the access plate from the
installation. Refer to Section Two, Hydraulic Hose machine.
and Fitting Torque Specifications.
Note: In extreme cold conditions, 20°F / -6°C and
below, warm the engine for 5 minutes before
operating to prevent hydraulic system damage.
Part No. 84793 GS-84 • GS-90 3 - 37

CHECKLIST E PROCEDURES REV B
9 Close the two hydraulic shutoff valves located 11 Tag, disconnect and plug the two suction hoses
at the hydraulic tank. that are attached to the hydraulic tank
shutoff valves or tank.
engine must not be started with 12 Tag, disconnect and plug the tank return hose
the hydraulic tank shutoff valves in at the tank.
the closed position or component
13 Tag, disconnect and plug the T-fitting located at
damage will occur. If the tank
the tank with the 2 hoses connected to it.
valves are closed, remove the key
from the key switch and tag the 14 Remove the hydraulic tank strap retaining
machine to inform personnel of the fasteners and remove the hydraulic tank strap
condition. 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
tank could become unbalanced
and fall if it is not properly
open closed
supported and secured to the
10 Remove the drain plug from the hydraulic tank lifting device when it is removed
and completely drain the tank into a suitable from the machine.
container. See capacity specifications. 17 If equipped, remove the suction strainers from
Bodily injury hazard. Spraying the tank and clean them using a mild solvent.
hydraulic oil can penetrate and 18 Rinse out the inside of the tank using a mild
burn skin. Loosen hydraulic solvent.
the oil pressure to dissipate 19 If equipped, install the suction strainers using
gradually. Do not allow oil to squirt Loctite® 567 on the pipe threads.
or spray. Note: Always use Loctite® 567 on all pipe threads.
Bodily injury hazard. Beware of 20 Install the drain plug using Loctite® 567 on the
hot engine parts and oil. Contact pipe threads.
with hot oil and/or hot engine parts
may cause severe burns. Note: Always use Loctite® 567 on all pipe threads.
3 - 38 GS-84 • GS-90 Part No. 84793

REV B CHECKLIST E PROCEDURES
21 Install the hydraulic tank onto the machine. E-2

22 Install the hydraulic tank strap. Perform Engine Maintenance -
23 Install the two suction hoses. Ford Models
24 Install the tank return hose.
25 Install the T-fitting with the 2 hoses connected
to it. Engine specifications require that this procedure
26 Fill the tank with hydraulic oil until the level is be performed every 2400 hours or every two
within the top 2 inches / 5.1 cm from the top of years, whichever comes first.
the sight gauge. Do not overfill. Refer to Section
2, Specifications.
27 Clean up any oil that may have spilled during Ford LRG-425 EFI Operator Handbook
the procedure. (Ford part number FPP 194-302) OR the
28 Open the hydraulic tank shutoff valves.
Component damage hazard.
Be sure to open the two hydraulic Ford LRG-425 EFI Operator Handbook
tank shutoff valves and prime the Genie part number 84792
pump after installing the hydraulic
tank. Ford DSG-423 EFI Operator Handbook
Refer to Repair procedure 6-2, Genie part number 119488
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.
Part No. 84793 GS-84 • GS-90 3 - 39

CHECKLIST E PROCEDURES REV B
E-3 E-4
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Deutz Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 3000 hours or two years, be performed every 12,000 hours.
Required maintenance procedures and additional engine information is available in the
engine information is available in the Deutz 2011 Operation Manual
Deutz 2011 Operation Manual (Deutz part number 0297 9929).
Deutz 2011 Operation Manual Genie part number 84794
3 - 40 GS-84 • GS-90 Part No. 84793

June 2007 Section 4 • Repair Procedures
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.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of this
reverse order.
machine.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine. Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operator’s manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
available and ready for use. situation which, if not avoided,
could result in death or serious
Use only Genie approved replacement parts. injury.
Read each procedure completely and adhere Indicates a potentially hazardous
to the instructions. Attempting shortcuts may situation which, if not avoided,
produce hazardous conditions. may cause minor or moderate
Unless otherwise specified, perform each injury.
repair procedure with the machine in the Indicates a potentially hazardous
following configuration: situation which, if not avoided,
· Machine parked on a firm, level surface may result in property damage.
· Platform in the stowed position Indicates that a specific result is expected after
· Key switch in the off position with the key performing a series of steps.
removed Indicates that an incorrect result has occurred
· The red Emergency Stop button in the off after performing a series of steps.
· Wheels chocked
from the machin
Part No. 84793 GS-84 • GS-90 4-1

Section 4 • Repair Procedures June 2007
Platform Controls REV A
The platform controls, used to activate machine 1-1

functions from the platform or while standing on the
ground, contain a printed circuit board, joystick, Circuit Boards
decal membrane pad, buttons and LEDs. All of
these components are replaceable. How to Remove the Platform
The function speed parameters in the Electronic Controls Circuit Board
Control Module are easily adjusted by moving the
1 Push in the red Emergency Stop button to the
joystick, pressing a button or activating a toggle
off position at both the ground and platform
switch in a specific order when the ECM is in the
controls.
programming mode (PS showing in the diagnostic
display window). 2 Loosen the platform control box lid retaining
fasteners. Open the control box lid.
For further information or assistance, consult the
Genie Industries Service Department. 3 Visually locate the circuit board mounted to the
inside of the platform control box lid.
a
4 Secure the control box lid in a level position.
NC 1
5 Tag and disconnect the wire connectors from
b 2
the red Emergency Stop button.

6 Tag and disconnect the wire harness
c connectors from the platform controls circuit
board.
electrically charged circuits could
d
other jewelry.
e
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
a alarm H1
b red Emergency Stop button P2
with a metal part of the machine
c joystick controller JC1 that is grounded at all times when
d circuit board U3 handling printed circuit boards OR
e platform up/down and outrigger use a grounded wrist strap.
up/down toggle switch TS21
Note: 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.
4-2 GS-84 • GS-90 Part No. 84793

REV B
Platform Components
2-1 4 Cut the zip ties that secure the power to
platform wiring to the bottom of the platform.
Platform
Component damage hazard. Be
sure not to cut the power to
How to Remove the Platform platform wiring.
Bodily injury hazard. This 5 Cut the zip ties that secure the platform controls
procedure requires specific repair wiring to the bottom of the platform.
skills, lifting equipment and a
suitable workshop. Attempting this Component damage hazard. Be
procedure without these skills and sure not to cut the platform
tools could result in death or controls wiring.
serious injury and significant
component damage. Dealer
service is required. 7 Raise the platform slightly and return the safety
arm to the stowed position.
Note: Perform this procedure with the platform in
the stowed position and the platform extension 8 Lower the platform to the stowed position. Turn
deck(s) fully retracted and locked in position. the machine off.
1 Start the engine from the ground controls and 9 Locate the quick disconnect for the platform
raise the platform approximately 18 feet / 5.5 m controls under the platform at the steer end of
from the ground. the machine.
2 Release the safety arm latch, lift the safety arm 10 Tag and disconnect the platform controls from
and rotate to a vertical position. Lock the safety the control cable at the steer end of the
arm in position. machine.
Note: Be sure that the safety arm is locked in the 11 Remove the platform control box from the
vertical position. platform and lay it off to the side.
3 Lower the platform onto the safety arm. Turn 12 Remove the mounting fasteners that hold the
the machine off. platform controls quick disconnect plug to the
platform.
clear of the safety arm when 13 Lay the platform controls wiring off to the side.
lowering the platform. Component damage hazard. The
Component damage hazard. The platform controls wiring can be
linkset cross tube can be damaged if it is kinked or pinched.
damaged if excessive force is 14 Remove the AC power to platform outlet
applied. Do not continue to lower bracket mounting fasteners.
the platform after the safety arm
makes contact with the cross tube.
Part No. 84793 GS-84 • GS-90 4-3

PLATFORM COMPONENTS REV B
15 Remove the AC outlet box and bracket from the 20 Place a lifting strap from a second overhead
platform and lay them off to the side. Do not crane under the platform at the non-steer end of
disconnect the wiring. the machine for support. Do not apply any lifting
pressure.
AC power to platform wiring can Component damage hazard. The
be damaged if it is kinked or platform railings can be damaged
pinched. if used to lift the platform. Do not
attach the lifting straps to the
Note: If your machine is equipped with an air line to
platform railings.
platform option, the air line must be disconnected
from the platform before removal. 21 Remove the pin retaining fasteners from each
platform slider block pivot pin. Do not remove
16 Remove the pin retaining fasteners from the the pins.
platform centering links located under the
platform on both sides of the machine. Do not 22 Use a slide hammer to remove each platform
remove the pins. slider block pivot pin.
17 Place a rod through the platform centering link Crushing hazard. The platform will
pin and twist to remove the pin. Rest the fall when the platform slider block
platform centering link on the scissor arm. pivot pins are removed if not
properly supported by the
overhead cranes.
23 Secure the platform slider blocks to the platform
to prevent them from sliding out of the channel
when the platform is removed from the
machine.
24 Carefully lift the platform off of the machine and
place it on a structure capable of supporting it.
18 Repeat step 17 for the platform centering link Crushing hazard. The platform will
pivot pin on the other side of the machine. become unbalanced and fall when
it is removed from the machine if
19 Place a lifting strap from an overhead crane not properly supported by the
under the platform at the steer end of the overhead cranes.
machine for support. Do not apply any lifting
pressure. Bodily injury hazard. The platform
slider blocks could fall out from
Component damage hazard. The under the platform if they are not
platform railings can be damaged secured to the platform.
if used to lift the platform. Do not
attach the lifting straps to the
platform railings.
4-4 GS-84 • GS-90 Part No. 84793

REV B PLATFORM COMPONENTS
2-2 7 Attach a strap from the platform extension deck

railings to the carriage on the forklift to help
Platform Extension Deck support the platform extension deck.
8 Remove the three V-roller and extension deck
How to Remove a Platform lock bracket mounting fasteners from the
Extension Deck extension deck at the tank side of the machine.
Note: Perform this procedure with the platform in 9 Carefully pull the V-roller and extension deck
the stowed position and the platform extension lock assembly out of the extension deck.
deck(s) fully retracted and locked in position.
10 Remove the fasteners from the roller wheels
Note: If the machine is equipped with the dual located under the platform extension deck.
extension deck option, repeat this procedure for Remove the roller wheels.
the other platform extension deck. 11 Carefully slide the platform extension deck out
1 Steer end extension deck: Remove the of the platform and place it on a structure
platform controls from the platform and lay them capable of supporting it.
off to the side of the machine. Crushing hazard. The platform
2 Remove the retaining pins from the four black extension deck could become
plastic railing guides. Lower the railing guides in unbalanced and fall when
the down direction. removed from the machine if not
properly supported and secured to
3 Remove the mounting fasteners from the the forklift.
platform extension deck stop brackets at both
sides of the deck.
Note: The platform extension deck stop brackets
are located above the platform V-roller wheels.
4 At the platform extension deck to be removed,

position a fork lift with the forks even with the
bottom of the platform extension deck.
5 Lift the platform extension deck lock handle.
6 Carefully slide the platform extension deck out
until the platform extension deck makes contact
with the carriage on the forklift.
Part No. 84793 GS-84 • GS-90 4-5

Scissor Components REV B
2
11
3
12
4
13
14
6
7 15
8 16
9 17
18
10 19
Non-steer End Steer End
1 Platform centering link 10 Number 1 pivot pins (non-steer end)

2 Number 3 inner arm 11 Number 3 outer arm
3 Number 3 center pivot pins 12 Lift cylinder rod-end pivot pin
4 Number 3 pivot pins (non-steer end) 13 Number 3 pivot pins (steer end)
5 Number 2 outer arm 14 Number 2 center pivot pins
6 Number 2 inner arm 15 Number 2 pivot pins (steer end)
7 Number 2 pivot pins (non-steer end) 16 Number 1 outer arm
8 Number 1 inner arm 17 Number 1 center pivot pins
9 Lift cylinder barrel-end pivot pin 18 Chassis centering link
4-6 GS-84 • GS-90 Part No. 84793

REV B SCISSOR COMPONENTS
3-1 5 Use a soft metal drift to remove the lift cylinder

rod-end pivot pin (index #12). Lower the rod
Scissor Assembly, end of the lift cylinder down onto the number 2
GS-3384 and GS-3390 inner arm (index #6).
Crushing hazard. The lift cylinder
How to Disassemble the could fall when the lift cylinder rod-
Scissor Assembly end pivot pin is removed if not
properly supported by the
Bodily injury hazard. This overhead crane.
procedure requires specific repair
6 Tag, disconnect and plug the hydraulic hoses
from the lift cylinder. Cap the fittings on the
suitable workshop. Attempting this
cylinder.
procedure without these skills and
tools could result in death or Bodily injury hazard. Spraying
serious injury and significant hydraulic oil can penetrate and
component damage. Dealer burn skin. Loosen hydraulic
service is required. connections very slowly to allow
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose must be
or spray.
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose 7 Cut the zip ties attaching the hydraulic hoses to
and Fitting Torque Specifications. the lift cylinder. Lay the hoses out of the way.
1 Remove the platform. See 2-1, How to Remove Component damage hazard.
the Platform. Hoses can be damaged if they are
kinked or pinched.
2 Remove the cables from the platform centering
link (index #1) at the hydraulic tank side of the 8 Remove the cables from the number 2 inner
machine. arm (index #6) and lay the cables off to the
side.
3 Remove the pin retaining fasteners from the lift
cylinder rod-end pivot pin (index #12). Do not Component damage hazard.
remove the pin. Cables can be damaged if they
are kinked or pinched.
4 Attach a lifting strap from an overhead crane to
the lifting eye at the rod end of the lift cylinder. 9 Remove the pin retaining fasteners from the
cable tray pivot pin at the number 3 inner arm
(index #2).
Part No. 84793 GS-84 • GS-90 4-7

SCISSOR COMPONENTS REV B
10 Place a rod through the cable tray pivot pin and 17 Use a slide hammer to remove both number 3
twist to remove the pin. Lower the cable tray pivot pins (index #13) from the steer end of the
down. machine.
Component damage hazard. 18 Carefully remove the number 3 inner and outer
Cables can be damaged if they arms (index #2 and #11) from the machine.
Crushing hazard. The number 3
inner and outer arms could
become unbalanced and fall when
they are removed from the
machine if not properly supported
by the overhead crane.
Note: If further disassembly of the scissor arm pair
is required, see How to Disassemble a Scissor
Arm Pair.
11 Secure both ends of the number 3 inner and
19 Secure the non-steer end of the number 2 inner
outer arms (index #2 and #11) together with a
and outer arms (index #5 and #6) and the non-
strap or other suitable device.
steer end of the number 1 inner and outer arms
12 Attach a lifting strap from an overhead crane to (index #8 and #16) together with a strap or
the number 3 inner and outer arms (index #2 other suitable device.
and #11) at the steer end of the machine. Do
not apply any lifting pressure.
the number 1 outer arm (index #16) at the non-
13 Attach a lifting strap from an overhead crane to steer end of the machine. Do not apply any
the number 3 inner and outer arms (index #2 lifting pressure.
and #11) at the non-steer end of the machine.
21 Remove the pin retaining fasteners from the
Do not apply any lifting pressure.
number 1 pivot pins (index #10) at the non-
14 Remove the pin retaining fasteners from both steer end of the machine.
number 3 pivot pins (index #4) at the non-steer
22 Use a slide hammer to remove both number 1
end of the machine. Do not remove the pins.
pivot pins (index #10) from the non-steer end of
15 Remove the pin retaining fasteners from both the machine.
number 3 pivot pins (index #13) at the steer end
23 Carefully lift the number 1 outer arm at the
of the machine. Do not remove the pins.
non-steer end approximately 15 inches / 40 cm.
24 Place a 6 x 6 x 32 inch / 15 x 15 x 80 cm long
pivot pins (index #4) from the non-steer end of
block across both sides of the chassis under
the machine.
the barrel end of the lift cylinder.
4-8 GS-84 • GS-90 Part No. 84793

25 Lower the number 1 outer arm (index #16) onto 35 Remove the pin retaining fasteners from the
the block. cable tray pivot pin at the cross tube of the
number 2 inner arm (index #6).
clear of moving parts when 36 Place a rod through the cable tray pivot pin and
lowering the arms onto the block. twist to remove the pin. Lower the cable tray
onto the number 1 inner arm (index #8).
the lifting eyes on the lift cylinder. Crushing hazard. The cable tray
may fall if not properly supported
27 Remove the lift cylinder barrel-end pivot pin
28 Use a soft metal drift to remove the lift cylinder
Cables can be damaged if they
barrel-end pivot pin (index #9).
29 Carefully remove the lift cylinder from the
37 Secure both ends of the number 2 inner and
machine.
Crushing hazard. The lift cylinder strap or other suitable device.
could become unbalanced and fall
when it is removed from the
the number 2 inner and outer arms (index #5
and #6) at the steer end of the machine. Do not
apply any lifting pressure.
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 Do not apply any lifting pressure.
the slide blocks.
40 Remove the pin retaining fasteners from both
Crushing hazard. Keep hands number 1 pivot pins (index #10) at the
clear of moving parts when non-steer end of the machine. Do not remove
lowering the arms onto the blocks. the pins.
32 Secure the number 1 outer arm (index #16) to 41 Remove the pin retaining fasteners from both
the slide blocks. number 1 pivot pins (index #19) at the steer end
33 Remove the strap installed in step 19.
34 Support the cable tray with an overhead crane. pivot pins (index #10) from the non-steer end of
the machine.
Part No. 84793 GS-84 • GS-90 4-9

43 Use a slide hammer to remove both number 2 50 Place a rod through each chassis centering link
pivot pins (index #15) from the steer end of the pivot pin and twist to remove the pin. Rest the
machine. centering links on the chassis.
44 Carefully remove the number 2 inner and outer 51 Remove the pin retaining fasteners from the
arms (index #5 and #6) from the machine. number 1 inner arm slide blocks (index #19) at
the steer end of the machine.
inner and outer arms could 52 Use a slide hammer to remove the number 1
become unbalanced and fall when 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.
Arm Pair.
45 Remove the cables from the number 1 inner
arm (index #8).
46 Secure both ends of the number 1 inner and they are removed from the
outer arms (index #8 and #16) together with a machine if not properly supported
strap or other suitable device. by the overhead crane.
47 Attach a lifting strap from an overhead crane to Note: If further disassembly of the scissor arm pair
the number 1 inner and outer arms (index #8 is required, see How to Disassemble a Scissor
and #16) at the steer end of the machine. Do Arm Pair.
chassis centering link pivot pins (index #18) at
the number 1 inner arm.
4 - 10 GS-84 • GS-90 Part No. 84793

How to 4 Place a 12 inch / 30 cm block under the center

of the scissor arm pair. Lower the scissor arm
Disassemble a Scissor Arm Pair pair onto the block.
Bodily injury hazard. This 5 Remove the external snap rings from both
procedure requires specific repair center pivot pins.
suitable workshop. Attempting this 6 Use a soft metal drift to remove both center
procedure without these skills and pins.
tools could result in death or 7 Carefully separate the scissor arm pair.
component damage. Dealer Crushing hazard. The scissor
service is required. arms could become unbalanced
and fall if not properly supported
1 Attach a lifting strap from an overhead crane to by the overhead cranes.
the end of the outer arm.
Note: Attach the lifting strap to the end of the
scissor arm that has the casting pointing upwards.
a outer arm
b inner arm
2 Attach a lifting strap from a second overhead

crane to the end of the inner arm.
scissor arm that has the casting pointing upwards.
3 Raise the scissor arms with the overhead

cranes approximately 12 inches / 30 cm.
Part No. 84793 GS-84 • GS-90 4 - 11

2 14
4 15
16
5
17
18
6
19
7
20
8
9 21
10
22
11
12 23
13 24
1 Platform centering link 13 Number 1 pivot pins (non-steer end)

2 Number 4 outer arm 14 Number 4 inner arm
3 Number 4 center pivot pins 15 Number 4 pivot pins (steer end)
4 Number 4 pivot pins (non-steer end) 16 Number 3 outer arm
5 Number 3 center pivot pins 17 Lift cylinder rod-end pivot pin
6 Number 3 pivot pins (non-steer end) 18 Number 3 inner arm
7 Number 2 center pivot pins 19 Number 3 pivot pins (steer end)
11 Lift cylinder barrel-end pivot pin 23 Chassis centering link
12 Number 1 outer arm
4 - 12 GS-84 • GS-90 Part No. 84793

3-2 4 Secure both ends of the number 4 inner and

Scissor Assembly, GS-4390 strap or other suitable device.
How to Disassemble the the number 4 inner and outer arms (index #14
Scissor Assembly and #2) at the steer end of the machine. Do not
apply any lifting pressure.
Bodily injury hazard. This
procedure requires specific repair 6 Attach a lifting strap from an overhead crane to
skills, lifting equipment and a the number 4 inner and outer arms (index #14
suitable workshop. Attempting this and #2) at the non-steer end of the machine.
procedure without these skills and Do not apply any lifting pressure.
tools could result in death or
service is required.
installation. Refer to Section Two, Hydraulic Hose 9 Use a slide hammer to remove both number 4
and Fitting Torque Specifications. pivot pins (index #4) from the non-steer end of
the machine.
1 Remove the platform. See 2-1, How to Remove
the Platform. 10 Use a slide hammer to remove both number 4
pivot pins (index #15) from the steer end of the
2 Remove the cables from the platform centering machine.
link (index #1) at the hydraulic tank side of the
machine. 11 Carefully remove the number 4 inner and outer
arm (index #14) and lay the cables off to the Crushing hazard. The number 4
side. inner and outer arms could
Component damage hazard. they are removed from the
Cables can be damaged if they machine if not properly supported
are kinked or pinched. by the overhead crane.
Arm Pair.
Part No. 84793 GS-84 • GS-90 4 - 13

12 Remove the pin retaining fasteners from the lift 20 Cut the zip ties attaching the hydraulic hoses to
cylinder rod-end pivot pin (index #17). Do not the lift cylinder. Lay the hoses out of the way.
remove the pin.
13 Attach a lifting strap from an overhead crane to Hoses can be damaged if they are
the lifting eye at the rod end of the lift cylinder. kinked or pinched.
14 Use a soft metal drift to remove the lift cylinder 21 Remove the cables from the number 3 inner
rod-end pivot pin (index #17). Lower the rod arm (index #18) and lay the cables off to the
end of the lift cylinder down. side.
Crushing hazard. The lift cylinder Component damage hazard.
could fall if not properly supported Cables can be damaged if they
when the pin is removed. are kinked or pinched.
15 Block the steer end wheels and center a lifting 22 Remove the pin retaining fasteners from the
jack of ample capacity under the non-steer end cable tray pivot pin at the number 3 inner arm.
of the drive chassis.
23 Place a rod through the cable tray pivot pin and
16 Loosen the wheel lug nuts on one of the non- twist to remove the pin. Lower the cable tray
steer wheels. Do not remove them. down.
17 Raise the machine approximately Component damage hazard.
2 inches / 5 cm. Place blocks under the chassis Cables can be damaged if they
for support. are kinked or pinched.
Crushing hazard. The chassis will
fall if not properly supported.
18 Remove the wheel lug nuts. Remove the tire
and wheel assembly.
from the lift cylinder. Cap the fittings on the
cylinder.
hydraulic oil can penetrate and 24 Secure both ends of the number 3 inner and
burn skin. Loosen hydraulic outer arms (index #18 and #16) together with a
connections very slowly to allow strap or other suitable device.
or spray.
4 - 14 GS-84 • GS-90 Part No. 84793

25 Attach a lifting strap from an overhead crane to 32 Secure the non-steer end of the number 2 inner
the number 3 inner and outer arms (index #18 and outer arms (index #8 and #20) and the non-
and #16) at the steer end of the machine. Do steer end of the number 1 inner and outer arms
not apply any lifting pressure. (index #10 and #12) together with a strap or
other suitable device.
the number 3 inner and outer arms (index #18 33 Attach a lifting strap from an overhead crane to
and #16) at the non-steer end of the machine. the number 1 outer arm (index #12) at the non-
Do not apply any lifting pressure. steer end of the machine. Do not apply any
lifting pressure.
number 3 pivot pins (index #6) at the non-steer 34 Remove the pin retaining fasteners from the
end of the machine. Do not remove the pins. number 1 pivot pins (index #13) at the non-
steer end of the machine.
number 3 pivot pins (index #19) at the steer end 35 Use a slide hammer to remove both number 1
of the machine. Do not remove the pins. pivot pins (index #13) from the non-steer end of
the machine.
pivot pins (index #6) from the non-steer end of 36 Carefully lift the number 1 outer arm at the non-
the machine. steer end approximately 15 inches / 40 cm.
30 Use a slide hammer to remove both number 3 37 Place a 6 x 6 x 32 inch / 15 x 15 x 80 cm long
pivot pins (index #19) from the steer end of the block across both sides of the chassis under
machine. the barrel end of the lift cylinder.
31 Carefully remove the number 3 inner and outer 38 Lower the number 1 outer arm (index #12) onto
arms (index #18 and #16) from the machine. the block.
Crushing hazard. The number 3 Crushing hazard. Keep hands
inner and outer arms could clear of moving parts when
become unbalanced and fall when lowering the arms onto the block.
the lifting eyes on the lift cylinder.
Arm Pair. 41 Use a soft metal drift to remove the lift cylinder
Part No. 84793 GS-84 • GS-90 4 - 15

42 Carefully remove the lift cylinder from the 49 Place a rod through the cable tray pivot pin and
machine. twist to remove the pin. Lower the cable tray
could become unbalanced and fall Crushing hazard. The cable tray
when it is removed from the may fall if not properly supported
machine if not properly supported by the overhead crane.
43 Carefully lift the number 1 outer arm (index #12) Cables can be damaged if they
approximately 2 inches / 5 cm and remove the are kinked or pinched.
block.
44 Lower the number 1 outer arm (index #12) onto
the slide blocks.
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. 50 Secure both ends of the number 2 inner and
47 Support the cable tray with an overhead crane. strap or other suitable device.
48 Remove the pin retaining fasteners from the 51 Attach a lifting strap from an overhead crane to
cable tray pivot pin at the cross tube of the the number 2 inner and outer arms (index #8
number 2 inner arm (index #8). and #20) at the steer end of the machine. Do
4 - 16 GS-84 • GS-90 Part No. 84793

54 Remove the pin retaining fasteners from both 61 Attach a lifting strap from an overhead crane to
number 2 pivot pins (index #21) at the steer end the number 1 inner and outer arms (index #10
of the machine. Do not remove the pins. and #12) at the non-steer end of the machine.
pivot pins (index #9) from the non-steer end of 62 Remove the pin retaining fasteners from both
the machine. chassis centering link pivot pins (index #23) at
pivot pins (index #21) from the steer end of the 63 Place a rod through each chassis centering link
machine. pivot pin and twist to remove the pin. Rest the
centering links on the chassis.
arms (index #8 and #20) from the machine. 64 Remove the pin retaining fasteners from the
number 1 inner arm slide blocks (index #24) at
become unbalanced and fall when 65 Use a slide hammer to remove the number 1
they are removed from the inner arm slide block pivot pins (index #24).
Note: If further disassembly of the scissor arm pair the non-steer end of the machine.
Arm Pair.
arm (index #10).
59 Secure both ends of the number 1 inner and become unbalanced and fall when
outer arms (index #10 and #12) together with a they are removed from the
strap or other suitable device. machine if not properly supported
the number 1 inner and outer arms (index #10 Note: If further disassembly of the scissor arm pair
and #12) at the steer end of the machine. Do is required, see How to Disassemble a Scissor
not apply any lifting pressure. Arm Pair.
Part No. 84793 GS-84 • GS-90 4 - 17

How to Disassemble a Scissor 2 Attach a lifting strap from a second overhead

Arm Pair
Bodily injury hazard. This scissor arm that has the casting pointing upwards.
skills, lifting equipment and a 3 Raise the scissor arms with the overhead
suitable workshop. Attempting this cranes approximately 12 inches / 30 cm.
procedure without these skills and 4 Place a 12 inch / 30 cm block under the center
tools could result in death or of the scissor arm pair. Lower the scissor arm
serious injury and significant pair onto the block.
service is required. 5 Remove the external snap rings from both
center pivot pins.
the end of the outer arm. 6 Use a soft metal drift to remove both center
pins.
scissor arm that has the casting pointing upwards. 7 Carefully separate the scissor arm pair.
Crushing hazard. The scissor
arms could become unbalanced
by the overhead cranes.
a outer arm
b inner arm
4 - 18 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 4 - 19

1
18
2
4 19
5 20
6 21
7 22
8 23
9 24
10 25
11 26
12
27
13 28
14 29
15 30
16
31
17

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
5 Number 4 outer arm 20 Number 4 inner arm
6 Number 4 center pivot pins 21 Upper lift cylinder rod-end pivot pin
9 Upper lift cylinder barrel-end pivot pin 24 Lower lift cylinder rod-end pivot pin
11 Number 3 center pivot pins 26 Number 2 inner arm
12 Number 2 center pivot pins 27 Number 2 outer arm
15 Lower lift cylinder barrel-end pivot pin 30 Chassis centering link
31 Number 1 pivot pins (steer end)
4 - 20 GS-84 • GS-90 Part No. 84793

3-3 4 Secure both ends of the number 5 inner and

Scissor Assembly, GS-5390 strap or other suitable device.
How to Disassemble the the number 5 inner and outer arms (index #2
Scissor Assembly and #18) at the steer end of the machine. Do
procedure requires specific repair 6 Attach a lifting strap from an overhead crane to
skills, lifting equipment and a the number 5 inner and outer arms (index #2
suitable workshop. Attempting this and #18) at the non-steer end of the machine.
procedure without these skills and Do not apply any lifting pressure.
tools could result in death or
service is required.
installation. Refer to Section Two, Hydraulic Hose 9 Use a slide hammer to remove both number 5
and Fitting Torque Specifications. pivot pins (index #4) from the non-steer end of
the machine.
1 Remove the platform. See 2-1, How to Remove
the Platform. 10 Use a slide hammer to remove both number 5
pivot pins (index #19) from the steer end of the
2 Remove the cables from the platform centering machine.
link (index #1) and upper cable bridge at the
hydraulic tank side of the machine. 11 Carefully remove the number 5 inner and outer
arm (index #2) and lay the cables off to the Crushing hazard. The number 5
side. inner and outer arms could
Component damage hazard. they are removed from the
Cables can be damaged if they machine if not properly supported
are kinked or pinched. by the overhead crane.
Arm Pair.
Part No. 84793 GS-84 • GS-90 4 - 21

12 Remove the pin retaining fasteners from the 19 Remove the pin retaining fasteners from both
upper lift cylinder rod-end pivot pin (index #21). number 4 pivot pins (index #7) at the non-steer
Do not remove the pin. end of the machine. Do not remove the pins.
13 Attach a lifting strap from an overhead crane to 20 Remove the pin retaining fasteners from both
the lifting eye at the rod end of the upper lift number 4 pivot pins (index #22) at the steer end
cylinder. of the machine. Do not remove the pins.
14 Use a soft metal drift to remove the upper lift 21 Use a slide hammer to remove both number 4
cylinder rod-end pivot pin (index #21). Lower pivot pins (index #7) from the non-steer end of
the rod end of the upper lift cylinder down. the machine.
Crushing hazard. The upper lift 22 Use a slide hammer to remove both number 4
cylinder could fall when the upper pivot pins (index #22) from the steer end of the
lift cylinder rod-end pivot pin is machine.
removed if not properly supported
23 Support the rod end of the upper lift cylinder
with a suitable lifting device.
arm (index #20) and lay the cables off to the
arms (index #20 and #5) from the machine
side.
while guiding the rod end of the upper lift
Component damage hazard. cylinder out of the scissor arms.
Cables can be damaged if they
the number 4 inner and outer arms (index #20 Component damage hazard. The
and #5) at the steer end of the machine. Do not upper lift cylinder may fall if not
apply any lifting pressure. properly supported when the
number 4 inner and outer arms
are removed.
and #5) at the non-steer end of the machine. Note: If further disassembly of the scissor arm pair
Do not apply any lifting pressure. is required, see How to Disassemble a Scissor
Arm Pair.
4 - 22 GS-84 • GS-90 Part No. 84793

25 Lower the rod end of the upper lift cylinder onto 33 Place a rod through the cable tray pivot pin and
the cross tube of the number 3 inner arm twist to remove the pin. Lower the cable tray
(index #8). down.
from the upper lift cylinder. Cap the fittings on
the cylinder.
the oil pressure to dissipate Component damage hazard.
gradually. Do not allow oil to squirt Cables can be damaged if they
or spray. are kinked or pinched.
27 Remove the zip ties securing the hydraulic 34 Remove the pin retaining fasteners from the
hoses to the upper lift cylinder. hose tray pivot pin at the number 3 inner arm
28 Remove the pin retaining fasteners from the (index #11) on the ground controls side of the
lower cylinder rod-end pivot pin (index #24). machine.
29 Use a soft metal drift to remove the lower lift 35 Place a rod through the hose tray pivot pin and
cylinder rod-end pivot pin. twist to remove the pin. Lower the hose tray
down.
30 Carefully lower the rod end of the lower lift
cylinder onto the engine cover. Component damage hazard.
Hoses can be damaged if they are
31 Remove the cables and hydraulic hoses from kinked or pinched.
the number 3 inner arm (index #8) and lay the
cables and hoses off to the side. 36 Secure both ends of the number 3 inner and
Component damage hazard. strap or other suitable device.
Cables and hoses can be
damaged if they are kinked or 37 Attach a lifting strap from an overhead crane to
pinched. the number 3 inner and outer arms (index #8
and #23) at the steer end of the machine. Do
32 Remove the pin retaining fasteners from the not apply any lifting pressure.
cable tray pivot pin at the number 3 inner arm
(index #8) on the hydraulic tank side of the
machine.
Part No. 84793 GS-84 • GS-90 4 - 23

38 Attach a lifting strap from an overhead crane to 44 Secure the non-steer end of the number 2 inner
the number 3 inner and outer arms (index #8 and outer arms (index #26 and #27) and the
and #23) at the non-steer end of the machine. non-steer end of the number 1 inner and outer
Do not apply any lifting pressure. arms (index #14 and #16) together with a strap
or other suitable device.
number 3 pivot pins (index #10) at the non- 45 Attach a lifting strap from an overhead crane to
steer end of the machine. Do not remove the the number 1 outer arm (index #16) at the non-
pins. steer end of the machine. Do not apply any
lifting pressure.
number 3 pivot pins (index #25) at the steer end 46 Remove the pin retaining fasteners from the
of the machine. Do not remove the pins. number 1 pivot pins (index #17) at the non-
pivot pins (index #10) from the non-steer end of 47 Use a slide hammer to remove both number 1
the machine. pivot pins (index #17) from the non-steer end of
the machine.
pivot pins (index #25) from the steer end of the 48 Carefully lift the number 1 outer arm at the non-
machine. steer end approximately 15 inches / 40 cm.
43 Carefully remove the number 3 inner and outer 49 Place a 6 x 6 x 32 inch / 15 x 15 x 80 cm long
arms (index #8 and #23) and upper lift cylinder block across both sides of the chassis under
from the machine. the barrel end of the lift cylinder.
Crushing hazard. The number 3 50 Lower the number 1 outer arm (index #16) onto
inner and outer arms could the block.
lowering the arms onto the block.
the lifting eyes on the lift cylinder.
Arm Pair. 52 Remove the lift cylinder barrel-end pivot pin
53 Use a soft metal drift to remove the lift cylinder
4 - 24 GS-84 • GS-90 Part No. 84793

54 Carefully remove the lift cylinder from the 61 Place a rod through the cable tray pivot pin and
machine. twist to remove the pin. Lower the cable tray
could become unbalanced and fall Crushing hazard. The cable tray
when it is removed from the may fall if not properly supported
machine if not properly supported by the overhead crane.
55 Carefully lift the number 1 outer arm (index #16) Cables can be damaged if they
approximately 2 inches / 5 cm and remove the are kinked or pinched.
block.
56 Lower the number 1 outer arm (index #16) onto
the slide blocks.
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. 62 Secure both ends of the number 2 inner and
59 Support the cable tray with an overhead crane. strap or other suitable device.
60 Remove the pin retaining fasteners from the 63 Attach a lifting strap from an overhead crane to
cable tray pivot pin at the cross tube of the the number 2 inner and outer arms (index #26
number 2 inner arm (index #26). and #27) at the steer end of the machine. Do
number 2 pivot pins (index #13) at the non-
steer end of the machine. Do not remove the
pins.
Part No. 84793 GS-84 • GS-90 4 - 25

66 Remove the pin retaining fasteners from both 73 Attach a lifting strap from an overhead crane to
number 2 pivot pins (index #28) at the steer end the number 1 inner and outer arms (index #14
of the machine. Do not remove the pins. and #16) at the non-steer end of the machine.
pivot pins (index #13) from the non-steer end of 74 Remove the pin retaining fasteners from both
the machine. chassis centering link pivot pins (index #30) at
pivot pins (index #28) from the steer end of the 75 Place a rod through each chassis centering link
machine. pivot pin and twist to remove the pin. Rest the
centering links on the chassis.
arms (index #26 and #27) from the machine. 76 Remove the pin retaining fasteners from the
number 1 inner arm slide blocks (index #31) at
become unbalanced and fall when 77 Use a slide hammer to remove the number 1
they are removed from the inner arm slide block pivot pins (index #31).
Note: If further disassembly of the scissor arm pair the non-steer end of the machine.
Arm Pair.
arm (index #14).
the number 1 inner and outer arms (index #14 Note: If further disassembly of the scissor arm pair
and #16) at the steer end of the machine. Do is required, see How to Disassemble a Scissor
not apply any lifting pressure. Arm Pair.
4 - 26 GS-84 • GS-90 Part No. 84793

How to Disassemble a Scissor 2 Attach a lifting strap from a second overhead

Arm Pair
Bodily injury hazard. This scissor arm that has the casting pointing upwards.
skills, lifting equipment and a 3 Raise the scissor arms with the overhead
suitable workshop. Attempting this cranes approximately 12 inches / 30 cm.
procedure without these skills and 4 Place a 12 inch / 30 cm block under the center
tools could result in death or of the scissor arm pair. Lower the scissor arm
serious injury and significant pair onto the block.
service is required. 5 Remove the external snap rings from both
center pivot pins.
the end of the outer arm. 6 Use a soft metal drift to remove both center
pins.
scissor arm that has the casting pointing upwards. 7 Carefully separate the scissor arm pair.
Crushing hazard. The scissor
arms could become unbalanced
by the overhead cranes.
a outer arm
b inner arm
Part No. 84793 GS-84 • GS-90 4 - 27

3-4 5 Place a rod through each platform centering link

pivot pin and twist to remove the pin. Rest the
Wear Pads centering links on the scissor arms.
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. 6 Remove the pin retaining fasteners from each
platform slide block pivot pin. Do not remove
2 Place a lifting strap from a second overhead
the pins.
crane under the platform at the non-steer end of
the machine for support. Do not attach the 7 Use a slide hammer to remove each platform
lifting straps from the overhead crane to the slide block pivot pin.
platform railings.
Crushing hazard. The platform will
3 Lift the platform slightly using the overhead fall when the platform slider block
cranes just enough to take the pressure off the pivot pins are removed if not
platform slide block pivot pins. properly supported by the
overhead cranes.
4 Remove the pin retaining fasteners from each
platform centering link pivot pin at the platform. 8 Move each slide block towards the center of the
platform and carefully remove each platform
slide block from the platform.
9 Remove the retaining fasteners from the wear
pads on the slide blocks. Remove the wear
pads.
10 Install the new wear pads onto the scissor arm
slide blocks.
11 Install the slide blocks onto the platform.
4 - 28 GS-84 • GS-90 Part No. 84793

12 Align the holes in the slide blocks with the holes 4 Release the latches on the engine tray and fully
in the scissor arms. slide the engine tray out.
13 Install the slide block pivot pins and the pin 5 Insert a 6 inch / 15 cm screwdriver or rod into
retaining fasteners. the engine tray lock hole located near the
14 Attach the platform centering links to the
tray from moving.
platform and install the platform centering link
pivot pins and the pin retaining fasteners. 6 Remove the retaining fasteners from the top
engine cover plate. Remove the plate from the
Chassis Scissor Arm Wear Pads:
machine.
Note: If removing the steer end slide blocks, the 7 Loosen the retaining fasteners from each side
engine top and side covers need to be removed engine cover plate. Remove the engine side
first. Proceed to step 1. cover plates from the machine.
Note: If removing the non-steer end slide blocks, 8 Start the engine from the ground controls.
proceed to step 11.
9 Raise the platform slightly and return the safety
1 Start the engine from the ground controls and arm to the stowed position.
from the ground. 10 Lower the platform to the stowed position.
2 Release the safety arm latch, lift the safety arm 11 Secure the ends of the scissor arms together at
and rotate to a vertical position. Lock the safety both ends of the machine with a tie down strap
arm in position. or other appropriate device.
Note: Be sure that the safety arm is locked in the 12 Attach a lifting strap from an overhead crane to
vertical position. the end of the scissor arms that need the slide
blocks removed.
3 Lower the platform onto the safety arm. Turn
13 Raise the scissor arms using the overhead
the machine off.
crane just enough to take the pressure off the
Crushing hazard. Keep hands slide block pivot pins.
lowering the platform.
chassis slide block pivot pin.
linkset cross tube can be
damaged if excessive force is
applied. Do not continue to lower
Part No. 84793 GS-84 • GS-90 4 - 29

15 Use a slide hammer to remove the chassis slide 3-5

block pivot pin. Remove the slide block from the
machine by sliding it out the end of the slider Lift Cylinder(s)
channel.
The lift cylinders are double acting hydraulic
Crushing hazard. The platform will cylinders. The GS-3384, GS-3390 and GS-4390
fall when the platform slide block use one lift cylinder; the GS-5390 uses two. Each
pivot pins are removed if it is not lift cylinder is equipped with a counterbalance
properly supported by the valve to prevent movement in the event of a
overhead cranes. hydraulic line failure.
16 Remove the retaining fasteners from the wear
pads on the slide blocks. Remove the wear How to Remove the Lift Cylinder
pads. GS-3384, GS-3390 and GS-4390:
17 Install the new wear pads onto the scissor arm
Bodily injury hazard. The
slide blocks.
counterbalance valve in the lift
18 Install the slide blocks onto the chassis. cylinder is factory set. Do not
attempt to adjust the
19 Align the holes in the slide blocks with the holes counterbalance valve. Attempting
in the scissor arms. to adjust the counterbalance valve
20 Install the slide block pivot pins and the pin could result in death or serious
retaining fasteners. injury and significant component
damage. Dealer service is strongly
21 Repeat steps 12 through 20 for the remaining recommended.
scissor arm wear pads.
22 Install the top engine cover plate. procedure requires specific repair
23 Tighten the engine side cover plate fasteners. skills, lifting equipment and a
24 Close and latch the engine slide out tray. procedure without these skills and
25 Lower the platform to the stowed position. tools could result in death or
service is strongly recommended.
installation. Refer to Section Two, Hydraulic Hose

from the ground.
4 - 30 GS-84 • GS-90 Part No. 84793

2 Release the safety arm latch, lift the safety arm 6 Attach a lifting strap from an overhead crane or
and rotate to a vertical position. Lock the safety similar lifting device to the lifting eye at the rod
arm in position. end of the lift cylinder for support.
Note: Be sure that the safety arm is locked in the 7 Attach a lifting strap from a second overhead
vertical position. crane or similar lifting device to the lifting eye at
the barrel end of the lift cylinder for support.
3 Lower the platform onto the safety arm. Turn
the machine off. 8 Remove the lift cylinder rod-end pivot pin
retaining fastener. Use a soft metal drift to
Crushing hazard. Keep hands remove the pin.
lowering the platform. Crushing hazard. The lift cylinder
will fall if it is not properly
Component damage hazard. The supported.
damaged if excessive force is 9 Carefully lower the cylinder onto the cross tube
applied. Do not continue to lower of the number 2 inner arm. Protect the cylinder
the platform after the safety arm rod from damage.
4 Tag, disconnect and plug the hydraulic hoses counterbalance valve on the lift
from the lift cylinder. Cap the fittings on the cylinder can be damaged if it is
cylinder. allowed to come in contact with
the scissor arm cross tube.
hydraulic oil can penetrate and 10 Remove the lift cylinder barrel-end pivot pin
burn skin. Loosen hydraulic retaining fastener. Use a soft metal drift to
connections very slowly to allow remove the pin.
or spray.
supported.
5 Cut the zip ties attaching the hydraulic hoses to
11 Carefully pull the lift cylinder out the non-steer
the lift cylinder. Lay the hoses out of the way.
end of the machine through the scissor arms
Component damage hazard. and safety arm. Remove the lift cylinder from
Hoses can be damaged if they are the machine.
kinked or pinched.
may become unbalanced and fall
machine if not properly supported.
Part No. 84793 GS-84 • GS-90 4 - 31

GS-5390: 3 Lower the platform onto the safety arm. Turn

the machine off.
Bodily injury hazard. The
counterbalance valves in the lift Crushing hazard. Keep hands
cylinders are factory set. Do not clear of the safety arm when
attempt to adjust the lowering the platform.
counterbalance valves. Attempting
to adjust the counterbalance
valves will result in death or
damaged if excessive force is
applied. Do not continue to lower
service is strongly recommended.
Bodily injury hazard. This 4 Tag, disconnect and plug the hydraulic hoses
procedure requires specific repair from the lift cylinder. Cap the fittings on the
skills, lifting equipment and a cylinder.
procedure without these skills and Bodily injury hazard. Spraying
tools could result in death or hydraulic oil can penetrate and
serious injury and significant burn skin. Loosen hydraulic
component damage. Dealer connections very slowly to allow
service is strongly recommended. the oil pressure to dissipate
Note: When removing a hose assembly or fitting, or spray.
replaced and then torqued to specification during 5 Lower lift cylinder: Cut the zip ties attaching
installation. Refer to Section Two, Hydraulic Hose the hydraulic hoses to the lift cylinder. Lay the
and Fitting Torque Specifications. hoses out of the way.
1 Start the engine from the ground controls and Component damage hazard.
raise the platform approximately 18 feet / 5.5 m Hoses can be damaged if they are
from the ground. kinked or pinched.
2 Release the safety arm latch, lift the safety arm 6 Attach a lifting strap from an overhead crane or
and rotate to a vertical position. Lock the safety similar lifting device to the lifting eye at the rod
arm in position. end of the lift cylinder for support.
Note: Be sure that the safety arm is locked in the

vertical position.
4 - 32 GS-84 • GS-90 Part No. 84793

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
remove the pin.
supported.
9 Carefully lower the cylinder to a horizontal
position. Protect the cylinder rod from damage.
counterbalance valve on the lift
cylinder can be damaged if it is
allowed to come in contact with
the scissor arm cross tube.
remove the pin.
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.
may become unbalanced and fall
machine if not properly supported.
Part No. 84793 GS-84 • GS-90 4 - 33

Engines REV C
4-1 How to Repair the Ford

RPM Adjustment LRG425 Engine
Repair procedures and additonal engine
Refer to Maintenance Procedure B-6,
information are available in the
Check and Adjust the Engine RPM.
Ford LRG-425 EFI Service Manual
(Ford part number 194-303) OR the
4-2 Ford LRG-425 EFI Fuel Injection Diagnosis
Engine Fault Codes - (Ford part number 194-306).
Ford Models
See 5-6, Engine Fault Codes, Ford Models
Ford LRG-425 EFI Service Manual
4-3 Ford LRG-425 EFI Fuel Injection Diagnosis

Engine Repair
How to Repair the Deutz How to Repair the Ford

F3L 2011 Engine DSG423 Engine
Repair procedures and additonal engine Repair procedures and additonal engine
information are available in the information are available in the
Deutz 2011 Operation Manual Ford DSG-423 EFI Operator Handbook
(Deutz part number 0297 9929) OR the (EDI part number 1060020) OR the
Deutz 2011 Workshop Manual Ford DSG-423 EFI Service Manual
(Deutz part number 297 9959). (EDI part number 1060040).
Deutz 2011 Operation Manual Ford DSG-423 EFI Operator Handbook

Genie part number 84794 Genie part number 119488
Deutz 2011Workshop Manual Ford DSG-423 EFI Service Manual

Genie part number 112574 Genie part number 119494
4 - 34 GS-84 • GS-90 Part No. 84793

REV C ENGINES
4-4 Ford LRG425:

Flex Plate 3 Remove the hose clamp from the air cleaner
hose that connects to the throttle body.
The flex plate couples the engine to the pump. The
4 Disconnect the valve cover vent hose from the
flex plate is bolted to the engine flywheel and has a
air cleaner.
cut-out in the center for the pump coupler.
5 Remove the air filter mounting fasteners.
a b c d e 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.
f Explosion and fire hazard. Engine
fuels are combustible. Replace the
a pump
b pump shaft fuel hoses in an open, well-
c coupler ventilated area away from heaters,
d flex plate sparks, flames and lighted
e flywheel tobacco. Always have an
f 7/16 inch / 11 mm gap - Deutz F3L 2011
f 7/16 inch / 11 mm gap - Ford LRG425 approved fire extinguisher within
f 0.080 inch / 2 mm gap - Ford DSG423 easy reach.
Explosion and fire hazard. Liquid
How to Remove the Flex Plate - Petroleum Gas (LPG) is kept at a
Ford Models very high pressure. Fuel may be
expelled under pressure if the
All models: hose is removed too quickly.
Loosen the LPG supply hose very
slowly to allow the fuel pressure to
dissipate gradually. Wrap a cloth
2 Insert a 6 inch / 15 cm screwdriver or rod into around LPG supply hose to
the engine tray lock hole located near the absorb leaking fuel before
engine tray roller wheels to prevent the engine disconnecting them.
tray from moving.
Liquid Petroleum Gas (LPG).
Contact with LPG may cause
severe burns.
Part No. 84793 GS-84 • GS-90 4 - 35

ENGINES REV C
8 Remove the ground wire for the LPG solenoid All models:
from the ECM mounting fastener.
15 Center a lifting jack under the engine oil pan.
9 Remove the engine ECM mounting bracket
fasteners. Remove the engine ECM from the 16 Place a wood block between the lifting jack and
engine slide out tray and carefully lay it off to the engine oil pan.
the side. Component damage hazard. The
Component damage hazard. The engine oil pan can become
engine ECM is a sensitive damaged if the engine is raised
instrument. It can be damaged with the lifting jack without the
internally if the ECM is dropped or wood block between the lifting jack
sustains any physical shock, even and the engine oil pan.
if the damage is not visible. 17 Remove the fasteners securing the bell housing
10 Remove the exhaust pipe clamp from the to the slide out tray.
exhaust pipe support bracket. 18 Raise the engine slightly with the lifting jack to
Ford DSG423: take the pressure off the rubber vibration
isolators under the bell housing. Remove the
11 Tag and disconnect the exhaust gas sensor in rubber vibration isolators.
the exhaust pipe adjacent to the engine exhaust
manifold.
the pump and bell housing assembly for
12 Remove the exhaust pipe, located between the support. Do not apply any lifting pressure.
exhaust manifold and muffler, from the
20 Remove all of the bell housing to engine
machine.
fasteners.
13 Remove the medium pressure filter assembly
21 Carefully pull the pump and bell housing away
from the muffler mount and lay it to the side.
from the engine and secure it from moving.
14 Remove the muffler and mufler mount assembly
from the machine.
kinked or pinched.
22 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
4 - 36 GS-84 • GS-90 Part No. 84793

REV C ENGINES
How to Remove the Flex Plate - How to Install the Flex Plate
Deutz Models 1 Install the flex plate onto the engine flywheel
1 Release the latches on the engine tray and fully with the raised spline towards the pump.
slide the engine tray out. 2 Ford models: Torque the flex plate mounting
2 Insert a 6 inch / 15 cm screwdriver or rod into bolts in sequence to 14 ft-lbs / 19 Nm.
the engine tray lock hole located near the Deutz models: Torque the flex plate mounting
engine tray roller wheels to prevent the engine bolts in sequence to 28 ft-lbs / 38 Nm.
tray from moving.
3 Ford models: Torque the flex plate mounting
3 Remove the hose clamp from the air cleaner bolts in sequence to 20 ft-lbs / 27 Nm.
hose that connects to the engine.
Deutz models: Torque the flex plate mounting
4 Remove the air filter mounting fasteners. bolts in sequence to 40 ft-lbs / 54 Nm.
Remove the air filter from the engine and lay it
off to the side. 1
5 Remove the exhaust pipe clamp from the

exhaust pipe support bracket.
6 3
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.
4 5
kinked or pinched.
9 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel. 2
Flex plate bolt torque sequence
Part No. 84793 GS-84 • GS-90 4 - 37

ENGINES REV C
4 Install the pump coupler onto the pump shaft

with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine. 6 5
a b c d e
3
2
4 1
f Bell housing bolt torque sequence
(Ford LRG425)
a pump
b pump shaft 6
c pump coupler
d flex plate with raised spline 1 B
B
e engine flywheel 3
f 7/16 inch / 11 mm gap A
5 Apply Loctite® removable thread sealant to the

pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm. 4 A
6 Ford LRG425 and Deutz models: Install the

pump and bell housing assembly. Torque the
bell housing mounting bolts labeled "C" in C C
sequence to 28 ft-lbs / 38 Nm. 7 B 5

2
Ford DSG423 models: Install the pump and
bell housing assembly. Torque the bell housing Bell housing bolt torque sequence
mounting bolts labeled "A" and "B" in sequence (Ford DSG423)
to 28 ft-lbs / 38 Nm and the mounting bolts 6 1
labeled "C" to 49 ft-lbs / 66 Nm.
10 8
When installing the pump, do not
force the pump coupler into the 4
flexplate or damage to the pump 3
shaft seal may occur.
Component damage hazard. Do
not force the drive pump during
11 12
installation or the flex plate teeth
may become damaged.
7 5
2 9
Bell housing bolt torque sequence
(Deutz F3L 2011)
4 - 38 GS-84 • GS-90 Part No. 84793

REV C ENGINES
7 Ford LRG-425 and Deutz models: Torque the

bell housing mounting bolts labeled "C" in
sequence to 40 ft-lbs / 54 Nm.
Ford DSG-423 models: Torque the bell
housing mounting bolts labeled "A" and "B" in
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "C" to 70 ft-lbs / 95 Nm.
8 Ford models: Install the air cleaner mount
bracket onto the bell housing. Install the
fasteners and torque to 28 ft-lbs / 38 Nm.
Part No. 84793 GS-84 • GS-90 4 - 39

Ground Controls REV C
5-1 5-2
Auxiliary Platform Lowering Controller Adjustments
In the event of an engine failure, activating the All machine function speeds are determined by the
back-up manual lowering and manual lowering percentage of total ECM voltage output. The
enable switches will lower the platform when the speeds of the following machine functions may be
red Emergency Stop buttons are pulled out to the adjusted to compensate for wear in the hydraulic
on position at both the ground and platform pump and drive motors.
controls. The auxiliary down switches/buttons are
located at the ground control panel. There is no · Stowed drive speed
adjustment required. · High torque drive speed
One 12V DC battery is used to start the engine, · Raised drive speed
power the auxiliary pump and the ECM. The · Platform lift speed
battery is located behind the ground control door
· Platform lower speed
assembly.
· 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.
Tip-over hazard. This procedure
must only be performed by a
trained service professional.
Attempting this procedure without
the necessary skills will result in
death or serious injury.
of obstructions.
How to
Determine the Revision Level
position at both platform and ground controls.
Result: The revision level of the ECM will
appear in the LED display window.
4 - 40 GS-84 • GS-90 Part No. 84793

REV C GROUND CONTROLS
How to Adjust the Stowed Drive b

a
Speed
c
specified in this procedure. Setting d
specifications could cause the a diagnostic display
machine to tip over resulting in b blue platform up button
c lift function enable button
death or serious injury. d yellow platform down button
Note: On machines with software revision B1 or Result: TUNE SPEEDS is showing in the diagnostic
lower, stowed drive speeds in forward and reverse display window. The ECM is now in
are simultaneously adjusted, resulting in both programming mode.
directions of travel operating at the same speed.
On machines with software revision C0 or higher, 5 Press the lift function enable button.
the stowed forward drive speed and the stowed
6 Use the yellow platform down arrow to scroll to
reverse drive speed may be adjusted independent
max high speed drive.
of one another. See 5-2, How to Determine the
Revision Level. Result: MAX HIGH SPEED DRIVE is showing in the
diagnostic display window.
Models with software revision B1 or lower:
7 Press the lift function enable button.
1 Pull out the red Emergency Stop button to the
on position at the platform controls. 8 Press the yellow platform down button to
decrease the drive speed or press the blue
2 Push in the red Emergency Stop button to the platform up button to increase the drive speed.
off position at the ground controls. Refer to Section 2, Specifications.
3 Turn the key switch to ground control. Note: The performance achieved should always be
4 Press and hold both the blue platform up and within specifications.
yellow platform down buttons. Pull out the red 9 Press the lift function enable button.
Emergency Stop button to the on position at the
ground controls. 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.
Part No. 84793 GS-84 • GS-90 4 - 41

GROUND CONTROLS REV C
Models with software revision C0 or higher:

a b
on position at the platform controls. c

off position at the ground controls. d
3 Turn the key switch to ground control.

a diagnostic display
4 Press and hold both the blue platform up and b blue platform up button
yellow platform down buttons. Pull out the red d yellow platform down button
ground controls. 10 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnostic 11 Use the yellow platform down arrow to scroll to
display window. The ECM is now in max rev high speed drive.
programming mode.
Result: MAX REV HIGH SPEED DRIVE is showing in
5 Press the lift function enable button. the diagnostic display window.
6 Use the yellow platform down arrow to scroll to 12 Press the lift function enable button.
max fwd high speed drive.
13 Press the yellow platform down button to
Result: MAX FWD HIGH SPEED DRIVE is showing in decrease the drive speed or press the blue
the diagnostic display window. platform up button to increase the drive speed.
Refer to Section 2, Specifications.
Note: The performance achieved should always be
within specifications.
platform up button to increase the drive speed. 14 Press the lift function enable button.
Note: The performance achieved should always be off position at the ground controls.
16 Check the stowed drive speed of the machine.
9 Press the lift function enable button. Refer to the Maintenance procedure B-15, Test
the Drive Speed - Stowed Position.
Result: TUNE SPEEDS is showing in the diagnostic
display window. The ECM is now in
programming mode.
4 - 42 GS-84 • GS-90 Part No. 84793

How to Adjust the b

a
High Torque Drive Speed
c
death or serious injury. c lift function enable button
d yellow platform down button
Note: On machines with software revision B1 or
4 Press and hold both the blue platform up and
lower, high torque drive speeds in forward and
yellow platform down buttons. Pull out the red
reverse are simultaneously adjusted, resulting in
both directions of travel operating at the same
ground controls.
speed.
On machines with software revision C0 or higher, Result: TUNE SPEEDS is showing in the diagnostic
the high torque forward drive speed and the high display window. The ECM is now in
torque reverse drive speed may be adjusted programming mode.
independent of one another. See 5-2, How to
Determine the Revision Level. 5 Press the lift function enable button.
Models with software revision B1 or lower:
max high torque drive.
Result: MAX HIGH TORQUE DRIVE is showing in the
on position at the platform controls.
3 Turn the key switch to ground control. decrease the drive speed or press the blue
platform up button to increase the drive speed.

Part No. 84793 GS-84 • GS-90 4 - 43


a b


yellow platform down buttons. Pull out the red c lift function enable button
Emergency Stop button to the on position at the d yellow platform down button
programming mode.
Result: MAX REV HIGH TORQUE DRIVE is showing in
max fwd high torque drive.
Result: MAX FWD HIGH TORQUE DRIVE is showing in decrease the drive speed or press the blue
7 Press the lift function enable button. Refer to Section 2, Specifications.
8 Press the yellow platform down button to Note: The performance achieved should always be
decrease the drive speed or press the blue within specifications.
platform up button to increase the drive speed.

programming mode.
4 - 44 GS-84 • GS-90 Part No. 84793

How to Adjust the Raised Drive b

a
Speed
c
death or serious injury. c lift function enable button
Note: On machines with software revision B1 or
lower, raised drive speeds in forward and reverse 5 Press the lift function enable button.
are simultaneously adjusted, resulting in both 6 Use the yellow platform down arrow to scroll to
directions of travel operating at the same speed. raised drive speed.
On machines with software revision C0 or higher,
the raised forward drive speed and the raised Result: MAX RAISED DRIVE SPEED is showing in the
reverse drive speed may be adjusted independent diagnostic display window.
of one another. See 5-2, How to Determine the 7 Press the lift function enable button.
Revision Level.
Note: The GS-5390 will not drive with the platform decrease the raised drive speed or press the
raised above 33 feet / 6.1 m. blue platform up button to increase the raised
Models with software revision B1 or lower: drive speed. Refer to Section 2, Specifications.
2 Push in the red Emergency Stop button to the 9 Press the lift function enable button.
off position at the ground controls. 10 Push in the red Emergency Stop button to the
3 Turn the key switch to ground control. off position at the ground controls.
4 Press and hold both the blue platform up and 11 Check the raised drive speed of the machine.
yellow platform down buttons. Pull out the red Refer to the Maintenance procedure B-16, Test
Emergency Stop button to the on position at the the Drive Speed - Raised Position.
ground controls.
programming mode.
Part No. 84793 GS-84 • GS-90 4 - 45


a b


programming mode.
Result: MAX REV RAISED DRIVE SPEED is showing in
max fwd high torque drive.
Result: MAX FWD RAISED DRIVE SPEED is showing in decrease the drive speed or press the blue
platform up button to increase the drive speed. 14 Press the lift function enable button.
Note: The performance achieved should always be off position at the ground controls.
16 Check the raised drive speed of the machine.
9 Press the lift function enable button. Refer to the Maintenance procedure B-16, Test
the Drive Speed - Raised Position.
programming mode.
4 - 46 GS-84 • GS-90 Part No. 84793

How to Adjust the Lift Speed b

a


ground controls. 8 Press the yellow platform down button to
decrease the maximum lift speed or press the
blue platform up button to increase the
maximum lift speed. Refer to Section 2,
programming mode.
Specifications.
6 Use the yellow platform down arrow to scroll to within specifications.
lift speed.
Result: MAX LIFT SPEED is showing in the
diagnostic display window. 10 Push in the red Emergency Stop button to the
11 Check the lift speed of the machine. Refer to
Part No. 84793 GS-84 • GS-90 4 - 47

How to Adjust the Platform Lower b

a
Speed
c
d
3 Turn the key switch to ground control. b blue platform up button
4 Press and hold both the blue platform up and d yellow platform down button
Emergency Stop button to the on position at the 7 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnostic decrease the platform descent speed or press
display window. The ECM is now in the blue platform up button to increase the
programming mode. platform descent speed. Refer to Section 2,
Specifications.
6 Use the yellow platform down arrow to scroll to within specifications.
descent speed.
Result: MAX DESCENT SPEED is showing in the
diagnostic display window. 10 Push in the red Emergency Stop button to the
11 Check the lower speed of the machine. Refer to
4 - 48 GS-84 • GS-90 Part No. 84793

How to Adjust the b

a
Platform Settling Speed
c
d
3 Turn the key switch to ground control. b blue platform up button
4 Press and hold both the blue platform up and d yellow platform down button
yellow platform down buttons. Pull out the red 7 Press the lift function enable button.
decrease the platform settling speed or press
Result: TUNE SPEEDS is showing in the diagnostic the blue platform up button to increase the
display window. The ECM is now in platform settling speed.
programming mode.
Component Damage Hazard. The
5 Press the lift function enable button. Platform Settling Speed is
6 Use the yellow platform down arrow to scroll to intended to slow the rate of
settling speed. platform descent just before the
reaching the stowed position.
Result: MAX SETTLING SPEED is showing in the Adjust the Platform Settling Speed
diagnostic display window. until the Platform Settling Speed
percentage is 3 to 5 points less
than the Platform Lowering
Speed percentage.
Part No. 84793 GS-84 • GS-90 4 - 49

How to Adjust the Steer Speed b

a

3 Turn the key switch to ground control. a diagnostic display

b blue platform up button
yellow platform down buttons. Pull out the red d yellow platform down button
Result: TUNE SPEEDS is showing in the diagnostic 8 Press the yellow platform down button to
display window. The ECM is now in decrease the steering speed or press the blue
programming mode. platform up button to increase the steering
speed.
steering speed. 10 Push in the red Emergency Stop button to the
Result: STEERING SPEED is showing in the
4 - 50 GS-84 • GS-90 Part No. 84793

5-3 Machine Option Definitions

Software Configuration
Descent Delay: This option halts descent at
The Electronic Control Module (ECM) contains approximately 12 feet / 3.6 m. All controls must
programming for all configurations of the GS-84 be released for 4 to 6 seconds before descent is
and GS-90. Machines can be adjusted to a re-enabled. Required for Europe.
different configuration using the buttons at the Lift/Drive Cut Out: Lift and drive functions are
ground controls. To determine the software disabled when the down limit switch is activated
revision level, see 7-2, How to Determine the and the machine is on a slope exceeding the
Revision Level. rating on the serial plate. Activated for all
ANSI and CSA models with machines.
all software revisions: Motion Alarm: The motion alarm will sound
1 Turn the key switch to ground controls and pull when activating a function.
out the red Emergency Stop buttons to the on Motion Beacons: The flashing beacons operate
position at both platform and ground controls. only when activating a function.
Result: The revision level of the ECM will
Overload: This cuts out all functions when the
appear in the LED display window. Note the
platform overload pressure switch is tripped. The
result.
red Emergency Stop button must be cycled
2 Push in the red Emergency Stop button to the before any function can be resumed. Required
off position at the ground controls. for Europe.
3 Press and hold both the blue platform up and Sim Operation: When enabled, this allows
yellow platform down buttons. Pull out the red some machine functions to be activated
Emergency Stop button to the on position at the simultaneously. Required to be disabled for
ground controls. European models.
Result: TUNE SPEEDS is showing in the diagnostic Beacons: When installed on the machine, the
display window. flashing beacons operate continuously when the
key switch is turned to ground or platform
a b controls and both red Emergency Stop buttons
are pulled out to the on position.
c
Part No. 84793 GS-84 • GS-90 4 - 51

Models with software revision D0 and lower, 9 Press the lift function enable button.
proceed to step 8.
Result: DESCENT DELAY is showing in the
Models with software revisions E0 and higher,
diagnostic display window. Press the lift
proceed to step 4.
function enable button to activate or deactivate
4 Use the yellow platform down arrow to scroll to the descent delay option.
select model.
10 Models with software revisions F0, E0, D0
Result: SELECT MODEL is showing in the and lower: Use the yellow platform down arrow
diagnostic display window. The ECM is now in to scroll to lift/drive cutout.
programming mode. Result: LFT/DRV CUTOUT ON is showing in the
5 Press the lift function enable button. diagnostic display window.
Result: GS68 DUAL FUEL is showing in the Result: LFT/DRV CUTOUT OFF is showing in the
diagnostic display window. diagnostic display window. Press the lift
function enable button to activate the lift/drive
6 GS-84 models with gasoline/LPG power: cutout option.
Use the yellow platform down arrow to
scroll to GS84 DUAL FUEL. Note: The lift/drive cutout option should be
activated or in the ON position.
GS-84 models with diesel power:
Use the yellow platform down arrow to 11 Use the yellow platform down arrow to scroll to
scroll to GS84 DIESEL. motion alarm.
GS-90 models with gasoline/LPG power: Result: MOTION ALARM is showing in the
Use the yellow platform down arrow to diagnostic display window.
scroll to GS90 DUAL FUEL.
12 Press the lift function enable button to activate
GS-90 models with diesel power: or deactivate the motion alarm option OR use
Use the yellow platform down arrow to the yellow platform down arrow to scroll to
scroll to GS90 DIESEL. motion beacon.
7 Press the lift function enable button to activate Result: MOTION BEACON is showing in the
the model/power option. diagnostic display window.
Result: SELECT MODEL is showing in the 13 Press the lift function enable button to activate
diagnostic display window. or deactivate the motion beacon option.
8 Use the yellow platform down arrow to scroll to Note: For this option to function correctly, the
select options. machine must be equipped with flashing beacons.
Result: SELECT OPTIONS is showing in the
diagnostic display window. The ECM is now in
programming mode.
4 - 52 GS-84 • GS-90 Part No. 84793

14 Models with platform overload (option): Use 17 Use the yellow platform down arrow to scroll to
the yellow platform down arrow to scroll to generator option.
overload.
Result: GENERATOR AUTO is showing in the
Result: OVERLOAD ON is showing in the diagnostic diagnostic display window. Press the lift
display window. function enable button to activate or deactivate
the generator option.
Result: OVERLOAD OFF is showing in the
diagnostic display window. Press the lift Note: For this option to function correctly, the
function enable button to activate the overload machine must be equipped with the required
option. generator components and the software set to
GENERATOR AUTO or GENERATOR ON.
sim operation. 18 Use the yellow platform down arrow to scroll to
Result: SIM OPERATION ON is showing in the outriggers option.
diagnostic display window. Result: OUTRIGGERS AUTO is showing in the
Result: SIM OPERATION OFF is showing in the
the outrigger option. Proceed to step 22.
function enable button to activate the sim
operation option. Note: For this option to function correctly, the
machine must be equipped with the required
Note: For all models except CE, the sim operation
outrigger components and the software set to
option should be activated or in the ON position.
OUTRIGGERS AUTO or OUTRIGGERS ON.
Models with software revisions E0, D0 or lower,
proceed to step 16. 19 Use the yellow platform down arrow to scroll to
Models with software revisions F0 and higher, beacons option.
proceed to step 19. Result: BEACONS OFF is showing in the diagnostic
display window. Press the lift function enable
button to activate or deactivate the beacons
beacons option.
option.
Result: BEACONS AUTO is showing in the
Note: For this option to function, the machine must
be equipped with flashing beacons.
the beacons option.
be equipped with flashing beacons and the
software set to BEACONS AUTO or BEACONS ON.
Part No. 84793 GS-84 • GS-90 4 - 53

20 Use the yellow platform down arrow to scroll to CE models with all software revisions:
generator option.
Result: GENERATOR OFF is showing in the out the red Emergency Stop buttons to the on
diagnostic display window. Press the lift position at both platform and ground controls.
the generator option. Result: The revision level of the ECM will
appear in the LED display window. Note the
Note: For this option to function correctly, the result.
generator components. 2 Push in the red Emergency Stop button to the
outriggers option.
Result: OUTRIGGERS OFF is showing in the Emergency Stop button to the on position at the
diagnostic display window. Press the lift ground controls.
the outrigger option.
display window.
Note: For this option to function correctly, the
machine must be equipped with the required a b
outrigger components.
c
ANSI and CSA models with
all software revisions:
d
return to the main menu. a diagnostic display
Result: RETURN TO MAIN MENU is showing in the c lift function enable button
diagnostic display window. d yellow platform down button
23 Press the lift function enable button. Models with software revision D0 and lower,
proceed to step 8.
Models with software revisions E0 and higher,
proceed to step 4.
off position at the ground controls. 4 Use the yellow platform down arrow to scroll to
select model.
Result: SELECT MODEL is showing in the
programming mode.
4 - 54 GS-84 • GS-90 Part No. 84793

5 Press the lift function enable button. 10 Models with software revisions F0, E0, D0
and lower: Use the yellow platform down arrow
Result: GS68 DUAL FUEL is showing in the
to scroll to lift/drive cutout.
Result: LFT/DRV CUTOUT ON is showing in the
6 GS-84 models with gasoline/LPG power:
scroll to GS84 DUAL FUEL. Result: LFT/DRV CUTOUT OFF is showing in the
function enable button to activate the lift/drive
cutout option.
scroll to GS84 DIESEL.
Note: The lift/drive cutout option should be
GS-90 models with gasoline/LPG power:
activated or in the ON position.
scroll to GS90 DUAL FUEL. 11 Use the yellow platform down arrow to scroll to
motion alarm.
Use the yellow platform down arrow to Result: MOTION ALARM is showing in the
scroll to GS90 DIESEL. diagnostic display window.
7 Press the lift function enable button to activate 12 Press the lift function enable button to activate
the model/power option. or deactivate the motion alarm option OR use
the yellow platform down arrow to scroll to
Result: SELECT MODEL is showing in the
motion beacon.
Result: MOTION BEACON is showing in the
select options.
or deactivate the motion beacon option.
programming mode. Note: For this option to function correctly, the
9 Press the lift function enable button. machine must be equipped with flashing beacons.
Result: DESCENT DELAY ON is showing in the 14 Use the yellow platform down arrow to scroll to
diagnostic display window. overload.
Result: DESCENT DELAY OFF is showing in the Result: OVERLOAD ON is showing in the diagnostic
diagnostic display window. Press the lift display window.
function enable button to activate the descent Result: OVERLOAD OFF is showing in the
delay option. diagnostic display window. Press the lift
Note: For CE models, the descent delay option function enable button to activate the overload
should be activated or in the ON position. option.
Note: For CE models, the overload option should
be activated or in the ON position.
Part No. 84793 GS-84 • GS-90 4 - 55

15 Use the yellow platform down arrow to scroll to 18 Use the yellow platform down arrow to scroll to
sim operation. outriggers option.
Result: SIM OPERATION OFF is showing in the Result: OUTRIGGERS AUTO is showing in the
diagnostic display window. diagnostic display window. Press the lift
Result: SIM OPERATION ON is showing in the
the outrigger option. Proceed to step 22.
function enable button to deactivate the sim Note: For this option to function correctly, the
operation option. machine must be equipped with the required
outrigger components and the software set to
Note: For CE models, the sim operation option
OUTRIGGERS AUTO or OUTRIGGERS ON.
should be deactivated or in the OFF position.
Models with software revisions E0, D0 or lower,
beacons option.
proceed to step 16.
Models with software revisions F0 and higher, Result: BEACONS OFF is showing in the diagnostic
proceed to step 19. display window. Press the lift function enable
button to activate or deactivate the beacons
16 Use the yellow platform down arrow to scroll to option.
beacons option.
Result: BEACONS AUTO is showing in the be equipped with flashing beacons.
function enable button to activate or deactivate 20 Use the yellow platform down arrow to scroll to
the beacons option. generator option.
Note: For this option to function, the machine must Result: GENERATOR OFF is showing in the
be equipped with flashing beacons and the diagnostic display window. Press the lift
software set to BEACONS AUTO or BEACONS ON. function enable button to activate or deactivate
the generator option.
generator option. Note: For this option to function correctly, the
Result: GENERATOR AUTO is showing in the generator components.
function enable button to activate or deactivate 21 Use the yellow platform down arrow to scroll to
the generator option. outriggers option.
Note: For this option to function correctly, the Result: OUTRIGGERS OFF is showing in the
machine must be equipped with the required diagnostic display window. Press the lift
generator components and the software set to function enable button to activate or deactivate
GENERATOR AUTO or GENERATOR ON. the outrigger option.
Note: For this option to function correctly, the
outrigger components.
4 - 56 GS-84 • GS-90 Part No. 84793

CE models with all software revisions: 5-4

22 Use the yellow platform down arrow to scroll to Level Sensor -
return to the main menu. Models without Outriggers
Result: RETURN TO MAIN MENU is showing in the
diagnostic display window. The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
Result: SELECT OPTIONS is showing in the received from the level sensor.
The tilt alarm sounds when the incline of the
24 Push in the red Emergency Stop button to the chassis exceeds 2° to the side, or 3° to the front or
off position at the ground controls. rear.
How to Install and Calibrate the

Level Sensor
Tip-over hazard. Failure to install
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.
If you are not installing a new level sensor,
proceed to step 10.

off position at the platform controls.
4 Remove the ground control panel retaining
fasteners and open the panel.
5 Locate the level sensor behind the ground
control panel.
Part No. 84793 GS-84 • GS-90 4 - 57

6 Tag and disconnect the wire harness from the 9 Connect the wire harness to the level sensor.
level sensor.
10 Turn the key switch to platform control and pull
7 Remove the level sensor retaining fasteners. out the red Emergency Stop buttons to the on
Remove the level sensor from the machine. position at both the ground and platform
controls.
8 Install the new level sensor onto the machine
with the "Y" on the level sensor base closest to 11 Tighten the level sensor adjusting fasteners
the steer end of the machine. Install and tighten until the bubble in the top of the level sensor is
the level sensor retaining fasteners. centered in the circles.
Tip-over hazard. The tilt level Note: Be sure there are threads showing through
sensor must be installed with the the top of the adjusting fasteners.
"Y" on the level sensor base
closest to the steer end of the Result: The tilt sensor alarm should not sound.
machine. Failure to install the tilt 12 Center a lifting jack under the drive chassis at
level sensor as instructed could the ground controls side of the machine.
result in the machine tipping over
causing death or serious injury. 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
MODELS steel block under both wheels at the ground
WITHOUT controls side of the machine.
a
OUTRIGGERS 15 Lower the machine onto the blocks.
d
16 Raise the platform approximately 16 feet / 5 m.
Y
b X c 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.
Level sensor - models without outriggers
18 Raise the machine slightly.
a chassis
b level sensor
c "X" indicator
d "Y" indicator
4 - 58 GS-84 • GS-90 Part No. 84793

19 Remove the blocks from under both wheels. 5-5

20 Lower the machine and remove the jack. Level Sensor -
21 Center a lifting jack under the drive chassis at Models with Outriggers
the engine side of the machine.
The Electronic Control Module (ECM) is
22 Raise the machine approximately
programmed to deactivate the lift and drive
4 inches / 10 cm.
functions and activate an alarm when a signal is
23 Models with RT tires: Place a received from the level sensor.
3 x 10 x 10 inch / 7.62 x 25 x 25 cm thick steel
block under both wheels at the ground controls When the outriggers are stowed, the tilt alarm
side of the machine. sounds when the incline of the chassis exceeds 2°
Models with flotation tires: Place a to the side.
3.15 x 10 x 10 inch / 8 x 25 x 25 cm thick steel When the outriggers are deployed, the tilt alarm
block under both wheels at the ground controls sounds when the incline of the chassis exceeds
side of the machine. 0.8° to the side.
24 Lower the machine onto the blocks.
At all times, the tilt alarm sounds when the incline
25 Raise the platform approximately 16 feet / 5 m. of the chassis exceeds 3° to the front or rear.
Result: The drive function and the lift function How to Install and Calibrate the
will not operate and the tilt alarm will sound at
180 beeps per minute. Level Sensor
Result: The level sensor alarm does not sound. Tip-over hazard. Failure to install
Adjust the level sensor until the alarm just or calibrate the level sensor as
begins to sound. instructed could result in the
machine tipping over causing
26 Lower the platform to the stowed position. death or serious injury. Do not
27 Push in the red Emergency Stop button to the install or calibrate the level sensor
off position at both the ground and platform other than specified in this
controls. procedure.
28 Turn the key switch to the off position. 1 Perform this procedure with the machine on a
firm, level surface that is free of obstructions.
30 Remove the blocks from under both wheels.
31 Lower the machine and remove the jack.
Part No. 84793 GS-84 • GS-90 4 - 59

3 Remove the ground control panel retaining 11 Install the new level sensor onto the machine
fasteners and open the panel. with the "X" on the level sensor base closest to
the steer end of the machine. Install and tighten
4 Locate the level sensor behind the ground
the level sensor retaining fasteners.
control panel.
Tip-over hazard. The tilt level
5 Disconnect the platform controls from the
sensor must be installed with the
machine at the platform.
"X" on the level sensor base
6 Open the large ground control panel door and closest to the steer end of the
locate the Electronic Control Module (ECM) machine. Failure to install the tilt
wire harness to platform controls wire harness level sensor as instructed could
connection below the ground controls. result in the machine tipping over
causing death or serious injury.
harness from the ECM wire harness.
8 Securely connect the platform controls to the
ECM wire harness.
If you are not installing a new level sensor,
proceed to step 13.
Install the level sensor: MODELS
9 Tag and disconnect the wire harness from the WITH
level sensor. OUTRIGGERS
d a
10 Remove the three level sensor retaining
X
fasteners. Remove the level sensor from the c Y b
machine.
Level sensor - models with outriggers
a chassis
b level sensor
c "Y" indicator
d "X" indicator
4 - 60 GS-84 • GS-90 Part No. 84793

12 Connect the wire harness to 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.
controls. Start the engine. Note: Be sure there are threads showing through
the top of each adjusting nut.
14 Set a multimeter to read DC voltage.
Adjust the side-to-side axis: 21 Disconnect the positive and negative leads.
22 Apply Sentry Seal to the adjusting nuts.
15 Without disconnecting the wire harness from
the level sensor, connect the negative lead of 23 Push in the red Emergency Stop button to the
the multimeter to the black wire at the level off position at the platform controls.
sensor.
24 Press and hold the auto level button and press
16 Without disconnecting the wire harness from and hold the left front outrigger button. Pull out
the level sensor, connect the positive lead of the red Emergency Stop button to the on
the multimeter to the yellow wire at the level position at the platform controls.
sensor.
25 Continue to hold the auto level button and left
17 Adjust the side-to-side axis of the level sensor front outrigger button for approximately 3
until the multimeter reads 2.5V DC. Tap the top seconds or until a beep is heard.
of the level sensor lightly with fingers after each
turn of an adjusting nut.
off position at the platform controls.
Note: Be sure there are threads showing through
Confirm the side-to-side level sensor setting:
the top of each adjusting nut.
27 Center a lifting jack under the drive chassis at
18 Disconnect the positive lead of the multimeter
the ground control side of the machine.
from the level sensor wire harness
Adjust the front-to-back axis:
6 inches / 15 cm.
19 Without disconnecting the wire harness from 29 Models with RT tires: Place a
the level sensor, connect the positive lead of 3 x 10 x 10 inch / 7.62 x 25 x 25 cm thick steel
the multimeter to the blue wire at the level block under both wheels at the ground controls
sensor. side of the machine
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.
Part No. 84793 GS-84 • GS-90 4 - 61

30 Lower the machine onto the blocks. 39 Lower the machine onto the blocks.
31 Pull out the red Emergency Stop button to the 40 Raise the platform approximately 16 feet / 5 m.
on position at platform controls. Start the
Result: The platform stops raising and the tilt
engine.
alarm will sound at 180 beeps per minute.
32 Raise the platform approximately 16 feet / 5 m.
Result: The platform does not stop raising and
Result: The platform stops raising and the tilt the tilt alarm does not sound. The level sensor
alarm will sound at 180 beeps per minute. must be replaced. Repeat this procedure
beginning with step 9.
Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor Note: For reference only, the output of the level
must be replaced. Repeat this procedure sensor should be approximately 3.3V DC. To
beginning with step 9. confirm, connect the positive lead of a multimeter
to the yellow wire at the level sensor, and the
Note: For reference only, the output of the level
negative lead to the black wire.
sensor should be approximately 1.7V DC. To
confirm, connect the positive lead of a multimeter 41 Lower the platform to the stowed position.
to the yellow wire at the level sensor, and the
negative lead to the black wire. 42 Raise the machine slightly.
Confirm the front-to-back level sensor setting:
36 Center a lifting jack under the drive chassis at 45 Center a lifting jack under the drive chassis at
the tank side of the machine. the steer end of the machine.
37 Raise the machine approximately 46 Raise the machine approximately

6 inches / 15 cm. 6 inches / 15 cm.
38 Models with RT tires: Place a 47 Models with RT tires: Place a

3 x 10 x 10 inch / 7.62 x 25 x 25 cm thick steel 4.36 x 10 x 10 inch / 11.07 x 25 x 25 cm thick
block under both wheels at the ground controls steel block under both wheels at the steer end
side of the machine of the machine
Models with flotation tires: Place a Models with flotation tires: Place a
3.15 x 10 x 10 inch / 8 x 25 x 25 cm thick steel 4.58 x 10 x 10 inch / 11.63 x 25 x 25 cm thick
block under both wheels at the ground controls steel block under both wheels at the steer end
side of the machine. of the machine.
4 - 62 GS-84 • GS-90 Part No. 84793

48 Lower the machine onto the blocks. 57 Lower the machine onto the blocks.
49 Raise the platform approximately 16 feet / 5 m. 58 Raise the platform approximately 16 feet / 5 m.
Result: The platform stops raising and the tilt Result: The platform stops raising and the tilt
alarm will sound at 180 beeps per minute. alarm will sound at 180 beeps per minute.
Result: The platform does not stop raising and Result: The platform does not stop raising and
the tilt alarm does not sound. The level sensor the tilt alarm does not sound. The level sensor
must be replaced. Repeat this procedure must be replaced. Repeat this procedure
beginning with step 9. beginning with step 9.
Note: For reference only, the output of the level Note: For reference only, the output of the level
sensor should be approximately 1.5V DC. To sensor should be approximately 3.4V DC. To
confirm, connect the positive lead of a multimeter confirm, connect the positive lead of a multimeter
to the blue wire at the level sensor, and the to the blue wire at the level sensor, and the
negative lead to the black wire. negative lead to the black wire.
50 Lower the platform to the stowed position. 59 Lower the platform to the stowed position.
51 Raise the machine slightly. 60 Raise the machine slightly.
52 Remove the blocks from under both wheels. 61 Remove the blocks from under both wheels.
53 Lower the machine and remove the jack. 62 Lower the machine and remove the jack.
54 Center a lifting jack under the drive chassis at 63 Turn the key switch to the off position.
the non-steer end of the machine.
6 inches / 15 cm.
56 Models with RT tires: Place a
steel block under both wheels at the steer end
of the machine
steel block under both wheels at the steer end
of the machine.
Part No. 84793 GS-84 • GS-90 4 - 63

5-6 4 Move and hold the run/test toggle switch to the

test position.
Engine Fault Codes -
Result: The check engine light should turn on.
Ford Models The check engine light should begin to blink.
How to Retrieve Engine Fault 5 Continue to hold the run/test toggle switch in the
test position. Count the blinks and note the
Codes results. Refer to Section 5, Fault Codes, for
definition of engine fault codes.
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses Note: Fault codes are two or three digits. The
signals from the sensors to initiate sequential fuel check engine light will blink the first digit of a two
injection and make constant and instantaneous digit code then will pause for 1.2 seconds and then
changes to ignition timing, fuel delivery and throttle blink the second digit. For example: the check
position to maintain the engine's running condition engine light blinks 5 consecutive times, pauses for
at its highest efficiency while at the same time 1.2 seconds and then blinks 1 time. That would
keeping exhaust emissions to a minimum. When a indicate code 51. The ECM is able to store up to
sensor fails or returns signals that are outside of six individual fault codes. There will be a 2.4
set parameters, the ECM will store a fault code in second pause between codes.
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
Refer to Section 5, Fault Codes. Use the Ford be reset to clear the fault code from the ECM. See
Engine ECM Fault Code Chart within Section 5 to 5-6, How to Clear Engine Fault Codes from the
aid in identifying the fault. ECM.
1 Open the ground controls side cover.
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 - 64 GS-84 • GS-90 Part No. 84793

How to Clear Engine Fault Codes

from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Locate the battery under the ground control

panel.
2 Disconnect the negative battery cable from the
battery for a minimum of 20 minutes.
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. 84793 GS-84 • GS-90 4 - 65

Hydraulic Pumps REV C
6-1 3 Ford models: Close the valve on the LPG tank,

then disconnect the hose from the tank (if
Lift/Steer Pump equipped). Move the fuel select toggle switch at
the ground controls to the LPG position.
the O-ring on the fitting and/or hose end must be Deutz models: Hold the manual fuel shut-off
replaced and then torqued to specification during lever clockwise in the closed position.
installation. Refer to Section 2, Hydraulic Hose and
a
Fitting Torque Specifications.
How to Test the Lift/Steer Pump

1 Tag, disconnect and plug the high pressure
hydraulic hose from the lift/steer pump.
or spray.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the lift/steer Deutz models
pump. a manual fuel shut-off lever

controls.
5 Observe the pressure gauge while cranking the
engine. Immediately stop if the pressure
reaches or exceeds 3500 psi / 241 bar.
a
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.
b 6 Remove the pressure gauge and connect the

hydraulic hose.
a drive pump
b lift/steer pump
4 - 66 GS-84 • GS-90 Part No. 84793

REV C HYDRAULIC PUMPS
How to Remove the 3 Insert a 6 inch / 15 cm screwdriver or rod into

Lift/Steer Pump engine tray roller wheels to prevent the engine
1 Locate the three hydraulic tank valves at the tray from moving.
hydraulic tank. Close the valves. 4 Tag, disconnect and plug the hydraulic hoses
from the lift/steer pump . Cap the fittings on the
pump.
open closed gradually. Do not allow oil to
squirt or spray.
engine must not be started with 5 Remove the pump mounting fasteners.
the hydraulic tank shutoff valves in Carefully remove the pump.
damage will occur. If the tank Component damage hazard..
valves are closed, remove the key Be sure to open the two hydraulic
from the key switch and tag the tank valves and prime the pump
machine to inform personnel of the after installing the pump.
condition. See 6-2, How to Prime the Pump.
Note: The hydraulic tank shutoff valves can be

accessed from under the hydraulic tank tray.

Part No. 84793 GS-84 • GS-90 4 - 67

HYDRAULIC PUMPS REV C
6-2 3 Tag, disconnect and plug the hydraulic hoses

from the drive pump. Cap the fittings on the
Drive Pump pump.
The drive pump is a bi-directional variable Bodily injury hazard. Spraying

displacement piston pump. The pump output is hydraulic oil can penetrate and
controlled by the electronic displacement controller burn skin. Loosen hydraulic
(EDC), located on the pump. The only adjustment connections very slowly to allow
that can be made to the pump is the neutral or null the oil pressure to dissipate
adjustment. Any internal service to the pump gradually. Do not allow oil to
should only be performed at an authorized squirt or spray.
Sundstrand-Sauer service center. Contact the 4 Support the drive pump with a suitable lifting
Genie Industries Service Department to locate device and remove the two drive pump
your local authorized service center. mounting fasteners.
How to Remove the Drive Pump 5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
work area and surfaces where this 6 Remove the drive pump from the machine.
procedure will be performed must Component damage hazard. The
be clean and free of debris that hydraulic pump may become
could get into the hydraulic system unbalanced and fall if not properly
and cause severe component supported when removed from the
damage. Dealer service is machine.
recommended.
Note: When removing a hose assembly or fitting, When installing the pump, do not
the O-ring on the fitting and/or hose end must be force the pump coupler into the
replaced and then torqued to specification during flexplate or damage to the pump
installation. Refer to Section Two, Hydraulic Hose shaft seal may occur.
1 Remove the lift/steer pump. See 6-1, How to sure to open the two hydraulic
Remove the Lift/Steer Pump. tank valves and prime the pump
2 Disconnect the electrical connections at the after installing the pump.
Electronic Displacement Controller (EDC) Note: Before installing the pump, verify proper
located on the drive pump. pump coupler spacing. See 4-3, Flex Plate.
4 - 68 GS-84 • GS-90 Part No. 84793

REV C HYDRAULIC PUMPS
How to Prime the Pump 3 Ford models: Close the valve on the LPG tank,
then disconnect the hose from the tank
Component damage hazard. Be (if equipped). Move the fuel select toggle switch
sure that the hydraulic tank shutoff at the ground controls to the LPG position.
valves are in the open position
before priming the pump. The Deutz models: Hold the manual fuel shut-off
engine must not be started with lever clockwise in the closed position.
the hydraulic tank shutoff valves in a
damage will occur.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to either diagnostic nipple on the drive
manifold.
controls.
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 325 psi / 22.4 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.
check for hydraulic leaks.
Part No. 84793 GS-84 • GS-90 4 - 69

HYDRAULIC PUMPS REV C
How to Adjust the Pump Neutral 9 Turn the adjustment screw in a clockwise
direction to a position halfway between the
Models with Eaton Pumps: positions noted in steps 7 and 8.
1 Raise the drive wheels off the ground and set 10 While holding the adjustment screw in position,
the chassis on blocks. tighten the adjustment screw locknut. Torque to
9-11 ft-lbs / 12-15 Nm.
2 Locate the pump at the rear of the engine. Tag
and disconnect the wire harness from the 11 Turn the engine off. Remove the blocks and
Electronic Displacement Controller (EDC) coils lower the machine to the ground.
at the pump.
3 Locate the pump neutral adjustment screw at
the top of the solenoid valve body at the pump.
a
4 Tee a 0 to 1000 psi / 0 to 75 bar pressure
gauge into the hydraulic line at the smaller filter b
port at the rear of the pump.
c
5 Start and run the engine at low idle.
6 Loosen the lock nut of the pump neutral d
adjustment screw at the top of the EDC.
7 Turn the adjustment screw in a clockwise
direction until the reading on the pressure
gauge drops to its lowest point. Note the
position of the screw.
8 Turn the adjustment screw in a counter
clockwise direction until the reading on the
pressure gauge reaches it highest point.
Continue to turn the adjustment screw in a
a pump neutral adjustment screw
counter clockwise direction until the reading on
b EDC
the pressure gauge drops to its lowest point. c large filter port
Note the position of the screw. d smaller filter port
4 - 70 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 4 - 71

Manifolds REV A
7-1
Function Manifold Components - Models with Outriggers
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index Schematic
No. Description Item Function Torque
1 Check valve,
5 psi / 0.3 bar .................................... AA .......... Platform down circuit ................................... 20 ft-lbs / 27 Nm
2 Diagnostic nipple .............................. AB .......... Testing
3 Relief valve, 3500 psi / 241.3 bar .... AC .......... System relief ............................................... 20 ft-lbs / 27 Nm
4 Proportional solenoid valve ............. AD .......... All functions ................................................. 35 ft-lbs / 47 Nm
5 Relief valve, 2000 psi / 138 bar ........ AE .......... Steering and outrigger circuit ...................... 25 ft-lbs / 34 Nm
6 Diagnostic nipple .............................. AF .......... Testing
7 DO3 valve, 3 position 4 way ............ AG .......... Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
8 Solenoid valve, 3 position 4 way ..... AH .......... Steer left/right .............................................. 25 ft-lbs / 34 Nm
9 Orifice - Plug, 0.150 inch / 3.8 mm ... AI ........... Platform down circuit
10 Flow regulator,
0.1 gpm / 0.38 L/min ......................... AJ .......... Bleeds off proportional
valve to tank ................................................ 20 ft-lbs / 27 Nm
11 DO3 valve, 3 position 4 way ............. AK .......... Outrigger up/down ............................... 30-35 in-lbs / 3-4 Nm
4 - 72 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
1 2
AA
AB
AC
3
AD
Y9 4
AE
5
AF
Y4 6
Y3
AH
AJ
AI
Y7
Y40
AG
7
11
AK
Note: 'alpha' callouts refer

to corresponding notes on
Y8
the hydraulic schematic
Y39
Note: 'alpha-numeric' callouts

refer to corresponding notes
on the electrical schematic 10 9 8
Part No. 84793 GS-84 • GS-90 4 - 73

MANIFOLDS REV A
7-2
Function Manifold Components - Models without Outriggers
The function manifold is located in the chassis tray on the ground controls side of the machine.
Index Schematic
1 Check valve,
5 psi / 0.3 bar .................................... AA .......... Platform down circuit ................................... 20 ft-lbs / 27 Nm
2 Diagnostic nipple .............................. AB .......... Testing
3 Relief valve, 3500 psi / 241.3 bar .... AC .......... System relief ............................................... 20 ft-lbs / 27 Nm
4 Proportional solenoid valve ............. AD .......... All functions ................................................. 35 ft-lbs / 47 Nm
5 Relief valve, 2000 psi / 138 bar ........ AE .......... Steer circuit ................................................. 25 ft-lbs / 34 Nm
6 Diagnostic nipple .............................. AF .......... Testing
7 DO3 valve, 3 position 4 way ............ AG .......... Platform up/down ................................. 30-35 in-lbs / 3-4 Nm
8 Solenoid valve, 3 position 4 way ..... AH .......... Steer left/right .............................................. 25 ft-lbs / 34 Nm
9 Orifice - Plug, 0.150 inch / 3.8 mm ... AI ........... Platform down circuit
10 Flow regulator,
0.1 gpm / 0.38 L/min ......................... AJ .......... Bleeds off proportional
valve to tank ................................................ 20 ft-lbs / 27 Nm
4 - 74 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
1 2
AA
AB
AC
3
AD
Y9 4
AE
5
AF
Y4 6
Y3
AH
AJ AI
Y7
AG
7

Y8

on the electrical schematic 10 9 8
Part No. 84793 GS-84 • GS-90 4 - 75

MANIFOLDS REV A
7-3
Drive Manifold Components
The drive manifold is located under the function manifold.
Index Schematic
1 Flow divider/combiner valve .............. EA ......... Controls flow to front and rear
drive motors ................................................. 50 ft-lbs / 68 Nm
2 Orifice - Plug, 0.043 inch / 1.1 mm .... EB ......... Balances flow from flow divider/
combiner (item EL) to front drive
motors
3 Diagnostic nipple ............................... EC ........ Testing "P2" pressure port
4 Orifice - Plug, 0.046 inch / 1.2 mm .... ED ........ Balances flow from flow divider/
combiner (item EK) to rear drive
motors .......................................................... 25 ft-lbs / 34 Nm
5 Relief valve, 280 psi / 19.3 bar .......... EE ......... Charge pressure circuit ................................ 20 ft-lbs / 27 Nm
6 Solenoid valve, 2 position 3 way ....... EF ......... 2-speed motor shift circuit ............................ 20 ft-lbs / 27 Nm
7 Orifice - Plug, 0.035 inch / 0.9 mm .... EG ........ Brake circuit
8 Orifice - Plug, 0.045 inch / 1.1 mm .... EH ........ 2-speed motor shift circuit
9 Shuttle valve, 2 position 3 way .......... EI .......... 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 3 way ....... EJ ......... 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 ......... 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 front and rear
drive motors ................................................. 25 ft-lbs / 34 Nm
14 Diagnostic nipple ............................... EN ........ Testing "P1" pressure port
4 - 76 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
EA
1
EB
2
EC
3
ED
4
EE
Y2
5
EH
Y1 EF
6
EG
EN
14
EM
13
EL
12
EK
11
Y2 Note: 'alpha-numeric' callouts

EJ refer to corresponding notes
10 on the electrical schematic
EI
Y1
9 8 7
Part No. 84793 GS-84 • GS-90 4 - 77

MANIFOLDS REV A
7-4
Oscillate Manifold Components, GS-90 Models (option)
The oscillate manifold is located under the function manifold.
Index Schematic
1 Solenoid valve, 2 position 2 way ....... DA ........ Oscillate activation ....................................... 25 ft-lbs / 34 Nm
2 Relief valve, 3500 psi / 241.3 bar ...... DB ........ System relief ................................................ 20 ft-lbs / 27 Nm
3 Relief valve, 900 psi / 62 bar ............. DC ........ Float circuit relief .......................................... 20 ft-lbs / 27 Nm
4 Priority flow regulator,
1 gpm / 3.8 L/min ............................... DD ........ Oscillate circuit ............................................. 25 ft-lbs / 34 Nm
5 Solenoid valve, 2 position 3 way ....... DE ........ Right oscillate circuit .................................... 20 ft-lbs / 27 Nm
6 Solenoid valve, 2 position 3 way ....... DF ......... Left oscillate circuit ....................................... 20 ft-lbs / 27 Nm
7 Solenoid valve, 2 position 2 way ....... DG ........ Oscillate float ............................................... 25 ft-lbs / 34 Nm
4 - 78 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
DA
Y55
DB
2
Y54
DG
7 DC
3
Y56
DF
6
Y57 Note: 'alpha' callouts refer
DE Note: 'alpha-numeric' callouts

5
on the electrical schematic
Y55
DD Y54
4
Y56
Part No. 84793 GS-84 • GS-90 4 - 79

MANIFOLDS REV A
7-5 5 Determine the test weight for your machine.

Refer to the specifications below.
Valve Adjustments -
Function Manifold Rated work load at full height, maximum
GS-3384 and GS-3390 2500 lbs

How to Adjust the System Relief 1135 kg
Valve GS-4390 1500 lbs
(most models - refer to capacity indicator decal) 680 kg
Note: Perform this procedure with a minimum
hydraulic oil temperature of 32°F / 0°C and a GS-4390 1800 lbs
maximum hydraulic oil temperature of (some models - refer to capacity indicator decal) 816 kg
120°F / 48°C.
GS-5390 1500 lbs
Note: Be sure that the hydraulic oil level is between 680 kg
the full and add marks on the oil level indicator.
1 Models with outriggers: Deploy the outriggers 6 Using a suitable lifting device, place the test
and level the machine. weight, determined in step 5, at the center of
Models without outriggers: Chock both sides the platform floor. Secure the weight to the
of the wheels at the steer end of the machine. platform.
2 Locate the system relief valve on the function 7 Turn the key switch to platform control and pull
manifold (item AC). out the red Emergency Stop button to the on
3 Connect a 0 to 5000 psi / 0 to 350 bar
controls. Start the engine.
pressure gauge to the test port on the function
manifold (item AB). 8 Press and hold the lift function enable button.
Note: Perform this test from the ground with the
platform controls. Do not stand in the platform.
4 - 80 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
9 Activate the platform up function and fully raise 14 Using a suitable lifting device, add an additional
the platform while observing the pressure weight to the platform not to exceed 20% of the
reading on the pressure gauge. maximum rated work load at full height. Secure
the weight to the platform. Refer to the
Result: The hydraulic pressure should not
specifications below.
exceed 3500 psi / 241 bar.
Result: The platform should lift and fully raise. Additional test weight
Proceed to step 13. GS-3384 and GS-3390 500 lbs
Result: The platform does not fully raise OR 227 kg
raises too easily. Proceed to step 10. GS-4390 375 lbs
Component damage hazard. Do (most models - refer to capacity indicator decal) 170 kg
not continue to operate the GS-4390 450 lbs
machine if the hydraulic pump is (some models - refer to capacity indicator decal) 204 kg
cavitating.
GS-5390 375 lbs
10 Turn the machine off. Hold the system relief 170 kg
valve with a wrench and remove the cap.
11 Adjust the internal hex socket. Turn it clockwise
15 Activate the platform up function and attempt to
to increase the pressure or counterclockwise to
raise the platform.
decrease the pressure. Install the relief valve
cap. Result: The platform does not raise. Proceed to
step 21.
12 Repeat this procedure beginning with step 7.
Result: The platform lifts. Proceed to step 16.
13 Fully lower the platform.
16 Lower the platform to the stowed position
17 Turn the machine off. Hold the system relief
valve with a wrench and remove the cap.
18 Adjust the internal hex socket. Turn it
counterclockwise to decrease the pressure.
Install the relief valve cap.
19 Start the engine.
20 Repeat this procedure beginning with step 15.
21 Turn the machine off and remove the weight
from the platform.
Part No. 84793 GS-84 • GS-90 4 - 81

MANIFOLDS REV A
How to Adjust the Steer Relief 7-6

Valve Valve Adjustments -
1 Connect a 0 to 3000 psi / 0 to 250 bar pressure Drive Manifold
gauge to the test port (item AB) on the function
manifold. How to Adjust the Charge
2 Start the engine from the platform controls. Pressure Relief Valve
3 Press and hold the function enable switch and 1 Connect a 0 to 600 psi / 0 to 50 bar pressure
hold the steer thumb rocker switch in the right gauge to test port #2 (item EC) on the drive
direction. Allow the wheels to completely turn to manifold.
the right, then continue holding the switch while
observing the pressure reading on the pressure 2 Start the engine from the platform controls.
gauge. Note the pressure. Refer to Section 2, 3 Drive the machine slowly in the direction
Specifications. indicated by the blue arrow on the platform
4 Turn the engine off. Use a wrench to hold the controls and observe the pressure reading on
relief valve and remove the cap (item AE). the pressure gauge. Refer to Section 2,
Specifications.
to increase the pressure or counterclockwise to Component damage hazard.
decrease the pressure. Install the relief valve Driving the machine in reverse will
cap. place excessive pressure on the
pressure gauge and will damage
Tip-over hazard. Do not adjust the gauge. Do not drive the
the relief valve higher than machine in a reverse direction.
specified.
4 Turn the engine off. Use a wrench to hold the
6 Repeat steps 2 through 3 to confirm the relief charge pressure relief valve and remove the
valve pressure. cap (item EE).
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.
4 - 82 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
7-7
Generator Manifold Components
The generator manifold is located below the ground controls.
Index Schematic
1 Solenoid valve, 2 position 3 way ............. AL .......... Generator on/off .................................... 25 ft-lbs / 34 Nm
2 Flow regulator, 4.3 gpm / 16.3 L/min ...... AM .......... Generator speed ................................... 20 ft-lbs / 27 Nm
3 Relief valve, 3000 psi / 206.8 bar ........... AN .......... Generator circuit ................................... 20 ft-lbs / 27 Nm

AL
1
Y29

on the electrical schematic
AM
2
AN
3
Part No. 84793 GS-84 • GS-90 4 - 83

MANIFOLDS REV A
7-8 5 Connect the positive and negative leads from a

multimeter of sufficient capacity to the electrical
Valve Adjustments - outlet at the generator.
Generator Manifold Result: The reading on the multimeter should be
112 to 118V AC.
How to Adjust the Generator
Result: If the reading on the multimeter is not
Voltage 112 to 118V AC, proceed to step 6.
Bodily injury hazard. Spraying 6 Turn the key switch to the off position.
burn skin. Loosen hydraulic 7 Use a wrench to hold the generator flow
connections very slowly to allow regulator valve (item AM) and remove the cap.
gradually. Do not allow oil to squirt AL
or spray.
other jewelry. a
Note: Be sure that the hydraulic oil level is between

the full and add marks on the oil level indicator.
1 Disconnect all electrical tools from the machine. AM
b
2 Start the engine from the platform controls. AN
3 Press the generator select switch.
a generator manifold
Result: The generator should activate and the b flow regulator
engine should go to high rpm. 8 Adjust the internal hex socket. Turn it clockwise
4 Connect an electrical tool, which does not draw to increase the AC voltage or counterclockwise
more than 15A, to the electrical outlet at the to decrease the AC voltage. Install the flow
platform controls and run the tool at full speed. regulator valve cap.
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.
9 Repeat steps 2 through 5 to confirm the
generator AC voltage.
4 - 84 GS-84 • GS-90 Part No. 84793

REV A MANIFOLDS
7-9 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 20°C
within the coil. Zero resistance or infinite resistance that your air temperature increases or decreases
indicates the coil has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Description Specification

resistance values outside specification can
Proportional valve, 12V DC 4.1Ω
produce erratic operation. When coil resistance
(schematic item AD)
decreases below specification, amperage
increases. As resistance rises above specification, DO3 valve, 3 position 4 way, 10V DC 3.6Ω
voltage increases. (schematic items AG and AK)
While valves may operate when coil resistance is Solenoid valve, 3 position 4 way 7.2Ω
outside specification, maintaining coils within 10V DC with diode (schematic item AH)
specification will help ensure proper valve function
Solenoid valve, 2 position 2 way 10V DC 5.5Ω
over a wide range of operating temperatures. (schematic items CA, CB, CC and CD)
Electrocution hazard. Contact with Solenoid valve, 2 position 3 way 6Ω
electrically charged circuits could 10V DC (schematic item AL)
Remove all rings, watches and Solenoid valve, 2 position 2 way 7.5Ω
other jewelry. 12V DC with diode (schematic item DA)
Note: If the machine has been in operation, allow Solenoid valve, 2 position 3 way 10Ω
the coil to cool at least 3 hours before performing 12V DC with diode (schematic items DE and DF)
this test. Solenoid valve, 2 position 2 way 10Ω
12V DC with diode (schematic item DG)
1 Tag and disconnect the wiring from the coil to
be tested. Solenoid valve, 2 position 3 way 7Ω
10V DC with diode (schematic items EF and EJ)
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 84793 GS-84 • GS-90 4 - 85

MANIFOLDS REV A
How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all COIL
a
of its valve coils. Properly functioning coil diodes d
MULTI
METER
protect the electrical circuit by suppressing voltage
spikes. Voltage spikes naturally occur within a
function circuit following the interruption of c -
electrical current to a coil. Faulty diodes can fail to
+
b
protect the electrical system, resulting in a tripped
10 W 9V
circuit breaker or component damage. RESISTOR BATTERY
Electrocution hazard. Contact with c

b
+
-
Remove all rings, watches and a multimeter
other jewelry. b 9V battery
c 10Ω resistor
1 Test the coil for resistance. See 7-12, How to d coil
Test a Coil. Note: Dotted lines in illustration indicate a
reversed connection as specified in
2 Connect a 10Ω resistor to the negative terminal step 6
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the 5 Momentarily connect the positive lead from the
coil. multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
Note: The battery should read 9V DC or more
when measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
Ω
Resistor, 10Ω reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
3 Set a multimeter to read DC amperage. The coil is good.
Note: The multimeter, when set to read DC Result: If one or both of the current readings are
amperage, should be capable of reading up to 800 0 mA, or if the two current readings do not differ
mA. by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
4 Connect the negative lead to the other terminal replaced.
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
4 - 86 GS-84 • GS-90 Part No. 84793

REV A
Fuel and Hydraulic Tanks
8-1 6 Remove the entry ladder mounting fasteners.
Remove the entry ladder from the machine.
Fuel Tank
Crushing hazard. The entry ladder
could become unbalanced and fall
How to Remove the Fuel Tank when it is removed from the
Explosion and fire hazard. Engine machine if it is not properly
fuels are combustible. Remove the supported.
fuel tank in an open, well- 7 Remove the retaining fasteners from the access
ventilated area away from heaters, plate located behind the hydraulic and fuel tank
sparks, flames and lighted tray.
tobacco. Always have an
approved fire extinguisher within 8 Locate and close the 2 fuel tank shutoff valves
easy reach. located at the fuel tank (if equipped).
Explosion and fire hazard. Never 9 Tag, disconnect and plug the fuel supply and
drain or store fuel in an open return hoses.
container due to the possibility of
10 Remove the fuel filler cap from the tank.
fire.
11 Using an approved hand-operated pump, drain
Explosion and fire hazard. When
the fuel tank into a suitable container. Refer to
transferring fuel, connect a
grounding strip between the
machine and pump or container. Explosion and fire hazard. When
transferring fuel, connect a
1 Turn the key switch to ground control and pull
grounding wire between the
machine and pump or container.
controls. Note: Be sure to only use a hand operated pump
suitable for use with gasoline and/or diesel fuel.
2 Start the engine and raise the platform
approximately 18 feet / 5.5 m from the ground. 12 Remove the fuel tank hold down strap retaining
fasteners. Remove the straps from the fuel
tank.
arm in position. 13 Support and secure the fuel tank to an
appropriate lifting device.
Note: Be sure that the safety arm is locked in the
vertical position. 14 Remove the fuel tank from the machine.
4 Lower the platform onto the safety arm. Turn Component damage hazard. The
the engine off. fuel tank is plastic and may
become damaged if allowed to fall.
clear of the safety arm when Note: Clean the fuel tank and inspect
lowering the platform. for cracks and other damage before installing.
the entry ladder on the hydraulic tank side of
the machine.
Part No. 84793 GS-84 • GS-90 4 - 87

FUEL AND HYDRAULIC TANKS REV A
8-2 4 Lower the platform onto the safety arm. Turn

the engine off.
Hydraulic Tank
The primary functions of the hydraulic tank are to clear of the safety arm when
cool, clean and deaerate the hydraulic fluid during lowering the platform.
operation. It utilizes internal suction strainers for 5 Attach a lifting strap from an overhead crane to
the pump supply lines and has an external return the entry ladder on the hydraulic tank side of
line filter with a filter condition indicator. the machine.
How to Remove the 6 Remove the entry ladder mounting fasteners.
Remove the entry ladder from the machine.
Hydraulic Tank
Crushing hazard. The entry ladder
Component damage hazard. The could become unbalanced and fall
work area and surfaces where this when it is removed from the
procedure will be performed must machine if it is not properly
be clean and free of debris that supported.
could get into the hydraulic
system. 7 Remove the retaining fasteners from the access
plate located behind the hydraulic and fuel tank
Note: When removing a hose assembly or fitting, tray.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during 8 Close the two hydraulic shutoff valves located
installation. Refer to Section Two, Hydraulic Hose at the hydraulic tank (if equipped).
1 Turn the key switch to ground control and pull

out the red Emergency Stop buttons to the ON
controls.
2 Start the engine and raise the platform
approximately 18 feet / 5.5 m from the ground. open closed
3 Release the safety arm latch, lift the safety arm Component damage hazard. The
and rotate to a vertical position. Lock the safety engine must not be started with
arm in position. the hydraulic tank shutoff valves in
Note: Be sure that the safety arm is locked in the the CLOSED position or component
vertical position. 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.
4 - 88 GS-84 • GS-90 Part No. 84793

REV A FUEL AND HYDRAULIC TANKS
9 Remove the drain plug from the hydraulic tank

and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
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 hydraulic tank from the machine.
Crushing hazard. The hydraulic
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.
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.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
Part No. 84793 GS-84 • GS-90 4 - 89

Steer Axle Components REV B
9-1 7 Tag, disconnect and plug the hoses from the

drive motor. Cap the fittings on the drive motor.
Yoke and Drive Motor
How to Remove the Yoke burn skin. Loosen hydraulic
and Drive Motor connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
installation. Refer to Section Two, Hydraulic Hose 8 Support and secure the yoke and drive motor
and Fitting Torque Specifications. assembly to a lifting jack.
1 Block the non-steer wheels and center a lifting 9 Remove the cotter pin from the tie rod clevis
jack under the drive chassis at the steer end of pin.
the machine. Note: Always use a new cotter pin when installing
2 Loosen the wheel lug nuts. Do not remove a clevis pin.
them.
10 Remove the retaining fastener from the steer
3 Raise the machine approximately cylinder rod end pivot pin. Remove the pivot
2 inches / 5 cm. Place blocks under the chassis pin.
for support.
11 Remove the retaining fastener from the lower
Crushing hazard. The chassis will yoke pivot pin.
fall if it is not properly supported.
12 Place a rod through the pin and twist to remove
4 Remove the wheel lug nuts. Remove the tire the pin.
and wheel assembly.
13 Repeat steps 11 and 12 for the upper yoke
5 Remove the hose clamps retaining fasteners pivot pin.
from the drive motor guard. Remove the hose
14 Remove the yoke and drive motor assembly
clamps.
from the machine.
6 Remove the retaining fasteners from the drive
Crushing hazard. The yoke and
motor guard. Remove the drive motor guard
drive motor assembly may
from the yoke.
become unbalanced and fall if not
properly supported and secured to
the lifting jack when it is removed
from the machine.
4 - 90 GS-84 • GS-90 Part No. 84793

REV B STEER AXLE COMPONENTS
How to Remove a Drive Motor 5 Remove the hose clamps retaining fasteners
from the drive motor guard. Remove the hose
Component damage hazard. clamps.
Repairs to the motor should only
be performed by an authorized 6 Remove the retaining fasteners from the drive
dealer. motor guard. Remove the drive motor guard
from the yoke.
work area and surfaces where this 7 Tag, disconnect and plug the hoses from the
procedure will be performed must drive motor. Cap the fittings on the drive motor.
be clean and free of debris that Bodily injury hazard. Spraying
could get into the hydraulic system hydraulic oil can penetrate and
and cause severe component burn skin. Loosen hydraulic
damage. Dealer service is connections very slowly to
recommended. allow the oil pressure to
Note: When removing a hose assembly or fitting, dissipate gradually. Do not
the O-ring on the fitting and/or hose must be allow oil to squirt or spray.
replaced and then torqued to specification during 8 Remove the drive motor mounting fasteners.
installation. Refer to Section Two, Hydraulic Hose Remove the drive motor.
Note: There is an O-ring on the drive motor and
1 Loosen the wheel lug nuts. Do not remove drive hub assembly. It is installed between the
them. drive motor and drive hub. Be sure that the O-ring
is in place when installing the drive motor onto the
2 Block the non-steer end wheels and center a
machine.
lifting jack of ample capacity under the steer
end of the drive chassis.
Mounting bolt torque specifications
Drive motor to drive hub, dry 75 ft-lbs
2 inches / 5 cm. Place blocks under the chassis
102 Nm
for support.
Drive motor to drive hub, lubricated 56 ft-lbs
76 Nm
and wheel assembly.
Part No. 84793 GS-84 • GS-90 4 - 91

STEER AXLE COMPONENTS REV B
9-2 3 Remove the pin retaining fasteners from the

rod-end pivot pin. Place a rod through the pin
Steer Cylinder and twist to remove the pin.
Note: Note the location and the amount of the
How to Remove the spacers at the barrel end of the steer cylinder.
Steer Cylinder
4 Remove the steer cylinder from the machine.

from the steer cylinder. Cap the fittings on the
cylinder.
connections very slowly to
allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
barrel-end pivot pin. Place a rod through the pin
and twist to remove the pin.
Note: Note the location and the amount of the
spacers at the barrel end of the steer cylinder.
4 - 92 GS-84 • GS-90 Part No. 84793

REV B STEER AXLE COMPONENTS
9-3 Oscillate Limit Switches LS22, LS23

Oscillating Axle Option The right and left oscillating limit switches, LS22
(GS-90 models) and LS23 respectively, are normally closed limit
switches, held in the open position when the
machine is on a level surface.
How the
When the left rear or right rear wheel 'drops', the
Oscillating Axle Functions limit switch will relax and close its circuit, sending
When driving the GS-90 with the platform in the power to the appropriate oscillating valve coil.
stowed position, the oscillating axle function
FROM PLATFORM CONTROLS EMERGENCY STOP
ensures that all four wheels maintain solid contact
with the ground, delivering the maximum traction J2-C1/C3
available. LS6
PLAT
N.C.
When driving the GS-90 with the platform raised DOWN
LIMIT
above the down limit switch height, the oscillating SWITCH
axle function is limited in that the oscillating J2-C5

cylinders only respond to input from the oscillating CR84 CR85
CR42 OSCILLATE OSCILLATE
axle limit switches, located on the rear axle. POWER STOWED RAISED
J2-C6
Oscillate Stowed Relay CR84 86 30 2 86 30 11 86 30 12 U5

ELECTRONIC
CONTROL
Terminal 30 of the Oscillate Stowed relay, CR84, 85 87 87A 85 87 87A 85 87 87A
MODULE
receives power from the Platform Down limit

switch, LS6. When the platform is raised above N.C.H.O. N.C.H.O.
LS6, power to terminal 30 will be cut. CB2 LS23 LS22

20A LEFT RIGHT
OSCILLATE OSCILLATE
Terminal 86 of CR84 is connected to pin J2-C5 at LIMIT SWITCH LIMIT SWITCH
the ECM. Pin J2-C5 is powered anytime the Brake

Release valve coil Y2 is energized, thus energizing
B1
CR84 terminal 87 and, ultimately, all four oscillating +
valve coils, allowing oil to pass between the Y54 Y56
oscillating cylinders. J2-C5 continues to power
terminal 86 for 0.5 seconds after Y2 is de-
energized.
-
Oscillate Raised Relay CR85 Y57 Y55
B1 12 VOLT BATTERY
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE

Y57 RIGHT OSC
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.
Part No. 84793 GS-84 • GS-90 4 - 93

Non-steer Axle Components REV B
10-1 3 Remove the drive motor mounting fasteners.

Drive Motor and Brake 4 Slide the drive motor shaft out of the brake and
remove the drive motor from the machine.
How to Remove a Drive Motor 5 Remove the brake from the drive hub.
and Brake Note: There are two O-rings on the drive motor
and brake assembly. One is installed between the
brake and drive hub and another between the
Repairs to the motor should only
brake and drive motor. Be sure that both O-rings
be performed by an authorized
are in place when installing the brake and drive
Sundstrand-Sauer dealer.
motor onto the machine.
work area and surfaces where this Mounting bolt torque specifications
procedure will be performed must
Drive motor to drive hub, dry 75 ft-lbs
be clean and free of debris that
102 Nm
could get into the hydraulic system
and cause severe component Drive motor to drive hub, lubricated 56 ft-lbs
damage. Dealer service is 76 Nm
recommended.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Block the steer wheels.
from the drive motor and brake. Cap the fittings
on the drive motor and brake.
or spray.
4 - 94 GS-84 • GS-90 Part No. 84793

REV B NON-STEER AXLE COMPONENTS
10-2 10-3
Drive Hub Oscillating Axle
How to Remove a Drive Hub See 9-3, Oscillating Axle Option (GS-90 models)

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
3 Loosen the wheel lug nuts. Do not remove
them.
2 inches / 5 cm. Place blocks under the chassis
for support.
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.
Crushing hazard. The drive
hub may become unbalanced and
fall if it is not properly supported
and secured to the lifting jack.
Mounting bolt torque specifications
Drive hub to axle, lubricated 180 ft-lbs

(thread locker on bolt threads) 244 Nm
Part No. 84793 GS-84 • GS-90 4 - 95

Outrigger Components REV A
11-1 5 Attach a lifting strap from an overhead crane to

the barrel end of the outrigger cylinder for
Outrigger Cylinder support. Do not apply any lifting pressure.
6 Remove the outrigger cylinder mounting
How to Remove an Outrigger fasteners. Remove the outrigger cylinder from
Cylinder (if equipped) the machine.
Note: Perform this procedure with the platform in Crushing hazard. The outrigger
the stowed position and the outriggers fully cylinder may become unbalanced
retracted. and fall if not properly supported
Note: When removing a hose assembly or fitting, machine.
replaced and then torqued to specification during Note: If the outrigger cylinder is being replaced,
installation. Refer to Section Two, Hydraulic Hose remove the shoulder pin from the barrel end of the
and Fitting Torque Specifications. outrigger cylinder and install it onto the new
cylinder.
1 Remove the outrigger footpad.
a
2 Remove the mounting fasteners from the
outrigger cover. Remove the cover. CA CB
CC CD
3 Tag and disconnect the wiring from the
outrigger cylinder solenoid valve.
4 Tag, disconnect and plug the hydraulic hoses b
from the outrigger cylinder. Cap the fittings on
the cylinder.
or spray. a valve coil
b outrigger cylinder
4 - 96 GS-84 • GS-90 Part No. 84793

REV B
Platform Overload Components
12-1 6 Securely connect the platform controls to the
ECM wire harness.
Platform Overload System
7 Using a suitable lifting device, place a test
weight, corresponding to the maximum load as
How to Calibrate the Platform indicated on the capacity indicator decal, in the
Overload System (if equipped) center of the platform floor. Secure the weight
to the platform. Refer to the chart below.
On machines with platform overload systems,
proper calibration is essential to safe machine GS-3384 and GS-3390 1878 kg
operation. An improperly calibrated platform
overload system could result in the system failing GS-4390 1286 kg
to sense an overloaded platform. The stability of (most models - refer to capacity indicator decal)
the machine is compromised and it could tip over.
GS-4390 1421 kg
Note: Be sure the hydraulic oil level is between the (some models - refer to capacity indicator decal)
full and add marks on the oil level indicator. GS-5390 1410 kg
Note: Perform this procedure with the machine on
a firm, level surface that is free of obstructions.
All models: out the red Emergency Stop button to the on
1 Models with outriggers: Deploy the outriggers controls. Start the engine.
and level the machine.
9 Raise the platform to approximately 6 m.
2 Apply a thin layer of dry film lubricant to the
area of the chassis where the scissor arm wear 10 Release the safety arm latch, lift the safety arm
pads make contact. and rotate to a vertical position. Lock the safety
arm in position.
3 Disconnect the platform controls from the
machine at the platform. 11 Loosen the retaining ring and remove the switch
adjustment cover from the pressure switch(es).
4 Open the large ground control panel door and
locate connector joining the Electronic Control Note: The pressure switch is located on the lift
Module (ECM) wire harness and the platform cylinder.
controls wire harness. 12 Using a small slotted screwdriver, turn the
Note: This connection is just below the ground adjustment screw of the platform overload
controls. pressure switch(es) one-quarter turn into the
hydraulic line.
harness from the ECM wire harness. 13 Push in the red Emergency Stop button to the
Part No. 84793 GS-84 • GS-90 4 - 97

PLATFORM OVERLOAD COMPONENTS REV B
GS-3384, GS-3390 and GS-4390 models: 15 Raise the platform until the position indicator
corresponds to the maximum load position of
14 Pull out the red Emergency Stop button to the the capacity indicator decal.
on position at the ground controls. Wait 3
seconds and start the engine. Tip-over hazard. Raising the
platform with maximum load
Result: The alarm doesn't sound and the engine above the maximum load position,
will start and run. Proceed to step 15. as shown on the capacity indicator
Result: The engine will not start and an alarm is decal on the side of the platform,
sounding. Repeat this procedure beginning with could result in the machine tipping
step 12. over, resulting in death or serious
injury. Do not raise the platform
Note: The red Emergency Stop button must be above the maximum load position
cycled after each quarter turn of the nut (or of the capacity indicator decal.
adjustment screw) to allow the platform overload
system to reset. Note: To perform this step, the system relief valve
will need to be adjusted.
Note: Wait a minimum of 3 seconds between each
quarter turn of the nut (or adjustment screw) to Note: To help complete this part of the procedure,
allow the platform overload system to reset. apply a piece of tape to the underside of the
platform at a point which corresponds to the
maximum load position of the capacity indicator
decal before raising the platform.
Result: The engine continues to run. Proceed to
step 16.
Result: The engine has stopped and an alarm is
sounding. Proceed to step 17.
4 - 98 GS-84 • GS-90 Part No. 84793

REV B PLATFORM OVERLOAD COMPONENTS
Set the pressure switch Set the maximum height limit switch
16 Turn the nut (or adjustment screw) of the 21 Using a suitable lifting device, place a test
platform overload pressure switch out of the weight in the center of the platform floor.
hydraulic line until the overload alarm sounds Secure the weight to the platform. Refer to the
and the engine stops running. chart below.
Note: Turning the nut (or adjustment screw) out of GS-3384 and GS-3390 1135 kg
the hydraulic line will activate the alarm; turning the
nut (or adjustment screw) into the hydraulic line will GS-4390 680 kg
deactivate the alarm. (most models - refer to capacity indicator decal)
17 Slowly turn the nut (or adjustment screw) of the GS-4390 816 kg
platform overload pressure switch one-quarter (some models - refer to capacity indicator decal)
turn into the hydraulic line.
18 Push in the red Emergency Stop button to the 22 Raise the platform to approximately 6 m.
19 Pull out the red Emergency Stop button to the and rotate to a vertical position. Lock the safety
on position at the ground controls. Wait 3 arm in position.
seconds and start the engine.
24 Remove the maximum height limit switch cam
Result: The alarm doesn't sound and the engine fasteners. Remove the cam from the machine
will start and run. Proceed to step 20. so that the limit switch will not be activated.
Result: The engine will not start and an alarm is 25 Raise the platform until it is approximately
sounding. Repeat this procedure beginning with 65 cm less than full height.
step 17.
Note: The red Emergency Stop button must be
cycled after each quarter turn of the nut (or
adjustment screw) to allow the platform overload
system to reset.
Note: Wait a minimum of 3 seconds between each

quarter turn of the nut (or adjustment screw) to
allow the platform overload system to reset.
20 Return the safety arm to the stowed position.
Lower the platform to the stowed position.
Note: After returning the safety arm to the stowed
position, use the auxiliary down function to lower
the platform.
Part No. 84793 GS-84 • GS-90 4 - 99

26 Raise the platform in 5 cm increments until the 29 Start the engine and fully raise the platform.
overload alarm sounds and the engine stops
running. Proceed to step 27.
step 30.
Result: The alarm does not sound and the
Result: An alarm sounds and the engine stops
engine continues to run when the platform
running. Repeat this procedure beginning with
reaches full height. Repeat this procedure
step 24.
30 Lower the platform to approximately 6 m.
a b c d
Proceed to step 59.
GS-5390 models:
on position at the ground controls. Wait 3
seconds and start the engine.
GS-3384
Result: The alarm doesn't sound and the engine
GS-3390 will start and run. Proceed to step 33.
GS-4390
Result: The engine will not start and an alarm is
GS-5390 sounding. Repeat this procedure beginning with
step 12.
Note: The red Emergency Stop button must be
Limit switch legend cycled after each quarter turn of the adjustment
a load sense delay limit switch screw to allow the platform overload system to
b down limit switch reset.
c maximum height limit switch
d maximum height limit switch cam Note: Wait a minimum of 3 seconds between each
quarter turn of the adjustment screw to allow the
27 Install and adjust the maximum height limit
platform overload system to reset.
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.
4 - 100 GS-84 • GS-90 Part No. 84793

33 Raise the platform until the position indicator Set the maximum height pressure switch
corresponds to the maximum load position of
the capacity indicator decal. 34 Working on platform overload pressure switch 1
(parallel to the cylinder on early models) with a
Tip-over hazard. Raising the small slotted screwdriver, turn the adjustment
platform with maximum load screw out of the hydraulic line just until the
above the maximum load position, overload alarm sounds and the engine stops
as shown on the capacity indicator running. Refer to the illustrations below.
decal on the side of the platform,
could result in the machine tipping Note: Turning the screw out of the hydraulic line
over, resulting in death or serious will activate the alarm; turning the screw into the
injury. Do not raise the platform hydraulic line will deactivate the alarm.
above the maximum load position Note: The white/black wire should be connected to
of the capacity indicator decal. this pressure switch.
Note: To perform this step, the system relief valve
will need to be adjusted.
Parallel
Note: To help complete this part of the procedure, to cylinder
apply a piece of tape to the underside of the (switch 1)
platform at a point which corresponds to the
maximum load position of the capacity indicator
decal before raising the platform.
Perpendicular
to cylinder
step 34. (switch 2)
Result: The engine has stopped and an alarm is
sounding. Proceed to step 35.
(switch 2)
(switch 1)
Part No. 84793 GS-84 • GS-90 4 - 101

35 Slowly turn the adjustment screw of the platform 41 Slowly turn the adjustment screw of the platform
overload pressure switch into the hydraulic line overload pressure switch into the hydraulic line
in 90° increments just until the overload alarm in 90° increments just until the overload alarm
doesn't sound and the engine will start and run. doesn't sound and the engine will start and run.
Note: To allow for the platform overload system Note: To allow for the platform overload system
delay, wait 3 seconds between each quarter turn of delay, wait 3 seconds between each quarter turn of
the adjustment screw. the adjustment screw.
Note: To allow the platform overload system to Note: To allow the platform overload system to
reset, the red Emergency Stop button must be reset, the red Emergency Stop button must be
cycled after each quarter turn of the adjustment cycled after each quarter turn of the adjustment
screw. screw.
36 Activate the dual pressure switch limit switch, 42 Turn the screw of the platform overload
located on the cylinder, by fully rotating the pressure switch into the hydraulic line an
roller arm of the limit switch. Secure the roller additional one-quarter turn.
arm in the activated position.
43 Deactivate the dual pressure switch limit switch,
37 Start the engine. which was activated in step 36.
Set the platform stowed pressure switch 44 Raise the platform slightly and return the safety
arm to the stowed position.
38 Working on platform overload pressure switch 2
(perpendicular to the cylinder on early models), 45 Lower the platform to the stowed position.
remove the retaining ring securing the switch
Set the maximum height limit switch
adjustment cover to the pressure switch. Refer
to the illustrations at step 34. 46 Using a suitable lifting device, place a test
weight in the center of the platform floor.
39 Slide the switch adjustment cover away from
Secure the weight to the platform. Refer to the
the tee fitting, exposing the slotted switch
chart below.
adjustment screw inside.
40 Using a small slotted screwdriver, turn the GS-5390 680 kg
adjustment screw just until the overload alarm
sounds and the engine stops running.
Note: Turning the screw out of the hydraulic line
will activate the alarm; turning the screw into the 48 Release the safety arm latch, lift the safety arm
hydraulic line will deactivate the alarm. and rotate to a vertical position. Lock the safety
arm in position.
4 - 102 GS-84 • GS-90 Part No. 84793

49 Remove the maximum height limit switch cam 54 Start the engine and fully raise the platform.
fasteners. Remove the cam from the machine
so that the limit switch will not be activated.
step 55.
50 Raise the platform until it is approximately
Result: An alarm sounds and the engine stops
65 cm less than full height.
running. Repeat this procedure beginning with
51 Raise the platform in 5 cm increments until the step 49.
overload alarm sounds and the engine stops
55 Lower the platform to approximately 6 m.
running. Proceed to step 52.
engine continues to run when the platform Confirm the platform stowed
reaches full height. Repeat this procedure pressure switch setting
a b c d
58 Raise the platform to approximately 4 m in
0.5 m increments.
Result: The engine should continue to run.
Proceed to step 59.
Result: The engine stops running. Using a small
screwdriver, turn the screw of the platform
GS-3384 overload pressure switch, perpendicular to the
cylinder, into the hydraulic line in 90°
GS-3390 increments until the alarm does not sound and
GS-4390 the engine will start and run. Repeat this
GS-5390 procedure beginning with step 47.
Note: To allow for the platform overload system
delay, wait 3 seconds between each adjustment.
Limit switch legend
Note: To allow the platform overload system to
a load sense delay limit switch
b down limit switch
reset, the red Emergency Stop button must be
c maximum height limit switch cycled after each adjustment.
d maximum height limit switch cam
52 Install and adjust the maximum height limit

switch cam until the limit switch activates just
before the point reached in step 51. Securely
tighten the cam fasteners. Do not over tighten.
53 Use the auxiliary down function to lower the
platform approximately 15 cm.
Part No. 84793 GS-84 • GS-90 4 - 103

All models: 65 Push in the red Emergency Stop button to the

Disable the descent delay function
59 Push in the red Emergency Stop button to the on position at the ground controls.
Note: For more information on programming, refer
60 Turn the key switch to ground control. to Section 4, Repair.
61 Press and hold both the blue platform up and Calibrate the load sense delay limit switch
Emergency Stop button to the on position at the 67 Turn the key switch to platform control. Start the
ground controls. engine.
Result: TUNE SPEEDS is showing in the diagnostic 68 Lower the platform until the load sense delay
display window. limit switch activates and the platform stops
lowering. Release the joystick.
a b
engine continues to run. Proceed to step 76.
c
Result: The alarm sounds and the engine stops
running. The load sense delay limit switch
d
needs to be calibrated. Proceed to step 69.
a diagnostic display 69 Raise the platform to approximately 6 m.

c lift function enable button 70 Release the safety arm latch, lift the safety arm
d yellow platform down button and rotate to a vertical position. Lock the safety
arm in position.
SELECT OPTIONS. 71 Loosen the fasteners securing the load sense
delay limit switch cam just enough to allow
Result: SELECT OPTIONS is showing in the movement of the cam.
programming mode. 72 Working from the outside of the machine, rotate
the load sense delay limit switch cam in a
63 Press the lift function enable button. clockwise direction until the cam lobe is
Result: DESCENT DELAY ON is showing in the approximately 1 mm lower. Tighten the
diagnostic display window. fasteners. Do not over tighten.
64 Press the lift function enable button to 73 Return the safety arm to the stowed position.
deactivate the descent delay option. 74 Raise the platform approximately 1 m.
Result: DESCENT DELAY OFF is showing in the 75 Repeat this procedure beginning with step 68.
4 - 104 GS-84 • GS-90 Part No. 84793

Enable the descent delay function Calibrate the down limit switch
76 Push in the red Emergency Stop button to the 84 Turn the key switch to platform control. Start the
off position at the ground controls. engine.
77 Turn the key switch to ground control. 85 Raise the platform approximately 1 m.
78 Press and hold both the blue platform up and 86 Lower the platform until the down limit switch
yellow platform down buttons. Pull out the red activates and the platform stops lowering.
Emergency Stop button to the on position at the Quickly release the controls and then
ground controls. immediately attempt to lower the platform to
the stowed position.
display window. Result: The platform stops for 4 to 6 seconds.
Release the joystick and proceed to step 94.
select options. Result: The platform stops and then will
immediately begin to lower again. The down
limit switch needs to be calibrated. Proceed to
step 87.
programming mode.
Result: DESCENT DELAY OFF is showing in the
arm in position.
89 Loosen the fasteners securing the down limit
the descent delay option.
switch cam just enough to allow movement of
Result: DESCENT DELAY ON is showing in the the cam. Refer to the illustration at step 51.
90 Working from the outside of the machine, rotate
82 Push in the red Emergency Stop button to the the down limit switch cam in a clockwise
off position at the ground controls. direction until the cam lobe is approximately
1 mm lower. Tighten the fasteners. Do not over
83 Pull out the red Emergency Stop button to the tighten.
on position at the ground controls.
Note: When adjusting the down limit switch cam,
do not move cam which activates the load sense
delay limit switch.
Part No. 84793 GS-84 • GS-90 4 - 105

91 Raise the platform approximately 1 m. 101 Install the cover onto the platform overload
pressure switch or switch box and securely
tighten the cover retaining fasteners. Do not
93 Repeat this procedure beginning with step 86. over tighten.
94 Lower the platform to the stowed position and 102 Apply Sentry Seal to one of the cover retaining
remove the weight from the platform. fasteners where it contacts the platform
overload pressure switch box.
Result: The platform lowers to the stowed
position. Proceed to step 99. 103 Return the safety arm to the stowed position.
Result: The platform stops lowering. The down 104 Lower the platform to the stowed position.
limit switch needs to be calibrated. Proceed to
101 Calibrate the system relief valve. See 7-5,
step 95.
How to Adjust the System Relief Valve.
arm in position.
97 Loosen the fasteners securing the down limit
switch cam just enough to allow movement of
the cam.
98 Working from the outside of the machine, rotate
the down limit switch cam in a counter
clockwise direction until the cam lobe is
approximately 1 mm higher. Tighten the
fasteners. Do not over tighten.
Note: When adjusting the down limit switch cam,
do not move cam which activates the load sense
delay limit switch.

100 Release the safety arm latch, lift the safety
arm and rotate to a vertical position. Lock the
safety arm in position.
4 - 106 GS-84 • GS-90 Part No. 84793

June 2007 Section 5 • Fault Codes
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.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each could result in death or serious
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
· Machine parked on a firm, level surface
· Platform in the stowed position hydraulic oil can penetrate and
· Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
· The red Emergency Stop button in the off
gradually. Do not allow oil to
squirt or spray.
· Wheels chocked
from the machine
Part No. 84793 GS-84 • GS-90 5-1

Section 5 • Fault Codes June 2007
FAULT CODES
About This Section LED Diagnostic Readout

When a malfunction is discovered, the fault code
charts in this section will help a service
professional pinpoint the cause of the problem. To
use this section, basic hand tools and certain
pieces of test equipment are required—voltmeter,
ohmmeter, pressure gauges.
General Repair Process
The diagnostic readout displays numerical codes

Malfunction Identify Troubleshoot that provide information about the machine
discovered symptoms operating status and about malfunctions. The dot
to the right of the numbers remain on when a
fault code is displayed.
problem
still exists The codes listed in the Fault Code Chart
describe malfunctions and can aid in
Return to Inspect Perform troubleshooting the machine by pinpointing the
service problem and test repair area or component affected.
solved
5-2 GS-84 • GS-90 Part No. 84793

REV B
Fault Code Chart
Fault Code LED Condition Result Solution
SYSTEM READY Green Normal operation
01 Red Internal ECM error. System shutdown. Replace ECM.

INTERNAL ECU
FAULT
02 Red
Platform/ECM communication
System shutdown.
Troubleshoot control cable OR
PLATFORM ECU error. troubleshoot platform controls.
FAULT
20 Red
Engine start button fault at
Engine will not start. Replace ECM.
CHASSIS START ground controls.
SW FAULT
21 Starting aid button fault at
CHASSIS CHOKE Red Starting aid disabled. Replace ECM.
ground controls.
SW FAULT
22 Up switch fault at ground
CHASSIS UP SW Red Platform up function inoperable. Replace ECM.
controls.
FAULT
23 Platform up/down enable Platform up/down functions
CHASSIS LIFT SW Red Replace ECM.
button fault at ground controls. disabled.
FAULT
24 Red
Down switch 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 microswitch.
FAULT
26 Red Right turn switch fault.
Malfunctioning steer right
Troubleshoot steer right microswitch.
RIGHT TURN SW microswitch.
FAULT
27 Red
Function enable switch on
Machine functions disabled.
Release function enable switch on
DRIVE ENABLE joystick is activated when joystick before power up OR replace
SW FLT machine is turned on. joystick.
28 Drive joystick off neutral when Release joystick before power up OR

OFF NEUTRAL Red Machine functions disabled.
machine is turned on. replace joystick.
DRIVE JOYSTICK
29 Lift enable button fault at the Troubleshoot button OR replace printed
PLATFORM LIFT Red Lift function disabled.
platform controls. circuit board at platform controls.
SW FAULT
30 Replace up/down switch at platform
OFF NEUTRAL Red Up/down switch off neutral. Up/down function disabled.
controls.
LIFT JOYSTICK
31 Starting aid fault at the Troubleshoot button OR replace printed
PLATFORM Red Starting aid disabled.
CHOKE SW platform controls. circuit board at platform controls.
FAULT
32 Red
Engine start button fault at
Engine will not start.
Troubleshoot button OR replace printed
PLATFORM platform controls. circuit board at platform controls.
START SW FAULT
33 Red
Left front outrigger enable
Outriggers disabled.
LEFT FRONT button fault at platform
circuit board at platform controls.
OUTRIG SW FLT controls.
Part No. 84793 GS-84 • GS-90 5-3

FAULT CODE CHART REV B

34 Right front outrigger enable
RIGHT FRONT Red button fault at platform Outriggers disabled.
35 Left rear outrigger enable

LEFT REAR Red button fault at platform Outriggers disabled.
36 Right rear outrigger enable

RIGHT REAR Red button fault at platform Outriggers disabled.
37 Outrigger autolevel enable

AUTO LEVEL Red button fault at platform Outriggers disabled.
SWITCH FAULT controls.
49 High speed drive function will not

DRIVE COIL 1 Red Drive coil 1 (Y1) fault. Troubleshoot coil OR wiring.
operate.
FAULT
DRIVE COIL 2 Red Drive coil 2 (Y1A) fault. Troubleshoot coil OR wiring.
operate.
FAULT
DRIVE COIL 3 Red Drive coil 3 (Y1B) fault. Troubleshoot coil OR wiring.
operate.
FAULT
52 Lift and outrigger functions are
FUNC PROP COIL Red Proportional coil (Y9) fault. Troubleshoot coil OR wiring.
disabled.
FAULT
54 Red Up coil (Y8) fault. Platform will not raise. Troubleshoot coil OR wiring.
UP COIL FAULT
55
DOWN COIL Red Down coil (Y7) fault. Platform will not lower. Troubleshoot coil OR wiring.
FAULT
56
RIGHT TURN COIL Red Right turn coil (Y3) fault. Machine will not turn right. Troubleshoot coil OR wiring.
FAULT
57
LEFT TURN COIL Red Left turn coil (Y4) fault. Machine will not turn left. Troubleshoot coil OR wiring.
FAULT
58 Red Brake release coil (Y2) fault. Brakes will not release. Troubleshoot coil OR wiring.
BRAKE COIL
FAULT
60 Red Forward 1 coil (Y6) fault.
Drives slow or not at all when
Troubleshoot coil OR wiring.
FORWARD 1 COIL elevated.
FAULT
61 Red Reverse 1 coil (Y5) fault.
REVERSE 1 COIL elevated.
FAULT
62 Red Forward 2 coil (Y6A) fault.
FORWARD 2 COIL elevated.
FAULT
63 Red Reverse 2 coil (Y5A) fault.
REVERSE 2 COIL elevated.
FAULT
5-4 GS-84 • GS-90 Part No. 84793

REV B FAULT CODE CHART

Check the engine oil level OR check
66 wiring from the oil 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.
68
LOW ECU Red Low ECM voltage. System shutdown. Charge battery.
VOLTAGE
69 Red Low RPM. Engine idle RPM too low.
Consult Genie Industries Service
LOW ENGINE 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 Left front outrigger disabled. Troubleshoot coil OR wiring.
fault.
OTRG COIL FLT
81 Red
Left rear outrigger coil (Y33)
Left rear outrigger disabled. Troubleshoot coil OR wiring.
LEFT REAR OTRG fault.
COIL FLT
82 Red
Right front outrigger coil (Y36)
Right front outrigger disabled. Troubleshoot coil OR wiring.
RIGHT FRONT fault.
OTRG COIL FLT
83 Right rear outrigger coil (Y34)
RIGHT REAR Red Right rear outrigger disabled. Troubleshoot coil OR wiring.
fault.
OTRG COIL FLT
84 Outrigger extend coil (Y40)
OUTRIGGER EXT Red Outrigger extend function disabled. Troubleshoot coil OR wiring.
fault.
COIL FLT
85 Red
Outrigger retract coil (Y39)
Outrigger retract function disabled. Troubleshoot coil OR wiring.
OUTRIGGER RET fault.
COIL FLT
86 Red
Outrigger slowdown coil (Y44) Outrigger slow extend function
OUTRIGGER fault. disabled.
SLOW COIL FLT
90
2 SPEED COIL Red 2 speed coil (Y1) fault High torque drive function disabled. Troubleshoot coil OR wiring.
FAULT
92 Drive pump forward
DRIVE FWD PROP Red Drive forward function disabled. Troubleshoot coil OR wiring.
proportional coil (Y51) fault
COIL FAULT
93 Red
Drive pump reverse
Drive reverse function disabled. Troubleshoot coil OR wiring.
DRIVE REV PROP proportional coil (Y51) fault
COIL FAULT
94 Red Wrong machine type selected Machine will not operate. Correct selection.
MACHINE TYPE
FAULT
Part No. 84793 GS-84 • GS-90 5-5

Ford LRG425 ECM Fault Code Chart REV A
Code Problem Cause Solution
Closed Loop Multiplier Heated Oxygen Sensor wiring and/or

111
Repair wiring and/or connections OR replace
High (LPG) connections open or shorted OR sensor is faulty sensor OR repair vacuum and exhaust leaks.
OR there are vacuum leaks or exhaust leaks.
112
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 1) open or shorted OR sensor is faulty.
Repair wiring and/or connections OR
replace sensor.
113
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 2) open or shorted OR sensor is faulty.
The post cat Heated Oxygen Sensor wiring

and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114
Post-cat oxygen
sensor open sensor is cold, non-responsive or inactive for the post cat oxygen sensor.
60 seconds or longer.
Heated Oxygen Sensor wiring and/or Repair wiring and/or connections OR replace
connections open or shorted OR sensor is sensor OR repair any vacuum and exhaust leaks
Closed Loop Multiplier
121 High (Gasoline)
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
OR test the fuel pressure OR clean or replace the
fuel injectors.
injectors need cleaning or replacing.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
122
Closed Loop Multiplier or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low (Gasoline) fuel injectors are stuck open OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or

124
Closed Loop Multiplier connections open or shorted OR sensor is
sensor OR replace fuel OR test and repair the
Low (LPG) faulty OR fuel quality is poor OR fuel system
fuel system components.
components may be faulty.
133 Gasoline cat monitor
Repair exhaust leaks OR there is an emissions

134
There are exhaust leaks OR the catalyst system
LPG cat monitor efficiency is below the acceptable level. compliance issue. Contact Ford Power Products
for assistance.
135 NG cat monitor

connections open or shorted OR sensor is Repair heated oxygen sensor wiring and/or
Adaptive Lean Fault -
141
faulty OR there are vacuum or exhaust leaks connections OR replace sensor OR repair
High Limit (Gasoline) OR one or more fuel injectors faulty or stuck vacuum and exhaust leaks OR test the fuel
closed OR fuel quality is poor OR fuel pressure OR clean or replace the fuel injectors.
pressure is too low.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
Adaptive Rich Fault -
142
or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low Limit (Gasoline) fuel injectors are stuck closed OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

connections open or shorted OR sensor is
143
Adaptive Learn High sensor OR repair any vacuum and exhaust
faulty OR there are vacuum leaks or exhaust
(LPG) leaks OR replace fuel OR test and repair the
leaks OR fuel quality is poor OR fuel system
fuel system components.
Engine wire harness may have an intermittent Repair short in engine wire harness
Adaptive Learn Low
144 (LPG)
short to 5V DC or 12V DC OR fuel system
OR test and repair the fuel system
components.
5-6 GS-84 • GS-90 Part No. 84793

REV A FORD LRG425 ECM FAULT CODE CHART
161
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair
System Voltage Low
battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
162
Alternator is overcharging the battery when
System Voltage High Repair or replace the alternator.
engine RPM is greater than 1500 rpm.
IAT sensor wiring and/or connections are open or

211 IAT High Voltage shorted OR sensor is faulty OR engine intake air
temperature is too cold.
sensor OR direct warmer air into air intake.
IAT sensor wiring and/or connections are open or

212 IAT Low Voltage shorted OR sensor is faulty OR engine intake air
temperature is too hot.
sensor OR direct cooler air into air intake.
Air intake temperature is greater than 200° F with

213
IAT Higher Than
the engine greater than 1000 rpm OR air intake
Expected (1)
system has leaks OR IAT sensor is faulty. Check air intake system for damage and proper
routing of air intake components OR replace the
Air intake temperature is greater than 210° F with IAT sensor.
IAT Higher Than
214 Expected (2)
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair sensor
215 Oil Pressure Low and/or connections open or shorted OR engine wiring and/or connections OR fill engine oil level
to specification.
oil level too low.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR

221 CHT/ECT High Voltage sensor wires and/or connections open or shorted
OR sensor is faulty.
repair open or shorted wiring to sensor OR
replace sensor.
Engine cooling system is malfunctioning and
222 CHT/ECT Low Voltage overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240° F. Repair engine cooling system problems OR
223
CHT Higher Than repair open or shorted wiring to sensor OR
Expected (1) overheating the engine OR sensor wires and/or replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty specification.
Coolant temperature at the cylinder head is 250° F.

224
CHT Higher Than
Expected (2) overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
231
Open or shorted wiring and/or connections to MAP
MAP High Pressure
sensor OR sensor is faulty.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
232
Open or shorted wiring and/or connections to MAP
MAP Low Voltage
sensor OR sensor is faulty.
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.
Crankshaft position sensor wiring and/or

242 Crank Sync Noise connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Crankshaft position sensor wiring and/or Be sure system ground connections are in place
243 Never Crank Synced
At Start
connections open or shorted OR there is a poor
and secure OR repair wiring and/or connections
to sensor OR replace sensor.
Crankshaft position sensor wiring and/or

244 Camshaft Sensor Loss connections open or shorted OR there is a poor
Part No. 84793 GS-84 • GS-90 5-7

FORD LRG425 ECM FAULT CODE CHART REV A

Camshaft position sensor wiring and/or Be sure system ground connections are in place
245 Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and/or connections
system ground connection OR sensor is faulty. to sensor OR replace sensor.
253
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock sensor
Knock Sensor Open
shorted OR sensor is faulty. OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR repair
254 Excessive Knock Signal shorted OR there is excessive engine vibration
OR sensor is faulty.
wiring and/or connections to knock sensor OR
replace knock sensor.
311
Open wiring and/or connections to fuel injector #1
Injector Driver #1 Open
OR fuel injector #1 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #1
Wiring and/or connections to fuel injector #1 is OR replace fuel injector #1 OR replace the ECM.
312 Injector Driver #1 Shorted shorted OR fuel injector #1 is faulty OR
ECM is faulty.
313
ECM is faulty.
315
ECM is faulty.
321
ECM is faulty.
Open wiring and/or connections to fuel pump OR

351
Fuel Pump Loop Open or
fuel pump power shorted to ground OR fuel pump
High Side Short to Ground
is faulty. Repair wiring and/or connections to fuel pump OR
replace fuel pump.
352
Fuel Pump High Side Wiring and/or connections to fuel pump shorted to
Shorted to Power power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not opening

MegaJector Delivery completely OR the line between the MegaJector
353 Pressure Higher Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR
OR MegaJector is faulty. repair the line between the MegaJector and
Fuel pressure too low OR LPG lockoff not opening carburetor OR repair engine cooling system OR
MegaJector Delivery completely OR the line between the MegaJector replace the MegaJector.
354 Pressure Lower Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
The ECM doesn't get any response from the Check CAN circuits for continuity and shorts to
355 MegaJector
Communication Lost
MegaJector, or an incorrect response for 500ms
period or longer.
power or ground and for continuity and repair as
necessary OR replace the MegaJector.
The MegaJector detects voltage greater than 18
361 MegaJector Voltage
Supply High
volts for 5 seconds anytime the engine is cranking
Repair charging system OR replace the
MegaJector.
or running.
The MegaJector detects voltage less than 9.5 volts Repair VBAT power or ground circuit to ECM and
362
MegaJector Voltage
for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair
Supply Low
running. charging system OR replace the MegaJector.
5-8 GS-84 • GS-90 Part No. 84793

REV A FORD LRG425 ECM FAULT CODE CHART
363 MegaJector Internal The MegaJector detects an internal fault. Open or

Actuator Fault Detection short in power, ground or CAN circuits.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
364 MegaJector Internal The MegaJector detects an internal circuitry failure.
Circuitry Fault Detection Open or short in power, ground or CAN circuits. necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.
MegaJector Internal The MegaJector detects an internal
365 Communication Fault communications failure. Open or short in power,
ground or CAN circuits.
Detection
411
Open wiring and/or connections to ignition
Coil Driver #1 Open
coil #1 OR ignition coil #1 is faulty. Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
412
Wiring and/or connections to ignition coil #1
Coil Driver #1 Shorted
shorted OR ignition coil #1 is faulty
413
Open wiring and/or connections to ignition
Coil Driver #2 Open
coil #2 OR ignition coil #2 is faulty. Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
414
Wiring and/or connections to ignition coil #2
Coil Driver #2 Shorted
shorted OR ignition coil #2 is faulty
511 FPP1 High Voltage
512 FPP1 Low Voltage
513 FPP1 Higher than IVS Limit

If this fault appears on your machine, contact
Not used.
the Genie Industries Service Department.
514 FPP1 Lower than IVS Limit
531 TPS1 (Signal Voltage) High The #1 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
532 TPS1 (Signal Voltage) Low sensor #1 is faulty.
to sensor OR replace throttle position sensor #1.
533 TPS2 (Signal Voltage) High The #2 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
534 TPS2 (Signal Voltage) Low sensor #2 is faulty.
to sensor OR replace throttle position sensor #2.
The throttle position sensor wiring and/or

535 TPS1 Higher than TPS2 connections for either TPS1 or TPS2 open or
Be sure engine harness wiring and connections
are in place and secure OR repair wiring and/or
shorted OR there is a poor system ground
connections to one or both TPS sensors OR
536 TPS1 Lower than TPS2 connection OR one or both throttle position
sensors are faulty.
replace one or both TPS sensors.
Governor actuator is stuck closed OR wiring

537 Throttle Unable to Open and/or connections open or shorted OR
governor actuator is faulty. Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Governor actuator is stuck open OR wiring
538 Throttle Unable to Close and/or connections open or shorted OR
governor actuator is faulty.
Engine harness wiring and/or connections open

545
Repair wiring and/or connections in engine
Governor Interlock Failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
Part No. 84793 GS-84 • GS-90 5-9

FORD LRG425 ECM FAULT CODE CHART REV A
551 Max Governor Speed

Override
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
552 FPP1 Low Voltage sticking open OR there are air leaks between the
throttle body and cylinder head.
operation OR repair any air leaks between the
throttle body and cylinder head.
553 FPP1 Higher than IVS Limit
611 COP Failure
612 Invalid Interrupt
613 A/D Loss

Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
614 RTI 1 Loss secure OR replace ECM.
615 Flash Checksum Invalid
616 RAM Failure
631
External 5V DC Ref
Lower than Expected Engine harness wiring and/or connections open Locate and repair any engine harness wiring
or shorted to ground OR there is a faulty engine damage or shorts OR locate and troubleshoot or
632
External 5V DC Ref sensor OR ECM is faulty. repair faulty engine sensor OR replace ECM.
Higher than Expected
655 RTI2 Loss Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
656 RTI3 Loss
secure OR replace ECM.
5 - 10 GS-84 • GS-90 Part No. 84793

REV A
Ford DSG423 ECM Fault Code Chart
Code Description Code Description
111 CL (closed loop) high LPG 212 IAT (intake air temperature) low voltage
112 EGO open / lazy pre-cat 1 213 IAT (intake air temperature) higher than expected 1
113 EGO open / lazy pre-cat 2/post-cat 1 214 IAT (intake air temperature) higher than expected 2
114 EGO open / lazy post-cat 1 215 Oil pressure low
115 EGO open / lazy post-cat 2 221 ECT/CHT (engine/cylinder head temp) high voltage
121 CL (closed loop) high gasoline bank 1 222 ECT/CHT (engine/cylinder head temp) low voltage
122 CL (closed loop) low gasoline bank 1 223 CHT higher than expected 1
124 CL (closed loop) low LPG 224 CHT higher than expected 2
133 Gasoline catalyst monitor 1 225 ECT higher than expected 1
134 LPG catalyst monitor 226 ECT higher than expected 2
141 AL (adaptive learning) high gasoline bank 1 231 MAP (manifold absolute pressure) high pressure
142 AL (adaptive learning) low gasoline bank 1 232 MAP (manifold absolute pressure) low pressure
143 AL (adaptive learning) high LPG 234 BP (barometric pressure) high pressure
144 AL (adaptive learning) low LPG 235 BP (barometric pressure) low pressure
161 Battery voltage high 242 Crank sync noise
162 Battery voltage low 243 Never crank synced at start
163 AUX analog PD1 high 244 Cam loss
164 AUX analog PD1 low 245 Cam sync noise
165 AUX analog PU3 high 246 Crank loss
166 AUX analog PU3 low 253 Knock 1-2 sensor open 1
167 AUX analog PUD1 high 254 Knock 1-2 excessive signal 1
168 AUX analog PUD1 low
171 AUX analog PUD2 high
173 AUX analog PUD3 high
181 AUX DIG1 high
182 AUX DIG1 low
183 AUX DIG2 high
184 AUX DIG2 low

For further engine fault code troubleshooting and
185 AUX DIG3 high
diagnostic information, refer to the Ford DSG-423
186 AUX DIG3 low
EFI Service Manual (EDI part number 1060040).
211 IAT (intake air temperature) high voltage
Ford DSG 423 EFI Operator Handbook
Part No. 84793 GS-84 • GS-90 5 - 11

FORD DSG423 ECM FAULT CODE CHART REV A
261 FP (fuel pressure) high voltage 531 TPS1 (throttle position sensor) high voltage
262 FP (fuel pressure) low voltage 532 TPS1 (throttle position sensor) low voltage
271 FT (fuel temperature) gasoline high voltage 533 TPS2 (throttle position sensor) high voltage
272 FT (fuel temperature) gasoline low voltage 534 TPS2 (throttle position sensor) low voltage
273 FT (fuel temperature) gaseous fuel high voltage 535 TPS1 (throttle position sensor) higher than TPS2
274 FT (fuel temperature) gaseous fuel low voltage 536 TPS1 (throttle position sensor) lower than TPS2
311 Injector loop open OR low-side short to ground 1 537 Unable to reach higher TPS (throttle position sensor)
312 Injector coil shorted 1 538 Unable to reach lower TPS (throttle position sensor)
313 Injector loop open OR low-side short to ground 2 539 TPS 1-2 simultaneous voltages
314 Injector coil shorted 2 541 AUX analog PU1 high
315 Injector loop open OR low-side short to ground 3 542 AUX analog PU1 low
316 Injector coil shorted 3 543 AUX analog PU2 high
321 Injector loop open OR low-side short to ground 4 544 AUX analog PU2 low
322 Injector coil shorted 4 551 Max govern speed override
351 FPump motor loop open OR high-side shorted to ground 552 Fuel rev limit
352 Fpump motor high-side shorted to power 553 Spark rev limit
353 EPR delivery pressure higher than expected 611 COP failure
354 EPR delivery pressure lower than expected 612 Invalid interrupt
355 EPR comm lost 613 A/D loss
359 Fuel run-out longer than expected 614 RTI 1 loss
361 EPR voltage supply high 615 Flash checksum invalid
362 EPR voltage supply low
363 EPR internal actuator fault detection
364 EPR internal circuitry fault detection
365 EPR internal comm fault detection
411 Primary loop open OR low-side short to ground 1
412 Primary coil shorted 1

5 - 12 GS-84 • GS-90 Part No. 84793

REV A FORD DSG423 ECM FAULT CODE CHART
616 RAM failure 744 PWM5 short to power
631 5VE1 low voltage 761 MIL (malfunction indicator light) control ground short
632 5VE1 high voltage 762 MIL (malfunction indicator light) open
633 5VE2 high voltage 763 MIL (malfunction indicator light) control short to power
634 5VE2 low voltage 771 Tach output ground short
635 5VE1-5VE2 simultaneous out-of-range 772 Tach output short to power
641 Rx inactive 1629 J1939 TSC1 message receipt lost
642 Rx noise 1630 J1939 ETC message receipt lost
643 Invalid packet format
644 Shutdown request
646 CAN Tx failure
647 CAN Rx failure
648 CAN address conflict failure
655 RTI 2 loss
656 RTI 3 loss
711 Relay control ground short
712 Relay coil open
713 Relay coil short to power
714 Fpump relay control ground short
715 Fpump relay coil open
716 Fpump relay coil short to power
721 Start relay control ground short
722 Start relay coil open
723 Start relay coil short to power
731 PWM1-gauge1 open / ground short
732 PWM1-gauge1 short to power

741 PWM4 open / ground short
742 PWM4 short to power
743 PWM5 open / ground short
Part No. 84793 GS-84 • GS-90 5 - 13

5 - 14 GS-84 • GS-90 Part No. 84793

June 2007 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules
or spray.
and operating instructions in the appropriate
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 84793 GS-84 • GS-90 6-1

Section 6 • Schematics June 2007
Electronic Control Module Layout

REV A
Platform controls
Engine
Flashing beacons
Pump
To outriggers
Up limit switch
Down limit
To platform overload switch
(CE models)
Electronic Control Module
J1 J2
Level
sensor
Oscillate manifold
Drive manifold
Horn
Function manifold Ground controls
6-2 GS-84 • GS-90 Part No. 84793

Electronic Control Module Pin-Out Legend

REV A
Electronic Control
C 1 6 12 Module
C 1
A 1
(ECM)
B 1
12
12
12
B 1 6 12
A 1 6 12 J1 J2
12
B 1
12
C 1
12
A 1
J1 Connector J2 Connector
Pin Description Pin Description
A1 Right Turn Coil Y3 (output) A1 Up Limit Switch LS5 (input)
A2 Left Turn Coil Y4 (output) A2 Down Limit Switch LS6 (input)
A3 Up Coil Y8 (output) A3 Aux Down Power (input)
A4 Brake Coil Y2 (output) A4 Aux Down Relay CR23 Terminal 86 (output)
A5 Plug A5 Key Switch Terminal 3 (input)
A6 Plug A6 Level Sensor S7 (white) (input)
A7 Plug A7 Plug
A8 Plug A8 Plug
A9 Down Coil Y7 (output) A9 Plug
A10 2 Speed Coil (output) A10 Platform Controls (ground) (input)
A11 Plug A11 Platform Controls (data +) (input)
A12 Plug A12 Platform Controls (data -) (input)
B1 Generator Coil Y29 (output) B1 Level Sensor S8 (blue) (input)

B2 Reverse Coil / EDC Y51 (output) B2 Level Sensor S8 (black) (input)
B3 Forward Coil / EDC Y51 (output) B3 Level Sensor S8 (yellow) (input)
B4 Proportional Coil Y9 (+) (output) B4 Plug
B5 Right Front Outrigger Coil Y36 (output) B5 Plug
B6 Outrigger Extend Coil Y40 (output) B6 Plug
B7 Outrigger Retract Coil Y39 (output) B7 Engine Start Relay CR1 Terminal 86 (output)
B8 Plug B8 Ignition Relay CR8 Terminal 86 (output)
B9 Left Front Outrigger Coil Y35 (output) B9 Engine High Idle (output)
B10 Left Rear Outrigger Coil Y33 (output) B10 Level Sensor S7/S8 (red) (output)
B11 Right Rear Outrigger Coil Y34 (output) B11 Horn Relay Cr5 Terminal 86 (output)
B12 LPG Select Coil Y50 (output) B12 Alarm (output)
C1 Plug C1 System Power (input)

C2 Platform Overload (input) C2 System Power (input)
C3 Right Front Outrigger Limit Switch LS13 (input) C3 System Power (input)
C4 Right Rear Outrigger Limit Switch LS15 (input) C4 Engine Starting Aid (output)
C5 Left Front Outrigger Limit Switch LS12 (input) C5 Oscillate Stowed Relay CR84 Terminal 86 (output)
C6 Left Rear Outrigger Limit Switch LS14 (input) C6 Oscillate Raised Relay CR85 Terminal 86 (output)
C7 Alternator (input) C7 Ground (output)
C8 Engine Oil Pressure SW2 (input) C8 Plug
C9 Engine Water Temp SW1 / Engine Oil Temp SW3 C9 Plug
C10 Plug (Input) C10 Aux Down Relay Cr23 Terminal 87 (output)
C11 Plug C11 Flashing Beacons Fs1 (output)
C12 Plug C12 ECM Power (input)
Part No. 84793 GS-84 • GS-90 6-3

Ford Engine Relay Layout

REV B
Ford LRG425
F5-15A
Power
F4-15A F3-20A
Relay
F2-5A F1-30A
Starter Fuel Pump

Relay Relay
Ford DSG423
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A F6-10A
NOTE
GS-84: F6 added after serial
number GS8407-41311
GS-90: F6 added after serial
number GS9007-43786
Note:
For detailed wire color information, refer to
the Ford engine wiring harness diagrams.
6-4 GS-84 • GS-90 Part No. 84793

Wiring Diagram - Platform Control Box

REV A
COIL CORD ASSEMBLY
H1
ALARM
BK
NC 1
RD
P2
EMERGENCY
STOP
OR
BL
JC1 WH
JOYSTICK
CONTROLLER
1 5
J5
GY
4
J3
BK
U3
RD 1 PLATFORM
CONTROLS
CIRCUIT
BK BOARD
PP
YL
WH/BL
1 14
GY
BL
J2
OR
RD
WH
BN
6
BK
YL
TS20 BL
OR RD
1
TS21 J1
TS20 PLATFORM UP/DOWN TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS)

TS21 PLATFORM UP/DOWN / OUTRIGGER UP/DOWN TOGGLE SWITCH (MODELS WITH OUTRIGGERS)
Part No. 84793 GS-84 • GS-90 6-5

Limit Switch Legend

REV B
g
a HY
DR
AU
b LIC
TA h
c
NK
SID
E
d
e GR
OU
ND
CO
NT
RO
LS
IDE
i
a up limit switch LS5 f dual pressure switch LS26

(GS-5390 models) (GS-5390 CE models)
(hydraulic tank side)
g outrigger deployed
b up limit switch LS5A (all models)
(GS-5390 models) • left front LS12
(hydraulic tank side) • right front LS13
• left rear LS14
c down limit switch LS6 • right rear LS15
(ground controls side)
h outrigger deployed
d load sense delay LS25 (GS-5390 CE models) (lower)
(CE models) • left front LS12A
(ground controls side) • right front LS13A
• left rear LS14A
e maximum height LS24 • right rear LS15A
(CE models)
(ground controls side) i oscillate axle (GS-90 models)
• left axle LS23
• right axle LS22
(located inside axle)
6-6 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6-7

Electrical Schematics Abbreviation and Wire Color Legends

REV A
Code Description Code Description Code Description

B1 Battery FB1 Flashing Beacons QD Quick disconnect
BN Button FL1 Fusible link, battery to alternator QD3 Control cable to ground
QD4 Control cable to platform
BN1 Engine stop G Gauge
BN2 Engine start G1 Volt meter R6 Resistor, 510 ohm
BN3 Starting aid
BN4 High idle
G6 Hour meter S Sensor
G8 Diagnostic display
BN5 Horn S5 Platform overload pressure
BN6 High torque GND Ground switch (option)
BN7 Generator H Horn or alarm S7 Level sensor
BN9 Platform up (models without outriggers)
H1 Alarm
BN14 LPG select S8 Level sensor
H2 Automotive-style horn
BN15 Horn/left rear outrigger (models with outriggers)
H5 Alarm
BN16 Outrigger function enable
BN17 High torque/left front outrigger JC1 Joystick controller SW Switch
BN20 Autolevel KS1 Key switch SW1 Engine coolant temperature
BN23 Auxiliary down SW2 Engine oil pressure
L LED or light SW3 Engine oil temperature
BN24 Right rear outrigger
L2 Check engine SW4 Hydraulic oil temperature
BN85 Left front outrigger
L50 System status SW5 Function enable
BN86 Right front outrigger
BN87 Left rear outrigger LS Limit switch SW6 Steer left/right
BN91 Auxiliary down enable LS5 Platform up (5390 only) U Electronic component
C5 Capacitor, 4700 uF LS6 Platform down U3 Platform controls circuit board
LS12 Left front outrigger U5 Electronic control module
CB Circuit breaker LS13 Right front outrigger U32 Glow plug (option)
CB2 System power, 20A LS14 Left rear outrigger
CB7 Oil cooler, 20A LS15 Right rear outrigger Y Valve coil
CB8 Engine high idle, 25A LS22 Right oscillate Y1 Parallel
LS23 Left oscillate Y2 Brake release
CR Control relay
Y3 Steer right
LS24 Maximum height
CR1 Engine start LS25 Load sense delay Y4 Steer left
CR1A Power to starter LS26 Dual pressure switch (5390) Y7 Platform down
CR4 High idle Y8 Platform up
CR5 Horn M Motor
Y9 Proportional control
CR8 Ignition M1 Cooling fan Y29 Generator on (option)
CR15 Starting aid M2 Auxiliary pump Y33 Left rear outrigger
CR17 Oil cooler M3 Engine starter Y34 Right rear outrigger
CR23 Auxiliary down M4 Fuel pump Y35 Left front outrigger
CR41 Control system
N.C. Normally closed Y36 Right front outrigger
CR42 Power Y39 Outrigger retract
CR58 Forward/reverse N.O. Normally open
Y40 Outrigger extend
CR77 Down enable P Power switch Y50 LPG
CR82 Lift enable P1 Emergency stop button (ground) Y51 Electronic displacement control
CR84 Oscillate stowed P2 Emergency stop button (platform) Y54 Oscillate float
CR85 Oscillate raised Y55 Oscillate enable
PS2 Platform overload pressure switch
D Power supply Y56 Left oscillate
Q Solenoid Y57 Right oscillate
D1 Alternator
D7 Voltage regulator Q3 High idle
Q8 Fuel shut off
Wire Color Legend - Ford Engine
BL BLUE GY GREY P PURPLE

BK BLACK LB LIGHT BLUE R RED
BR BROWN LG LIGHT GREEN T TAN
DB DARK BLUE N NATURAL W WHITE
DG DARK GREEN O ORANGE Y YELLOW
GN GREEN PK PINK
Wire Color Legend - GS-84 & GS-90
1. Wires in the LRG425 engine schematic are labeled with
Ford circuit number, color and wire gauge
BL BLUE GY GREY RD RED
2. Wires in the DSG423 engine schematic are labeled with
BK BLACK OR ORANGE WH WHITE
color and wire gauge.
BR BROWN PP PURPLE YL YELLOW
3. Internal splices are not shown.
6-8 GS-84 • GS-90 Part No. 84793

Electrical Symbols Legend

REV A
KS1 KEY SWITCH

B
PLATFORM Fuse or AUX

PUMP
STARTER
CONTROL Circuit breaker Fusible link
M2
B M3
T Auxiliary pump Engine starter
G6
GROUND
CONTROL
Hour meter Emergency Stop

Key switch button N.O. QD4
C C
LEVEL SENSOR
CIRCUIT BOARD
A A
S7 B B
LEVEL
D D
86 30 K5 Horn SENSOR
E E
85 87 87A
Flashing beacon
Level sensor
Quick disconnect
(models without outriggers)
Relay
Pressure S8
A switch 2 AXIS
Solenoid valve TILT LEVEL
D1 S SENSOR
I
Level sensor
Alternator
(models with outriggers)
Temperature
switch
LED
Resistor
Spark plug
Toggle switch
FWD
REV
HALL EFFECT
Diode GENERATOR
JC1
JOYSTICK
CONTROLLER
Solenoid
+ M5
SW5 SW6
FUNCTION ENABLE
LEFT
RIGHT
N.C. N.O. STEER

LEFT/ RIGHT
Drive pump EDC

-
Limit switch
12V DC Joystick
Battery
Part No. 84793 GS-84 • GS-90 6-9

Wiring Harness - Ford LRG-425 EFI

Part 1 of 2 REV A
6 361 R 16 361 R 16
INJ +
7 555 T 16 555 T 16
INJ 1
8 557 BR-Y 16 557 BR-Y 16
INJ 3
9 558 BR-LB 16 558 BR-LB 16
INJ 4
10 556 W 16 556 W 16
INJ 2
11 743 GY 18
INJ 5
12 359 GY-R 18
INJ 6
31
AUX OUT 2
21 18 O-Y 18
EGR
19 198 DG-O 18
AUX ANA PD1
20 358 LG-BK 18
MAP
15 151 LB-BK 18 151 LB-BK
FPP 1
27 743 GY 18 307 BK-Y 18
IAT
28 354 LG-R 18 354 LG-R 18
ECT
17 307 BK-Y 18
IVS
18 150 DG-W 18
AUX ANA PU1
16 114 LB-Y 18
FPP 2
22 352 BR-LG 18
EGR PWM
23 360 BR-PK 18
EGR RECIRC
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
ANA_RTN
14 351 BR-W 18 351 BR-W 18
5 VOLT REF
3 16 R-LG 18 16 R-LG 18
VSW
33 350 GY 18 358 LG-BK 18
CRANK -
32 349 DB 18 359 GY-R 18
CRANK +
35 452 GY-R 18 18 O-Y 18
CAM -
34 282 DB-O 18 198 DG-O 18
CAM +
4 361 R 16 150 DG-W 18
VBAT CAM CRANK
5 361 R 16 361 R 14 114 LB-Y 18
VBAT
25 392 R-LG 18 352 BR-LG 18
EGO 2
24 74 GY-LB 18 360 BR-PK 18
EGO 1
EGO 3
26 O2 SENSOR 361 R 14
29
KNK +
30
KNK -
J1 BLACK 361A R 16 361A R 16 O2

570 BK-W 16 570 BK-W 16 SENSOR 355 GY-W 18
357 Y-W 18
74 GY-LB 18 392 R-LG 18 151 LB-BK 18
359 GY-R 18 359 GY-R 18 317 GY-O 18
J2 GREY TWR 342 LG-P 18

4 570 BK-W 16 242 DG 18
SPK PWR GROUND A
1 850 Y-BK 18 1 2 3
COIL 1 1 COIL 1
2 851 Y-R 18 361A R 16 361A R 16
COIL 2 2 VBAT B
3
COIL 3 3 COIL 2
13
COIL 4 LOCKOFF SOLENOID 669 DG-W 18
24
COIL 5 458 O-BK 18
25
COIL 6
22 342 LG-P 18
STARTER LOCKOUT
23 242 DG 18
FUEL LOCKOFF
9 926A LB-O 18 926A LB-O 18
FUEL PUMP
32 15 R-Y 18 15 R-Y 18
RELAY CONTROL
30 355 GY-W 18
TPS1
31 357 Y-W 18
TPS2
28 151 LB-BK 18
DBW +
29 317 GY-O 18
DBW -
6 511 LG-R 18 511 LG-R 18
BRAKE SWITCH
7 253 DG-W 18 253 DG-W 18
OIL PRESSURE
8 11 T-Y 18 11 T-Y 18
TACH
27 658 PK-LG 18 658 PK-LG 18
MIL
10 238 DG-Y 18 238 DG-Y 18
FUEL PUMP MON
5 71 O-LG 18 71 O-LG 18
AUX OUT 1
14 72 Y-BK 18 72 Y-BK 18
FUEL SELECT
15 148 Y-R 18 148 Y-R 18
AUX ANA PU2
16 306 T-LB 18 306 T-LB 18
GOV SELECT 1
17 307 BK-Y 18 307 BK-Y 18
GOV SELECT 2
11 169 LG-BK 18 169 LG-BK 18
ROAD SPEED +
12 172 LB-R 18 172 LB-R 18
ROAD SPEED -
26 77 DB-Y 18
GASEOUS TRIM
33 349A DB 18 349A DB 18
OVERSPEED
18 662 DG-P 18 662 DG-P 18
CAN +
19 459 O-LG 18 459 O-LG 18
CAN -
20 642 DG-O 18 642 DG-O 18
RS 485 +
21 461 O 18 461 O 18
RS 485 -
34 669 DG-W 18 669 DG-W 18
RS 232 TX
35 458 O-BK 18 458 O-BK 18
RS 232 RX
TRIM VALVE
TWR
77 DB-Y 18
A
361A R 16 361A R 16
B
WPTWR2_GY
E1429B
6 - 10 GS-84 • GS-90 Part No. 84793

Wiring Harness - Ford LRG-425 EFI

REV A Part 2 of 2
361 R 16 361 R 16 361 R 16 361 R 16
555 T 16 FORD
557 BR-Y 16
558 BR-LB 16 42 PIN
556 W 16
743 GY 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2 CONNECTOR 570 BK-W 16 39 R-W 18

359 GY-R 18 16 WATER TEMP
WATER
ACT TEMP
151 LB-BK 151 LB-BK

14 FPP1
307 BK-Y 18 307 BK-Y 18
25 IVS
354 LG-R 18 359 GY-R 18
570 BK-W 16
F1 30A
570 BK-W 16 570 BK-W 12 570 BK-W 12 34 GROUND
ECT 570 BK-W 16
F2 5A
16 R-LG 18 16 R-LG 18
1 VSW
570 BK-W 16
570 BK-W 16 MAP_CONN F3 20A
570 BK-W 16 361 R 14 361 R 14 361 R 12
TWR
9 VBATT
351 BR-W 18 351 BR-W 18
C
16 R-LG 18 361 R 14
358 LG-BK 18 358 LG-BK 18
B
359 GY-R 18 359 GY-R 18
A
18 O-Y 18 18 O-Y 18
38 EGR ANA IN
198 DG-O 18 198 DG-O 18
32 ANA AUX PD1
150 DG-W 18 150 DG-W 18
37 ANA AUX PU1
114 LB-Y 18 114 LB-Y 18
12 FPP2
352 BR-LG 18 352 BR-LG 18
40 EGR PWM
360 BR-PK 18 360 BR-PK 18
41 EGR REC
361 R 14
359 GY-R 18 359 GY-R 18
33 ANA RTN
351 BR-W 18 351 BR-W 18
31 VREF
MTRTWR6 MTRSHD6 16 R-LG 18 32 R-LB 16
THROTTLE 13 STARTER CONTROL
355 GY-W 18
TWR SHD 355 GY-W 18 FUEL PUMP 86 30 STARTER
A A 6
357 Y-W 18 357 Y-W 18 RELAY RELAY
B B 5
151 LB-BK 18 151 LB-BK 18
C C 4 85 87 87A
317 GY-O 18 317 GY-O 18 86 30 32 R-LB 16
D D 1 15 STARTER IN (INTERUPT)
359 GY-R 18 351 BR-W 18 32 R-LB 16
E E 3 39 STARTER IN (AUTOCRANK)
351 BR-W 18 359 GY-R 18 85 87 87A
F F 2
342 LG-P 18 342 LG-P 18
FPP_COMM F4 15A
359 GY-R 18 D 787A PK-BK 16 787A PK-BK 16
RTN 5 FUEL PUMP
351 BR-W 18 C
5V
669 DG-W 18 B
TX
458 O-BK 18 A
RX 86 30 POWER
TWR
RELAY
85 87 87A
926A LB-O 18
F5 15A
15 R-Y 18 361 R 16 361 R 16
253 DG-W 18
OIL PRESSURE
511 LG-R 18 511 LG-R 18

4 BRAKE
253 DG-W 18 253 DG-W 18
26 OIL PRES
11 T-Y 18 11 T-Y 18 2 TACH
658 PK-LG 18 658 PK-LG 18
6 MIL
238 DG-Y 18
71 O-LG 18 71 O-LG 18
21 AUX OUT1
72 Y-BK 18 72 Y-BK 18
7 FUEL SELECT
148 Y-R 18 148 Y-R 18
10 AUX ANA PU2
306 T-LB 18 306 T-LB 18
24 GOV SELECT 1
307 BK-Y 18 307 BK-Y 18
23 GOV SELECT 2
169 LG-BK 18 169 LG-BK 18
35 ROADSPEED +
172 LB-R 18 172 LB-R 18
36 ROADSPEED -
349A DB 18 349A DB 18
30 OVERSPEED
662 DG-P 18 662 DG-P 18
28 CAN +
459 O-LG 18 459 O-LG 18
29 CAN -
642 DG-O 18 642 DG-O 18
11 RS 485+
461 O 18 461 O 18
3 RS 485-
669 DG-W 18 669 DG-W 18
20 RS 232+
458 O-BK 18 458 O-BK 18
18 RS 232-
TWR SHD
570 BK-W 16
A A PLUG (GROUND)
361A R 16
B B PLUG (RELAY POWER)
361A R 16 459 O-LG 18
C C PLUG (CAN -) MEGAJECTOR
662 DG-P 18
D D PLUG (CAN +)
E1429B MTRTWR4 MTRSHD4
Part No. 84793 GS-84 • GS-90 6 - 11

Wiring Harness - Ford DSG-423 EFI

Part 1 of 2 REV B
IGNITION COILS
R 16 R 16
ENGINE ECM Y/BK 18
CONNECTOR W/PK 18
Y/RD 18 GY/LB 18
1 Y/BK 18 DG/P 18
SPK_COIL1A W/PK 18 DB/O 18
2
SPK_COIL1B
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1
9
UEGOC
UEGOP
10 CAM
11
UEGPR DG/O 18 W/LG 18
12
AUX ANA PD1 W/LG 18
13
(FRP) AUX ANA PD2 DG/P 18 DG/P 18
14
CAN1 + O/LG 18 O/LG 18
15
CAN1 -
16
CAN2 - BR/W 18
17
CAN2 + LG/R 18
18
AUX ANA PD3 BR/W 18
19
5V EXT 1 GY/R 18 GY/R 18
20
5V RTN GY/LB 18
21
EGO1 GY/Y 18
22
EGO2
23 LG/BK 18 BOSCH
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM + DB/O 18 3
28 GY 18
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32
5V RTN 2
33 LB/R 18
PULSE IN T/LB 18 T/LB 18
34
GOV 1 DG/W 18 BK/W 16
35
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18
38
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2 BK/O 18
40
(IVS) AUX ANA PU3 W/LB 18 R/LG 18
41
(BRAKE) AUX DIG 3 BK/Y 18
42 BK/Y 18
(GOV2) AUX DIG 4 T/Y 18
43
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2 P/LB 18
46
AUX ANA PUD1 GY/W 18 R/T 14
47
TPS 1 Y/W 18
48
TPS 2 Y/DB 18
49
(FUELSELECT)AUX DIG1
50
AUX DIG 2
51 Y/R 18
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18
53 LB/BK 18
FPP1
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18
55 DG 18
PC TX
56 O 18
PC RX DB/W 18
57
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18
61
EGOH 2 BK/LG 18 BR/W 18 BR/W 18
62
EGOH 1
63
INJ HS T 16
64
INJ1 LS BR/Y 16 BK/LG 18
65
INJ2 LS BR/LB 16
66
INJ3 LS W 16 GY/W 18
67
INJ4 LS Y/W 18
68
INJ5 LS BK/W 16 LB/DG 18
69
GROUND BR/W 18
70
INJ6 LS BK/W 16 GY/R 18
71
AUX PWM8 LG/P 18 GY/O 18
72
STARTER R/Y 18
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW + BK/W 16
81
GROUND GY/O 18
82
DBW - R/BK 18
83
AUX PWM5 REC R/W 18
84 R/BK 18
AUX PWM5 O/LG 18
85
AUX PWM1 R/W 18 BK/O 18
86
AUX PWM4 T/GN 18 DG/W 18
87
AUX PWM2 T/Y 18
88
AUX PWM4 REC
89 PK/LG 18
FP REC AUX PWM3 REC BK/R 16 BK/R 16
90
FUEL PUMP AUX PWM3 O/LG 18
R 16 W 16 Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
W/R 18 O 18
A
INJECTOR CYL #2 GY/R 18
B
R 16 BN/LB 16 LPG
TEMPERATURE
GY/R 18 1
ANA RTN
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
A 5
INJECTOR CYL #4 R/LG 18
B
DG/P 18
6
UNUSED
LB/O 18
Y/R 18 UNUSED
LPG DG/P 18 7
CAN +
R 16 BR/Y 16
LOCKOFF KNOCK
O/LG 18 8
CAN -
SENSOR DIAGNOSTIC CONNECTOR

R/LG 18
R 16
INJECTOR CYL #3
R 16 T 16 PK/BK 16
INJECTOR CYL #1
R 16 R 16
EDI 1782000F ES0400A
6 - 12 GS-84 • GS-90 Part No. 84793


REV B Part 1 of 2
HO2S #1
R 16 R 16 HO2S #2
BK/LG 18 GY/R 18 SHD
GY/LB 18 GY/YL 18 A
GY/LB 18
R 16 B
GY/R 18
BK/LB 18 C
D
GY/Y 18
GY/R 18 TWR GASOLINE

A
LG/W 18
B SENSOR
BR/W 18
W/LG 18 W/LG 18 C INTERFACE
D
DG/P 18
MTRTWR4 FORD
O/LG 18
42 PIN
BR/W 18 CONNECTOR
LG/R 18 LG/R 18
GY/R 18 GY/R 18
GROUND BR 16 BR 16
34 GND
BK/W 12
RING
CHT
LG/W
DG/BK LB/R 18 36 ROADSPEED -
LB/R 18 LG/BK 18 35 ROADSPEED +
T/LB 18 T/LB 18 24 GOV SELECT 1
BK/W 16
BK/W 16
BK/W 16
LB/BK 18 LB/BK 18
14 FPP1
BK/LB 18
F2
R/LG 18 R/LG 18 R/LG 18 R/LG 18 1 VSW
BK/Y 18
5A VSW
F3
R/T 14 R/T 14 R 14
10A ECM
BK/Y 18
23 GOV SELECT 2
O/LG 18
29 CAN -
DG/P 18
28 CAN +
DG/O 18 DG/O 18
32 ANA AUX PD1
DB/W 18 DB/W 18
37 AUX ANA PU2B
LB/Y 18 LB/Y 18
12 FPP2
GY/R 18 GY/R 18 33 ANA RTN

BR/W 18 BR/W 18 31 VREF
BK/LG 18 BOSCH THROTTLE

BATT(+) R 12 R 12 R 14
GY/W 18 GY/W 18
Y/W 18 Y/W 18 6 RING R 16
LB/DG 18 LB/DG 18 5 3
BR/W 18 BR/W 18 4 2
GY/R 18 GY/R 18 3 1
GY/O 18 GY/O 18 2
1
ALTERNATOR
LG/P 18 DG/W 18
R/Y 18
OIL PRESSURE
R/BK 18 R/BK 18 21 AUX PWM 5
R/W 18 R/W 18 16 AUX PWM 4
BK/O 18 BK/O 18 25 IVS

DG/W 18 DG/W 18 26 OIL PRES
T/Y 18 T/Y 18 2 TACH
PK/LG 18 PK/LG 18 6 MIL
BK/R 16 BK/R 16 18 FUEL PUMP -
O/LG 18 O/LG 18
39 AUX OUT1
Y/DB 18 Y/DB 18
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
O 18 O 18 3 RS 232-
FUEL PUMP
LB/PK 16
F4 W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16 PK/BK 16 PK/BK 16 5 FUEL PUMP +
15A
FUEL PUMP RELAY

LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
R 16 30 SOLENOID 87A
TERMINATION
LB/PK 16
PK/BK 16 87 LB/PK 16 30 CONNECTOR
R/LG 18 86 87 W/PK 16
SHD TWR
87A RING W 18 W 18 2
CAN + TERM
R/LG 18 R/LG 18 86
RELAY
OMRON DG/P 18 3
CAN +
LG/P 18 85
FPP O/LG 18 1
CAN -
BK/W 18 6
GROUND
PK/BK 16 PK/BK 16 4
UNUSED
5
UNUSED
8
UNUSED
F1
R16 R/LB 16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A EPR EPR
R 16
R 16 R 16
30
F5 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
ES0400A EDI 1782000F
Part No. 84793 GS-84 • GS-90 6 - 13


Part 1 of 2 REV A
IGNITION COILS
R 16 R 16
ENGINE ECM Y/BK 18
CONNECTOR W/PK 18
Y/RD 18 GY/LB 18
1 Y/BK 18 DG/P 18
SPK_COIL1A W/PK 18 DB/O 18
2
SPK_COIL1B
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1
9
UEGOC
UEGOP
10 CAM
11
UEGPR DG/O 18 W/LG 18
12
AUX ANA PD1 W/LG 18
13
(FRP) AUX ANA PD2 DG/P 18 DG/P 18
14
CAN1 + O/LG 18 O/LG 18
15
CAN1 -
16
CAN2 - BR/W 18
17
CAN2 + LG/R 18
18
AUX ANA PD3 BR/W 18
19
5V EXT 1 GY/R 18 GY/R 18
20
5V RTN GY/LB 18
21
EGO1 GY/Y 18
22
EGO2
23 LG/BK 18 BOSCH
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM + DB/O 18 3
28 GY 18
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32
5V RTN 2
33 LB/R 18
PULSE IN T/LB 18 T/LB 18
34
GOV 1 DG/W 18 BK/W 16
35
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18
38
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2 BK/O 18
40
(IVS) AUX ANA PU3 W/LB 18 R/LG 18
41
(BRAKE) AUX DIG 3 BK/Y 18
42 BK/Y 18
(GOV2) AUX DIG 4 T/Y 18
43
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2 P/LB 18
46
AUX ANA PUD1 GY/W 18 R/T 14
47
TPS 1 Y/W 18
48
TPS 2 Y/DB 18
49
(FUELSELECT)AUX DIG1
50
AUX DIG 2
51 Y/R 18
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18
53 LB/BK 18
FPP1
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18
55 DG 18
PC TX
56 O 18
PC RX DB/W 18
57
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18
61
EGOH 2 BK/LG 18 BR/W 18 BR/W 18
62
EGOH 1
63
INJ HS T 16
64
INJ1 LS BR/Y 16 BK/LG 18
65
INJ2 LS BR/LB 16
66
INJ3 LS W 16 GY/W 18
67
INJ4 LS Y/W 18
68
INJ5 LS BK/W 16 LB/DG 18
69
GROUND BR/W 18
70
INJ6 LS BK/W 16 GY/R 18
71
AUX PWM8 LG/P 18 GY/O 18
72
STARTER R/Y 18
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW + BK/W 16
81
GROUND GY/O 18
82
DBW - R/BK 18
83
AUX PWM5 REC R/W 18
84 R/BK 18
AUX PWM5 O/LG 18
85
AUX PWM1 R/W 18 BK/O 18
86
AUX PWM4 T/GN 18 DG/W 18
87
AUX PWM2 T/Y 18
88
AUX PWM4 REC
89 PK/LG 18
FP REC AUX PWM3 REC BK/R 16 BK/R 16
90
FUEL PUMP AUX PWM3 O/LG 18
R 16 W 16 Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
W/R 18 O 18
A
INJECTOR CYL #2 GY/R 18
B
R 16 BN/LB 16 LPG
TEMPERATURE
GY/R 18 1
ANA RTN
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
A 5
INJECTOR CYL #4 R/LG 18
B
DG/P 18
6
UNUSED
LB/O 18
Y/R 18 UNUSED
LPG DG/P 18 7
CAN +
R 16 BR/Y 16
LOCKOFF KNOCK
O/LG 18 8
CAN -
SENSOR DIAGNOSTIC CONNECTOR

R/LG 18
R 16
INJECTOR CYL #3
R 16 T 16 PK/BK 16
INJECTOR CYL #1
R 16 R 16
EDI 1782000G ES0400B
6 - 14 GS-84 • GS-90 Part No. 84793


REV A Part 2 of 2
HO2S #1
R 16 R 16 HO2S #2
BK/LG 18 GY/R 18 SHD
GY/LB 18 GY/YL 18 A
GY/LB 18
R 16 B
GY/R 18
BK/LB 18 C
D
GY/Y 18
GY/R 18 TWR GASOLINE

A
LG/W 18
B SENSOR
BR/W 18
W/LG 18 W/LG 18 C INTERFACE
D
DG/P 18
MTRTWR4 FORD
O/LG 18
42 PIN
BR/W 18 CONNECTOR
LG/R 18 LG/R 18
GY/R 18 GY/R 18
GROUND BR 16 BR 16
34 GND
BK/W 12
RING
CHT
LG/W
DG/BK LB/R 18 36 ROADSPEED -
LB/R 18 LG/BK 18 35 ROADSPEED +
T/LB 18 T/LB 18 24 GOV SELECT 1
BK/W 16
BK/W 16
BK/W 16
LB/BK 18 LB/BK 18
14 FPP1
BK/LB 18
F2
R/LG 18 R/LG 18 R/LG 18 R/LG 18 1 VSW
BK/Y 18
5A VSW
F3
R/T 14 R/T 14 R 14
10A ECM
BK/Y 18
23 GOV SELECT 2
O/LG 18
29 CAN -
DG/P 18
28 CAN +
DG/O 18 DG/O 18
32 ANA AUX PD1
DB/W 18 DB/W 18
37 AUX ANA PU2B
LB/Y 18 LB/Y 18
12 FPP2
GY/R 18 GY/R 18 33 ANA RTN

BR/W 18 BR/W 18 31 VREF
BATT(+) R 12 R 12 R 14
BK/LG 18 BOSCH THROTTLE R 16
GY/W 18 GY/W 18
Y/W 18 Y/W 18 6 RING
LB/DG 18 LB/DG 18 5 3
BR/W 18 BR/W 18 4 2
R/LG 18
GY/R 18 GY/R 18 3 1
GY/O 18 GY/O 18 2
1
ALTERNATOR
LG/P 18 DG/W 18
R/Y 18
OIL PRESSURE
R/BK 18 R/BK 18 21 AUX PWM 5
R/W 18 R/W 18 16 AUX PWM 4
BK/O 18 BK/O 18 25 IVS

DG/W 18 DG/W 18 26 OIL PRES
T/Y 18 T/Y 18 2 TACH
PK/LG 18 PK/LG 18 6 MIL
BK/R 16 BK/R 16 18 FUEL PUMP -
O/LG 18 O/LG 18
39 AUX OUT1
Y/DB 18 Y/DB 18
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
O 18 O 18 3 RS 232-
FUEL PUMP
LB/PK 16
F4 W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16 PK/BK 16 PK/BK 16 5 FUEL PUMP +
15A
FUEL PUMP RELAY

LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
R 16 30 SOLENOID 87A
TERMINATION
LB/PK 16
PK/BK 16 87 LB/PK 16 30 CONNECTOR
R/LG 18 86 87 W/PK 16
SHD TWR
87A RING W 18 W 18 2
CAN + TERM
R/LG 18 R/LG 18 86
RELAY
OMRON DG/P 18 3
CAN +
LG/P 18 85
FPP O/LG 18 1
CAN -
BK/W 18 6
GROUND
PK/BK 16 PK/BK 16 4
UNUSED
5
UNUSED
8
UNUSED
F6 F1
R16 R/T 16 R16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A ALTERNATOR 10A EPR EPR
R 16
R 16 R 16
30
F5 R 16 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
ES0400B EDI 1782000G
Part No. 84793 GS-84 • GS-90 6 - 15

Electrical Schematic
ANSI Models with Ford Power - Part 1 of 3 REV B
F9 5A FUSE P1EMERGENCY STOP
KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7
CR41 CR42 CR1 CR23 CR84 CR85

CONTROL POWER CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE
SYSTEM (ESTOP 2) HORN IGNITION START DOWN STOWED RAISED
(ESTOP 1) AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
N.C.H.O. N.C.H.O.
2
FUSE G6 LS23 LS22

LINK L2 LEFT RIGHT
1 OSCILLATE OSCILLATE
H2 A
LIMIT SWITCH LIMIT SWITCH
D1 S
AB15
I
GOV. SPEED SELECT OR/RD 23
R6 FUEL SELECT BK/WH 7
510 W
6 MALFUNCTION LED BL
1 KEY ON WH
24 KEEP ALIVE POWER WH CD2 CD3
B1 SW20 9 VPWR RD
ENGINE SELF TEST
CD4 CD5
+ 18 SELF TEST SWITCH BK/RD
34 GROUND BN
Y54 Y56 Y50
5 FUEL PUMP BL/WH
FORD
M4
STARTER ENGINE HARNESS
AUX
-
M3 M4 PUMP
FUEL PUMP
M2
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
GROUND
H2 AUTOMOTIVE-STYLE HORN
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
AUXILIARY PUMP RELAY
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
MACHINE SHOWN IN THE STOWED
POSITION WITH THE POWER OFF ES7163F
6 - 16 GS-84 • GS-90 Part No. 84793

REV B ANSI Models with Ford Power - Part 2 of 3
AB1
AB3 AB3
(GS-5390) OIL COOLER

(OPTION)
LS5A J2-C12 BATTERY 12V (+)
RD
WH
PLAT N.C. CD13
UP
LIMIT
SW4 CB7
SWITCH HYDRAULIC 20A
N.C. OIL TEMP
AB4
86 30 8
CR17 LEVEL SENSOR
N.C.
LS6 HYDRAULIC CIRCUIT BOARD
AB1 PLAT 85 87 87A OIL COOLER

DOWN
LS5
PLAT N.C.
LIMIT
SWITCH UP FAN M1 S7 LEVEL
SENSOR
LIMIT
FAN MOTOR
SWITCH MODELS WITHOUT
AB2 BATTERY 12V (-) OUTRIGGERS
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
J2-A1
U5
J1-C7 BN23 BN91 ELECTRONIC CONTROL MODULE
AUXILIARY DOWN AUXILIARY DOWN ENABLE
J2-C10
J1-A3
J1-A10
J2-B9
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
J1-A9
J1-B12
AB12
REV
FWD
AB9
Y4 Y1 Y9 Y51
EDC
M5
Y8 Y7 SW1 SW2
Y3 Y2
M5 HYDRAULIC PUMP
SW1 ENGINE COOLANT TEMPERATURE
SW2 ENGINE OIL PRESSURE

Y4 STEER LEFT
Y1 TWO SPEED MOTOR STROKE

Y3 STEER RIGHT
Y2 BRAKE RELEASE
Y9 PROPORTIONAL FLOW CTRL
Y51 FORWARD/REVERSE COIL

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES7163F POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 17

QD4 QD3 P2
BK EMERGENCY
WH/RD 4 4 4 4 BK POWER TO PLATFORM STOP
RD
RD/WH 3 3 3 3 RD POWER TO GROUND
BL 1 1 1 1 WH GROUND WH J5 PIN1
BK 2 2 DATA LINK (HIGH) BL
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
DATA LINK (LOW) J5 PIN5
OUTRIGGERS
(STANDARD ON GS-5390)
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
CD11 CD11 CD12 CD12 U3 D7
PLATFORM CONTROLS VOLTAGE 5V DC
PRINTED CIRCUIT BOARD REGULATOR
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
LS12 LS13 LS14 LS15 TILT LEVEL
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
O-RIG O-RIG O-RIG O-RIG J2 PIN3
LIMIT LIMIT LIMIT LIMIT PP
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER
SWITCH SWITCH SWITCH SWITCH GY

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
N.O. N.O. N.O. N.O. OR STEER
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5

ELECTRONIC CONTROL MODULE PIN3 STARTING AID BN3
PIN4 ENGINE START BN2

J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
PIN5 HIGH TORQUE BN6
CD1
PIN6 GENERATOR BN7
PIN7 LPG SELECT BN14
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4
PIN9 LF OUTRIGGER ENABLE BN85
PIN10 RF OUTRIGGER ENABLE BN86
PIN11 LR OUTRIGGER ENABLE BN87

H5 FB1
Y35 Y33 Y39 PIN12 RR OUTRIGGER ENABLE BN24
Y29 GENERATOR (OPTION)
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM
Y39 OUTRIGGER RETRACT
S8 2-AXIS LEVEL SENSOR

Y36 RIGHT FRONT OUTRIGGER
Y34 RIGHT REAR OUTRIGGER
Y40 OUTRIGGER EXTEND

Y35 LEFT FRONT OUTRIGGER
Y33 LEFT REAR OUTRIGGER
PIN13 LIFT FUNCTION BN9
PIN14 ORGR AUTOLEVEL ENABLE BN20
PIN15 SYSTEM STATUS L50
YL
J1 PIN4
PLATFORM UP/DOWN TS20
BL -OR-
J1 PIN3
PLATFORM & OUTRIGGER
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
POSITION WITH THE POWER OFF ES7163F
CONTROLS
6 - 18 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 19

KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7

(ESTOP 1) AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
N.C.H.O. N.C.H.O.
2
G6 LS23 LS22
R6 L2 LEFT RIGHT
510 W 1 OSCILLATE OSCILLATE
H2 LIMIT SWITCH LIMIT SWITCH
D1 SI AB15
A (TO FORD ECM)
FUEL SELECT BK/WH 7
1 KEY ON WH
B1 SW20
ENGINE SELF TEST
CD4 CD5
5 FUEL PUMP BL/WH
Y54 Y56 Y50
18 FUEL PUMP GND
M4 FORD ENGINE
STARTER ECM
-
M4 AUX
PUMP
M3 FUEL PUMP
M2
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
POSITION WITH THE POWER OFF ES0442A
6 - 20 GS-84 • GS-90 Part No. 84793

AB1
AB3 AB3

(OPTION)
RD
WH
PLAT N.C. CD13
UP
LIMIT
SW4 CB7
N.C. OIL TEMP
AB4
86 30 8
CR17 LEVEL SENSOR
N.C.

DOWN
LS5
PLAT N.C.
LIMIT
SENSOR
LIMIT
FAN MOTOR
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
J2-A1
U5
J2-C10
J1-A3
J1-A10
J2-B9
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
J1-A9
J1-B12
AB12
REV
FWD
AB9
Y4 Y1 Y9 Y51
EDC
M5
Y8 Y7 SW1 SW2
Y3 Y2
M5 HYDRAULIC PUMP

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES0442A POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 21

QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
CONTROLS
6 - 22 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 23

KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7

(ESTOP 1) AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
N.C.H.O. N.C.H.O.
2
G6 LS23 LS22
L2 LEFT RIGHT
D1 SI AB15
A TO FORD GOV. SPEED SELECT OR/RD 23
ALTERNATOR
FUSE FUEL SELECT BK/WH 7
TO
FORD ECM 6 MALFUNCTION LED BL
1 KEY ON WH
B1 SW20
ENGINE SELF TEST
CD4 CD5
5 FUEL PUMP BL/WH
Y54 Y56 Y50
18 FUEL PUMP GND
M4 FORD ENGINE
STARTER ECM
-
M4 AUX
PUMP
M3 FUEL PUMP
M2
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
POSITION WITH THE POWER OFF ES0442B
6 - 24 GS-84 • GS-90 Part No. 84793

AB1
AB3 AB3

(OPTION)
RD
WH
PLAT N.C. CD13
UP
LIMIT
SW4 CB7
N.C. OIL TEMP
AB4
86 30 8
CR17 LEVEL SENSOR
N.C.

DOWN
LS5
PLAT N.C.
LIMIT
SENSOR
LIMIT
FAN MOTOR
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
J2-A1
U5
J2-C10
J1-A3
J1-A10
J2-B9
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
J1-A9
J1-B12
AB12
REV
FWD
AB9
Y4 Y1 Y9 Y51
EDC
M5
Y8 Y7 SW1 SW2
Y3 Y2
M5 HYDRAULIC PUMP

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES0442B POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 25

QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
CONTROLS
6 - 26 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 27

CE Models with Ford Power - Part 1 of 3 REV C
KS1 KEY SWITCH
2
B1 AB7
PLATFORM
CONTROL
PS2A PLATFORM OVERLOAD PRESSURE SWITCH
4
B
R25 LS26
3 5 OHM DUAL PW PS2B PLATFORM OVERLOAD PRESSURE SWITCH
GROUND (GS-5390 ONLY)
CONTROL
CR41
CONTROL CR42 CR1 CR23 CR84 CR85
SYSTEM POWER CR5 CR8 ENGINE AUXILIARY OSCILLATE OSCILLATE
(ESTOP 1) (ESTOP 2) HORN IGNITION START DOWN STOWED RAISED
AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
CB2
20A 2 N.C.H.O. N.C.H.O.
FUSE
G6 LS23 LS22
LINK L2 LEFT RIGHT
H2 A
D1 S
AB15
I
R6 FUEL SELECT BK/WH 7
510 W
1 KEY ON WH
B1 SW20 9 VPWR RD
ENGINE SELF TEST
CD4 CD5
34 GROUND BN
Y54 Y56 Y50
5 FUEL PUMP BL/WH
AUX
FORD PUMP
M4
STARTER ENGINE HARNESS M2
-
M3 M4
FUEL PUMP
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
GROUND
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
POSITION WITH THE POWER OFF ES7174F1
6 - 28 GS-84 • GS-90 Part No. 84793

REV C CE Models with Ford Power - Part 2 of 3
(GS-5390 ONLY)
CD6
AB3 AB3
LS12A
N.C.H.O.
LOWER
LF O-RIG
OIL COOLER
(OPTION)
LIMIT SWITCH
CD7 N.C. J2-C12 BATTERY 12V (+)
RD
WH
LS13A CD13
N.C.H.O.
LOWER LS5A SW4 CB7

RF O-RIG PLAT
LIMIT SWITCH HYDRAULIC 20A
CD8 UP OIL TEMP
N.C.
LIMIT
LS14A
N.C.H.O.
SWITCH
LOWER 86 30 8
CR17 LEVEL SENSOR
N.C.
LS6 LR O-RIG
LIMIT SWITCH
N.C. HYDRAULIC CIRCUIT BOARD

CD9
DOWN
LS15A LS5
N.C.H.O.
LIMIT
SWITCH LOWER PLAT
FAN M1 S7 LEVEL
SENSOR
RR O-RIG UP
FAN MOTOR
LIMIT SWITCH LIMIT MODELS WITHOUT
AB2 CD10 SWITCH BATTERY 12V (-) OUTRIGGERS
AB5
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-A1
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
U5
BN23 BN91
J1-A3
J1-A9
J1-C7 ELECTRONIC CONTROL MODULE

J2-C10
J1-A10
J2-B9 AB12
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
AB9
J1-B12 CD10
AB13
86 30 9 N.C. N.C.
CR82 CR77
LIFT
ENABLE
85 87 87A
LS24 DOWN LS25
REV
FWD
ENABLE
(GS-5390 ONLY) MAX LOAD
86 30 10 HEIGHT SENSE
CR82A LIMIT 86 30 DELAY Y4 Y1 Y9 Y51
LIFT SWITCH LIMIT EDC
85 87 87A
ENABLE 85 87 87A SWITCH
A10
AB14
B10 AB8
Y7 M5
IF GS-5390,
B10 BECOMES AB11 Y8
NOT USED
ON GS-5390
C5 SW1 SW2
4700 uF Y3 Y2
M5 HYDRAULIC PUMP

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES7174F1 POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 29

QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
POSITION WITH THE POWER OFF ES7174F1
CONTROLS
6 - 30 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 31

KS1 KEY SWITCH
2
B1 AB7
PLATFORM
CONTROL
4
B
R25 LS26
CONTROL
CR41
AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
CB2
20A 2 N.C.H.O. N.C.H.O.
G6 LS23 LS22
R6 L2 LEFT RIGHT
510 W 1 OSCILLATE OSCILLATE
D1 SI AB15
A (TO FORD ECM)
FUEL SELECT BK/WH 7
1 KEY ON WH
B1 SW20
ENGINE SELF TEST
CD4 CD5
5 FUEL PUMP BL/WH
Y54 Y56 Y50
18 FUEL PUMP GND
M4 FORD ENGINE
AUX
PUMP
STARTER ECM M2
-
M4
M3 FUEL PUMP
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
6 - 32 GS-84 • GS-90 Part No. 84793

(GS-5390 ONLY)
CD6
AB3 AB3
LS12A
N.C.H.O.
LOWER
LF O-RIG
OIL COOLER
(OPTION)
LIMIT SWITCH
RD
WH
LS13A CD13
N.C.H.O.
LOWER LS5A SW4 CB7

RF O-RIG PLAT
CD8 UP OIL TEMP
N.C.
LIMIT
LS14A
N.C.H.O.
SWITCH
LOWER 86 30 8
CR17 LEVEL SENSOR
N.C.
LS6 LR O-RIG
LIMIT SWITCH

CD9
DOWN
LS15A LS5
N.C.H.O.
LIMIT
SWITCH LOWER PLAT
FAN M1 S7 LEVEL
SENSOR
RR O-RIG UP
FAN MOTOR
AB5
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-A1
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
U5
BN23 BN91
J1-A3
J1-A9

J2-C10
J1-A10
J2-B9 AB12
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
AB9
J1-B12 CD10
AB13
86 30 9 N.C. N.C.
CR82 CR77
LIFT
ENABLE
85 87 87A
LS24 DOWN LS25
REV
FWD
ENABLE
85 87 87A
A10
AB14
B10 AB8
Y7 M5
IF GS-5390,
B10 BECOMES AB11 Y8
NOT USED
ON GS-5390
C5 SW1 SW2
4700 uF Y3 Y2
M5 HYDRAULIC PUMP

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES0443A POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 33

QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
CONTROLS
6 - 34 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 35

KS1 KEY SWITCH
2
B1 AB7
PLATFORM
CONTROL
4
B
R25 LS26
CONTROL
CR41
AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
CB2
20A 2 N.C.H.O. N.C.H.O.
G6 LS23 LS22
L2 LEFT RIGHT
D1 SI AB15
A TO FORD GOV. SPEED SELECT OR/RD 23
ALTERNATOR
FUSE FUEL SELECT BK/WH 7
TO
FORD ECM 6 MALFUNCTION LED BL
1 KEY ON WH
B1 SW20
ENGINE SELF TEST
CD4 CD5
5 FUEL PUMP BL/WH
Y54 Y56 Y50
18 FUEL PUMP GND
M4 FORD ENGINE
AUX
PUMP
STARTER ECM M2
-
M4
M3 FUEL PUMP
Y57 Y55
D1 ALTERNATOR
SW20 ENGINE TEST
K1 STARTER RELAY
M4 FUEL PUMP
B1 12 VOLT BATTERY
M3 STARTER MOTOR
G6 ENGINE HOURMETER
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE
Y50 LPG
Y57 RIGHT OSC
M2 AUXILIARY PUMP
OSCILLATING AXLE
(GS-90)
(OPTION)
- NOTE -
POSITION WITH THE POWER OFF ES0443B1
6 - 36 GS-84 • GS-90 Part No. 84793

(GS-5390 ONLY)
CD6
AB3 AB3
LS12A
N.C.H.O.
LOWER
LF O-RIG
OIL COOLER
(OPTION)
LIMIT SWITCH
RD
WH
LS13A CD13
N.C.H.O.
LOWER LS5A SW4 CB7

RF O-RIG PLAT
CD8 UP OIL TEMP
N.C.
LIMIT
LS14A
N.C.H.O.
SWITCH
LOWER 86 30 8
CR17 LEVEL SENSOR
N.C.
LS6 LR O-RIG
LIMIT SWITCH

CD9
DOWN
LS15A LS5
N.C.H.O.
LIMIT
SWITCH LOWER PLAT
FAN M1 S7 LEVEL
SENSOR
RR O-RIG UP
FAN MOTOR
AB5
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-A1
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
U5
BN23 BN91
J1-A3
J1-A9

J2-C10
J1-A10
J2-B9 AB12
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
AB9
J1-B12 CD10
AB13
86 30 9 N.C. N.C.
CR82 CR77
LIFT
ENABLE
85 87 87A
LS24 DOWN LS25
REV
FWD
ENABLE
85 87 87A
A10
AB14
B10 AB8
Y7 M5
IF GS-5390,
B10 BECOMES AB11 Y8
NOT USED
ON GS-5390
C5 SW1 SW2
4700 uF Y3 Y2
M5 HYDRAULIC PUMP

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES0443B1 POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 37

QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
POSITION WITH THE POWER OFF ES0443B1
CONTROLS
6 - 38 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 39

ANSI Models with Deutz Power REV C
Part 1 of 3

KS1 KEY SWITCH
2
B1
PLATFORM
CONTROL
4
B
3
GROUND
CONTROL
CB2 20A
AB7

(ESTOP 1) AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
2 N.C.H.O. N.C.H.O.
F T G6 LS23 LS22
D1 1
LEFT
OSCILLATE
RIGHT
OSCILLATE
H2
AB15
F21
30 50
70A FUSE CR4
HIGH IDLE
45
CR15 CD2 CD3
B1 STARTING 86 30
STARTER
AID CD4 CD5
+
86 30 85 87 87A Y54 Y56
M3 85 87 87A F17
15A FUSE
U32
AUX
-
Q8 GLOW
PUMP
FUEL
PLUG
(OPTION)
Q3
SHUT OFF HIGH IDLE M2
SOLENOID Y57 Y55
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
Q3 HIGH IDLE SOLENOID
G6 ENGINE HOURMETER
U32 GLOW PLUG
F21 70A FUSE
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE

Y57 RIGHT OSC
M2 AUXILIARY PUMP

(OPTION)
OSCILLATING AXLE
NOTE: F21 ADDED TO MACHINE
(GS-84 AFTER SERIAL NUMBER GS8407-41372) (GS-90)
(GS-90 AFTER SERIAL NUMBER GS9007-44126) (OPTION)
- NOTE -
NOTE: F17 REPLACED WITH 25 AMP CIRCUIT BREAKER CB8
MACHINE SHOWN IN THE STOWED (GS-84 AFTER SERIAL NUMBER GS8406-41256)
POSITION WITH THE POWER OFF (GS-90 AFTER SERIAL NUMBER GS9006-43638)
ES7164J
6 - 40 GS-84 • GS-90 Part No. 84793

REV C ANSI Models with Deutz Power
Part 2 of 3
AB1
AB3 AB3

(OPTION)
RD
WH
PLAT N.C. CD13
UP
LIMIT
SW4 CB7
N.C. OIL TEMP
AB4
86 30 8
CR17 LEVEL SENSOR
N.C.

DOWN
LS5
PLAT N.C.
LIMIT
SENSOR
LIMIT
FAN MOTOR
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J2-A2
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
J2-A1
U5
J2-C4
J1-A3
J1-A10
J2-C10
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
J1-A9
J2-B9
AB12
REV
FWD
AB9
Y4 Y1 Y9 Y51
EDC
M5
Y8 Y7 SW3 SW2
Y3 Y2
M5 HYDRAULIC PUMP
SW3 ENGINE OIL TEMPERATURE

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES7164J POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 41

ANSI Models with Deutz Power REV C
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
POSITION WITH THE POWER OFF ES7164J
CONTROLS
6 - 42 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 43

CE Models with Deutz Power REV D
Part 1 of 3

KS1 KEY SWITCH
2
B1 AB7
PLATFORM
CONTROL
4
B
R25 LS26
CONTROL
CR41
AB1
86 30 1 86 30 2 86 30 5 86 30 4 86 30 3 86 30 6 86 30 11 86 30 12
85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A 85 87 87A
CB2
20A
2 N.C.H.O. N.C.H.O.
F T G6 LS23 LS22
D1 LEFT
OSCILLATE
RIGHT
OSCILLATE
1
H2
AB15
F21
30 50
70A FUSE CR4
HIGH IDLE
45
CR15 CD2 CD3
B1 STARTING 86 30
STARTER
AID CD4 CD5
+
86 30 85 87 87A Y54 Y56
M3 85 87 87A F17
15A FUSE
U32
AUX
-
Q8 GLOW
PUMP
FUEL
PLUG
(OPTION)
Q3
SHUT OFF HIGH IDLE M2
SOLENOID Y57 Y55
K1 STARTER RELAY
B1 12 VOLT BATTERY
M3 STARTER MOTOR
D1 ALTERNATOR
Q8 FUEL SHUT OFF
Q3 HIGH IDLE SOLENOID
G6 ENGINE HOURMETER
U32 GLOW PLUG
F21 70A FUSE
Y54 OSC FLOAT
Y56 LEFT OSC
Y55 OSC ENABLE

Y57 RIGHT OSC
M2 AUXILIARY PUMP

(OPTION)
OSCILLATING AXLE
NOTE: F21 ADDED TO MACHINE
(GS-84 AFTER SERIAL NUMBER GS8407-41372) (GS-90)
(GS-90 AFTER SERIAL NUMBER GS9007-44126) (OPTION)
- NOTE -
NOTE: F17 REPLACED WITH 25 AMP CIRCUIT BREAKER CB8
MACHINE SHOWN IN THE STOWED (GS-84 AFTER SERIAL NUMBER GS8406-41256)
POSITION WITH THE POWER OFF (GS-90 AFTER SERIAL NUMBER GS9006-43638)
ES7175M1
6 - 44 GS-84 • GS-90 Part No. 84793

REV D CE Models with Deutz Power
Part 2 of 3
(GS-5390 ONLY)
CD6
AB3 AB3
LS12A
N.C.H.O.
LOWER
LF O-RIG
OIL COOLER
(OPTION)
LIMIT SWITCH
RD
WH
LS13A CD13
N.C.H.O.
LOWER LS5A SW4 CB7

RF O-RIG PLAT
CD8 UP OIL TEMP
N.C.
LIMIT
LS14A
N.C.H.O.
SWITCH
LOWER 86 30 8
CR17 LEVEL SENSOR
N.C.
LS6 LR O-RIG
LIMIT SWITCH

CD9
DOWN
LS15A LS5
N.C.H.O.
LIMIT
SWITCH LOWER PLAT
FAN M1 S7 LEVEL
SENSOR
RR O-RIG UP
FAN MOTOR
AB5
BK
J2-C1/C3
J2-C6
J2-C5
J2-A4
J2-B7
J2-B8
J2-B11
J1-C2
J2-A2
J2-A1
J2-C12
J2-A5
J2-A3
J2-B2
J2-A6
J2-B10
U5
BN23 BN91
J1-A3
J1-A9

J2-C4
J1-A10
J2-C10 AB12
J1-A2
J1-A4
J1-B4
J1-A1
J1-C8
J1-B2
J1-B3
J1-C9
J2-B9 AB9
CD10
AB13
86 30 9 N.C. N.C.
CR82 CR77
LIFT
ENABLE
85 87 87A
LS24 DOWN LS25
REV
FWD
ENABLE
85 87 87A
A10
AB14
B10 AB8
Y7 M5
IF GS-5390,
B10 BECOMES AB11 Y8
NOT USED
ON GS-5390
C5 SW3 SW2
4700 uF Y3 Y2
M5 HYDRAULIC PUMP
SW3 ENGINE OIL TEMPERATURE

Y4 STEER LEFT

Y3 STEER RIGHT
Y2 BRAKE RELEASE

Y8 PLATFORM UP
Y7 PLATFORM DOWN
S7 LEVEL SENSOR
- NOTE -
ES7175M1 POSITION WITH THE POWER OFF
Part No. 84793 GS-84 • GS-90 6 - 45

CE Models with Deutz Power REV D
Part 3 of 3
QD4 QD3 P2
BK EMERGENCY
RD
2 2 BL J5 PIN4
OR 5 5 5 5 OR OR
OUTRIGGERS
(OPTION ON GS-3384,3390 and 4390)
J5 PIN2
12V DC
GY
J2 PIN1
HALL EFFECT
S8 J2 PIN2
YL
GENERATOR
JC1
WH JOYSTICK
2 AXIS J2 PIN12
J2 PIN13
BN
CONTROLLER
LF RF LR RR SENSOR
BL
GROUND
J2 PIN4
DATA LINK (-)
DATA LINK (+)
GND FROM PLAT
POWER

SW5
PITCH
J5 PIN3
SW6
ROLL
FUNCTION ENABLE
LEFT
RIGHT
J2 PIN5
BK LEFT/ RIGHT
J2 PIN6
RD
BL
YL
BK
RD
J2 PIN7
J2 PIN8
WH/BL
J2 PIN14
J1-C5
J1-C3
J1-C6
J1-C4
J2-B10
J2-B1
J2-B3
J2-B2
J2-A10
J2-A11
J2-A12
POUT1
U5 PIN2 HORN BN5


J1-B10
J2-B12
J1-B11
J2-C11
J1-B7
J1-B6
J1-B5
J1-B9
J2-C7
J1-B1
CD1
PIN6 GENERATOR BN7
Y36 Y34 Y40 Y29

PIN8 HIGH IDLE BN4

H5 FB1
(OPTION)
FB1 FLASHING BEACON
ECM GROUND
H5 ALARM


YL
J1 PIN4
BL -OR-
J1 PIN3
RD UP/DOWN
J1 PIN1 Ts21
BK
J1 PIN5
J3 PIN1
RD +
- NOTE - J3 PIN2
BK
H1
ALARM PLATFORM
POSITION WITH THE POWER OFF ES7175M1
CONTROLS
6 - 46 GS-84 • GS-90 Part No. 84793

Part No. 84793 GS-84 • GS-90 6 - 47

Hydraulic Schematics Component Call-out Legend

REV A
Item Function Item Function Item Function

A Steer circuit BA High speed bypass CA Right front outrigger autolevel
B Auxiliary pump circuit BB High speed bypass CB Left front outrigger autolevel
C Steer circuit BC Balances fluid flow from flow CC Right rear outrigger autolevel
D System relief divider/combiner BO to non-steer end CD Left rear outrigger autolevel
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 DB Oscillate system relief
H All finctions drive motors DC Oscillate float relief
I Platform up/down BE Charge pressure circuit that removes hot DD Flow regulator
J Outrigger extend/retract oil from low pressure side of drive pump DE Right oscillate cylinder
K Outrigger extend circuit and allows low pressure flow path for DF Left oscillate cylinder
L Outrigger retract circuit brake releae and 2-speed motor shift DG Oscillate float
BF Testing ‘P1’ pressure port
AA Platform down circuit BG Testing ‘P2’ pressure port EA Flow divider/combiner, front-to-rear
AB Testing BH Charge pressure circuit EB Orifice; controls side-to-side flow at
AC System relief BI Brake release circuit the steer end
AD Proportional/differential sensing valve BJ 2-speed motor shift circuit EC Test port #2
AE Steering/outrigger circuit BK Brake release circuit ED Orifice; controls side-to-side flow at
AF Testing BL 2-speed motor shift circuit the non-steer end
AG Platform up/down BM 2-speed motor shift circuit EE Charge pressure circuit
AH Steer left/right BN Balance fluid flow from flow EF 2-speed motor shift circuit
AI Platform down circuit divider/combiner BM to flow EG Orifice, brake circuit
AJ Bleeds off proportional valve to tank. divider combiner valves BO and BP EH Orifice, 2-speed motor shift circuit
AK Outrigger extend/retract BO Controls flow to non-steer end drive EI Hot oil relief, charge pressure circuit
AL Generator on motors in forward and reverse EJ Brake release circuit
AM Generator relief BP Controls flow to steer end drive motors in EK Flow divider/combiner, balances
AN Generator flow forward and reverse side-to-side flow at the non-steer end
AO Accumulator BQ Controls fluid flow to flow divider/combiner EL Flow divider/combine, balances
AP Platform overload valves BO and BP in forward and reverse side-to-side flow at the steer end
EM Orifice, controls front-to-rear flow
EN Test port #1
6 - 48 GS-84 • GS-90 Part No. 84793

Hydraulic Symbols Legend

REV A
Brake
Relief valve
Filter
Check valve
Priority flow regulator
Fixed displacement
pump
Hot oil
Accumulator shuttle valve
Y9
Bi-directional
variable speed motor
Orifice
M
Variable speed motor Proportional
Shut off valve solenoid valve
Y7 Y8
Dual acting cylinder

Solenoid operated
3 position 4 way
Counterbalance Y27
directional valve
valve
Y4 Y3
Solenoid operated
2 position 2 way valve,
normally closed with Solenoid operated
Flow regulator manual over-ride 3 position 4 way
valve
Y2 directional valve
50% 50% Y49A
Flow Solenoid operated

Solenoid operated
divider/combiner 2 position 3 way
2 position 2 way
valve directional valve
directional valve
Part No. 84793 GS-84 • GS-90 6 - 49

Hydraulic Schematic
Part 1 of 2 REV C
RIGHT RIGHT
FRONT REAR
2SPD BRK M1A M1B M3B M3A
0.045 in
1.1 mm
EH
EF Y1 Y2 EJ
EM 0.090 in
2.3 mm
0.035 in
0.9 mm
EG 50% EL 50%
EK
P1
50% 50%
50% 50%
EN TP1 EE
EA
0.043 inch
EB ED 0.046 inch
1.1 mm 1.2 mm
EC TP2 280 psi
DRIVE 19.3 bar EI
MANIFOLD
P2
T M2B M2A M4A M4B
LEFT LEFT
FRONT REAR
P1 P2
Y51 3750 psi

258.6 bar
E
10.6 gpm 9.1 gpm 0 to 32.5 gpm OIL
40.1 L/min 34.4 L/min 0 to 123 L/min 3750 psi
258.6 bar COOLER
(OPTION)
325 psi
22.4 bar DRIVE PUMP
25 psi
1.7 bar

to components shown in
the manifold illustrations.
Refer to the Repair Section.
HYDRAULIC TANK
HS7043C
6 - 50 GS-84 • GS-90 Part No. 84793

Hydraulic Schematic
REV C Part 2 of 2
OSCILLATING AXLE OUTRIGGERS

(GS-90) (STANDARD ON GS-5390)
(OPTION) PLATFORM LIFT CYLINDER LIFT CYLINDER (OPTION ON GS-3384, GS-3390 AND GS-4390)
OVERLOAD (ALL MODELS) (GS-5390)
(OPTION)
LEFT RIGHT RIGHT LEFT RIGHT LEFT
FRONT FRONT REAR REAR
PS2 CA CB CC CD
AP
3800 psi 3800 psi

262 bar 262 bar
Y36 Y35 Y34 Y33
4.5:1 4.5:1
AO STEER CYLINDERS STEER CYLINDER

DF Y56 GS-3384: 1800 psi / 124 bar
Y57 GS-3390: 1800 psi / 124 bar (GS-90) (GS-84)
DE GS-4390: 1800 psi / 124 bar LEFT RIGHT
GS-5390: 1100 psi / 76 bar
DC AB
TP1 L2 L1 S1 S2 LEV1 LEV2
900 psi
62 bar DG
FUNCTION AI
Y54 0.15 in
MANIFOLD 3.8 mm
DB
AA
3500 psi
241.3 bar Y7 Y8 AH AK
DD
1 gpm Y4 Y3 Y40 Y39
Y9
3.8 L/min AD
AE
AG
2000 psi
OSCILLATE DA 138 bar
MANIFOLD Y55
0.1 gpm
AJ
0.38 L/min
AC
(SEE NOTE BELOW)
P T AUXP TP2
AF
GENERATOR • NOTE •
(OPTION) SYSTEM RELIEF
VALVE PRESSURE
AL (SCHEMATIC ITEM ‘AC’)
4.5 gpm GS-3384: 2700 to 2900 psi
AM 17 L/min 186 to 200 bar
GS-3390: 2700 to 2900 psi
186 to 200 bar
Y29
GS-4390: 2900 to 3100 psi
200 to 214 bar
3000 psi GS-5390: 2900 to 3100 psi
AN 207 bar 200 to 214 bar
AUXILIARY
2000 psi
137.9 bar
POWER
UNIT

to components shown in
the manifold illustrations.
Refer to the Repair Section.
HS7037L
Part No. 84793 GS-84 • GS-90 6 - 51

6 - 52 GS-84 • GS-90 Part No. 84793

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 America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
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Phone +61 7 3375 1660
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Part No.
Service Manual
84793
Rev E
(from serial number GS8406-40833)
(from serial number GS9006-42686)
GS-84•GS-90

Genie 5394

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Par ts Manual

GS-3384 from GS8406-40833

GS-3390 from GS9006-42686

GS-4390 from GS9006-42686

GS-5390 from GS9006-42686

Part No. 84793

Important Serial Number Information

Copyright © 2001 by Genie Industries

ii GS-84 • GS-90 Part No. 84793

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg GS30 05 A - 12345

Serial number Serial number

Part No. 84793 GS-84 • GS-90 iii

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iv GS-84 • GS-90 Part No. 84793

Do Not Perform Maintenance

Part No. 84793 GS-84 • GS-90 v

Personal Safety Workplace Safety

Indicates a potentially hazardous Be sure to properly dispose of old oil or

Be aware of potential crushing hazards

vi GS-84 • GS-90 Part No. 84793

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 84793 GS-84 • GS-90 vii

Section 3 Rev Scheduled Maintenance Procedures, continued

viii GS-84 • GS-90 Part No. 84793

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 84793 GS-84 • GS-90 ix

Section 4 Rev Repair Procedures

x GS-84 • GS-90 Part No. 84793

Section 4 Rev Repair Procedures, continued

Part No. 84793 GS-84 • GS-90 xi

Section 5 Rev Fault Codes

Section 6 Rev Schematics

xii GS-84 • GS-90 Part No. 84793

Section 6 Rev Schematics, continued

Part No. 84793 GS-84 • GS-90 xiii

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GS-84 • GS-90 Part No. 84793

Fluid capacities Tire size LSW 305-546 NHS

Hydraulic tank 32 gallons Tire ply rating 10

Tire diameter 33 in Wheel diameter 16.5 in

Continuous improvement of our products is a

Part No. 84793 GS-84 • GS-90 2-1

Performance Specifications Function speed, maximum from platform controls

GS-3384, GS-3390 and GS-4390 50%

Rated work load at full height, maximum

GS-3384 and GS-3390 2500 lbs

GS-4390 1500 lbs

GS-4390 1800 lbs

GS-5390 1500 lbs

2-2 GS-84 • GS-90 Part No. 84793

Hydraulic oil type Chevron Rykon MV equivalent

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible and

Biodegradable Petro Canada Environ MV 46

Fire resistant UCON Hydrolube HP-5046