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GS-4390
Genie GS-4390 Service Manual
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2
Table of Contents
Introduction
2
Serial Number Legend
3
Safety Rules
5
Table of Contents
7
Machine Specifications
15
Performance Specifications
16
Hydraulic Specifications
16
Hydraulic Component Specifications
17
Manifold Component Specifications
19
Valve Coil Resistance Specifications
19
Ford LRG-425 EFI Engine
20
Deutz F4L 1011F Engine
21
Deutz F3L 1011F Engine
22
Deutz F3L 2011 Engine
23
Deutz D2011L03I Engine
23
Hydraulic Hose and Fitting Torque Specifications
24
Part
26
Pre-Delivery Preparation Report
28
Maintenance Inspection Report
31
Checklist a Procedures
33
Inspect the Manuals and Decals
33
Perform Pre-Operation Inspection
34
Perform Function Tests
34
Perform Engine Maintenance - Ford Models
35
Perform Engine Maintenance - Deutz Models
35
Perform 30 Day Service
36
Perform Engine Maintenance - Deutz Models
36
Perform Engine Maintenance - Ford Models
37
Check the Hydraulic Return Filter Condition Indicator (if Equipped)
37
Perform Engine Maintenance - Deutz 1011F Models
38
Drain the Fuel Filter/ Water Separator - Deutz Models
38
Perform Engine Maintenance - Ford Models
39
Checklist B Procedures
40
Inspect the Battery
40
Inspect the Electrical Wiring
41
Perform Engine Maintenance - Deutz 1011F Models
42
Check the Exhaust System
42
Inspect the Engine Air Filter
43
Check and Adjust the Engine RPM
44
Confirm the Proper Brake Configuration
46
Inspect the Tires and Wheels (Including Lug Nut Torque)
46
Check the Oil Level in the Drive Hubs
47
Test the Key Switch
47
Test the Emergency Stop
48
Test the Automotive-Style Horn
48
Test the Fuel Select Operation - Ford Models
49
Test the Drive Brakes
50
Test the Drive Speed - Stowed Position
50
Test the Drive Speed - Raised Position
51
Perform Hydraulic Oil Analysis
52
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
53
Replace the Engine Air Filter Element - Ford Models
54
Perform Engine Maintenance - Ford Models
54
E Checklist C Procedure
55
Test the Platform Overload System (if Equipped)
55
Replace the Engine Air Filter Element - Deutz Models
56
Perform Engine Maintenance - Deutz Models
57
Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil
57
Perform Engine Maintenance - Ford Models
57
Checklist D Procedures
58
Check the Scissor Arm Wear Pads
58
Check the Free-Wheel Configuration
59
Replace the Drive Hub Oil
60
Replace the Fuel Filter / Water Separator - Deutz Models
60
Replace the Hydraulic Tank Return Filter
62
Perform Engine Maintenance - Deutz Models
63
C Checklist E Procedure
64
Test or Replace the Hydraulic Oil
64
Perform Engine Maintenance - Deutz 1011F Models
66
Perform Engine Maintenance - Ford Models
67
Perform Engine Maintenance - Deutz Models
67
Perform Engine Maintenance - Deutz 2011 Models
68
Perform Engine Maintenance - Ford Models (before Serial Number GS9003-41369)
68
Platform Controls
70
Circuit Boards
71
Joystick Controller
71
Controller Adjustments (before Serial Number GS9003-41523)
73
Software Configuration (before Serial Number GS9003-41523)
79
Platform Components
83
Platform
83
Platform Extension Deck
85
Scissor Components
86
Scissor Assembly, GS-3390
87
Scissor Assembly, GS-4390
93
Scissor Assembly, GS-5390
103
Wear Pads
115
Lift Cylinder(S)
117
RPM Adjustment
121
Engine Fault Codes - Ford Models
121
Flex Plate
121
Oil Temperature and Oil Pressure Switches - Deutz Models
125
Coolant Temperature and Oil Pressure Switches - Ford Models
126
Ground Controls
127
Auxiliary Platform Lowering
127
Controller Adjustments (after Serial Number GS9003-41522)
127
Software Configuration (after Serial Number GS9003-41522)
138
Level Sensor - Models Without Outriggers (before Serial Number 41158)
142
Level Sensor - Models Without Outriggers (after Serial Number 41157)
145
Level Sensor - Models with Outriggers
147
Engine Fault Codes - Ford Models
152
Hydraulic Pumps
154
Lift/Steer Pump
154
Drive Pump
156
Manifolds
157
Function Manifold Components - Models with Outriggers (before Serial Number 40519)
158
Function Manifold Components - Models with Outriggers (after Serial Number 40518)
160
Function Manifold Components - Models Without Outriggers (before Serial Number 40519)
162
Function Manifold Components - Models Without Outriggers (after Serial Number 40518)
164
Drive Manifold Components (before Serial Number GS9004-41691)
166
Drive Manifold Components (after Serial Number GS9004-41690)
168
Oscillate Manifold Components (Optional after Serial Number GS9004-41690)
170
Valve Adjustments - Function Manifold
172
Valve Adjustments - Drive Manifold
174
Generator Manifold Components
176
Valve Adjustments - Generator Manifold
177
Valve Coils
178
Fuel and Hydraulic Tanks
180
Fuel Tank
180
Hydraulic Tank
181
Steer Axle Components
183
Yoke and Drive Motor
183
Steer Cylinder
185
Tie Rod
186
Oscillating Axle Option (after Serial Number GS9004-41690)
187
Non-Steer Axle Components
188
Drive Motor and Brake
188
Drive Hub
189
Oscillating Axle
189
Outrigger Components
190
Outrigger Cylinder
190
Platform Overload Components
191
Platform Overload System
191
Fault Code Chart (before Serial Number GS9003-41523)
203
Fault Code Chart (after Serial Number GS9003-41522)
205
Ford Engine ECM Fault Code Chart (before Serial Number GS9003-41369)
208
Ford Engine ECM Fault Code Chart (after Serial Number GS9003-41368)
210
Electronic Control Module Layout (before Serial Number GS9003-41523)
216
A Electronic Control Module Pin-Out Legend
217
Electronic Control Module Layout (after Serial Number GS9003-41522)
218
Electronic Control Module Pin-Out Legend (after Serial Number GS9003-41522)
219
Ford Engine Relay Layout
220
Wiring Diagram - Platform Control Box (before Serial Number GS9003-41523)
221
Wiring Diagram - Platform Control Box (after Serial Number GS9003-41522)
222
Electrical Schematics Abbreviation and Wire Color Legends
223
Limit Switch Legend
224
Electrical Symbols Legend
226
A Electrical Schematic - Platform Overload (Option)
227
(Before Serial Number GS9003-41523)
227
Wiring Harness - Ford LRG-425 EFI (before Serial Number GS9003-41369)
228
Wiring Harness - Ford LRG-425 EFI (from Serial Number GS9003-41369 to GS9004-41693)
229
Wiring Harness - Ford LRG-425 EFI (after Serial Number GS9004-41693)
230
Electrical Schematic - Ford Models (before Serial Number 40428)
234
Electrical Schematic - Ford Models (from Serial Number 40428 to 40793)
238
Electrical Schematic - Ford Models (from Serial Number 40794 to 40995)
242
Electrical Schematic - Ford Models (from Serial Number 40996 to 41065)
246
(From Serial Number GS9003-41523 to GS9004-41693)
258
(From Serial Number GS9004-41694 to GS9005-42143)
262
(From Serial Number GS9005-42144 to GS9005-42203)
266
(From Serial Number GS9005-42204 to GS9005-42685)
270
(From Serial Number GS9003-41523 to GS9004-41693)
274
(From Serial Number GS9004-41694 to GS9005-42143)
278
(From Serial Number GS9005-42412 to GS9005-42685)
290
Electrical Schematic - Deutz Models (before Serial Number 40428)
294
(From Serial Number GS9003-41523 to GS9005-42143)
318
(From Serial Number GS9003-41523 to GS9005-42143)
319
(From Serial Number GS9005-42412 to GS9005-42685)
334
Hydraulic Schematics Component Call-Out Legend
338
Hydraulic Symbols Legend
339
Hydraulic Schematic (before Serial Number 40519)
341
Hydraulic Schematic (from Serial Number 40519 to GS9004-41690)
341
Hydraulic Schematic (from Serial Number GS9004-41691 to GS9005-42685)
342
Other manuals for Genie GS-4390
Maintenance Manual
97 pages
Operator's Manual
57 pages
5
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Genie GS-4390 Specifications
General
Fuel Type
Diesel
Lift Capacity
680 kg
Platform Width
1.83 m
Working Height
49 ft (14.94 m)
Drive Speed
3.5 mph
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