Genie GS-3384 Installation and operating manual

Service and Repair Manual
Serial Number Range
GS-3384
from GS8413-42181 to
GS8415-42382
from GS8416F-42383 to
GS8416F-45499
This
manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
GS
-
3390
from GS84F-45500
from GS9013-48427 to
GS
-
4390
GS9015-51063
from GS9016F-
51064 to
GS9016F-
53299
GS
-
5390
from GS90F-53300
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1272222
Rev A1
September 2016

Service and Repair Manual September 2016
Introduction
ii GS-84 • GS-90 Part No. 1272222
Intr oduct io n Intr oduct io n
Impor tant Inf ormati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group A/Type 2, 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2016 by Terex Corporation
1272222 Rev A, September 2015
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“GS” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual
Introduction
Part No. 1272222 GS-84 • GS-90 iii
RevisionHistory
Revision History
Revision Date Section Procedure / Page / Description
A 3/2016 Initial Release
A1 9/2016 Introduction Serial Number Legend
Reference Examples: Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv GS-84 • GS-90 Part No. 1272222
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located inside cover)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located inside cover)
5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1272222 GS-84 • GS-90 v
Section 1 Safet y Rul es Gener al Safety R ules
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.

Service and Repair Manual September 2016
Safety Rules
vi GS-84 • GS-90 Part No. 1272222
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure
thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injur
y or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a
potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clot
hing 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.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like
battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
com
ponents and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 1272222 GS-84 • GS-90 vii
Introduction Introduction ..........................................................................................................ii
Important Information............................................................................................. ii
Find a Manual for this Model.................................................................................. ii
Revision History .....................................................................................................iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules.............................................................................................v
Section 2 Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications ...................................................................................2
Hydraulic Specification...........................................................................................3
Hydraulic Component Specifications .....................................................................5
Manifold Component Specifications.......................................................................6
Ford MSG-425 EFI Engine Specifications .............................................................7
Deutz D2011 L03i Engine Specifications...............................................................8
Deutz D 2.9 L4 Engine Specifications....................................................................9
Hydraulic Hose and Fitting Torque Specifications ...............................................11
Torque Procedure ................................................................................................12

September 2016
Table of Contents
viii GS-84 • GS-90 Part No. 1272222
Section 3 Repair Procedures.............................................................................................13
Introduction ..........................................................................................................13
Platform Controls...............................................................................................15
1-1 Circuit Board..................................................................................................15
How to Remove the Platform Controls Circuit Board .....................................15
Platform Components .......................................................................................16
2-1 Platform..........................................................................................................16
How to Remove the Platform..........................................................................16
2-2 Platform Extension Deck ...............................................................................18
How to Remove the Platform Extension Deck................................................18
Scissor Components.........................................................................................19
3-1 Scissor Assembly, GS-3384 and GS-3390 ...................................................20
How to Disassemble the Scissor Assembly ...................................................20
How to Disassemble a Scissor Arm Pair........................................................24
3-2 Scissor Assembly, GS-4390..........................................................................26
How to Disassemble the Scissor Assembly ...................................................26
How to Disassemble a Scissor Arm Pair........................................................30
3-3 Scissor Assembly, GS-5390..........................................................................33
How to Disassemble the Scissor Assembly ...................................................33
How to Disassemble a Scissor Arm Pair........................................................38
3-4 Wear Pads.....................................................................................................39
How to Replace the Scissor Arm Wear Pad...................................................39
How to Replace the Chassis Scissor Arm Wear Pads...................................40
3-5 Lift Cylinders..................................................................................................42
How to Remove the Lift Cylinder - GS-3384, GS-3390 and GS-4390 ...........42
How to Remove the Lift Cylinder - GS-5390 ..................................................44

September 2016
Table of Contents
Part No. 1272222 GS-84 • GS-90 ix
Engines ...............................................................................................................46
4-1 RPM Adjustment - Deutz D2011L03i Models ................................................46
4-2 Engine Fault Codes........................................................................................46
4-3 Flex Plate .......................................................................................................46
How to Remove the Flex Plate - Ford Models................................................46
How to Remove the Flex Plate - Deutz Models..............................................47
How to Install the Flex Plate ...........................................................................48
Ground Controls.................................................................................................50
5-1 Auxiliary Platform Lowering ...........................................................................50
5-2 Controller Adjustments...................................................................................50
How to Determine the Revision Level.............................................................51
How to Adjust the Stowed Drive Speed..........................................................51
How to Adjust the High Torque Drive Speed..................................................52
How to Adjust the Raised Drive Speed...........................................................53
How to Adjust the Lift Speed...........................................................................55
How to Adjust the Platform Lower Speed.......................................................56
How to Adjust the Platform Settling Speed.....................................................57
How to Adjust the Steer Speed.......................................................................58
5-3 Software Configuration ..................................................................................58
5-4 Level Sensor - Models without Outriggers.....................................................63
How to Install and Calibrate the Level Sensor - Models without Outriggers...63
5-5 Level Sensor - Models with Outriggers..........................................................65
How to Install and Calibrate the Level Sensor - Models with Outriggers........65
Hydraulic Pump..................................................................................................69
6-1 Lift/Steer Pump ..............................................................................................69
How to Remove the Lift/Steer Pump...............................................................69
6-2 Drive Pump ....................................................................................................70
How to Remove the Drive Pump.....................................................................70
How to Prime the Pump..................................................................................71
How to Adjust the Pump Neutral.....................................................................72

September 2016
Table of Contents
x GS-84 • GS-90 Part No. 1272222
Manifolds ............................................................................................................74
7-1 Function Manifold Components - Models with Outriggers.............................74
7-2 Function Manifold Components - Models without Outriggers........................76
7-3 Traction Manifold Components......................................................................78
7-4 Oscillate Manifold Components, GS-90 (option)...........................................80
7-5 Welder Manifold Components (option)..........................................................82
7-6 Valve Adjustments - Function Manifold .........................................................83
How to Adjust the System Relief Valve ..........................................................83
How to Adjust the Steer Relief Valve..............................................................84
7-7 Valve Adjustments - Traction Manifold..........................................................85
How to Adjust the Charge Pressure Relief Valve...........................................85
7-8 Generator Manifold Components ..................................................................86
7-9 Valve Adjustments - Generator Manifold.......................................................87
How to Adjust the Generator Voltage.............................................................87
7-10 Generator Relief Valve Manifold Components............................................88
7-11 Valve Coils...................................................................................................89
Fuel and Hydraulic Tanks .................................................................................91
8-1 Fuel Tank.......................................................................................................91
8-2 Hydraulic Tank...............................................................................................92
Steer Axle Components ....................................................................................94
9-1 Yoke Assembly..............................................................................................94
How to Remove the Yoke and Drive Motor ....................................................94
How to Remove a Drive Motor........................................................................95
9-2 Steer Cylinder................................................................................................96
9-3 Oscillating Axle Option - GS-90 Models ........................................................96

September 2016
Table of Contents
Part No. 1272222 GS-84 • GS-90 xi
Non-steer Axle Components.............................................................................98
10-1 Drive Motor and Brake.................................................................................98
How to Remove a Drive Motor and Brake ......................................................98
10-2 Drive Hub.....................................................................................................99
How to Remove a Drive Hub ..........................................................................99
10-3 Oscillating Axle...........................................................................................100
Outrigger Components....................................................................................101
11-1 Outrigger Cylinder......................................................................................101
How to Remove an Outrigger Cylinder (if equipped)....................................101
Platform Overload Components.....................................................................102
12-1 Platform Overload System.........................................................................102
How to Calibrate the Platform Overload System ..........................................102
12-2 Platform Overload Recovery Message
(software version B3 and later) ..................................................................111
Section 4 Fault Codes.......................................................................................................113
Introduction.........................................................................................................113
Control System Fault Codes...........................................................................115
Control System Fault Codes ..............................................................................115
Fault Code Display - Deutz Models ................................................................119
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 Models..........................................................................119
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 Models..........................................................................120
Soft Key Functions and Icons - Deutz D 2.9 L4 Models...............................121
Main Menu Structure - Deutz D 2.9 L4 Models.............................................122
Deutz D 2.9 L4 Engine Fault Codes................................................................123
Ford MSG-425 Engine Fault Codes................................................................134
How to Retrieve Ford Engine Fault Codes ...................................................134
How to Clear Engine Fault Codes from the ECM .........................................134
Ford MSG-425 Engine Fault Codes...................................................................135

September 2016
Table of Contents
xii GS-84 • GS-90 Part No. 1272222
Section 5 Schematics .......................................................................................................141
Introduction ........................................................................................................141
Electrical Symbols Legend.................................................................................142
Hydraulic Symbols Legend ................................................................................143
Electrical Component and Wire Color Legends.................................................144
Ford Engine Relay Layout .................................................................................146
Electronic Control Module Layout......................................................................147
Electronic Control Module Pin-Out Legend .......................................................148
Ground Controls Wiring Panel Layout ...............................................................150
Wiring Diagram - Platform Control Box..............................................................151
Limit Switch Legend...........................................................................................152
Wiring Diagram - 12 kW Hydraulic Generator (option)......................................153
Electrical Schematics - Engine Harness .......................................................155
Ford MSG-425 EFI Engine Wire Harness .........................................................156
Deut]D 2.9 L4 Engine Wire Harness................................................................157
Hydraulic Schematics......................................................................................159
Hydraulic Schematic,
To Serial Numbers GS8415-42316 and GS9015-50184...........................160
Hydraulic Schematic,
From Serial Numbers GS84154-42317 and GS9015-50185.....................162
Electrical Schematics – ANSI and CSA Models............................................165
Electrical Schematic, Ford Engine Models (ANSI/CSA)....................................166
Electrical Schematic, Deutz Engine Models (ANSI/CSA)..................................170
Electrical Schematics – AS and CE Models..................................................173
Electrical Schematic, Ford Engine Models (AS/CE)..........................................174
Electrical Schematic, Deutz Engine Models (AS/CE)........................................178

September 2016 Service and Repair Manual
Specifications
Part No. 1272222 GS-84 • GS-90 1
Section 2 Speci ficati ons
Machi ne Spec ific ations
Machine Specifications
Fluid capacities
Hydraulic tank
30 g
allons
114 liters
Hydraulic system (including tank)
GS
-3384 and GS-3390 37.5 g
allons
142 liters
Hydraulic system (including tank)
GS
-4390 38.25 g
allons
145 liters
Hydraulic system (including tank)
GS
-5390 38.75 g
allons
147 liters
Fuel tank
30 g
allons
114 liters
Tires and wheels
High Flotation, air
-filled and foam-filled (all models)
Tire size
33/16LL500
Tire ply rating
10
Tire diameter x Tire width
33 in x 16 i
n
83.8 cm x 41 c
m
Wheel diameter x width
19.5 in x 14 i
n
49.5 cm x 35.6 c
m
Weight, foam
-filled 419 lbs (+/- 10 l
bs)
190 kg (+/- 4.5 k
g)
Weight, air
-filled 157 l
bs
71.2 k
g
Pressure, air
-filled 38 p
si
2.6 b
ar
Rough Terrain, foam
-filled (GS-90)
Tire size
LSW 305-
546 NHS
Tire ply rating
10
Tire weight, new foam
-filled
(minimum) (Rough terrain)
265 l
bs
120 k
g
Tire diameter x width
33 in x 12 i
n
83.8 cm x 30 c
m
Rough Terrain, foam
-filled (GS-84)
Tire size
51S3D1-
16.5 NHS
Tire ply rating, minimum
8
Tire diameter x width
30.8 in x 10.4 i
n
78.2 cm x 26.4 c
m
Weight, new foam
-filled (minimum)
(Rough terrain)
224 l
bs
101.6 k
g
Weight, new foam
-filled (minimum)
(Rough terrain, non
-marking) 228 l
bs
103.4 k
g
Tires and wheels
Wheel lugs
9 @ 5/8-
18
Lug nut torque, dry
125 ft-
lbs
169.5 Nm
Lug nut torque, lubricated
94 ft-
lbs
127.4 Nm

Service and Repair Manual September 2016
Specifications
2 GS-84 • GS-90 Part No. 1272222
Perf ormanc e Speci ficati ons
Performance Specifications
Drive speed, maximum
(GS-90)
Platform stowed
5 m
ph
40 ft / 5.5 s
ec
8 k
m/h
12.2 m / 5.5 s
ec
Platform raised
0.7 m
ph
40 ft / 39 s
ec
1.1 k
m/h
12.2 m / 39 s
ec
Drive speed, maximum (GS
-84)
Platform stowed
4 m
ph
40 ft / 6.8 s
ec
6.4 k
m/h
12.2 m / 6.8 s
ec
Platform raised
0.7 m
ph
40 ft / 39 s
ec
1.1 k
m/h
12.2 m / 39 s
ec
Braking distance, maximum
High range on paved surface
60 i
n
152.4 c
m
Gradeability
See Operator's Manual
Function speed, maximum from platform controls
(with maximum rated load in platform)
GS
-3384 and GS-3390
Platform up
Platform down
40 to 50 s
econds
24 to 34 s
econds
GS-4390
Platform up
Platform down
42 to 52 s
econds
34 to 44 s
econds
GS
-5390
Platform up
Platform down
50 to 60 s
econds
44 to 54 s
econds

September 2016 Service and Repair Manual
Specifications
Part No. 1272222 GS-84 • GS-90 3
Hydra ulic Sp ecific ation
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed
140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids
may not have
the same hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may
form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Service and Repair Manual September 2016
Specifications
4 GS-84 • GS-90 Part No. 1272222
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt
@ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

September 2016 Service and Repair Manual
Specifications
Part No. 1272222 GS-84 • GS-90 5
Hydra ulic C omp one nt Spec ifi cati ons
Hydraulic Component
Specifications
Drive Pump
Type
Bi directional,
variable displacement piston pump
Flow rate @ 250
0 rpm 0 to 32.5 g
pm
0 t
o 123 L/min
Drive pressure, maximum
3750 p
si
258.6 b
ar
Charge Pump
Type
Gerotor
Flow rate @ 250
0 rpm 9.1 g
pm
34.4 L/min
Charge pump pressure
325 p
si
22.4 b
ar
Function pump
Type
gear pump
Displacement
0.98 c
u in
16 c
c
Flow rate @ 250
0 rpm 10.6 g
pm
40.1 L/min
Hydraulic tank return line filter
1
0 micron with 25 p
si
/ 1.7 bar bypass
Auxiliary power unit
Relief valve
3700 p
si
255 b
ar
Function manifold
System relief
valve pressure,
maximum, GS
-3384 and GS-3390 2700 to 2900 p
si
186 to 200 b
ar
System relief valve pressure,
maximum, GS
-4390 and GS-5390 2900 to 3100 p
si
200 to 214 b
ar
Steer relief valve pressure,
GS
-3384 2700 to 2900 p
si
186 to 200 b
ar
Steer relief
valve pressure,
GS
-3390, GS-4390 and GS-5390 1950 to 2250 p
si
135 to 155 b
ar
Proportional valve flow regulator
0.1 g
pm
0.4 L/min
Drive manifold
Hot oil relief pressure
280 p
si
19 b
ar
Drive motors
Displacement (
2 speed motor) 0.54 to 1.52 c
u in
8.8 to 25 c
c
Drive hubs
Fluid capacity
26 f
l oz
769 c
c
Fluid type: SAE 9
0 multipurpose hypoid gear oil API
service classification GL5
Installation torque, lubricated
180 ft-
lbs
244 Nm

Service and Repair Manual September 2016
Specifications
6 GS-84 • GS-90 Part No. 1272222
Oscillate manifold (GS
-
90) (option)
System relief valve pressure
3500 p
si
241 b
ar
Float relief valve pressure
900 p
si
62 b
ar
Oscillate flow regulator
1 g
pm
3.8 L/min
Generator manifold (option)
Relief valve
2400 p
si
165.5 b
ar
Flow rate, maximum
4.3 g
pm
16.3 L/min
Welder manifold (option)
Relief valve
270 p
si
18.6 b
ar
Hydraulic motor (welder option)
Displacement
1.28 c
u in
21 c
c
Manif old Com pon e nt Sp eci fic ati on s
Manifold Component
Specifications
Plug torque
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-
lbs / 13 Nm
SAE No. 6
14 ft-
lbs / 19 Nm
SAE No. 8
38 ft-
lbs / 51 Nm
SAE No. 10
41 ft-
lbs / 55 Nm
SAE No. 12
56 ft-
lbs / 76 Nm

September 2016 Service and Repair Manual
Specifications
Part No. 1272222 GS-84 • GS-90 7
Ford M SG-42 5 EFI En gine Sp ecific ations
Ford MSG-425 EFI Engine
Displacement
153 c
u in
2.5 liters
Number of cylinders
4
Bore and Stroke
3.5 x 3.9 i
nches
89 x 100 m
m
Horsepower
60 @ 2500 r
pm
44 kW @ 2500 r
pm
Firing order
1 - 3 - 4 -
2
Low function idle
(computer controlled)
1600 r
pm
53.3 Hz
High function idle (computer
controlled)
2500 r
pm
83.3 Hz
Compression ratio
9.7:1
Compression pressure (approx.)
Pressure (psi or
bar) of lowest cylinder must be at least
75% of highest cylinder
Lubrication system
Oil pressure (operating
temperature @ 250
0 rpm) 29 to 39 p
si
2 to 2.7 b
ar
Oil capacity
(including filter)
6.7 q
uarts
6.4 l
iters
Oil Pressure switch
Oil pressure
switch point 7 to 9 p
si
0.48 to 0.62 b
ar
Oil viscosity requirements
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Electronic fuel pump
Fuel pressure, static
60 p
si
4.1 b
ar
Fuel flow rate
0.43 g
pm
1.6 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Ignition system
Spark plug type
Motorcraft AYFS-32Y-
R
Spark plug gap
0.049 to 0.053 i
nches
1.25 to 1.35 m
m
Engine coolant
Capacity
10 q
uarts
9.5 l
iters
Cylinder head temperature sending unit
Fault code set temperature
280°F
138°C
Engine shut
-down temperature
300°F
149°C
Starter motor
Normal engine cranking speed
200 to 250 r
pm
Current draw, no load
140-
200A
Current draw, maximum load
800A
Alternator
Alternator output
95A, 13.8V DC
Battery
Type
12V DC, Group 31
Quantity
1
Cold cranking ampere @ 0°F
1000A
Reserve capacity @ 25A rate
200 m
inutes

Service and Repair Manual September 2016
Specifications
8 GS-84 • GS-90 Part No. 1272222
Deutz D 20 11 L0 3i En gine Spec ific atio ns
Deutz D2011 L03i Engine
Displacement
142 c
u in
2.33 l
iters
Number of cylinders
3
Bore and Stroke
3.7 x 4.4 i
nches
94 x 112 m
m
Horsepower
49 @ 2800 r
pm
36 kW @ 2800 r
pm
Firing order
1 - 2 -
3
Low idle
Frequency
1500 r
pm
313 Hz
High idle
Frequency
2500 r
pm
522 Hz
Compression ratio
19:01
Governor
centrifugal mechanical
Valve Clearance, cold
Intake
0.012 to 0.016 i
n
0.3 to 0.4 m
m
Exhaust
0.020 to 0.024 i
n
0.5 to 0.6 m
m
Fuel injection system
Injection pump make
Bosch
Injection pump pressure,
maximum
15000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Lubrication system
Oil pressure
20 to 44 p
si
1.4 to 3 b
ar
Oil capacity (including filter)
9.5 quarts
9 liters
Oil change capacity
(including filter)
7.35 q
uarts
7 liters
Oil viscosity requirements
Unit ships with 15W
-40. Extreme operating
temperatures may require the use of alternative engine
oils. For
oil requirements, refer to the Engine Operator
Manual for your engine.
Oil temperature switch
Temperature switch point
300°F
149°C
Oil Pressure switch
Oil pressure switch point
22 p
si
1.5 b
ar
Starter motor
Current draw, no load
90A
Brush length,
minimum 0.27 i
n
12.7 m
m
Battery
Type
12V DC, Group 31
Quantity
1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 m
inutes
Alternator output
60A @ 14V DC
Fan belt deflection
3/8 to 1/2 inch
9 to 12 m
m