Genie GS-3384 User manual

Part No. 82259
Rev D
September 2005
(from serial number 40001 to GS8405-40832)
Service Manual

September 2005
GS-3384 Part No. 82259
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However ,several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
PO Box 97030
Redmond, WA 98073-9730 USA
www.genieindustries.com
e-mail:[email protected]
Copyright © 2002 by Genie Industries
82259 Rev D September 2005
First Edition, Fourth Printing
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"GS" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Introduction

September 2005
Part No. 82259 GS-3384 iii
Serial Number Legend
GS30 05 A - 12345
Model
Year of
manufacture
Facility code
(if applicable)
Sequence
number
PN - 77055
Model:
Model year: Manufacture date:
Maximum allowable inclination of the chassis:
Country of manufacture: USA
This machine complies with:
Serial number:
Rated work load (including occupants):
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Electrical schematic number:
Gradeability:
Maximum allowable side force :
Maximum number of platfrm occupants:
Machine unladen weight:
ANSI A92.6-1999
B354.2-01
GS-1930
GS3005A-12345
04/12/05
ES0141
2,714 lb / 1,231 kg
500 lb / 227 kg
N/A
N/A
100 lb / 445 kg
2
2005
Serial Number Legend

September 2005
GS-3384 Part No. 82259
iv
This page intentionally left blank.

September 2005
Part No. 82259 GS-3384
Safety Rules
Section 1 • Safety Rules
v
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.

September 2005
GS-3384 Part No. 82259
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
vi
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.
Workplace Safety
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 components and
cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
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 .
Section 1 • Safety Rules

September 2005
Part No. 82259 GS-3384
Table of Contents
vii
Introduction
ImportantInformation.........................................................................................ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules
General Safety Rules........................................................................................iv
Section 2 Rev Specifications
C Machine Specifications ................................................................................ 2 - 1
C Performance Specifications ......................................................................... 2 - 2
C Hydraulic Specifications............................................................................... 2 - 2
C Manifold Component Specifications ............................................................. 2 - 4
C GM 1.6L Engine........................................................................................... 2 - 5
C Ford LRG-425 EFI Engine ........................................................................... 2 - 6
C Duetz F3L 1011F Engine ............................................................................. 2 - 7
C Duetz F3L 2011 Engine ............................................................................... 2 - 8
C Hydraulic Hose and Fitting Torque Specifications........................................ 2 - 9
C 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
BChecklist A Procedures
A-1 Perform Pre-operation Inspection....................................................... 3 - 7
A-2 Perform Function Tests ...................................................................... 3 - 7
A-3 Perform Engine Maintenance - Ford models ...................................... 3 - 8
A-4 Perform Engine Maintenance - Deutz models .................................... 3 - 8
A-5 Check the Engine Coolant Level - GM Models ................................... 3 - 9
A-6 Inspect the Engine Air Filter - GM Models .......................................... 3 - 9
A-7 Check the Battery - GM Models........................................................ 3 - 10
A-8 Inspect the Radiator - GM Models .................................................... 3 - 12

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GS-3384 Part No. 82259
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures, continued
A-9 Check the Engine Fasteners - GM Models ....................................... 3 - 12
A-10 Perform 30 Day Service ................................................................... 3 - 12
A-11 Perform Engine Maintenance - Deutz Models .................................. 3 - 13
A-12 Perform Engine Maintenance - Ford Models .................................... 3 - 13
A-13 Check the Alternator Belt - GM Models ............................................ 3 - 14
A-14 Check the Hydraulic Return Filter Condition Indicator (if equipped).. 3 - 15
A-15 Perform Engine Maintenance - Deutz 1011F Models ....................... 3 - 15
A-16 Drain the Fuel Filter/ Water Separator - Deutz Models ..................... 3 - 16
A-17 Perform Engine Maintenance - Ford Models .................................... 3 - 17
A-18 Replace the Engine Oil and Filter - GM Models................................ 3 - 17
DChecklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 19
B-2 Inspect the Electrical Wiring ............................................................. 3 - 20
B-3 Perform Engine Maintenance - Deutz 1011F Models ....................... 3 - 21
B-4 Check the Exhaust System .............................................................. 3 - 21
B-5 Inspect the Engine Air Filter - Ford and Deutz Models...................... 3 - 22
B-6 Check and Adjust the Engine RPM .................................................. 3 - 23
B-7 Confirm the Proper Brake Configuration........................................... 3 - 25
B-8 Inspect the Tires and Wheels (including lug nut torque) ................... 3 - 25
B-9 Check the Oil Level in the Drive Hubs .............................................. 3 - 26
B-10 Test the Key Switch.......................................................................... 3 - 26
B-11 Test the Emergency Stop ................................................................. 3 - 27
B-12 Test the Automotive-style Horn (if equipped).................................... 3 - 27
B-13 Test the Fuel Select Operation - Ford and GM Models..................... 3 - 28
B-14 Test the Drive Brakes ....................................................................... 3 - 29
B-15 Test the Drive Speed - Stowed Position ........................................... 3 - 29
B-16 Test the Drive Speed - Raised Position ............................................ 3 - 30
B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 31
B-18 Replace the Medium and High Pressure Hydraulic Filter Elements.. 3 - 31

September 2005
Part No. 82259 GS-3384
TABLE OF CONTENTS
ix
Section 3 Rev Scheduled Maintenance Procedures, continued
B-19 Inspect the Fuel Tank Cap Venting System...................................... 3 - 32
B-20 Replace the Engine Air Filter Element - Ford and GM Models.......... 3 - 33
B-21 Perform Engine Maintenance - Ford Models .................................... 3 - 34
B-22 Replace the Fuel Filter - GM Models ................................................ 3 - 35
B-23 Check the Specific Gravity of the Engine Coolant - GM Models ....... 3 - 36
CChecklist C Procedure
C-1 Test the Platform Overload System (if equipped) ............................. 3 - 37
C-2 Replace the Engine Air Filter Element - Duetz Models ..................... 3 - 38
C-3 Perform Engine Maintenance - Deutz Models .................................. 3 - 38
C-4 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 39
C-5 Perform Engine Maintenance - Ford Models .................................... 3 - 39
C-6 Clean the PCV Hoses and Fittings - GM Models .............................. 3 - 40
C-7 Change or Recondition the Engine Coolant - GM Models................. 3 - 40
C-8 Replace the LPG Filter - GM Models ................................................ 3 - 41
C-9 Replace the Spark Plugs and Spark Plug Wires - GM Models ......... 3 - 42
DChecklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 43
D-2 Check the Free-wheel Configuration ................................................ 3 - 44
D-3 Replace the Drive Hub Oil ................................................................ 3 - 45
D-4 Replace the Fuel Filter/Water Separator - Deutz Models.................. 3 - 45
D-5 Calibrate the Platform Overload System (if equipped) ...................... 3 - 46
D-6 Replace the Hydraulic Tank Return Filter ......................................... 3 - 53
D-7 Perform Engine Maintenance - Deutz Models .................................. 3 - 54
BChecklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 55
E-2 Change the Fuel Hoses - GM Models............................................... 3 - 57
E-3 Perform Engine Maintenance - Deutz 1011F Models ....................... 3 - 59
E-4 Perform Engine Maintenance - Ford Models .................................... 3 - 60
E-5 Perform Engine Maintenance - Deutz Models .................................. 3 - 60
E-6 Perform Engine Maintenance - Deutz 2011 Models ......................... 3 - 60

September 2005
GS-3384 Part No. 82259
TABLE OF CONTENTS
x
Section 4 Rev Repair Procedures
Introduction.................................................................................................. 4 - 1
CPlatform Controls
1-1 Circuit Boards .................................................................................... 4 - 2
1-2 Joystick Controller.............................................................................. 4 - 3
1-3 Controller Adjustments
(before serial number GS8403-40213)............................................... 4 - 5
1-4 SoftwareConfiguration
(before serial number GS8403-40213)............................................. 4 - 11
BPlatform Components
2-1 Platform ........................................................................................... 4 - 15
2-2 Platform Extension Deck.................................................................. 4 - 17
BScissor Components
3-1 Scissor Assembly, GS-3384 ............................................................ 4 - 18
3-2 Wear Pads ....................................................................................... 4 - 24
3-3 Lift Cylinder ...................................................................................... 4 - 26
CEngines
4-1 RPM Adjustment .............................................................................. 4 - 28
4-2 Engine Fault Codes - Ford Models................................................... 4 - 28
4-3 Flex Plate ......................................................................................... 4 - 28
4-4 Oil Temperature and Oil Pressure Switches - Deutz Models............ 4 - 33
4-5 Coolant Temperature and Oil Pressure Switches - Ford Models...... 4 - 34
4-6 Coolant Temperature and Oil Pressure Switches - GM Models ....... 4 - 35
CGround Controls
5-1 Auxiliary Platform Lowering.............................................................. 4 - 36
5-2 Controller Adjustments
(after serial number GS8403-40212)................................................ 4 - 36
5-3 SoftwareConfiguration
(after serial number GS8403-40212)................................................ 4 - 47
5-4 Level Sensor - Models without Outriggers
(before serial number 40077) ........................................................... 4 - 51

September 2005
Part No. 82259 GS-3384
TABLE OF CONTENTS
xi
Section 4 Rev Repair Procedures, continued
5-5 Level Sensor - Models without Outriggers
(after serial number 40076) .............................................................. 4 - 54
5-6 Level Sensor - Models with Outriggers............................................. 4 - 56
5-7 Engine Fault Codes - Ford Models................................................... 4 - 61
CHydraulic Pumps
6-1 Lift/Steer Pump ................................................................................ 4 - 62
6-2 Drive Pump ...................................................................................... 4 - 64
DManifolds
7-1 Function Manifold Components - Models with Outriggers ................ 4 - 66
7-2 Function Manifold Components - Models without Outriggers ........... 4 - 68
7-3 Drive Manifold Components
(before serial number GS8404-40297)............................................. 4 - 70
7-4 Drive Manifold Components
(after serial number GS8404-40296)................................................ 4 - 72
7-5 Valve Adjustments - Function Manifold ............................................ 4 - 74
7-6 Valve Adjustments - Drive Manifold ................................................. 4 - 75
7-7 Generator Manifold Components ..................................................... 4 - 76
7-8 Valve Adjustments - Generator Manifold.......................................... 4 - 77
7-9 Valve Coils ....................................................................................... 4 - 78
AFuel and Hydraulic Tanks
8-1 Fuel Tank ......................................................................................... 4 - 80
8-2 Hydraulic Tank ................................................................................. 4 - 81
BSteer Axle Components
9-1 Yoke and Drive Motor ...................................................................... 4 - 83
9-2 Steer Cylinder .................................................................................. 4 - 85
9-3 Tie Rod ............................................................................................ 4 - 85
ANon-steer Axle Components
10-1 Drive Motor and Brake ..................................................................... 4 - 86
10-2 Drive Hub ......................................................................................... 4 - 87
BOutrigger Components
11-1 Outrigger Cylinder ............................................................................ 4 - 88

September 2005
GS-3384 Part No. 82259
xii
TABLE OF CONTENTS
Section 5 Rev Fault Codes
Introduction.................................................................................................. 5 - 1
B Fault Code Chart
(before serial number GS8403-40213) ........................................................ 5 - 3
A Fault Code Chart
(after serial number GS8403-40212) ........................................................... 5 - 5
A Ford Engine ECM Fault Code Chart
(before serial number GS8404-40302) ........................................................ 5 - 8
A Ford Engine ECM Fault Code Chart
(after serial number GS8404-40301) ......................................................... 5 - 10

September 2005
Part No. 82259 GS-3384
TABLE OF CONTENTS
xiii
Section 6 Rev Schematics
Introduction.................................................................................................. 6 - 1
A Electronic Control Module Layout
(before serial number GS8403-40213) ........................................................ 6 - 2
A Electronic Control Module Pin-Out Legend
(before serial number GS8403-40213) ........................................................ 6 - 3
A Electronic Control Module Layout
(after serial number GS8403-40212) ........................................................... 6 - 4
A Electronic Control Module Pin-Out Legend
(after serial number GS8403-40212) ........................................................... 6 - 5
A Ford Engine Relay Layout ........................................................................... 6 - 6
A Wiring Diagram - Platform Control Box
(before serial number GS8403-40213) ........................................................ 6 - 7
A Wiring Diagram - Platform Control Box
(after serial number GS8403-40212) ........................................................... 6 - 8
A Electrical Schematics Abbreviation and Wire Color Legends....................... 6 - 9
A Electrical Symbols Legend......................................................................... 6 - 10
A Wiring Harness - GM 1.6 L ........................................................................ 6 - 11
A Wiring Harness - Ford LRG-425 EFI
(before serial number GS8404-40302) ...................................................... 6 - 12
A Wiring Harness - Ford LRG-425 EFI
(after serial number GS8404-40301) ......................................................... 6 - 14
B Electrical Schematic - GM Models
(before serial number 40044)..................................................................... 6 - 16
B Electrical Schematic - GM Models
(from serial number 40044 to 40067)......................................................... 6 - 20
B Electrical Schematic - GM Models
(from serial number 40068 to GS8403-40131)........................................... 6 - 24
A Electrical Schematic - GM Models
(from serial number GS8403-40132 to GS8403-40212) ............................ 6 - 28
A Electrical Schematic - GM Models
(after serial number GS8403-40212) ......................................................... 6 - 32
C Electrical Schematic - ANSI Models with Ford Power
(before serial number GS8404-40302) ...................................................... 6 - 36
C Electrical Schematic - ANSI Models with Ford Power
(from serial number GS8404-40302 to GS8405-40504) ............................ 6 - 40

September 2005
GS-3384 Part No. 82259
TABLE OF CONTENTS
xiv
Section 6 Rev Schematics,continued
B Electrical Schematic - ANSI Models with Ford Power
(from serial number GS8405-40505 to GS8405-40539) ............................ 6 - 44
A Electrical Schematic - ANSI Models with Ford Power
(from serial number GS8405-40540 to GS8405-40832) ............................ 6 - 48
B Electrical Schematic - CE Models with Ford Power
(before serial number GS8404-40302) ...................................................... 6 - 52
B Electrical Schematic - CE Models with Ford Power
(from serial number GS8404-40302 to GS8405-40504) ............................ 6 - 56
B Electrical Schematic - CE Models with Ford Power
(from serial number GS8405-40505 to GS8405-40539) ............................ 6 - 60
A Electrical Schematic - CE Models with Ford Power
(from serial number GS8405-40540 to GS8405-40617) ............................ 6 - 64
A Electrical Schematic - CE Models with Ford Power
(from serial number GS8405-40618 to GS8405-40832) ............................ 6 - 68
B Electrical Schematic - Deutz Models
(before serial number 40044)..................................................................... 6 - 72
B Electrical Schematic - Deutz Models
(from serial number 40044 to 40067)......................................................... 6 - 76
B Electrical Schematic - Deutz Models
(from serial number 40068 to GS8403-40131)........................................... 6 - 80
A Electrical Schematic - Deutz Models
(from serial number GS8403-40132 to GS8403-40212) ............................ 6 - 84
C Electrical Schematic - ANSI Models with Deutz Power
(from serial number GS8403-40213 to GS8405-40504) ............................ 6 - 88
B Electrical Schematic - ANSI Models with Deutz Power
(from serial number GS8405-40505 to GS8405-40832) ............................ 6 - 92
B Electrical Schematic - CE Models with Deutz Power
(from serial number GS8403-40213 to GS8405-40504) ............................ 6 - 96
B Electrical Schematic - CE Models with Deutz Power
(from serial number GS8405-40505 to GS8405-40832) .......................... 6 - 100
A Hydraulic Schematics Component Call-out and Symbols Legend ........... 6 - 103
B Hydraulic Schematic
(before serial number GS8404-40297) .................................................... 6 - 104
C Hydraulic Schematic
(from serial number GS8404-40297 to GS8405-40832) .......................... 6 - 106

REV C
Section 2 • Specifications
Part No. 82259 GS-3384 2 - 1
September 2005
Specifications
Machine Specifications
Fluid capacity (before serial number 40297)
Hydraulic tank 20 gallons
75.7 liters
Hydraulic system 24 gallons
(including tank) 91 liters
Fuel tank 20 gallons
75.7 liters
Fluid capacity (after serial number 40296)
Hydraulic tank 32 gallons
121 liters
Hydraulic system 35 gallons
(including tank) 132.5 liters
Fuel tank 30 gallons
114 liters
Tire 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
For operational specifications, refer to the
Operator's Manual.
Rough terrain, foam-filled
Tire size 10-16.5 NHS
Tire ply rating, minimum 6
Tire contact area 77.8 sq in
502 cm2
Overall tire diameter 31 in
79 cm
Wheel diameter 16.5 in
41.9 cm
Wheel width 8.25 in
21 cm
Weight 239 lbs (+/-10 lbs)
108.4 kg (+/-4.5 kg)
High Flotation, air-filled and foam-filled
Tire size 33/16LL500
Tire ply rating 10
Tire contact area 48 sq in
309.7 cm2
Tire diameter 33 in
83.8 cm
Tire width 16 in
41 cm
Wheel diameter 19.5 in
49.5 cm
Wheel width 14 in
35.6 cm
Weight, foam-filled 419 lbs (+/-10 lbs)
190 kg (+/-4.5 kg)
Weight, air-filled 157 lbs
71.2 kg
Pressure, air-filled 38 psi
2.6 bar
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV C
Section 2 • Specifications
2 - 2 GS-3384 Part No. 82259
September 2005
Performance Specifications
Drive speed, maximum
Platform stowed 4 mph
40 ft / 6.8 sec
6.4 km/h
12.2 m / 6.8 sec
Platform raised 0.7 mph
40 ft / 39 sec
1.1 km/h
12.2 m / 39 sec
Gradeability 50%
Rated work load at full height, maximum
GS-3384 2500 lbs
1135 kg
Function speed, maximum from platform controls
(with maximum rated load in platform)
GS-3384
Platform up 42 to 52 seconds
Platform down 25 to 35 seconds
Airborne noise emissions 80 dB
Maximum sound level at normal operation workstations
(A-weighted)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Hydraulic Specifications
Hydraulic Oil Specifications
Before serial number 40085
Hydraulic oil type Shell Donax TG (Dexron III)
After serial number 40084
Hydraulic oil type Chevron Rykon MV equivalent
ISO 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 have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 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
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 0°F / -17°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
SPECIFICATIONS

REV C
Section 2 • Specifications
Part No. 82259 GS-3384 2 - 3
September 2005
SPECIFICATIONS
Drive pump
Type: Bi-directional, variable displacement piston pump
Flow rate @ 3000 rpm 0 to 22 gpm
(before serial number GS8404-40297) 0 to 83.3 L/min
Flow rate @ 2500 rpm 0 to 32.5 gpm
(after serial number GS8404-40296) 0 to 123 L/min
Drive pressure, maximum 3650 psi
(before serial number GS8404-40297) 251.7 bar
Drive pressure, maximum 3750 psi
(after serial number GS8404-40296) 258.6 bar
Charge pump
Type: Gerotor
Flow rate @ 3000 rpm 8.7 gpm
(before serial number GS8404-40297) 32.9 L/min
Flow rate @ 2500 rpm 9.1 gpm
(after serial number GS8404-40296) 34.4 L/min
Charge pump pressure 360 psi
(before serial number GS8404-40297) 24.8 bar
Charge pump pressure 325 psi
(after serial number GS8404-40296) 22.4 bar
Function pump
Type: Gear
Displacement 1.025 cu in
(before serial number GS8404-40297) 16.8 cc
Displacement 0.98 cu in
(after serial number GS8404-40296) 16 cc
Flow rate @ 3000 rpm 12.6 gpm
(before serial number GS8404-40297) 47.7 L/min
Flow rate @ 2500 rpm 10.6 gpm
(after serial number GS8404-40296) 40.1 L/min
Hydraulic tank 10 micron with
return line filter 25 psi / 1.7 bar bypass
Auxiliary power unit
Relief valve 2000 psi
137.9 bar
Function manifold
System relief valve pressure 2700 to 2900 psi
186 to 200 bar
Steer relief valve pressure 2000 psi
138 bar
Proportional valve flow regulator 0.1 gpm
0.38 L/min
Drive manifold
Hot oil relief pressure 300 psi
(before serial number GS8404-40297) 20.7 bar
Hot oil relief pressure 280 psi
(after serial number GS8404-40296) 19.3 bar
Generator manifold (option)
Relief valve 3000 psi
207 bar
Flow rate, maximum 4.5 gpm
17 L/min
Drive motors
Displacement (2 speed motor) 0.6 to 1.5 cu in
(before serial number GS8404-40297) 9.8 to 24.6 cc
Displacement (2 speed motor) 0.54 to 1.52 cu in
(after serial number GS8404-40296) 8.8 to 25 cc
Drive hubs
Fluid capacity 17 fl oz
(before serial number GS8404-40297) 0.5 liters
Fluid capacity 26 fl oz
(after serial number GS8404-40296) 0.77 liters
Type: SAE 90 multipurpose hypoid gear oil
API service classification GL5
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV C
Section 2 • Specifications
2 - 4 GS-3384 Part No. 82259
September 2005
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 3 position 4 way 8.2 to 10.2Ω
10V DC with diode (schematic item G)
Proportional valve, 12V DC 3.1 to 5.1Ω
(schematic items H and AD)
DO3 valve, 3 position 4 way, 10V DC 2.6 to 4.6Ω
(schematic items I, J, AG and AK)
Solenoid valve, 3 position 4 way 6.2 to 8.2Ω
10V DC with diode (schematic item AH)
Solenoid valve, 2 position 2 way 5.7 to 7.7Ω
10V DC with diode (schematic items BA and BB)
Solenoid valve, 2 position 3 way 10V 8.2 to 10.2Ω
(schematic items BI and BJ)
Solenoid valve, 2 position 2 way 10V DC 4.5 to 6.5Ω
(schematic items CA, CB, CC and CD)
Solenoid valve, 2 position 3 way 5 to 7Ω
10V DC (schematic item AL)
Solenoid valve, 2 position 2 way 6.5 to 8.5Ω
12V DC with diode (schematic item DA)
Solenoid valve, 2 position 3 way 9 to 11Ω
12V DC with diode (schematic items DE and DF)
Solenoid valve, 2 position 2 way 9 to 11Ω
12V DC with diode (schematic item DG)
Solenoid valve, 2 position 3 way 6 to 8Ω
10V DC with diode (schematic items EF and EJ)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV C
Section 2 • Specifications
Part No. 82259 GS-3384 2 - 5
September 2005
SPECIFICATIONS
GM 1.6L Engine
Displacement 98 cu in
1.6 liters
Number of cylinders 4
Bore & stroke 3.11 x 3.21 inches
79 x 81.5 mm
Horsepower 53 @ 3000 rpm
39.5 kW @ 3000 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1600 rpm
Frequency 320 Hz
High idle 3000 rpm
Frequency 600 Hz
Compression ratio 9.4:1
Compression pressure (approx.)
Pressure (psi / bar) of lowest cylinder must be
at least 75% of highest cylinder
Lubrication system
Oil pressure 21 psi
(operating temp. @ 1500 rpm) 1.45 bar
Oil capacity 3.7 quarts
(including filter) 3.5 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operation Manual on your machine.
Starter motor
Normal engine cranking speed 150 to 200 rpm
Current draw, normal load 100-200A
Current draw, no load 35 to 85A
Maximum circuit voltage drop 0.5V DC
while starting (normal temperature)
Electronic fuel pump
Fuel pressure, regulated 10 psi
0.7 bar
Fuel flow rate 0.3 gpm
1.4 L/min
Ignition system
Spark plug gap 0.032 to 0.036 inches
0.8 to 0.9 mm
Engine coolant
Capacity 10 quarts
9.5 liters
Alternator
Output 70A, 14.5V DC
Fan belt deflection 3/8to 1/2inch
9 to 12 mm
Battery
Type 12V DC
Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

REV C
Section 2 • Specifications
2 - 6 GS-3384 Part No. 82259
September 2005
SPECIFICATIONS
Ford LRG-425 EFI Engine
Displacement 153 cu in
2.5 liters
Number of cylinders 4
Bore & stroke 3.78 x 3.4 inches
96.01 x 86.36 mm
Horsepower 70 @ 2500 rpm
52 kw @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Low idle (computer controlled) 1600 rpm
320 Hz
High idle (computer controlled) 2500 rpm
500 Hz
Compression ratio 9.4:1
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances - 0.035 to 0.055 inches
collapsed tappet 0.889 to 1.397 mm
Lubrication system
Oil pressure 40 to 60 psi
(operating temperature @ 2500 rpm) 2.75 to 4.1 bar
Oil capacity 4.5 quarts
(including filter) 4.3 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Engine coolant
Capacity 11.5 quarts
10.9 liters
Ignition system
Spark plug type Motorcraft AWSF-52-C
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.17 mm
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Current draw, maximum load 800A
Circuit voltage drop 0.5V DC
while starting, maximum (normal temperature)
Brush length, minimum 0.25 in
6.35 mm
Commutator run-out, maximum 0.005 inches
0.127 mm
Electronic fuel pump
Fuel pressure, static 63 psi
4.3 bar
Fuel flow rate 0.58 gpm
2.2 L/min
Alternator
Output 95A, 14.5V DC
Battery
Type 12V DC
Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.