Terex Genie GS84D-401 Installation and operating manual

Service and Repair Manual
Serial Number Range
GS™-3384
from GS84F-46000
from GS84D-
401
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
GS™-3390
from GS90F-56000
from GS90D-
3201
GS™-4390
GS™-5390
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1306587GT
Rev A
1
June 2021

Service and Repair Manual June 2021
Introduction
ii GS™-84 • GS™-90 Part No. 1306587GT
Introducti on Introduction
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: awp.tec[email protected]om
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
1306587GT Rev A, April 2021
Second 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.

June 2021 Service and Repair Manual
Introduction
Part No. 1306587GT GS™-84 • GS™-90 iii
Revision History
Revision Date Section Procedure / Page / Description
A 4/2021 Initial Release
A1 6/2021 Repair 9-1
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 June 2021
Introduction
iv GS™-84 • GS™-90 Part No. 1306587GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial label, (located inside cover)
5 Serial number, (stamped on chassis)

June 2021 Service and Repair Manual
Safety Rules
Part No. 1306587GT GS™-84 • GS™-90 v
Section 1 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.

Service and Repair Manual June 2021
Safety Rules
vi GS™-84 • GS™-90 Part No. 1306587GT
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 t
he 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.
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 clothing if the
situation warrants it.
Be aware of potential crushing
hazards such as moving parts, free
swinging or unsecured co
mponents
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 ha
ve
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 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 tim
e use (i.e., cotter pins and self-
locking nuts) are not reused. These
components m
ay 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.

June 2021
Table of Contents
Part No. 1306587GT GS™-84 • GS™-90 vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. 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 Oil Specifications....................................................................................3
Hydraulic Component Specifications .....................................................................6
Manifold Component Specifications.......................................................................7
Ford MSG-425 EFI Engine Specifications .............................................................8
Deutz D2011 L03i Engine Specifications ...............................................................9
Deutz TD 2.2 L3 Engine Specifications................................................................10
Deutz D 2.9 L4 Engine Specifications..................................................................11
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14

June 2021
Table of Contents
viii GS™-84 • GS™-90 Part No. 1306587GT
Section 3 Repair Procedures ............................................................................................. 16
Introduction .......................................................................................................... 16
Platform Controls............................................................................................... 18
1-1 Circuit Board .................................................................................................. 18
How to Remove the Platform Controls Circuit Board ..................................... 18
Platform Components ....................................................................................... 19
2-1 Platform.......................................................................................................... 19
How to Remove the Platform.......................................................................... 19
2-2 Platform Extension Deck ............................................................................... 21
How to Remove the Platform Extension Deck................................................ 21
Scissor Components ......................................................................................... 22
3-1 Scissor Assembly, GS-3384 and GS-3390 ................................................... 23
How to Disassemble the Scissor Assembly ................................................... 23
How to Disassemble a Scissor Arm Pair ........................................................ 27
3-2 Scissor Assembly, GS-4390.......................................................................... 29
How to Disassemble the Scissor Assembly ................................................... 29
How to Disassemble a Scissor Arm Pair ........................................................ 33
3-3 Scissor Assembly, GS-5390.......................................................................... 36
How to Disassemble the Scissor Assembly ................................................... 36
How to Disassemble a Scissor Arm Pair ........................................................ 41
3-4 Wear Pads ..................................................................................................... 42
How to Replace the Scissor Arm Wear Pad................................................... 42
How to Replace the Chassis Scissor Arm Wear Pads ................................... 43
3-5 Lift Cylinders .................................................................................................. 45
How to Remove the Lift Cylinder - GS-3384, GS-3390 and GS-4390 ........... 45
How to Remove the Lift Cylinder - GS-5390 .................................................. 47
3-6 Height Angle Sensor...................................................................................... 49
How to Replace the Height Angle Sensor ...................................................... 49

June 2021
Table of Contents
Part No. 1306587GT GS™-84 • GS™-90 ix
Engines................................................................................................................50
4-1 RPM Adjustment ............................................................................................50
4-2 Flex Plate .......................................................................................................50
How to Remove the Flex Plate - Ford Models ................................................50
How to Remove the Flex Plate - Deutz Models ..............................................51
How to Install the Flex Plate............................................................................52
4-3 Ford MSG-425 Engine Fault Codes...............................................................53
4-4 Engine Fault Codes - Deutz TD 2.2 L3 Models .............................................54
6-6 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.............54
4-6 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3...................................55
Ground Controls.................................................................................................56
5-1 Auxiliary Platform Lowering............................................................................56
5-2 Controller Adjustments...................................................................................56
How to Determine the Revision Level.............................................................57
How to Adjust the Stowed Drive Speed ..........................................................57
How to Adjust the High Torque Drive Speed ..................................................58
How to Adjust the Raised Drive Speed...........................................................59
How to Adjust the Lift Speed...........................................................................61
How to Adjust the Platform Lower Speed .......................................................62
How to Adjust the Platform Settling Speed .....................................................63
How to Adjust the Steer Speed.......................................................................64
5-3 Software Configuration...................................................................................64
5-4 Level Sensor - Models without Outriggers .....................................................69
How to Install and Calibrate the Level Sensor - Models without Outriggers...69
5-5 Level Sensor - Models with Outriggers ..........................................................71
How to Install and Calibrate the Level Sensor - Models with Outriggers........71

June 2021
Table of Contents
x GS™-84 • GS™-90 Part No. 1306587GT
Hydraulic Pump.................................................................................................. 75
6-1 Lift/Steer Pump .............................................................................................. 75
How to Remove the Lift/Steer Pump .............................................................. 75
6-2 Drive Pump .................................................................................................... 76
How to Remove the Drive Pump .................................................................... 76
How to Prime the Pump.................................................................................. 77
How to Adjust the Pump Neutral..................................................................... 78
Manifolds ............................................................................................................ 80
7-1 Function Manifold Components - Models with Outriggers............................. 80
7-2 Function Manifold Components - Models without Outriggers........................ 82
7-3 Traction Manifold Components...................................................................... 84
7-4 Oscillate Manifold Components, GS-90 (option) ........................................... 86
7-5 Welder Manifold Components (option) .......................................................... 88
7-6 Valve Adjustments - Function Manifold ......................................................... 89
How to Adjust the System Relief Valve .......................................................... 89
How to Adjust the Steer Relief Valve.............................................................. 90
7-7 Valve Adjustments - Traction Manifold .......................................................... 91
How to Adjust the Charge Pressure Relief Valve........................................... 91
7-8 Generator Manifold Components .................................................................. 92
7-9 Valve Adjustments - Generator Manifold....................................................... 93
How to Adjust the Generator Voltage ............................................................. 93
7-10 Generator Relief Valve Manifold Components ............................................ 94
7-11 Valve Coils................................................................................................... 95
Fuel and Hydraulic Tanks ................................................................................. 97
8-1 Fuel Tank....................................................................................................... 97
8-2 Hydraulic Tank............................................................................................... 98