Terex GS90D-4695 Installation and operating manual

Service and Repair Manual
Serial Number Range
GS™-3390
from GS90D-4695
from GS90M-
101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
GS™-4390
GS™-5390
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 132
5652GT
Rev A
1
December 2023

Service and Repair Manual December 2023
Introduction
ii GS™-3390 • GS™-4390 • GS™-5390 Part No. 1325652GT
Intr od ucti o n Intr od ucti o n
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 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 https://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
1325652GT Rev A, August 2023
Third 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.

December 2023 Service and Repair Manual
Introduction
Part No. 1325652GT GS™-3390 • GS™-4390 • GS™-5390 iii
Revision History
Revision Date Section Procedure / Page / Description
A 8/2023 Initial Release
A
1 12/2023 Front cover Add facility code and serial break
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 December 2023
Introduction
iv GS™-3390 • GS™-4390 • GS™-5390 Part No. 1325652GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial number, (stamped on chassis)
5 Serial label, (located inside cover)

December 2023 Service and Repair Manual
Safety Rules
Part No. 1325652GT GS™-3390 • GS™-4390 • GS™-5390 v
Section 1 Safet y R ul es
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 modify or alter a MEWP without prior
written permission from the manufacturer.
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 December 2023
Safety Rules
vi GS™-3390 • GS™-4390 • GS™-5390 Part No. 1325652GT
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 thoroughl
y. 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.
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 ha
zardous
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 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
components a
nd 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.

December 2023
Table of Contents
Part No. 1325652GT GS™-3390 • GS™-4390 • GS™-5390 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....................................................................................1
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................4
Manifold Component Specifications .......................................................................6
Ford MSG-425 EFI Engine Specifications .............................................................6
Deutz D2011 L03i Engine Specifications ...............................................................8
Deutz D436 L3i Engine Specifications ...................................................................9
Deutz TD 2.2 L3 Engine Specifications................................................................10
Deutz D 2.9 L4 Tier IV Engine Specifications ......................................................12
Deutz D 2.9 L4 Stage IV Engine Specifications ...................................................13
Weichai WP3.2 Engine Specifications .................................................................14
Hydraulic Hose and Fitting Torque Specifications ...............................................15
Torque Procedure ................................................................................................16

December 2023
Table of Contents
viii GS™-3390 • GS™-4390 • GS™-5390 Part No. 1325652GT
Section 3 Repair Procedures..............................................................................................18
Introduction ...........................................................................................................18
Platform Controls ...............................................................................................20
1-1 Circuit Board...................................................................................................20
How to Remove the Platform Controls Circuit Board ......................................20
Platform Components ........................................................................................21
2-1 Platform ..........................................................................................................21
How to Remove the Platform ..........................................................................21
2-2 Platform Extension Deck ................................................................................23
How to Remove the Platform Extension Deck ................................................23
Scissor Components..........................................................................................24
3-1 Scissor Assembly, GS-3390...........................................................................25
How to Disassemble the Scissor Assembly ....................................................25
How to Disassemble a Scissor Arm Pair.........................................................29
3-2 Scissor Assembly, GS-4390...........................................................................31
How to Disassemble the Scissor Assembly ....................................................31
How to Disassemble a Scissor Arm Pair.........................................................35
3-3 Scissor Assembly, GS-5390...........................................................................38
How to Disassemble the Scissor Assembly ....................................................38
How to Disassemble a Scissor Arm Pair.........................................................43
3-4 Wear Pads......................................................................................................44
How to Replace the Scissor Arm Wear Pad ...................................................44
How to Replace the Chassis Scissor Arm Wear Pads....................................45
3-5 Lift Cylinders...................................................................................................47
How to Remove the Lift Cylinder - GS-3390, GS-4390 ..................................47
How to Remove the Lift Cylinder - GS-5390 ...................................................49
3-6 Height Angle Sensor ......................................................................................51
How to Replace the Height Angle Sensor .......................................................51

December 2023
Table of Contents
Part No. 1325652GT GS™-3390 • GS™-4390 • GS™-5390 ix
Engines................................................................................................................52
4-1 RPM Adjustment ............................................................................................52
4-2 Flex Plate .......................................................................................................52
How to Remove the Flex Plate - Ford Models ................................................52
How to Remove the Flex Plate - Deutz, Weichai Models ...............................53
How to Install the Flex Plate............................................................................54
4-3 Ford MSG-425 Engine Fault Codes...............................................................55
4-4 Engine Fault Codes - Deutz TD 2.2 L3 Models .............................................56
4-5 Engine Fault Codes - Deutz D 2.9 L4, Weichai WP3.2 Models.....................56
4-6 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 ...................................57
Ground Controls.................................................................................................58
5-1 Auxiliary Platform Lowering............................................................................58
5-2 Controller Adjustments...................................................................................58
How to Determine the Revision Level .............................................................59
How to Adjust the Stowed Drive Speed ..........................................................59
How to Adjust the High Torque Drive Speed ..................................................60
How to Adjust the Raised Drive Speed ...........................................................61
How to Adjust the Lift Speed...........................................................................63
How to Adjust the Platform Lower Speed .......................................................64
How to Adjust the Platform Settling Speed .....................................................65
How to Adjust the Steer Speed .......................................................................66
5-3 Software Configuration...................................................................................66
5-4 Level Sensor - Models without Outriggers .....................................................71
How to Install and Calibrate the Level Sensor - Models without Outriggers...71
5-5 Level Sensor - Models with Outriggers ..........................................................73
How to Install and Calibrate the Level Sensor - Models with Outriggers........73

December 2023
Table of Contents
x GS™-3390 • GS™-4390 • GS™-5390 Part No. 1325652GT
Hydraulic Pump ..................................................................................................77
6-1 Lift/Steer Pump...............................................................................................77
How to Remove the Lift/Steer Pump...............................................................77
6-2 Drive Pump.....................................................................................................78
How to Remove the Drive Pump .....................................................................78
How to Prime the Drive Pump .........................................................................79
How to Adjust the Pump Neutral .....................................................................79
Manifolds .............................................................................................................81
7-1 Function Manifold Components - Models with Outriggers .............................81
7-2 Function Manifold Components - Models without Outriggers ........................83
7-3 Traction Manifold Components ......................................................................85
7-4 Oscillate Manifold Components, GS-90 (option)............................................87
7-5 Welder Manifold Components (option)...........................................................89
7-6 Valve Adjustments - Function Manifold..........................................................90
How to Adjust the System Relief Valve...........................................................90
How to Adjust the Steer Relief Valve ..............................................................91
7-7 Valve Adjustments - Traction Manifold...........................................................92
How to Adjust the Charge Pressure Relief Valve............................................92
7-8 Generator Manifold Components ...................................................................93
7-9 Valve Adjustments - Generator Manifold .......................................................94
How to Adjust the Generator Voltage..............................................................94
7-10 Generator Relief Valve Manifold Components.............................................95
7-11 Valve Coils ...................................................................................................96
Fuel and Hydraulic Tanks ..................................................................................98
8-1 Fuel Tank........................................................................................................98
8-2 Hydraulic Tank ...............................................................................................99