Rev A1, September 2016

Serial Number Range
from GS8413-42181 to GS8415-42382
from GS8416F-42383 to GS8416F-45499
from GS84F-45500
from GS9013-48427 to GS9015-51063
from GS9016F-51064 to GS9016F-53299
from GS90F-53300

Content:
INTRODUCTION
Important Information
Find a Manual for this Model
Revision History
Serial Number Legend

Section 1. SAFETY RULES
General Safety Rules

Section 2. SPECIFICATIONS
Machine Specifications
Performance Specifications
Hydraulic Specification
Hydraulic Component Specifications
Manifold Component Specifications
Ford MSG-425 EFI Engine Specifications
Deutz D2011 L03i Engine Specifications
Deutz D 2.9 L4 Engine Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure

Section 3. REPAIR PROCEDURES
Introduction
Platform Controls
1-1 Circuit Board
How to Remove the Platform Controls Circuit Board
Platform Components
2-1 Platform
How to Remove the Platform
2-2 Platform Extension Deck
How to Remove the Platform Extension Deck
Scissor Components
3-1 Scissor Assembly, GS-3384 and GS-3390
How to Disassemble the Scissor Assembly
How to Disassemble a Scissor Arm Pair
3-2 Scissor Assembly, GS-4390
How to Disassemble the Scissor Assembly
How to Disassemble a Scissor Arm Pair
3-3 Scissor Assembly, GS-5390
How to Disassemble the Scissor Assembly
How to Disassemble a Scissor Arm Pair
3-4 Wear Pads
How to Replace the Scissor Arm Wear Pad
How to Replace the Chassis Scissor Arm Wear Pads
3-5 Lift Cylinders
How to Remove the Lift Cylinder - GS-3384, GS-3390 and GS-4390
How to Remove the Lift Cylinder - GS-5390
Engines
4-1 RPM Adjustment - Deutz D2011L03i Models
4-2 Engine Fault Codes
4-3 Flex Plate
How to Remove the Flex Plate - Ford Models
How to Remove the Flex Plate - Deutz Models
How to Install the Flex Plate
Ground Controls
5-1 Auxiliary Platform Lowering
5-2 Controller Adjustments
How to Determine the Revision Level
How to Adjust the Stowed Drive Speed
How to Adjust the High Torque Drive Speed
How to Adjust the Raised Drive Speed
How to Adjust the Lift Speed
How to Adjust the Platform Lower Speed
How to Adjust the Platform Settling Speed
How to Adjust the Steer Speed
5-3 Software Configuration
5-4 Level Sensor - Models without Outriggers
How to Install and Calibrate the Level Sensor - Models without Outriggers
5-5 Level Sensor - Models with Outriggers
How to Install and Calibrate the Level Sensor - Models with Outriggers
Hydraulic Pump
6-1 Lift/Steer Pump
How to Remove the Lift/Steer Pump
6-2 Drive Pump
How to Remove the Drive Pump
How to Prime the Pump
How to Adjust the Pump Neutral
Manifolds
7-1 Function Manifold Components - Models with Outriggers
7-2 Function Manifold Components - Models without Outriggers
7-3 Traction Manifold Components
7-4 Oscillate Manifold Components, GS-90 (option)
7-5 Welder Manifold Components (option)
7-6 Valve Adjustments - Function Manifold
How to Adjust the System Relief Valve
How to Adjust the Steer Relief Valve
7-7 Valve Adjustments - Traction Manifold
How to Adjust the Charge Pressure Relief Valve
7-8 Generator Manifold Components
7-9 Valve Adjustments - Generator Manifold
How to Adjust the Generator Voltage
7-10 Generator Relief Valve Manifold Components
7-11 Valve Coils
Fuel and Hydraulic Tanks
8-1 Fuel Tank
8-2 Hydraulic Tank
Steer Axle Components
9-1 Yoke Assembly
How to Remove the Yoke and Drive Motor
How to Remove a Drive Motor
9-2 Steer Cylinder
9-3 Oscillating Axle Option - GS-90 Models
Non-steer Axle Components
10-1 Drive Motor and Brake
How to Remove a Drive Motor and Brake
10-2 Drive Hub
How to Remove a Drive Hub
10-3 Oscillating Axle
Outrigger Components
11-1 Outrigger Cylinder
How to Remove an Outrigger Cylinder (if equipped)
Platform Overload Components
12-1 Platform Overload System
How to Calibrate the Platform Overload System
12-2 Platform Overload Recovery Message (software version B3 and later)

Section 4. FAULT CODES
Introduction
Control System Fault Codes
Control System Fault Codes
Fault Code Display - Deutz Models
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models
Fault Code Display - Flashing and Solid LEDs - Deutz D 2.9 L4 Models
Soft Key Functions and Icons - Deutz D 2.9 L4 Models
Main Menu Structure - Deutz D 2.9 L4 Models
Deutz D 2.9 L4 Engine Fault Codes
Ford MSG-425 Engine Fault Codes
How to Retrieve Ford Engine Fault Codes
How to Clear Engine Fault Codes from the ECM
Ford MSG-425 Engine Fault Codes

Section 5. SCHEMATICS
Introduction
Electrical Symbols Legend
Hydraulic Symbols Legend
Electrical Component and Wire Color Legends
Ford Engine Relay Layout
Electronic Control Module Layout
Electronic Control Module Pin-Out Legend
Ground Controls Wiring Panel Layout
Wiring Diagram - Platform Control Box
Limit Switch Legend
Wiring Diagram - 12 kW Hydraulic Generator (option)
Electrical Schematics - Engine Harness
Ford MSG-425 EFI Engine Wire Harness
Deutz D 2.9 L4 Engine Wire Harness
Hydraulic Schematics
Hydraulic Schematic, To Serial Numbers GS8415-42316 and GS9015-50184
Hydraulic Schematic, From Serial Numbers GS84154-42317 and GS9015-50185
Electrical Schematics - ANSI and CSA Models
Electrical Schematic, Ford Engine Models (ANSI/CSA)
Electrical Schematic, Deutz Engine Models (ANSI/CSA)
Electrical Schematics - AS and CE Models
Electrical Schematic, Ford Engine Models (AS/CE)
Electrical Schematic, Deutz Engine Models (AS/CE)