Genie S-80 User manual

Service
Manual
Technical
Publications
First Edition, First Printing
Part No. 34032
S-80
®
S-85
®
S-80
S-85

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
ii
Introduction
®
Copyright © 1994 by Genie Industries
First Edition: First Printing, October 1994
Genie® is a registered trademark of
Genie Industries. Registered 2009987
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Patents Pending
Printed in U.S.A.
Important
Read, understand and obey the safety rules and
operating instructions in the Genie S-80 & Genie
S-85 Operator's Manual before attempting any
maintenance or repair procedure.
This service manual covers the Genie S-80 and
Genie S-85 2WD and 4WD models introduced in
1994.
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 a Genie dealer service center.
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 other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 U.S.A.
If you have any questions, call Genie Industries.
®
®
Genie North America
Telephone [phone]
Toll Free in U.S.A. 800 536-1800
Toll Free in Canada 800 426-8089
Fax [phone]
Genie Europe
Telephone [phone]
Fax [phone]

Part No. 34032 Genie S-80 & Genie S-85
Service Manual - First Edition
iii
Safety Rules
Section 1 - Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 & Genie S-85
Operator's Manual 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.

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
SAFETY RULES
iv
Section 1 - Safety Rules
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.
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:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
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, and lifting or
placing loads. Always wear approved steel-toed
shoes.

Part No. 34032 Genie S-80 & Genie S-85
Service Manual - First Edition
Table of Contents
v
Introduction
Important Information .....................................................................................................ii
Section One Safety Rules
General Safety Rules .................................................................................................... iii
Section Two Specifications
Machine Specifications............................................................................................. 2 - 1
Performance Specifications...................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................... 2 - 3
Bolt Torque Specifications........................................................................................ 2 - 4
Ford LSG 423 Engine Specifications........................................................................ 2 - 5
Deutz F4L Engine Specifications.............................................................................. 2 - 7
Section Three Scheduled Maintenance Inspections
Introduction............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C..................................................................................................................... 3 - 5
Table D..................................................................................................................... 3 - 6
Maintenance Inspection Report................................................................................ 3 - 7
Section Four Scheduled Maintenance Procedures
Introduction............................................................................................................... 4 - 1
A-1 Inspect the Manuals........................................................................................ 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts .................................................. 4 - 2
A-4 Check the Engine Oil Level............................................................................. 4 - 3
A-5 Check the Engine Coolant Level - Gasoline/LPG Models............................... 4 - 3
A-6 Check for Fuel Leaks...................................................................................... 4 - 3
A-7 Check the Hydraulic Oil Level......................................................................... 4 - 4
A-8 Check for Hydraulic Leaks .............................................................................. 4 - 4

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures, continued
A-9 Check the Tire Pressure ................................................................................. 4 - 5
A-10 Test the Extendable Axles .............................................................................. 4 - 5
A-11 Test the Platform and Ground Controls .......................................................... 4 - 6
A-12 Test the Auxiliary Power Operation ................................................................ 4 - 6
A-13 Test the Tilt Sensor......................................................................................... 4 - 7
A-14 Test the Limit Switches................................................................................... 4 - 8
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ........................... 4 - 10
A-16 Replace the Engine Air Filter ........................................................................ 4 - 11
B-1 Check the Engine Belt(s) .............................................................................. 4 - 12
B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 12
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ..................... 4 - 12
B-4 Check the Exhaust System........................................................................... 4 - 13
B-5 Check the Battery ......................................................................................... 4 - 14
B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 14
B-7 Inspect the Electrical Wiring.......................................................................... 4 - 15
B-8 Inspect the Tires and Wheels ....................................................................... 4 - 15
B-9 Confirm the Proper Brake Configuration....................................................... 4 - 16
B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 16
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 17
B-12 Check and Adjust the Engine RPM............................................................... 4 - 17
B-13 Test the Key Switch ...................................................................................... 4 - 19
B-14 Test the Emergency Stop Buttons ................................................................ 4 - 20
B-15 Test the Ground Control Override................................................................. 4 - 20
B-16 Test the Platform Self-leveling ...................................................................... 4 - 20
B-17 Test the Service Horn ................................................................................... 4 - 21
B-18 Test the Foot Switch ..................................................................................... 4 - 21
B-19 Test the Engine Idle Select ........................................................................... 4 - 21
B-20 Test the Fuel Select Operation - Gasoline/LPG Models ............................... 4 - 22
B-21 Test the Drive Enable System ...................................................................... 4 - 23
B-22 Test the Drive Brakes ................................................................................... 4 - 23
B-23 Test the Drive Speed - Stowed Position ....................................................... 4 - 24

Part No. 34032 Genie S-80 & Genie S-85
Service Manual - First Edition
TABLE OF CONTENTS
vii
Section Four Scheduled Maintenance Procedures, continued
B-24 Test the Alarm Package - Optional Equipment ............................................. 4 - 24
B-25 Perform Hydraulic Oil Analysis ..................................................................... 4 - 25
B-26 Check the Hydraulic Limit Switch Linkage .................................................... 4 - 25
B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 26
C-1 Check the Boom Wear Pads......................................................................... 4 - 27
C-2 Check the Extendable Axle Wear Pads ........................................................ 4 - 27
C-3 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 27
C-4 Check the Free-wheel Configuration ............................................................ 4 - 28
C-5 Grease the Turntable Rotation Bearing and Rotate Gear............................. 4 - 29
C-6 Replace the Torque Hub Oil ......................................................................... 4 - 29
C-7 Replace the Hydraulic Tank Filter................................................................. 4 - 31
C-8 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 31
C-9 Replace the Diesel Fuel Filter - Deutz Diesel Models................................... 4 - 32
C-10 Replace the Gasoline Fuel Filter - Gasoline/LPG Models............................. 4 - 32
C-11 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 34
C-12 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models..... 4 - 34
C-13 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 35
C-14 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models.................... 4 - 36
C-15 Check and Adjust the Ignition Timing - Gasoline/LPG Models...................... 4 - 37
C-16 Check the Engine Valve Clearances - Deutz Diesel Models......................... 4 - 37
C-17 Adjust the Turntable Rotation Gear Backlash ............................................... 4 - 37
D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 38
D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models............ 4 - 39
D-3 Change the Fuel Lines.................................................................................. 4 - 41
D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ........................ 4 - 42
D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ............... 4 - 42
D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models.......................... 4 - 43
D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models.......... 4 - 44
D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 44
D-9 Replace the Timing Belt - Gasoline/LPG Models.......................................... 4 - 44

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
TABLE OF CONTENTS
viii
Section Five Troubleshooting Flow Charts
Introduction............................................................................................................... 5 - 1
1 Engine Will Not Crank Over ............................................................................ 5 - 3
2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5
3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12
4 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models................................................................................. 5 - 15
5 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models................................................................................. 5 - 17
6 Engine High Idle Inoperative - Gasoline/LPG Models................................... 5 - 19
7 Engine Low Idle Inoperative - Gasoline/LPG Models.................................... 5 - 21
8 Engine High Idle Inoperative - Deutz Diesel Models..................................... 5 - 22
9 Engine Low Idle Inoperative - Deutz Diesel Models...................................... 5 - 24
10 All Functions Inoperative, Engine Starts and Runs....................................... 5 - 25
11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 26
12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 29
13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 30
14 Boom Up Function Inoperative ..................................................................... 5 - 31
15 Boom Down Function Inoperative................................................................. 5 - 33
16 Boom Extend Function Inoperative............................................................... 5 - 35
17 Boom Retract Function Inoperative .............................................................. 5 - 37
18 Turntable Rotate Function Inoperative.......................................................... 5 - 38
19 Turntable Rotate Left Function Inoperative................................................... 5 - 40
20 Turntable Rotate Right Function Inoperative ................................................ 5 - 41
21 All Platform Leveling Functions Inoperative .................................................. 5 - 42
22 Platform Level Up Function Inoperative........................................................ 5 - 43
23 Platform Level Down Function Inoperative ................................................... 5 - 44

Part No. 34032 Genie S-80 & Genie S-85
Service Manual - First Edition
TABLE OF CONTENTS
ix
Section Five Troubleshooting Flow Charts, continued
24 Platform Rotate Left Function Inoperative .................................................... 5 - 45
25 Platform Rotate Right Function Inoperative .................................................. 5 - 47
26 Jib Boom Up Inoperative - S-85 Models ....................................................... 5 - 49
27 Jib Boom Down Inoperative - S-85 Models................................................... 5 - 51
28 Drive Chassis Jack Function Inoperative...................................................... 5 - 53
29 Axle Extend/Retract Inoperative ................................................................... 5 - 54
30 Steer Left Function Inoperative..................................................................... 5 - 55
31 Steer Right Function Inoperative .................................................................. 5 - 56
32 All Drive Functions Inoperative, All Other Functions Operate Normally........ 5 - 57
33 Drive Forward Or Reverse Function Inoperative........................................... 5 - 60
34 Traction Function Inoperative ....................................................................... 5 - 61
35 Machine Will Not Drive At Full Speed ........................................................... 5 - 62
36 Machine Drives At Full Speed With Platform Raised or Extended................ 5 - 63
37 Drive Enable System Is Malfunctioning ........................................................ 5 - 64
38 Auxiliary Functions Inoperative ..................................................................... 5 - 65
Section Six Schematics
Introduction............................................................................................................... 6 - 1
Electrical Symbols Legend ....................................................................................... 6 - 2
Electrical Schematic - Gasoline/LPG Models ........................................................... 6 - 3
Ground Control Box Legend - Gasoline/LPG Models ............................................... 6 - 5
Relay Panel Legend - Gasoline/LPG Models ........................................................... 6 - 6
Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 7
Electrical Schematic - Diesel Models ....................................................................... 6 - 8
Ground Control Box Legend - Diesel Models ......................................................... 6 - 10
Platform Control Box Legend - Diesel Models........................................................ 6 - 11
Hydraulic Symbols Legend..................................................................................... 6 - 12
2WD Hydraulic Schematic...................................................................................... 6 - 13
4WD Hydraulic Schematic...................................................................................... 6 - 14

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
TABLE OF CONTENTS
x
Section Seven Repair Procedures
Introduction............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 6
1-3 Foot Switch ..................................................................................................... 7 - 8
1-4 Resistors......................................................................................................... 7 - 9
1-5 Toggle Switches ............................................................................................. 7 - 9
1-6 Control Relays .............................................................................................. 7 - 10
Platform Components
2-1 Platform ........................................................................................................ 7 - 11
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 11
2-3 Platform Rotator............................................................................................ 7 - 12
Jib Boom Components - S-85 Models
3-1 Jib Boom....................................................................................................... 7 - 14
3-2 Jib Boom Lift Cylinder................................................................................... 7 - 15
3-3 Jib Boom / Platform Rotate Manifold Components ....................................... 7 - 16
Boom Components
4-1 Plastic Cable Track....................................................................................... 7 - 17
4-2 Boom ............................................................................................................ 7 - 17
4-3 Boom Lift Cylinder ........................................................................................ 7 - 20
4-4 Extension Cylinders ...................................................................................... 7 - 20
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 21
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 22
Deutz Engine F4L 1011
6-1 RPM Adjustment........................................................................................... 7 - 23
6-2 Flex Plate...................................................................................................... 7 - 23
6-3 Oil Temperature and Oil Pressure Gauges................................................... 7 - 23
Ford LSG-423 Engine
7-1 Governor Actuator ........................................................................................ 7 - 24
7-2 Choke Adjustments....................................................................................... 7 - 25