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

Part No. 34032 Genie S-80 & Genie S-85
Service Manual - First Edition
TABLE OF CONTENTS
xi
Section Seven Repair Procedures, Ford LSG-423 Engine, continued
7-3 Timing Adjustment ........................................................................................ 7 - 26
7-4 Carburetor Adjustment.................................................................................. 7 - 26
7-5 RPM Adjustment........................................................................................... 7 - 26
7-6 Flex Plate...................................................................................................... 7 - 26
7-7 Water Temperature and Oil Pressure Gauges.............................................. 7 - 27
7-8 Vacuum Switch ............................................................................................. 7 - 27
Ground Controls
8-1 Control Relays .............................................................................................. 7 - 28
8-2 Toggle Switches, See 1-5, Toggle Switches................................................... 7 - 9
8-3 Wago®Components...................................................................................... 7 - 29
8-4 Resistor ........................................................................................................ 7 - 29
8-5 Power Relay ................................................................................................. 7 - 30
Hydraulic Pumps
9-1 Lift/Steer Pump ............................................................................................. 7 - 31
9-2 Drive Pump ................................................................................................... 7 - 31
Function Manifolds
10-1 Function Manifolds........................................................................................ 7 - 34
10-2 Valve Adjustments - Function Manifold......................................................... 7 - 37
Fuel and Hydraulic Tanks
11-1 Hydraulic Tank.............................................................................................. 7 - 40
11-2 Fuel Tank...................................................................................................... 7 - 41
Turntable Rotation Components
12-1 Rotation Hydraulic Motor .............................................................................. 7 - 42
12-2 Turntable Rotation Manifold Components .................................................... 7 - 44
2WD Steering Axle Components
13-1 Yoke and Hub ............................................................................................... 7 - 45
13-2 Steering Cylinders ........................................................................................ 7 - 46
13-3 Tie Rod Cylinder ........................................................................................... 7 - 47

Genie S-80 & Genie S-85 Part No. 34032
Service Manual - First Edition
TABLE OF CONTENTS
xii
Section Seven Repair Procedures, continued
4WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 48
14-2 Steering Cylinders ........................................................................................ 7 - 49
14-3 Tie Rod Cylinder ........................................................................................... 7 - 49
Extendable Axle Components
15-1 Extendable Axle............................................................................................ 7 - 50
15-2 Drive Chassis Hydraulic Jacks...................................................................... 7 - 51
15-3 Hydraulic Limit Switches ............................................................................... 7 - 52
15-4 Chassis Jack / Axle Manifolds ...................................................................... 7 - 53
Steer Manifold
16-1 Steer Manifold Components ......................................................................... 7 - 54
Non-steering Axle Components
17-1 Drive Motor ................................................................................................... 7 - 55
17-2 Torque Hub................................................................................................... 7 - 55
2WD Drive Manifold
18-1 2WD Drive Manifold Components................................................................. 7 - 56
18-2 Valve Adjustments ........................................................................................ 7 - 57
4WD Drive Manifold
19-1 4WD Drive Manifold Components................................................................. 7 - 58
19-2 Valve Adjustments ........................................................................................ 7 - 60

Part No. 34032 Genie S-80 & Genie S-85 2 - 1
Section 2 - SpecificationsService Manual - First Edition
Specifications
Machine Specifications
Stowed dimensions S-80 S-85
Length 36 ft 8 in 40 ft 7 in
11.2 m 12.4 m
Width, axles retracted 7 ft 111/2in 7 ft 111/2in
2.43 m 2.43 m
Width, axles extended 10 ft 10 ft
3.0 m 3.0 m
Height 9 ft 2 in 9 ft 2 in
2.79 m 2.79 m
Weight 33,380 lbs 35,860 lbs
15,141 kg 16,266 kg
Ground clearance 11 in 11 in
28 cm 28 cm
Operational dimensions
Maximum platform height 80 ft 85 ft
24.4 m 25.9 m
Maximum horizontal reach 71 ft 11 in 76 ft 11 in
21.9 m 23.4 m
Maximum turntable tailswing 3 ft 81/2in 3 ft 81/2in
113.0 cm 113.0 cm
Wheelbase 9 ft 0 in 9 ft 0 in
2.7 m 2.7 m
Minimum turning circle, 23 ft 1 in 23 ft 1 in
outside (axles extended) 7.0 m 7.0 m
Minimum turning circle, 10 ft 71/2in 10 ft 71/2in
inside (axles extended) 3.2 m 3.2 m
Turntable rotation continuous continuous
Platform rotation 160°160°
Maximum capacity 600 lbs 500 lbs
6 foot platform 272 kg 227 kg
Maximum capacity 500 lbs 500 lbs
8 foot platform 227 kg 227 kg
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
Platform dimensions 6 ft 8 ft
(Standard) (Optional)
Length 6 ft 8 ft
1.83 m 2.44 m
Width 30 in 36 in
76.2 cm 91.4 cm
Tires and wheels
Tire size 15-22.5 SAT
Tire ply rating 16
Tire contact area 113 sq in
729 sq cm
Overall tire diameter 43.3 in
110 cm
Tire pressure 100 psi
6.89 bar
Wheel diameter 22.5 in
57.1 cm
Wheel width 11.75 in
29.8 cm
Wheel lugs 10 @ 3/4 -16
Lug nut torque, dry bolts 420 ft-lbs
569.5 Nm
Lug nut torque, wet bolts 320 ft-lbs
433.9 Nm
Fluid capacities
Fuel tank 30 gallons
114 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 55 gallons
(including tank) 208 liters
Drive torque hub 50 fl oz
1.47 liters
Steer torque hub (4WD) 44 fl oz
1.30 liters
Turntable rotation 44 fl oz
torque hub 1.30 liters

2 - 2 Genie S-80 & Genie S-85 Part No. 34032
Section 2 - Specifications Service Manual - First Edition
PERFORMANCE SPECIFICATIONS
Boom function speeds, minimum/maximum
from platform controls
Jib Boom up 40 to 60 seconds
Jib Boom down 50 to 80 seconds
Boom up 90 to 120 seconds
Boom down 90 to 120 seconds
Boom extend 140 to 170 seconds
Boom retract 80 to 110 seconds
Turntable rotate - 360°
boom fully stowed 80 to 120 seconds
Turntable rotate - 360°
boom extended 210 to 240 seconds
Platform rotate - 160°10 to 20 seconds
Platform level up 35 to 65 seconds
Platform level down 25 to 55 seconds
Performance Specifications
Drive speeds, maximum 2WD 4WD
Boom stowed 3.8 mph 3.1 mph
Gasoline/LPG models 6.1 km/h 4.9 km/h
40 ft/7.2 sec 40 ft/8.8 sec
12.2 m/7.2 sec12.2 m/8.8 sec
Boom stowed 3.3 mph 3 mph
Deutz diesel models 5.3 km/h 4.8 km/h
40 ft/8.3 sec 40 ft/9.1 sec
12.2 m/8.3 sec12.2 m/9.1 sec
Boom raised or extended 0.68 mph 0.68 mph
All models 1.1 km/h 1.1 km/h
40 ft/40 sec 40 ft/40 sec
12.2 m/40 sec 12.2 m/40 sec
Gradeability (boom stowed) 2WD 4WD
Rough terrain 30% 38%

Part No. 34032 Genie S-80 & Genie S-85 2 - 3
Section 2 - SpecificationsService Manual - First Edition
HYDRAULIC SPECIFICATIONS
Hydraulic Specifications
Hydraulic fluid Dexron II equivalent
Drive pump
Type: bi-directional variable displacement piston pump
Displacement - 2500 rpm 0 to 30.3 gallons per minute
0 to 114.7 liters per minute
Maximum drive pressure 3500 psi
241.3 bar
Charge pressure
neutral position 360 psi 25 bar
drive position 250 psi 17 bar
Medium pressure filter 3 micron
Medium pressure filter 50 psi
bypass pressure 3.4 bar
Drive manifold
Brake 250 psi
relief pressure 17.2 bar
Steer end drive motors 4WD models
Displacement 1.52 cu in
per revolution 25 cc
Non-steer end drive motors
Displacement per revolution, variable 0.16 to 2.8 cu in
4WD (2 speed motor) 2.62 to 45.9 cc
Displacement per revolution, variable 1.12 to 2.8 cu in
2WD 18.4 to 45.9 cc
Function pump
Type: pressure balanced gear
Displacement - static 1.14 cu in
19 cc
Displacement - 2500 rpm 0 to 12.3 gallons per minute
0 to 46.6 liters per minute
Hydraulic tank circuit 10 micron with 25 psi
return line filter (1.7 bar) bypass
Function manifold
Function relief 3000 psi
valve pressure 207 bar
Boom down 2300 psi
relief valve pressure 159 bar
Boom extend 1950 psi
134 bar
Steer/axle extend 5 gallons per minute
flow regulator 18.9 liters per minute
Steer regulator 3.5 gallons per minute
13.2 liters per minute
Axle and jack cylinder pressure 2500 psi
172 bar
Auxiliary pump
Type: fixed displacement gear pump
Displacement - static 0.152 cu in
2.5 cc
Displacement 1.4 gallons per minute
5.3 liters per minute
Auxiliary pump 3000 psi
relief pressure 207 bar

2 - 4 Genie S-80 & Genie S-85 Part No. 34032
Section 2 - Specifications Service Manual - First Edition
BOLT TORQUE SPECIFICATIONS
24
32
20
28
18
24
16
24
14
20
Torque - Dry
inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters Torque - Dry inch-pounds Torque - Dry foot-pounds Torque - Dry Newton meters
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
5
6
11
14
23
28
41
48
68
75
102
122
149
163
204
231
353
407
583
637
868
949
60
68
144
168
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
7
8
16
19
34
34
61
68
95
109
149
163
204
231
298
326
515
570
814
895
1221
1356
Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
Bolt Torque Specifications
13
20
12
18
11
18
10
16
9
14
8
12
No. 10
1/4 inch
5/16 inch
3/8 inch
7/16 inch
1/2 inch
9/16 inch
5/8 inch
3/4 inch
7/8 inch
1 inch
Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

Part No. 34032 Genie S-80 & Genie S-85 2 - 5
Section 2 - SpecificationsService Manual - First Edition
FORD ENGINE LSG-423 SPECIFICATIONS
Ford Engine LSG-423
Displacement 140 cu in
2.3 liters
Number of cylinders 4
Bore & stroke 3.780 x 3.126 inches
96 x 79.4 mm
Horsepower 63 @ 4000 rpm
Firing order 1 - 3 - 4 - 2
Low idle - carburetor 900 rpm
Low idle - electronic governor 1600 rpm
High idle 2500 rpm
Governor electronic
Compression ratio 9.5:1
Compression pressure (approx.) 150 to 175 psi
10 to 12 bar
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances 0.040 to 0.050 inches
1.0 to 1.3 mm
Lubrication system
Oil pressure 40 to 60 psi
(operating temp. @ 2500 rpm) 2.75 to 4.1 bar
Oil capacity 5 quarts
(including filter) 4.7 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C 5W-30
-10°F to 90°F / -23°C to 32°C 10W-30
Temperature above 10W-40 to 10W-50
-10°F / -23°C
Temperature above 20W-40 or 20W-50
25°F / -4°C
Use oils meeting API classification SG (labeled SG/CC
or SG/CD) as they offer improved wear protection.
(units ship with 10W-40 SG/CC)
Starter motor
Normal engine cranking speed 110 rpm
Current draw, normal load 150A
Current draw, maximum load 460A
Current draw, no load 70A
Maximum circuit voltage drop 0.5V DC
while starting (normal temperature)
Brush length, new 0.50 in
12.7 mm
Brush length wear limit 0.25 in
6.35 mm
Brush spring tension 40 ounces
11 Newtons
Bolt torque 55 to 75 inch-pounds
through brush 6 to 8.5 Nm
Brush mounting 15 to 20 foot-pounds
bolt torque 20 to 27 Nm
Maximum commutator 0.005 inches
run-out 0.127 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fuel pump
Static pressure 5 to 7 psi
0.34 to 0.48 bar
Minimum volume flow 1 pint
(in 25 seconds) 473 cc

2 - 6 Genie S-80 & Genie S-85 Part No. 34032
Section 2 - Specifications Service Manual - First Edition
FORD ENGINE LSG-423 SPECIFICATIONS
Ignition System
Ignition spark advance 10°BTDC
Ignition coil primary 1.13 to 1.25W
resistance @ 75°F / 24°C
Ignition coil secondary 7700 to 9300W
resistance @ 75°F / 24°C
Spark plug type Motorcraft AWSF-52
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.18 mm
Engine coolant
Capacity 11.5 quarts
10.9 liters
Alternator
Output 35A, 14.5V
Fan belt deflection 3/8to 1/2inch
9 to 12 mm
Bolt torque specifications torque torque
Bolt description (size) ft-lbs Nm
Auxiliary shaft gear bolt (M-10) 28 to 40 38 to 54
Auxiliary shaft thrust 6 to 9 8 to 12
plate bolt (M-6)
Timing belt tensioner 28 to 40 38 to 54
pivot bolt (M-10)
Timing belt tensioner 14 to 21 19 to 28
adjusting bolt (M-8)
Camshaft gear bolt (M-12) 50 to 71 68 to 96
Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12
Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20
Carburetor spacer to 10 to 14 14 to 19
manifold bolt (M-8)
Crankshaft damper 103 to 133 140 to 180
bolt (M-14)
Cylinder head bolt (M-12): torque in sequence
first step 50 to 60 68 to 81
second step 80 to 90 108 to 122
Bolt torque specifications torque torque
Bolt description (size) ft-lbs Nm
Distributor clamp bolt (M-10) 14 to 21 19 to 28
Distributor vacuum tube 5 to 8 7 to 11
to manifold adaptor
Exhaust manifold to cylinder head bolt or nut (M-10):
torque in sequence
first step 14 to 19 19 to 26
second step 20 to 30 27 to 41
Flywheel to crankshaft 56 to 64 76 to 87
bolt (M-10)
Fuel pump to cylinder 14 to 21 19 to 28
block (M-8)
Intake manifold to 14 to 21 19 to 28
cylinder head bolt or nut (M-8)
Oil pressure sending unit to block 8 to 18 11 to 24
Oil pan drain plug to pan (M-14) 15 to 25 20 to 34
Oil pan to block (M-6) 10 to 13.5 14 to 18
Oil filter insert to block 20 to 35 27 to 47
Rocker arm cover to 5 to 8 7 to 11
cylinder head (M-6)
Spark plug to cylinder 5 to 10 7 to 14
head (M-14)
Temperature sending 8 to 18 11 to 24
unit to block (M-14)
Water jacket drain plug to block 23 to 28 31 to 38
Water pump to block bolt (M-8) 14 to 21 19 to 28
Auxiliary shaft cover bolt (M-6) 6 to 9 8 to 12
Water outlet connection 14 to 21 19 to 28
bolt (M-8)
Cylinder front cover bolt (M-6) 6 to 9 8 to 12
Inner timing belt cover 14 to 21 19 to 28
stud (M-8)
Outer timing belt cover 6 to 9 8 to 12
bolt (M-6)

Part No. 34032 Genie S-80 & Genie S-85 2 - 7
Section 2 - SpecificationsService Manual - First Edition
DEUTZ ENGINE F4L 1011 SPECIFICATIONS
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement diesel number 2-D
Alternator output 55A, 14V
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in
19 mm
Brush length, minimum 0.5 in
12.7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8to 1/2inch
9 to 12 mm
Bolt tightening specifications torque torque
Bolt description (size, grade) ft-lbs Nm
Camshaft/thrust bearing bolt 15 to 18 20 to 24
(M-8 x 35, 8.8)
Rocker arm bolts 15 to 18 20 to 24
(M-8 x 45, 8.8)
Rocker arm set screw nut 15 to 18 20 to 24
Cylinder head cover 6 to 7 8 to 10
Blower rotor nut 33 to 41 45 to 55
(M-17 Valeo or M-18 Bosch)
Blower carrier bolts 15 to 18 20 to 24
(M-8 x 50 Torx, 8.8)
V-belt pulley bolts 28 to 34 38 to 46
(M-10 x 16, 8.8)
Deutz Engine F4L 1011
Displacement 166.7 cu in
2.732 liters
Number of cylinders 4
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 56 @ 3000 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1300 rpm
High idle 2300 rpm
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 26 to 87 psi
1.8 to 6.0 bar
Oil capacity 11 quarts
(including filter) 10.5 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification
CC/SG or CD/SG grades.
(units ship with 10W-40 SG/CC)
Injection system
Injection pump make OMAP

2 - 8 Genie S-80 & Genie S-85 Part No. 34032
Section 2 - Specifications Service Manual - First Edition
DEUTZ ENGINE F4L 1011 SPECIFICATIONS
Bolt tightening specifications, continued
torque torque
Bolt description (size, grade) ft-lbs Nm
Idler pulley/V-belt pulley bolt 27 to 32 36 to 44
(M-10 x 25, 8.8)
Idler pulley for toothed belt 30 to 36 41 to 49
(M-10 x 50, 8.8)
Oil pump bolts 15 to 18 20 to 24
(M-8 x 35 Torx)
Oil filter bracket bolts 7 to 8 9 to 11
(M-8 x 20 Torx, 8.8)
Oil intake housing bolts 15 to 18 20 to 24
(M-8 x 75 Torx)
Fuel pump bolts 15 to 18 20 to 24
Injection pump bolts 15 to 18 20 to 24
Injector cap nut 30 to 37 40 to 50
Injector fastening bolt 15 to 18 20 to 24
Injection line 10 to 12 13.5 to 16.5
Air intake manifold bolts 15 to 18 20 to 24
(M-8 x 30, 8.8)
Air intake manifold, 3-hole 15 to 18 20 to 24
flange bolts (M-8 x 35 Torx, 8.8)
Exhaust manifold bolts 27 to 32 36 to 44
(M-10 x 30 Torx, 10.9)
Starter fastening bolts 28 to 34 38 to 46
(M-10 x 28, 8.8)
Starter carrier bolts 50 to 60 68 to 82
(M-12 x 28, 8.8)
Oil pan bolts 15 to 18 20 to 24
(M-8 x 16 Torx, 8.8)
Oil drain bolts 37 to 44 50 to 60
torque torque
ft-lbs Nm
Oil thermostat housing screw 37 to 44 50 to 60
plug (M-38 x 1.5)
Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 35 Torx, 8.8)
Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 80 Torx, 8.8)
Oil thermostat housing bolts 14 to 16 19 to 22
(M-6 x 105 Torx, 8.8)
Valve plunger housing bolts 14 to 16 19 to 22
(M-8 x 30 Torx, 8.8)
Alternator nuts (M-5) 3 4
Fuel bracket bolts (M-8 x 20, 8.8) 15 20
Adapter housing bolts 70 to 77 95 to 105
(M-12 x 35, 10.9 or M-12 x 75, 10.9)
first step second step
tightening tightening
torque angles
ft-lbs Nm 1st 2nd
Main bearing bolts 37 50 60°45°
Big end bolts 22 30 60°60°
Flywheel bolts 22 30 60°30°
Cylinder head step 1 22 30
studs step 2 59 80
step 3 118 160 120°NA
Camshaft/central bolt 22 30 150°NA
Crankshaft/central bolt 96 130 210°NA