Genie S-80 Service Manual
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Genie S-80 Service Manual

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

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  • Page 1 Technical Publications S-80 ® S-85 ® Service Manual S-85 S-80 First Edition, First Printing Part No. 34032...

  • Page 2: Introduction

    Telephone (206) 881-1800 Read, understand and obey the safety rules and Toll Free in U.S.A. 800 536-1800 operating instructions in the Genie S-80 & Genie Toll Free in Canada 800 426-8089 S-85 Operator's Manual before attempting any Fax (206) 883-3475 maintenance or repair procedure.

  • Page 3: Safety Rules

    Section 1 - Safety Rules 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...
  • Page 4 Be sure to properly dispose of old oil or such as moving parts, free swinging or other fluids. Use an approved container. unsecured components, and lifting or Please be environmentally safe. placing loads. Always wear approved steel-toed shoes. Genie S-80 & Genie S-85 Part No. 34032...

  • Page 5: Table Of Contents

    Check the Engine Coolant Level - Gasoline/LPG Models ....... 4 - 3 Check for Fuel Leaks ..................4 - 3 Check the Hydraulic Oil Level ................. 4 - 4 Check for Hydraulic Leaks ................4 - 4 Part No. 34032 Genie S-80 & Genie S-85...
  • Page 6 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 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ..4 - 44 Check the Toothed Belt - Deutz Diesel Models ..........4 - 44 Replace the Timing Belt - Gasoline/LPG Models .......... 4 - 44 Part No. 34032 Genie S-80 & Genie S-85...
  • Page 8 Turntable Rotate Right Function Inoperative ..........5 - 41 All Platform Leveling Functions Inoperative ..........5 - 42 Platform Level Up Function Inoperative ............5 - 43 Platform Level Down Function Inoperative ........... 5 - 44 Genie S-80 & Genie S-85 Part No. 34032 viii...
  • Page 9 Platform Control Box Legend - Diesel Models ............6 - 11 Hydraulic Symbols Legend ..................6 - 12 2WD Hydraulic Schematic ..................6 - 13 4WD Hydraulic Schematic ..................6 - 14 Part No. 34032 Genie S-80 & Genie S-85...
  • Page 10 RPM Adjustment ................... 7 - 23 Flex Plate ...................... 7 - 23 Oil Temperature and Oil Pressure Gauges ........... 7 - 23 Ford LSG-423 Engine Governor Actuator ..................7 - 24 Choke Adjustments ..................7 - 25 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 11 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 Part No. 34032 Genie S-80 & Genie S-85...
  • Page 12 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 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 13: Specifications

    8 foot platform 227 kg 227 kg Steer torque hub (4WD) 44 fl oz 1.30 liters Continuous improvement of our products is a Genie policy. Product specifications are subject to change Turntable rotation 44 fl oz without notice. torque hub 1.30 liters...

  • Page 14: Performance Specifications

    210 to 240 seconds Gradeability (boom stowed) Platform rotate - 160° 10 to 20 seconds Rough terrain Platform level up 35 to 65 seconds Platform level down 25 to 55 seconds 2 - 2 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 15: Hydraulic Specifications

    Displacement - static 0.152 cu in 18.4 to 45.9 cc 2.5 cc Displacement 1.4 gallons per minute 5.3 liters per minute Auxiliary pump 3000 psi relief pressure 207 bar Part No. 34032 Genie S-80 & Genie S-85 2 - 3...

  • Page 16: Bolt Torque Specifications

    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. 2 - 4 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 17: Ford Lsg 423 Engine Specifications

    (in 25 seconds) 473 cc 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) Part No. 34032 Genie S-80 & Genie S-85 2 - 5...
  • Page 18 Cylinder head bolt (M-12): torque in sequence Outer timing belt cover 6 to 9 8 to 12 first step 50 to 60 68 to 81 bolt (M-6) second step 80 to 90 108 to 122 2 - 6 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 19 (M-8 x 50 Torx, 8.8) (units ship with 10W-40 SG/CC) V-belt pulley bolts 28 to 34 38 to 46 Injection system (M-10 x 16, 8.8) Injection pump make OMAP Part No. 34032 Genie S-80 & Genie S-85 2 - 7...

  • Page 20: Deutz F4L Engine Specifications

    Crankshaft/central bolt 210° (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 2 - 8 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 21: Scheduled Maintenance Inspections

    The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. Part No. 34032 Genie S-80 & Genie S-85 3 - 1...
  • Page 22 Check the Tire Pressure A-10 Test the Extendable Axles A-11 Test the Platform and Ground Controls A-12 Test the Auxiliary Power Operation A-13 Test the Tilt Sensor A-14 Test the Limit Switches 3 - 2 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 23 Confirm the Proper Brake Configuration B-10 Check the Oil Level in the Torque Hubs B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models B-12 Check and Adjust the Engine RPM Part No. 34032 Genie S-80 & Genie S-85 3 - 3...
  • Page 24 See D-1 Test or Replace the Hydraulic Oil B-26 Check the Hydraulic Limit Switch Linkage Every 500 hours, perform the following engine maintenance procedure. B-27 Replace the Engine Oil and Filter - Deutz Diesel Models 3 - 4 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 25 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models C-15 Check and Adjust the Ignition Timing - Gasoline/LPG Models C-16 Check the Engine Valve Clearances - Deutz Diesel Models C-17 Adjust the Turntable Backlash Part No. 34032 Genie S-80 & Genie S-85 3 - 5...
  • Page 26 Clean the PCV Hoses and Fittings - Gasoline/LPG Models Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models Check the Toothed Belt - Deutz Diesel Models Replace the Timing Belt - Gasoline/LPG Models 3 - 6 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 27: Maintenance Inspection Report

    B-14 Emergency Stop D-5 Compression-gasoline B-15 Ground control override D-6 PCV hoses-gasoline B-16 Platform leveling D-7 Fuel injection-Deutz B-17 Service horn D-8 Toothed belt-Deutz B-18 Foot switch D-9 Timing belt-Ford Part No. 34032 Genie S-80 & Genie S-85 3 - 7...
  • Page 28 Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition Warm Cold Dealer Tools are New parts engine engine service required required required required suggested This page intentionally left blank. 3 - 8 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 29: Scheduled Maintenance Procedures

    · turntable rotated with the boom between the non-steering wheels · turntable secured with the turntable rotation lock pin · key switch in the position with the key removed · wheels chocked Part No. 34032 Genie S-80 & Genie S-85 4 - 1...

  • Page 30: Inspect The Manuals

    · cracks in welds or structural components 1 Refer to the Decals section in the Genie S-80 & Genie S-85 Operator's Manual · compartment covers and latches and use the decal list and illustrations to determine that all decals and placards are in place.

  • Page 31: Check The Engine Oil Level

    -10°F to 90°F / -23°C to 32°C 10W-40 gas (LPG) tank by turning it counterclockwise. above -4°F / -34°C 15W-40 Engine oil should have properties of API classification CC/SG or CD/SG grades. Part No. 34032 Genie S-80 & Genie S-85 4 - 3...

  • Page 32: Check The Hydraulic Oil Level

    2 inches (5 cm) of the sight gauge. Hydraulic oil specifications Hydraulic oil type Dexron II equivalent Tank capacity 45 gallons 170 liters Hydraulic system 55 gallons (including tank) 208 liters 4 - 4 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 33: Check The Tire Pressure

    7 Return the chassis jack control handle to the neutral position. Result: The lift jack cylinder should fully retract when the control handle is returned to neutral. Part No. 34032 Genie S-80 & Genie S-85 4 - 5...

  • Page 34: Test The Platform And Ground Controls

    Result: No function should operate, the engine Result: Each function should operate smoothly. should stop. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. 4 - 6 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 35: Test The Tilt Sensor

    Result: Each function should operate smoothly. Auxiliary power will not lift the boom past the drive limit switch unless the axles are fully extended. fuel tank tilt sensor ground control box Part No. 34032 Genie S-80 & Genie S-85 4 - 7...

  • Page 36: Test The Limit Switches

    Result: The machine should move at a reduced drive speed. drive limit switch boom Drive speed, maximum, raised or extended extension cylinder master cylinder All models 1 foot per second 0.3 meter per second 4 - 8 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 37 7 Lower the boom to the stowed position. 8 Extend the steer axle. 9 Raise the boom. Result: The boom should continue to raise to full height after the drive limit switch is activated. Part No. 34032 Genie S-80 & Genie S-85 4 - 9...

  • Page 38: Replace The Engine Oil And Filter - Gasoline/Lpg Models

    6 Use an oil filter wrench and remove the filter. 7 Apply a thin layer of oil to the new oil filter gasket (filter part no. 28656). Then install the filter and tighten it securely by hand. 4 - 10 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 39: Replace The Engine Air Filter

    10W-40 or 10W-50 5 Replace the end cap on the canister. above 25F / -4C 20W-40 or 20W-50 Air filters - Genie part numbers Use oils meeting API classification SG (labeled SG/CC Ford LSG-423 Engine 27916 or SG/CD) as they offer improved wear protection.

  • Page 40: Check The Engine Belt(S)

    Belt deflection - all models inch to inch Beware of hot engine 9 mm to 12 mm components. Contact with hot engine components may cause severe burns. 4 - 12 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 41: Check The Exhaust System

    6 Inspect the head cooling passages and fins for physical damage or foreign material, using a flashlight. 7 Clean the cylinder head cooling passages of debris and foreign material. engine pivot plate pivot plate retaining bolts Part No. 34032 Genie S-80 & Genie S-85 4 - 13...

  • Page 42: Check The Battery

    Do not overfill. filter should be replaced. See C-7, Replace the 6 Install the vent caps. Hydraulic Tank Filter. 4 - 14 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 43: Inspect The Electrical Wiring

    · inside of the platform control box Wheel lugs 10 @ · jib boom cable track (S-85 models) Lug nut torque, dry 420 ft-lbs 569.5 Nm Lug nut torque, wet 320 ft-lbs 433.9 Nm Part No. 34032 Genie S-80 & Genie S-85 4 - 15...

  • Page 44: Confirm The Proper Brake Configuration

    The free-wheel valve should Capacity 50 fl oz 44 fl oz always remain closed. 1.47 liters 1.30 liters Type: SAE 90 multipurpose hypoid gear oil - APIservice classification GL5 4 - 16 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 45: Check And Adjust The Engine Idle Mixture - Gasoline/Lpg Models

    Turntable rotate torque hub oil Capacity 44 fluid ounces 1.30 liters Type SAE 90 multipurpose hypoid gear oil - API service classification GL5 Part No. 34032 Genie S-80 & Genie S-85 4 - 17...
  • Page 46 1 Connect an rpm gauge to the engine, and then start the engine from the ground controls. Result: Low idle should be 1300 rpm. Skip to step 3 if the low idle rpm is correct. 4 - 18 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 47: Test The Key Switch

    The solenoid fully retracts, when activating high engine will shut off after 2 to 3 idle. seconds. Deutz Diesel models Low idle 1300 rpm High idle 2300 rpm Part No. 34032 Genie S-80 & Genie S-85 4 - 19...

  • Page 48: Test The Emergency Stop Buttons

    2 Adjust the platform to a level position using the platform leveling switch. 3 Raise and lower the boom through a full cycle. Result: The platform should remain level at all times to within ±5 degrees. 4 - 20 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 49: Test The Service Horn

    High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions simultaneously. This setting maintains a consistent high idle and is usually selected only when the generator option is being used. Part No. 34032 Genie S-80 & Genie S-85 4 - 21...

  • Page 50: Test The Fuel Select Operation - Gasoline/Lpg Models

    Low idle 1300 rpm fuel source is switched while the engine is running. High idle 2300 rpm 4 - 22 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 51: Test The Drive Enable System

    Result: The drive enable indicator light should come on. The brakes must be able to hold 6 Repeat steps 3 and 4. the machine on any slope it is able to climb. Part No. 34032 Genie S-80 & Genie S-85 4 - 23...

  • Page 52: Test The Drive Speed - Stowed Position

    DOWN 12.2 m/7.2 sec 12.2 m/8.8 sec moment and then release it. Deutz Diesel models 40 ft/8.3 sec 40 ft/9.1 sec 12.2 m/8.3 sec 12.2 m/9.1 sec 4 - 24 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 53: Perform Hydraulic Oil Analysis

    See D-1, Test or Replace the Hydraulic Oil. lock nut linkage rod spring valve actuator limit switch valve If the linkage functioning incorrectly, See 15-3, How to Set Up the Hydraulic Limit Switch Linkage. Part No. 34032 Genie S-80 & Genie S-85 4 - 25...

  • Page 54: Replace The Engine Oil And Filter - Deutz Diesel Models

    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. 4 - 26 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 55: Check The Boom Wear Pads

    Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions. Part No. 34032 Genie S-80 & Genie S-85 4 - 27...

  • Page 56: Check The Free-Wheel Configuration

    Collision hazard. Select a work site that is firm and level. 4 - 28 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 57: Grease The Turntable Rotation Bearing And Rotate Gear

    2 Remove both plugs and drain the oil. screwdriver lift pump The free-wheel valve should always remain closed. Part No. 34032 Genie S-80 & Genie S-85 4 - 29...
  • Page 58 4 Remove the plug from the side of the torque hub. Then drain the oil from the hub. 4 - 30 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 59: Replace The Hydraulic Tank Filter

    4 Start the engine from the ground controls. 5 Inspect the filter and related components to be sure that there are no leaks. Part No. 34032 Genie S-80 & Genie S-85 4 - 31...

  • Page 60: Replace The Diesel Fuel Filter - Deutz Diesel Models

    Always have an approved fire extinguisher within easy reach. Perform this procedure with the fuel filter engine off. oil filter 4 - 32 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 61 Repair the leak immediately. 6 Swing the engine pivot plate back to its original position and replace the two retaining bolts. Part No. 34032 Genie S-80 & Genie S-85 4 - 33...

  • Page 62: Replace The Pcv Valve - Gasoline/Lpg Models

    Extremely dirty conditions may require that the cap and rotor be replaced more often. Perform this procedure with the engine off. 4 - 34 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 63: Replace The Spark Plugs - Gasoline/Lpg Models

    8 Swing the engine pivot plate back to its original position and replace the two retaining bolts. 9 Start the engine from the ground controls and check the engine for proper operation. Part No. 34032 Genie S-80 & Genie S-85 4 - 35...

  • Page 64: Check And Adjust The Air/Lpg Mixture - Gasoline/Lpg Models

    Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw high idle mixture counterclockwise 2 turns. adjustment screw 4 - 36 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 65: Check And Adjust The Ignition Timing - Gasoline/Lpg Models

    Turntable Rotation Gear Clearances - Deutz Diesel Models Backlash. Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual (Deutz Number 02611642). Genie part number 29789. Part No. 34032 Genie S-80 & Genie S-85 4 - 37...

  • Page 66: Test Or Replace The Hydraulic Oil

    CLOSED component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 - 38 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 67: Change Or Recondition The Engine Coolant - Gasoline/Lpg Models

    Check the hydraulic tank for leaks. Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity (including tank) 208 liters Hydraulic fluid Dexron ll equivalent Part No. 34032 Genie S-80 & Genie S-85 4 - 39...
  • Page 68 Add water if needed. 9 Pour the proper coolant mixture (anti-freeze and water) for your climate into the radiator Ford Engine LSG-423 11.5 quarts Coolant capacity 10.9 liters until it is full. 4 - 40 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 69: Change The Fuel Lines

    Part No. 34032 Genie S-80 & Genie S-85 4 - 41...

  • Page 70: Check The Engine Valve Clearance - Gasoline/Lpg Models

    If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 4 - 42 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 71: Clean The Pcv Hoses And Fittings - Gasoline/Lpg Models

    3 Clean the hoses with a mild cleaning solvent. 4 Dry both hoses and inspect them for cracks and damage. Replace the hoses if they are damaged. pivot plate retaining bolts engine pivot plate Part No. 34032 Genie S-80 & Genie S-85 4 - 43...

  • Page 72: Check The Fuel Injection Pumps And Injectors - Deutz Diesel Models

    Injectors - Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual (Deutz number: 0291 1942). Genie part number 29789. Check the Toothed Belt - Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Operation Manual (Deutz number: 0297 4706 EN).
  • Page 73 Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures Part No. 34032 Genie S-80 & Genie S-85 4 - 45...
  • Page 74 Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-80 & Genie S-85 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate flow chart thoroughly.
  • Page 75 When a function will not operate with the same speed or power as a machine in good working condition, refer to the flow chart which most closely describes the problem. 5 - 2 Genie S-80 & Genie S-85 Part No. 34032...
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  • Page 78: Gasoline/Lpg Models

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  • Page 85: Engine Cranks Over But Will Not Start - Deutz Diesel Models

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  • Page 86 RUIQU[Z SUJ[RK 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ )NKIQ MXU[TJ ZU TU MUUJ 8KVGOX UVKT OT MXU[TJ ZKXSOTGR  UT )8 ]OXK ZU )8 MUUJ )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 13...
  • Page 87 -KTOK /TJ[YZXOKY 9KX\OIK INKIQ \URZGMK GZ *KVGXZSKTZ ZKXSOTGR  < < 8KVGOX VUYOZO\K YNUXZ OT XKJ ]OXK IOXI[OZ LXUS :( 8KVRGIK YZGXZ RUIQU[Z SUJ[RK 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 14 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 88: Engine Will Not Start On Lpg, But Will Start On Gasoline Gasoline/Lpg Models

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  • Page 89 )NKIQ XKYOYZGTIK UL UNSY 26- YURKTUOJ 8KVRGIK 26- YURKTUOJ  ZU  UNSY 8KIUTTKIZ 26- ZGTQ GTJ YZGXZKX ZNKT YKK 3GOTZKTGTIK YKIZOUT LUX 26- GJP[YZSKTZY 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 16 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 90: Engine Will Not Start On Gasoline, But Will Start On Lpg Gasoline/Lpg Models

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  • Page 91 )NKIQ XKYOYZGTIK UL 8KVRGIK GTZOJOKYKR GTZOJOKYKR \GR\K \GR\K  ZU  UNSY 8KIUTTKIZ YZGXZKX INKIQ GTZOJOKYKR GTJ L[KR \GR\K LUX JKLKIZY 58 YKK ,UXJ YKX\OIK SGT[GR LUX IGXH[XKZUX ZXU[HRKYNUUZOTM 5 - 18 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 92: Engine High Idle Inoperative - Gasoline/Lpg Models

    UT VXKIOYOUT MU\KXTUX < < )NKIQ \URZGMK GZ 8KVGOX UVKT OT ]NZ ]OXK ZKXSOTGR  UT )8 IOXI[OZ LXUS )8 ZKXSOTGR  ZU )8 < )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 19...
  • Page 93 ]OXK IOXI[OZ LXUS OMTOZOUT GTJ INKIQ \URZGMK GZ SUJ[RK ZU KRKIZXUTOI KRKIZXUTOI MU\KXTUX MU\KXTUX ZKXSOTGR  HXU]T ]OXK  ZU < 9KK 3GOTZKTGTIK YKIZOUT LUX MU\KXTUX GJP[YZSKTZY 58 XKVRGIK KRKIZXUTOI MU\KXTUX 5 - 20 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 94: Engine Low Idle Inoperative - Gasoline/Lpg Models

    INKIQ GTJUX XKVRGIK KRKIZXUTOI MU\KXTUX GTJ MU\KXTUX GIZ[GZUX 58 XKYZGXZ KTMOTK YKK ,UXJ YKX\OIK SGT[GR LUX IGXH[XKZUX ZXU[HRKYNUUZOTM KTMOTK MUKY ZU RU] OJRK 8KINKIQ KRKIZXUTOI MU\KXTUX GJP[YZSKTZY 58 XKVRGIK KRKIZXUTOI MU\KXTUX Part No. 34032 Genie S-80 & Genie S-85 5 - 21...

  • Page 95: Engine High Idle Inoperative - Deutz Diesel Models

    ZKXSOTGR  UT )8 < < )NKIQ \URZGMK GZ OTOZOGZK 8KVGOX UVKT OT HRQXKJ ZKXSOTGR  UT )8 ]OXK IOXI[OZ LXUS )8 ZU )8 < )UTZOT[KJ UT ZNK TK^Z VGMK 5 - 22 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 96 )NKIQ OL YVKKJ )NKIQ ROTQGMK UX HOTJY YURKTUOJ SU\KY OT GTJ XKVRGIK YURKTUOJ U[Z LXKKR_ SU\KY LXKKR_ 8KVRGIK YVKKJ YURKTUOJ 4UZK XKYOYZGTIK GIXUYY YURKTUOJ ZKXSOTGRY YNU[RJ HK GVVXU^OSGZKR_  UNSY Part No. 34032 Genie S-80 & Genie S-85 5 - 23...

  • Page 97: Engine Low Idle Inoperative - Deutz Diesel Models

    SU\KY LXKKR_ )NKIQ GJP[YZSKTZ UL ROTQGMK GTJ L[KR OTPKIZOUT Y_YZKS RU] OJRK 9KK 3GOTZKTGTIK YKIZOUT 9KK *K[Z` ]UXQYNUV SGT[GR ZU ZXU[HRKYNUUZ L[KR OTPKIZOUT Y_YZKS 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 24 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 98: All Functions Inoperative, Engine Starts And Runs

    Y]OZIN GTJ IXGTQ KTMOTK U\KX ]NORK UHYKX\OTM YVROTK JXO\K GZ XKGX UL SGOT V[SV YVROTK JUKY TUZ Z[XT +TMOTK ZU V[SV LRK^ VRGZK IU[VROTM OY JKLKIZO\K 9KK 8KVGOX YKIZOUT Part No. 34032 Genie S-80 & Genie S-85 5 - 25...

  • Page 99: All Lift And Steer Functions Inoperative, Drive Functions Operational

    Be sure axles are fully YZKKXOTM OTUVKXGZO\K extended. )NKIQ ZNK L[TIZOUT 8KVRGIK ZNK XKROKL \GR\K V[SV YKK 8KVGOX 58 SGTOLURJ NGY YKIZOUT OTZKXTGR JKLKIZY IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 8KVRGIK ZNK V[SV 5 - 26 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 100  VYO VXKYY[XK MG[MK VORUZ UVKXGZKJ J[SV HKZ]KKT ZNK N_JXG[ROI \GR\K NUYK ZU VORUZ VUXZ UL ZNK VORUZ UVKXGZKJ J[SV \GR\K RKYY ZNGT  VYO )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 27...
  • Page 101 XKROKL \GR\K 58 XKVGOX 58 XKVRGIK INGYYOY ROLZ PGIQ XKROKL \GR\K 58 XKVGOX 58 XKVRGIK LRU] XKM[RGZUX \GR\K OZKS ' GZ ZNK YZKKX SGTOLURJ 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 28 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 102: Ground Controls Inoperative, Platform Controls Operate Normally

    OTZKXTGR IGS OY IUTZGIZ LUX MXU[TJ IUTZGIZ UT ZNK QK_ GIZO\GZOTM MXU[TJ IUTZXURY Y]OZIN IUTZGIZ < 8KVRGIK QK_ Y]OZIN 8KVGOX UVKT OT XKJ ]OXK IOXI[OZ LXUS QK_ Y]OZIN ZU L[TIZOUT Y]OZINKY Part No. 34032 Genie S-80 & Genie S-85 5 - 29...

  • Page 103: Platform Controls Inoperative, Ground Controls Operate Normally

    )NKIQ \URZGMK GZ :6 8KVGOX UVKT OT HRQ ]OXK IOXI[OZ LXUS KSKXMKTI_ YZUV H[ZZUT ZU :6 < 8KVGOX UVKT OT HRQ ]OXK IOXI[OZ LXUS :6 ZU LUUZ Y]OZIN 58 XKVRGIK LUUZ Y]OZIN 5 - 30 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 104: Boom Up Function Inoperative

     ZU  UNSY /TZKXINGTMK LRU] XKM[RGZUX \GR\K OZKS ? L[TIZOUT UVKXGZKY 8KVRGIK JKLKIZO\K LRU] ]OZN G ROQK \GR\K XKM[RGZUX \GR\K OZKS > L[TIZOUT OTUVKXGZO\K )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 31...
  • Page 105 SGTOLURJ GTJ NURJ ZNK 58 I_ROTJKX L[TIZOUT Y]OZIN IU[TZKXHGRGTIK \GR\K RKYY ZNGT  VYO 8KVGOX I_ROTJKX 58 XKVRGIK I_ROTJKX IU[TZKXHGRGTIK \GR\K 58 SGTOLURJ NGY OTZKXTGR JKLKIZ IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 32 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 106: Boom Down Function Inoperative

    NGY OTZKXTGR JKLKIZY *OYIUTTKIZOTM N_JXG[ROI ROTKY UX GJP[YZOTM ZNK )UTZOT[KJ UT ZNK TK^Z I_ROTJKX IU[TZKXHGRGTIK VGMK \GR\K OT ZNOY YOZ[GZOUT IGT HK \KX_ JGTMKXU[Y 6RKGYK IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 33...
  • Page 107 /TZKXTGR JKLKIZ OT SGTOLURJ 58 UTK UL ZNK VXK\OU[Y ZKYZY OT\UR\OTM ZNK V[SV UX SGTOLURJ IUSVUTKTZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 34 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 108: Boom Extend Function Inoperative

    XKW[OXK Z]U VKUVRK /L G NKRVKX OY TUZ G\GORGHRK 8KVRGIK ZNK \GR\K OTZKXINGTMK ZNK \GR\K OZKS 9 ]OZN G ROQK \GR\K OZKS 6 L[TIZOUT OTUVKXGZO\K )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 35...
  • Page 109 /TZKXTGR JKLKIZ OT SGTOLURJ 58 UTK UL ZNK VXK\OU[Y ZKYZY OT\UR\OTM ZNK V[SV UX SGTOLURJ IUSVUTKTZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 36 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 110: Boom Retract Function Inoperative

    CR16 RKYY ZNGT  VYO relay. See Repair section. 8KVGOX I_ROTJKX 58 XKVRGIK I_ROTJKX IU[TZKXHGRGTIK \GR\K 58 SGTOLURJ NGY OTZKXTGR JKLKIZ IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 37...

  • Page 111: Turntable Rotate Function Inoperative

    XKW[OXK Z]U VKUVRK /L G 8KVRGIK ZNK \GR\K NKRVKX OY TUZ G\GORGHRK OTZKXINGTMK ZNK \GR\K OZKS 6 ]OZN G ROQK \GR\K OZKS 9 L[TIZOUT OTUVKXGZO\K )UTZOT[KJ UT ZNK TK^Z VGMK 5 - 38 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 112 SGTOLURJ GTJ NURJ ZNK 58 INKIQ XUZGZOUT HXGQK L[TIZOUT Y]OZIN 58 INKIQ XUZGZOUT ZUXW[K N[H RKYY ZNGT  VYO 8KVGOX XUZGZOUT SUZUX 58 SGTOLURJ NGY OTZKXTGR JKLKIZ IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 39...

  • Page 113: Turntable Rotate Left Function Inoperative

    MG[MK YZORR GZZGINKJ UVKXGZK ZNK L[TIZOUT 8KVGOX XUZGZOUT SUZUX RKYY ZNGT  VYO 8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 )UTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 40 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 114: Turntable Rotate Right Function Inoperative

    :NKT ]OZN VXKYY[XK 8KVGOX XUZGZOUT SUZUX MG[MK YZORR GZZGINKJ UVKXGZK ZNK L[TIZOUT RKYY ZNGT  VYO 8KVRGIK ZNK JOXKIZOUTGR )UTY[RZ -KTOK \GR\K 58 ZNK SGTOLURJ /TJ[YZXOKY 9KX\OIK NGY OTZKXTGR JKLKIZY *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 41...

  • Page 115: All Platform Leveling Functions Inoperative

    GZ G ZOSK )UTZOT[GRR_ SGYZKX I_ROTJKX SUTOZUX ZNK VXKYY[XK MG[MK J[XOTM HUUS [V *U TUZ GRRU] ZNK VXKYY[XK ZU K^IKKJ  VYO  VYO UX SUXK 8KVGOX UX XKVRGIK ZNK YRG\K I_ROTJKX 5 - 42 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 116: Platform Level Up Function Inoperative

    8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 43...

  • Page 117: Platform Level Down Function Inoperative

    8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 44 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 118: Platform Rotate Left Function Inoperative

     UX OTLOTOZK 8KSU\K HUZN ]OXKY LXUS UNSY \GR\K IUOR GTJ INKIQ 8KVRGIK ZNK IUOR XKYOYZGTIK GIXUYY ZNK IUOR ZKXSOTGRY  ZU  UNSY )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 45...
  • Page 119 8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 46 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 120: Platform Rotate Right Function Inoperative

    XUZGZK JOXKIZOUTGR \GR\K XKW[OXK Z]U VKUVRK /L G NKRVKX OY TUZ G\GORGHRK OTZKXINGTMK ZNK \GR\K OZKS 4 ]OZN G ROQK \GR\K OZKS 5 L[TIZOUT OTUVKXGZO\K )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 47...
  • Page 121 8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 48 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 122 8KSU\K HUZN ]OXKY LXUS  UX \GR\K IUOR GTJ INKIQ OTLOTOZK XKYOYZGTIK GIXUYY ZNK UNSY IUOR ZKXSOTGRY 8KVRGIK ZNK IUOR  ZU  UNSY )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 49...
  • Page 123 8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 50 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 124 U\KXXOJOTM ZNK \GR\K ]ORR XKW[OXK Z]U VKUVRK /L G NKRVKX OY TUZ G\GORGHRK OTZKXINGTMK ZNK \GR\K OZKS 4 ]OZN G ROQK \GR\K OZKS 5 L[TIZOUT OTUVKXGZO\K )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 51...
  • Page 125 8KVRGIK ZNK JOXKIZOUTGR \GR\K 58 ZNK SGTOLURJ NGY OTZKXTGR JKLKIZY 58 UTK UL ZNK VXK\OU[Y ZKYZY ]GY VUYYOHR_ U\KXRUUQKJ UX JOGMTUYKJ OTIUXXKIZR_ 8KINKIQ GTJUX IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 52 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 126: Drive Chassis Jack Function Inoperative

    8KVGOX UVKT OT 29 ]OXOTM 58 XKVRGIK 29 < 8KVGOX UVKT OT VU]KX Y[VVR_ ]OXKY ]OZN JOUJKY LXUS :( ZU :( 58 LXUS :( ZU :( 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 53...
  • Page 127 8KVGOX UVKT OT 29 ]OXOTM 58 XKVRGIK 29 < 8KVGOX UVKT OT VU]KX Y[VVR_ ]OXKY ]OZN JOUJKY LXUS :( ZU :( 58 LXUS :( ZU :( 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 54 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 128: Steer Left Function Inoperative

    8KSU\K HUZN ]OXKY LXUS UNSY YZKKX RKLZ IUOR GTJ INKIQ 8KVRGIK YZKKX RKLZ XKYOYZGTIK GIXUYY IUOR \GR\K IUOR ZKXSOTGRY  ZU  UNSY 8KVRGIK YZKKX \GR\K 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 55...

  • Page 129: Steer Right Function Inoperative

    8KSU\K HUZN ]OXKY LXUS UNSY YZKKX XOMNZ IUOR GTJ 8KVRGIK YZKKX XOMNZ INKIQ XKYOYZGTIK GIXUYY \GR\K IUOR IUOR ZKXSOTGRY  ZU  UNSY 8KVRGIK YZKKX \GR\K 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 56 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 130: All Drive Functions Inoperative, All Other Functions Operate Normally

    \URZGMK Y[VVR_ NUXYKVU]KX ROSOZKX GRZKXTGZUX UX HGZZKX_ HUGXJ ZKXSOTGR  58 XKVGOX UVKT OT ]NZ ]OXK IOXI[OZ Y[VVR_OTM < ZU ZKXSOTGR  < UX SUXK )UTZOT[KJ UT ZNK TK^Z VGMK Part No. 34032 Genie S-80 & Genie S-85 5 - 57...
  • Page 131 < GTJ INKIQ \URZGMK GZ IOXI[OZ LXUS NUXYK VU]KX ZKXSOTGR  UT JXO\K ROSOZKX HUGXJ ZU JXO\K IUTZXURRKX IUTZXUR ZKXSOTGR   ZU < )UTZOT[KJ UT ZNK TK^Z VGMK 5 - 58 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 132 58 XKVGOX UVKT OT ]NZ ZNK Z]U ]OXKY GZ +*) ]OXK IOXI[OZ LXUS :( ZU W[OIQ JOYIUTTKIZ +*) W[OIQ JOYIUTTKIZ  ZU < 8KVRGIK JXO\K V[SV +*) 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ Part No. 34032 Genie S-80 & Genie S-85 5 - 59...

  • Page 133: Drive Forward Or Reverse Function Inoperative

    T[RR TK[ZXGR 9KK JXO\K V[SV IUTZGIZ 9[TJYZXGTJ 9KXOKY  9[TJYZXGTJ G[ZNUXO`KJ 9KX\OIK 3GT[GR XKVGOX LGIOROZ_ Y_SVZUSY OSVXU\K )NKIQ GRR JXO\K YVKKJY GTJ SUTOZUX LUX XKI[XXOTM Y_SVZUSY 6UYYOHRK IUTZGSOTGZOUT OT N_JXG[ROI Y_YZKS 5 - 60 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 134: Traction Function Inoperative

    Service Manual - First Edition Section 5 - Troubleshooting Flow Charts Chart 34 Traction 9„•Æ•†uÆ…vƐˆqsy…„ Function †ˆ…r‚uƒÆs…„‰‘‚ÆEu„yu G„t‘‰ˆyu‰ÆWuˆ’ysu Inoperative Bu†qˆƒu„ Be sure all other functions operate normally. Part No. 34032 Genie S-80 & Genie S-85 5 - 61...

  • Page 135: Machine Will Not Drive At Full Speed

    ROSOZKX HUGXJ Be sure the free-wheel valve is closed on the TU IUTZOT[OZ_ drive pump. 8KGJP[YZ UX XKVRGIK NUXYKVU]KX ROSOZKX HUGXJ 9KK 8KVGOX YKIZOUT 58 IUTY[RZ -KTOK /TJ[YZXOKY 9KX\OIK *KVGXZSKTZ 5 - 62 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 136: Machine Drives At Full Speed With Platform Raised Or Extended

    8KVGOX ROSOZ Y]OZIN tampering. ]OXOTM 58 XKVRGIK HUUS ROLZ JXO\K ROSOZ Y]OZIN 58 Be sure orange wire XKVRGIK HUUS K^ZKTJ JXO\K ROSOZ Y]OZIN (cable 1) is properly attached to horsepower limiter. Part No. 34032 Genie S-80 & Genie S-85 5 - 63...

  • Page 137: Drive Enable System Is Malfunctioning

    VUYOZOUT ]OZN HUUS U\KX ZNK YZKKX ]NKKRY% =ORR NURJOTM ZNK JXO\K KTGHRK Y]OZIN GRRU] HUUS ZU JXO\K OT YZU]KJ VUYOZOUT U\KX YZKKX ]NKKRY% 8KVGOX UX XKVRGIK JXO\K KTGHRK ZUMMRK Y]OZIN 5 - 64 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 138: Auxiliary Functions Inoperative

    Y]OZIN GTJ INKIQ ZNK < \URZGMK GZ VUYOZO\K 8KVRGIK 68 XKRG_ VU]KX IGHRK UT G[^OROGX_ VU]KX [TOZ < )NKIQ G[^OROGX_ VU]KX [TOZ MXU[TJOTM IGHRK 58 XKVGOX UX XKVRGIK KRKIZXOI SUZUX Part No. 34032 Genie S-80 & Genie S-85 5 - 65...
  • Page 139 Service Manual - First Edition Section 5 - Troubleshooting Flow Charts This page intentionally left blank. 5 - 66 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 140 Read, understand and obey the safety rules or spray. and operating instructions printed in the General Repair Process Genie S-80 & Genie S-85 Operator's Manual. Be sure that all necessary tools and test equipment are available and ready for use. Identify...

  • Page 141: Electrical Symbols Legend

    Ignition start contactor module Glow plug Diode AUX. PUMP Auxiliary pump Limit switch Horsepower Dual axis normally open limiter board Ramp up and down held closed proportional controller Battery 6 - 2 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 142: Electrical Schematic - Gasoline/Lpg Models

    Section 6 - Schematics Service Manual Electrical Schematic - Gasoline/LPG Models 6 - 3 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 143 Service Manual Section 6 - Schematics Electrical Schematic - Gasoline/LPG Models Part No. 34032 Genie S-80 & Genie S-85 6 - 4...

  • Page 144: Ground Control Box Legend - Gasoline/Lpg Models

    Service Manual Section 6 - Schematics Ground Control Box Legend - Gasoline/LPG Models Part No. 34032 Genie S-80 & Genie S-85 6 - 5...

  • Page 145: Relay Panel Legend - Gasoline/Lpg Models

    Section 6 - Schematics Service Manual Relay Panel Legend - Gasoline/LPG Models 6 - 6 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 146: Platform Control Box Legend - Gasoline/Lpg Models

    Service Manual Section 6 - Schematics Platform Control Box Legend - Gasoline/LPG Models Part No. 34032 Genie S-80 & Genie S-85 6 - 7...

  • Page 147: Electrical Schematic - Diesel Models

    Section 6 - Schematics Service Manual Electrical Schematic - Diesel Models 6 - 8 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 148 Service Manual Section 6 - Schematics Electrical Schematic - Diesel Models Part No. 34032 Genie S-80 & Genie S-85 6 - 9...

  • Page 149: Ground Control Box Legend - Diesel Models

    Service Manual Section 6 - Schematics Ground Control Box Legend - Diesel Models Part No. 34032 Genie S-80 & Genie S-85 6 - 10...

  • Page 150: Platform Control Box Legend - Diesel Models

    Section 6 - Schematics Service Manual Platform Control Box Legend - Diesel Models 6 - 11 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 151: Hydraulic Symbols Legend

    2 pos., 2 way valve 4 way valve with pilot port 2-speed, bi-directional motor Solenoid operated dump valve Pump prime mover (motor) Pump prime mover Differential (engine) sensing valve Counterbalance valve Part No. 34032 Genie S-80 & Genie S-85 6 - 12...

  • Page 152: 2Wd Hydraulic Schematic

    Service Manual Section 6 - Schematics 2WD Hydraulic Schematic Part No. 34032 Genie S-80 & Genie S-85 6 - 13...

  • Page 153: 4Wd Hydraulic Schematic

    Service Manual Section 6 - Schematics 4WD Hydraulic Schematic Part No. 34032 Genie S-80 & Genie S-85 6 - 14...

  • Page 154: Repair Procedures

    Read, understand and obey the safety rules and operating instructions in the Return to Inspect Perform Genie S-80 & Genie S-85 Operator’s Manual. service and test repair problem solved Be sure that all necessary tools and parts are available and ready for use.

  • Page 155: Platform Controls

    Electrocution hazard. Contact to increase the voltage or counterclockwise to with electrically charged circuits decrease the voltage. may result in death or serious injury. Remove all rings, watches and other jewelry. 7 - 2 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 156 Emergency Stop button to Record the maximum voltage reading. position at both the ground and 15 Start the engine. platform controls. Do not start the engine. Part No. 34032 Genie S-80 & Genie S-85 7 - 3...
  • Page 157 Record the maximum voltage reading. to increase the voltage or counterclockwise to decrease the voltage. 15 Start the engine. 7 - 4 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 158 Emergency Stop button to the counterclockwise to decrease the voltage. position at both the ground and platform controls. Do not start the engine. Part No. 34032 Genie S-80 & Genie S-85 7 - 5...

  • Page 159: Horsepower Limiter Board

    17 Set the ramp rate: turn the trimpot to obtain output. a 3 second ramp speed. Turn the Gasoline/LPG models: Perform trimpot clockwise to increase the time or this procedure in gasoline mode. counterclockwise to decrease the time. 7 - 6 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 160 "B" potentiometer-maximum voltage output to the drive controller in the boom raised position "C" potentiometer-reaction rate or how fast the voltage output reacts to the change in engine rpm Part No. 34032 Genie S-80 & Genie S-85 7 - 7...

  • Page 161: Foot Switch

    (zero W) 12.2 m/8.3 sec 12.2 m/9.1 sec Boom raised or distance: 40 ft / 12 m extended 1 foot per second All models 30.5 cm per second 7 - 8 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 162: Resistors

    2 Connect the leads of an ohmmeter to the switch terminals in the following combinations terminal 4 to 6 no continuity listed below to check for continuity. terminal 5 to 6 no continuity Part No. 34032 Genie S-80 & Genie S-85 7 - 9...

  • Page 163: Control Relays

    86, then test the following terminal combinations. Test Desired result terminal 87 to 87a & 30 no continuity (infinite W) terminal 87 to 30 continuity (zero W) 7 - 10 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 164: Platform Components

    1 Extend the boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the boom slightly and place blocks under the platform. Then lower the boom until the platform is resting on the blocks. Part No. 34032 Genie S-80 & Genie S-85 7 - 11...

  • Page 165: Platform Rotator

    4 Remove the six mounting bolts from the platform mounting weldment, then remove the center bolt and slide the platform mounting weldment off of the platform rotator. 7 - 12 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 166 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right then left and inspect the bleed valves for leaks. Part No. 34032 Genie S-80 & Genie S-85 7 - 13...

  • Page 167: Jib Boom Components - S-85 Models

    Crushing hazard. The jib boom lift cylinder will fall when the pin is removed if it is not properly supported. 7 - 14 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 168: Jib Boom Lift Cylinder

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 34032 Genie S-80 & Genie S-85 7 - 15...

  • Page 169: Jib Boom / Platform Rotate Manifold Components

    2 Connect the leads from an ohmmeter to the valve coil terminals. Valve coil specification 2 position 3 way valve 6.3W 7 - 16 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 170: Boom Components

    1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the platform rotator and leveling slave cylinder. See 2-3, How to Remove the Platform Rotator. Part No. 34032 Genie S-80 & Genie S-85 7 - 17...
  • Page 171 1 Remove the boom. See 4-2, connections very slowly to allow How to Remove the Boom. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 - 18 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 172 2 boom tube. 11 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position. Part No. 34032 Genie S-80 & Genie S-85 7 - 19...

  • Page 173: Boom Lift Cylinder

    3 Retract the boom until the cylinder rod-end pin 7 Remove the pin retaining fastener from the lift is accessible in the number 3 boom tube. 7 - 20 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 174: Platform Leveling Master Cylinder

    Note the length of the cylinder after removal. The cylinder must be at the same length for installation. Part No. 34032 Genie S-80 & Genie S-85 7 - 21...

  • Page 175: Turntable Covers

    If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Alignment adjustments may be necessary when a new cover is installed. 7 - 22 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 176: Deutz Engine F4L 1011

    Leave a inch Do not crank the engine with the (12.7 mm) gap between the coupler and pump low oil pressure light on. end plate. Part No. 34032 Genie S-80 & Genie S-85 7 - 23...

  • Page 177: Ford Lsg-423 Engine

    Tighten the lock nut on the linkage rod. Rotate the actuator arm until it is at a 110 degree angle to the linkage rod. Then tighten the actuator arm fastener. 7 - 24 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 178: Choke Adjustments

    The choke butterfly may be adjusted to a fully closed (rich) position for colder climates and the poppet valve will provide a flow path during LPG fueled operation. lean rich Part No. 34032 Genie S-80 & Genie S-85 7 - 25...

  • Page 179: Timing Adjustment

    4 Assemble the engine and torque the pump mounting plate to 34 ft-lbs (46 Nm). 7 - 26 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 180: Water Temperature And Oil Pressure Gauges

    2 Apply mild suction to the vacuum port. Result: The switch should close and show full continuity (zero W). Component damage hazard. Do not short the vacuum switch terminals to ground. Part No. 34032 Genie S-80 & Genie S-85 7 - 27...

  • Page 181: Ground Controls

    86, then test the following terminal combinations. Test Desired result terminal 87 to 87a & 30 no continuity (infinite W) terminal 87 to 30 continuity (zero W) 7 - 28 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 182: Wago ® Components

    3 Locate the removal tab on the bottom or top side of the component. 4 Use the provided screwdriver to gently pry up on the tab of the component and remove it. Part No. 34032 Genie S-80 & Genie S-85 7 - 29...

  • Page 183: Power Relay

    2 Connect 12V DC to one of the small posts and a ground wire to the other small post, then test the following terminal combination. Test Desired result continuity (zero W) 2 large posts 7 - 30 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 184: Hydraulic Pumps

    If after installing the pump. the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 34032 Genie S-80 & Genie S-85 7 - 31...
  • Page 185 3 Crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 320 psi (22 bar). 7 - 32 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 186 Service Manual - First Edition Section 7 - Repair Procedures This page intentionally left blank. Part No. 34032 Genie S-80 & Genie S-85 7 - 33...

  • Page 187: Function Manifolds

    Check valve ........H ... Platform rotate left - differential sensing ......11-13 ft-lbs / 15-18 Nm Check valve ........L ... Platform level - differential sensing ......11-13 ft-lbs / 15-18 Nm 7 - 34 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 188 Service Manual - First Edition Section 7 - Repair Procedures FUNCTION MANIFOLDS Part No. 34032 Genie S-80 & Genie S-85 7 - 35...
  • Page 189 ......10-12 ft-lbs / 14-16 Nm Relief valve, 200 psi (13.7 bar) ..B ... Chassis lift jacks ....... 25-30 ft-lbs / 34-41 Nm Boom Function Dump Valves Drive Chassis Lift Jack Dump Valves 7 - 36 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 190: Valve Adjustments - Function Manifold

    6 Restart the engine. Hold the retract switch with Pressure 2300 psi the boom fully retracted, and recheck the valve 159 bar pressure. Main relief valve specifications Pressure 3000 psi 207 bar Part No. 34032 Genie S-80 & Genie S-85 7 - 37...
  • Page 191 Collision hazard. Impact with moving boom 134 bar components may cause death or serious injury. Use extreme caution when overriding a machine function. Identify the direction of machine movement before overriding a valve. 7 - 38 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 192 2 Connect the leads from an ohmmeter to the valve coil terminals. Valve coil specifications Proportional solenoid valve 3 position 4 way directional valve 4.5W Normally closed poppet valve Part No. 34032 Genie S-80 & Genie S-85 7 - 39...

  • Page 193: Fuel And Hydraulic Tanks

    3 Completely drain the oil from the tank by pressure reaches 320 psi (22 bar). removing the drain plug located in the bottom of the tank. Burn hazard. Contact with hot oil may cause severe burns. 7 - 40 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 194: Fuel Tank

    4 Use an appropriate lifting device to remove the tank from the machine. Clean the fuel tank and inspect for rust and corrosion before installing. Part No. 34032 Genie S-80 & Genie S-85 7 - 41...

  • Page 195: Turntable Rotation Components

    How to Remove the Turntable Rotation Brake or Torque Hub Locked position Refer to Maintenance Procedures, C-6, How to Replace the Torque Hub Oil. 7 - 42 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 196 (this will push the rotation gear into the rotation bearing). 3 Loosen the lock nut on the adjustment bolt. 4 Turn the adjustment bolt clockwise until it contacts the pivot plate. Part No. 34032 Genie S-80 & Genie S-85 7 - 43...

  • Page 197: Turntable Rotation Manifold Components

    18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm 7 - 44 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 198: 2Wd Steering Axle Components

    3 Block the non-steering wheels, and then center a lifting jack under the steering axle. 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. Part No. 34032 Genie S-80 & Genie S-85 7 - 45...

  • Page 199: Steering Cylinders

    3 Remove the steering cylinder. 5 Place the outer bearing into the hub. 7 - 46 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 200: Tie Rod Cylinder

    1 Straighten the steer wheels. 2 Measure the steer tires, front to front and back to back, using a measuring fixture. Part No. 34032 Genie S-80 & Genie S-85 7 - 47...

  • Page 201: 4Wd Steering Axle Components

    10 Attach a strap from a lifting device to the yoke/torque hub assembly for support. king pin torque hub yoke pivot pin tie rod cylinder steer cylinder 7 - 48 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 202: Steering Cylinders

    102 Nm 14-2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure. See repair procedure 13-2, How to Remove a Steering Cylinder. Part No. 34032 Genie S-80 & Genie S-85 7 - 49...

  • Page 203: Extendable Axle Components

    3 Block the wheels on the opposite end of the the oil pressure to dissipate machine, and then center a lifting jack under gradually. Do not allow oil to the axle to be removed. squirt or spray. 7 - 50 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 204: Extendable Axle

    3 Remove the retaining bolt, then the pivot pins 4 Remove the lift jack mounting fasteners. Then from each end of the cylinder. Remove the remove the jack from the machine. cylinder from the axle. Part No. 34032 Genie S-80 & Genie S-85 7 - 51...

  • Page 205: Hydraulic Limit Switches

    1 Install the hydraulic switch and connect the hydraulic hoses. 2 Install the linkage rod and leave the lock nut loose. lock nut linkage rod spring valve actuator limit switch valve 7 - 52 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 206: Chassis Jack / Axle Manifolds

    Relief valve, 200 psi (13.7 bar) ..A ... Hydraulic limit switch ......25-30 ft-lbs / 34-41 Nm Priority Flow Regulator Valve Chassis Jack/Axle Manifold Hydraulic Jack Check Valve Hydraulic Limit Switch Relief Valve Part No. 34032 Genie S-80 & Genie S-85 7 - 53...

  • Page 207: Steer Manifold Components

    55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm 7 - 54 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 208: Non-Steering Axle Components

    Torque specifications 433.9 Nm Drive motor mounting bolts 75 ft-lbs Drive torque hub mounting bolts 120 ft-lbs 102 Nm 163 Nm Drive motor mounting bolts 75 ft-lbs 102 Nm Part No. 34032 Genie S-80 & Genie S-85 7 - 55...

  • Page 209: 2Wd Drive Manifold

    Orifice 0.070 in (1.78 mm) ....D ... Drive circuit Flow divider/combiner valve ....C ... Controls flow to drive motors in forward and reverse ...... 25-30 ft-lbs / 34-41 Nm Diagnostic fitting ..........Testing 7 - 56 Genie S-80 & Genie S-85 Part No. 34032...

  • Page 210: Valve Adjustments

    6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge. Relief valve specifications Pressure 250 psi 17 bar Part No. 34032 Genie S-80 & Genie S-85 7 - 57...

  • Page 211: 4Wd Drive Manifold

    Orifice 0.070 in (1.78 mm) ....G ... Drive circuit, non-steer end Flow divider/combiner valve ....B ... Controls flow to flow divider/combiner valves 4 and 5 ... 25-30 ft-lbs / 34-41 Nm Diagnostic fitting ..........Testing 7 - 58 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 212 Service Manual - First Edition Section 7 - Repair Procedures 4WD DRIVE MANIFOLD Part No. 34032 Genie S-80 & Genie S-85 7 - 59...

  • Page 213: Valve Adjustments

    (index 2). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 7 - 60 Genie S-80 & Genie S-85 Part No. 34032...
  • Page 214 Genie North America 18340 NE 76th Street P.O. Box 97030 Redmond, Washington 98073-9730 Distributed By: Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England...

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