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S-80/S-85 Service Manual

1. sss 7 28 A1 Ground Control Box Wiring Diagram S 80 Perkins 704 30 Models after serial number 3576 sss 7 30 A Platform Control Box Wiring Diagram S 80 Perkins 704 30 Models after serial number 3576 ssssssess 7 31 PartNo 77832 Genie S 80 and Genie S 85 XV January 2004 TABLE OF CONTENTS Section 7 Rev Schematics continued A Electrical Schematic S 85 Deutz FAL 913 Models before serial number 3577 A Ground Control Box Wiring Diagram S 85 Deutz FAL 913 Models before serial number 3577 A Platform Control Box Wiring Diagram S 85 Deutz FAL 913 Models before serial number 3577 A Electrical Schematic S 85 Deutz FAL 913 Models after serial number 3576 A1 Electrical Schematic S 85 with Dual Battery Option Deutz FAL 913 Models after serial number 3576 A Electrical Schematic S 85 CE Models Deutz F4L 913 Models after serial number 3576 A1 Ground Control Box Wiring Diagram S 85 Deutz FAL 913 Models after serial number 3576 A Platform Control Box Wiring Diagram S 85 Deutz FAL 913 Models after serial number 3576 A1 Ground Control Box Wiring Diagram S 85 CE Models Deutz FAL 913 Models after serial number 3576 A Platform Control Box Wiring Diagram S 85 CE Models
2. 35 40 ft Ibs 47 54 Nm 29 Proportional solenoid valve SOP Turntable rotate circuit 35 40 ft Ibs 47 54 Nm 30 Differential sensing valve DD Meters flow to functions 35 40 ft Ibs 47 54 Nm 31 Check valve eeseee EE zs Differential sensing circuit boom extend retract 8 10 ft Ibs 10 15 Nm 32 Flow regulator valve 0 1 gpm 0 37 L MIN EE inus Bleeds off differential sensing valves to tank 25 30 ft Ibs 34 41 Nm 33 Flow regulator valve 0 6 gpm 2 27 L MIN GG Platform rotate circuit 25 30 ft Ibs 34 41 Nm Valve Coil Resistance Specification Plug Torque Specifications Solenoid valve 3 position 4 way 10V DC 60 schematic items A E N and S Description nex Size Torque Solenoid valve 2 position 3 way 10V DC 60 SAE No 4 8 16 13 ft lbs 18 Nm Schematic items D R and X SAE No 6 1 4 18 ft lbs 24 Nm Solenoid valve 2 position 3 way 10V DC 3 50 schematic item G SAE No 8 5 16 50 ft lbs 68 Nm Proportional solenoid valve 12V DC 5Q SAE No 10 9 16 55 ft Ibs 75 Nm schematic items K W and CC 5 42 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV B MANIFOLDS l a i i E
3. eeeeseesseesssseeeeeeeen nennen nennen rer nnne 5 67 12 2 SteerGylindar u 22 ah Mete esp e EE cabe tad ue 5 69 12 3 Tie Rod Cylinder iic aid ee ne 5 69 Xii Genie S 80 and Genie S 85 PartNo 77832 January 2004 a a iD n TABLE OF CONTENTS Section 5 Rev Repair Procedures continued A AWD Steer Axle Components Rev A 19 1 Yokeand Drive HUD i coto oc en ee 5 71 192 Drive Motor ns o EEEE 5 72 13 8 Drive Hubaa ese ra Rx er XE e e tere iger 5 73 13 4 Steering Cylinders See 12 2 Steer Cylinder uussssss 5 69 18 5 Tie Rod Cylinder See 12 3 Tie Rod Oylinder eeessssssssssss 5 69 A Norncsteer Axle Components Rev A 14 1 Drive Motor See 13 2 Drive Motor sssssseeeen nnne 5 72 14 2 Drive Hub See 13 3 Drive Hub seseaa aaa aaa aaa aaa aaa nana aa nnne 5 73 A Oscillating Axle Components Rev A 15 1 Oscillate Axle Cylinders sssseeseeneenneennnns 5 76 15 2 Valve Adjustments Oscillate Directional Valve nennen 5 77 A Extendable Axle Components Rev A 16 1 Extendable Axles nu een 5 78 16 2 Axle Extension Cylinder 444s4244044nnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn na 5 80 Section6 Rev FaultCodes Introduction zss2 2 n 6 1 A Faut Gades 2 cet A R A et I armenia 6 2 A Fa ltCodeCLiart eerte Eri eer tete Gaia dte bwa dia kd awk Eun 6 3 Part No 7
4. sss 5 8 74 TeiminalStpasz wiata iei eere atento tid tance nel 5 36 A Hydraulic Pumps 8 1 Function PUMP aaa Heredia a aeg a ed Fe ed beans 5 37 82 Drive PUM m 5 38 Part No 77832 Genie S 80 and Genie S 85 xi January 2004 TABLE OF CONTENTS Section 5 Rev Repair Procedures continued B Manifolds 9 1 Function Manifold Components View 1 ee eeee eee aaa aaa aaa aaa inaaae 5 40 9 2 Function Manifold Components View2 eee ueeeee eee a aaa aaa aaa aeianace 5 44 9 3 Valve Adjustments Function Manifold sseseeaa aaa aaa aaaa aaa eiannae 5 46 9 4 Turntable Rotation Manifold Components sse 5 48 9 5 Brake Two speed Manifold Components ssseeeeenee 5 49 9 6 Jib Boom Select Manifold Components S 85 ssssssssess 5 50 9 7 Axle Select Manifold Components ssseeeeeeen 5 52 9 8 2WD Drive Manifold Components sssssseseeeeeeeeeenenne 5 54 9 9 AWD Drive Manifold Components ssssssseeeeeemeennenns 5 56 9 10 Valve Adjustments Drive Manifold seeseeeeee 5 58 9 11 Valve COIS EE 5 59 B FuelandHydraulic Tanks UMEN cm 5 61 10 2 Hydraulic Tank essen mme nennen nnne 5 62 A Turntable Rotation Components 11 1 Turntable Rotation Drive Hub Assembly ssss 5 64 A 2WDSteer Axle Components 12 1 YokeandHub
5. sssssssseees 7 18 A Platform Control Box Wiring Diagram S 80 CE Models Deutz FAL 913 Models after serial number 3576 sssssseeee 7 19 XIV Genie S 80 and Genie S 85 Part No 77832 January 2004 a a iD n TABLE OF CONTENTS Section 7 Rev Schematics continued A Electrical Schematic S 80 GM 3 0L Models before serial number 3577 located at end of manual A Ground Control Box Wiring Diagram S 80 GM 3 0L Models before serial number 3577 sse 7 20 A Platform Control Box Wiring Diagram S 80 GM 3 0L Models before serial number 3577 sss 7 21 A Electrical Schematic S 80 GM 3 0L Models after serial number 3576 sss 7 22 A1 Ground Control Box Wiring Diagram S 80 GM 3 0L Models after serial number 3576 sss 7 24 A Platform Control Box Wiring Diagram S 80 GM 3 0L Models after serial number 3576 sse 7 25 A Electrical Schematic S 80 Perkins 704 30 Models before serial number 3577 located at end of manual A Ground Control Box Wiring Diagram S 80 Perkins 704 30 Models before serial number 3577 sess 7 26 A Platform Control Box Wiring Diagram S 80 Perkins 704 30 Models before serial number 3577 ssssssssss 7 27 A Electrical Schematic S 80 Perkins 704 30 Models after serial number 3576
6. T This list continues Please turn the page Function Platform rotate left right Platform rotate circuit prevents hydraulic hoses from draining back to tank Platform rotate circuit prevents hydraulic hoses from draining back to tank Boom retract Turntable rotate left right Boom extend retract circuit Boom extend Differential sensing circuit turntable rotate left right Boom extend retract circuit prevents overflowing the proportional valve Turntable rotate left right circuit prevents overflowing the proportional valve Boom extend retract circuit Differential sensing circuit platform level down Differential sensing circuit platform level up Platform level up down Boom up down circuit prevents overflowing the proportional valve Platform level down circuit Platform level up circuit Boom down Steer left right and axle extend retract Torque 25 30 ft Ibs 34 41 Nm 25 30 ft Ibs 34 41 Nm 25 30 ft Ibs 34 41 Nm 10 12 ft Ibs 14 16 Nm 25 30 ft Ibs 34 41 Nm 25 30 ft Ibs 34 41 Nm 15 18 ft Ibs 20 24 Nm 8 10 ft lbs 10 15 Nm 35 40 ft Ibs 47 54 Nm 35 40 ft Ibs 47 54 Nm 35 40 ft Ibs 47 54 Nm 8 10 ft lbs 10 15 Nm 8 10 ft lbs 10 15 Nm 25 30 ft Ibs 34 41 Nm 35 40 ft Ibs 47 54 Nm 35 40 ft Ibs 47 54 Nm 35 40 ft Ibs 47 54 Nm 10 12 ft Ibs 14 16 Nm 25 30 ft Ibs 34 41 Nm 25 30 ft Ibs
7. Normal engine cranking speed 350 rpm Current draw normal load 400A Current draw maximum load 600A Current draw minimum 100A Batteries Type 12V DC Size 13 x 613 16 x 93 8 inches 33 x 17 3 x 23 8 cm Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 9 to 11 psi 0 6 to 0 76 bar Fuel flow rate 0 3 gpm 1 14 L min Oil pressure minimum 18 psi Ignition system operating temp 2000 rpm 1 24 bar Spark plug type AC ACMR 43 LTS Oil capacity 5 quarts including filter 4 7 liters Spark plug gap 0 040 inches 1 01 mm Oil viscosity requirements Engine coolant Below O F 17 8 C 5W 30 Capacity 12 quarts Above 0 F 17 8 C 10W 30 11 4 liters Only use engine oils labeled For Gasoline Engines Alternator by the American Petroleum Institute API Output 66A 12V DC Fan belt deflection 1 2 inch 12 mm Part No 77832 Genie S 80 and Genie S 85 2 5 Section 2 Specifications January 2004 SPECIFICATIONS Deutz F4L 913 Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure 249 3 cu in 4 085 liters 4 4 02 x 4 92 inches 102 1 x 125 mm 76 2300 rpm i 3 4 2 18 1 Pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Low idle no load 1300 rpm High idle no load 2300 rpm Val
8. Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA 5 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 6 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Medium and high pressure filters The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit 7 Openthe engine side turntable cover and locate the two filters mounted below the hydraulic pumps The medium pressure filter is located on the right The high pressure filter is located on the left with the condition indicator 8 Place a suitable container under the filters 9 Remove the filter housing by using a wrench on the nut provided on the bottom of the housings 10 Remove the filter element from the housings 11 Inspect the housing seals and replace them if necessary 12 Install the new medium and high pressure filter elements into the housings and tighten them securely Medium and high pressure filters Genie part number 60857 CHECKLIST B PROCEDURES 13 Clean up any oil that may have spilled during the installation procedure 14 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 15 Start
9. Service Manual Part No 77832 Rev B1 January 2004 S 80 S 35 Introduction January 2004 Important Read understand and obey the safety rules and operating instructions in the Genie S 80 and S 85 Operator s Manualbefore attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications 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 all other manuals Contact Us http www genieindustries com e mail techsup genieind com Serial Number Information Genie Industries offers the following Service Manuals for thes
10. sees 7 54 Platform Control Box Wiring Diagram S 85 Perkins 704 30 Models after serial number 3576 sss 7 55 Hydraulic Schematic 2WD Models Rev A esssssssessnnnnennneennnnnnnnnennnnnnnennnn 7 56 Hydraulic Schematic 4WD Models Rev A ssee aaa aaa aaa aa aaaaaaaeeczaaaaaa 7 57 PartNo 77832 Genie S 80 and Genie S 85 xvii January 2004 ZR This page intentionally left blank xviii Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 2 Specifications REVA Specifications Machine Specifications Operational dimensions S 80 S 85 Stowed dimensions S 80 S 85 Platform height maximum 80 ft 85 ft 24 4 m 25 9m Length E wad pu Horizontal reach maximum 71 ft 11 in 76 ft 11 in 21 9m 23 4 m Width axles retracted 7Tftiilein 7ftilU2in Turntable tailswing maximum 3 ft 81 2 in 3 ft 81 2 in SM uidi 113 cm 113 cm Width axles extended 10 ft 10 ft Wheelbase 9 ft 9 ft 3m 3m 27m 27m Height 9ft2in 9ft2in Turning radius inside 10 ft71 2in X 10ft 71 2 in 2 8m 2 8m axles extended 3 23 m 3 23 m Ground clearance 11 in 11in Turning radius outside 23 ft 1 in 23 ft 1 in 27 9 cm 27 9 cm axles extended 7 03 m 7 03 m Weight 33 380 Ibs 36 450 Ibs Turntable rotation continuous continuous 15 141 kg 16 533 kg i Machine weights vary with option configurations Platform rotation 160 160 ial Plate f
11. 8 Adjust turntable rotation gear backlash Refer to Repair Procedure 11 1 How to Adjust the Turntable Rotation Gear Backlash Turntable rotate drive hub Oil capacity 32 fl oz 0 95 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures Checklist E Procedures REV B E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See repair procedure10 1 How to Remove the Fuel Tank 2 Close
12. All models 13 Turn the valve in a clockwise direction to be sure it is fully closed The free wheel valve is located on the drive pump and should always remain closed a drive pump b screwdriver c lift pump d free wheel valve REV B D 4 Check the Turntable Rotation Bearing Bolts Maintaining propertorque onthe turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Startthe engine from the platform controls and extend the axles 2 Turn the key switch to ground controls 3 Raise the boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie Service Parts part number 33484 4 Removethe boom storage area cover retaining fasteners Remove the cover 5 Besure that each turntable mounting bolt is torqued in sequence to 210 ft Ibs 285 Nm 28 1 POEM 12 0 17 so O 2 o 25 30 29 269 O3 E 9 14 Oo 02 10 19 62 27 Bolt torque sequence Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 6 Install the boom storage area cover and tighten the retaining fasteners 7 Raise the
13. 10 Remove the hydraulic tank from the machine AWARNING C shing hazard The hydraulic tank may become unbalanced and fall if it is not properly supported and secured to the lifting device 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using pipe thread sealant on the threads 14 Install the drain plug using pipe thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit REV B 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled 19 Open the hydraulic tank shutoff valves if equipped Component damage hazard CAUTION Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Referto Repair Procedure 8 2 How to Prime the Pump Always use pipe thread sealant when installing the drain plug and strainers 20 Operate all machine functions through a full cycle and check for leaks Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B Hydraulic oil specifications Before serial number 3349 Hydraulic oil type Shell Donax TG Dexron III After
14. 4 29 A 24 Check the Batteries nn 4 30 A 25 Grease the Turntable Rotation Bearing and Rotate Gear 4 31 A 26 Replace the Drive Hub Oil uee ooo e aaa aaa aaa aaa aaa aaa aeanaaaaeeea 4 32 A 27 Replace the Engine Oil and Filter GM Models nenn 4 34 A 28 Replace the Fuel Filter GM Models eeeeeeene 4 35 Checklist B Procedures B 1 Check the Engine Oil Cooler and Cooling Fins Deutz Models 4 36 B 2 Check the Engine Belt Deutz and Perkins Models 1 1 1111 4 37 B 3 Replace the Engine Air Filter Element e eeeeeeee aaa aaa winna 4 38 B 4 Check the Exhaust System eeee eeeee aaa aaa aaa aaa aaa enne 4 39 B 5 Replace the Hydraulic Filters uuu 4444444HHe nen nnnnnnnnnnennnnnnnennnn nennen 4 40 B 6 Confirmthe Proper Brake Configuration eseeeeeeeeee 4 42 B 7 Inspect the Tires and Wheels including lug nut torque 4 42 B 8 Check the Oil Level in the Drive Hubs ssseeeem 4 43 B 9 Check and Adjust the Engine RPM eeeeeee ee eea aaa aaa aa eaaaaaasznaacecca 4 44 B 10 Test the Key Switch uuussssssnnssnsnnnnnnnnnnannnnnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnannnen 4 46 B 11 Test the Emergency Stop sssssssssssesseeeeeeeennne a nnne 4 47 B 12 Testthe
15. 12 2 m apart 2 Startthe engine from the platform controls 3 Extend the axles 4 Move the engine idle select toggle switch to foot switch activated high idle rabbit and foot switch symbol 5 Press down the foot switch and raise the boom above horizontal 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES 8 Continue at full speed and note the time when the machine reference point crosses the finish line 9 Press down the foot switch and lower the boom to the stowed position 10 Extend the boom 3 feet 90 cm 11 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 12 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 13 Continue at top speed and note the time when the machine reference point crosses the finish line Drive speed maximum Raised or extended position 0 68 mph 1 1 km h 40 ft 45 5 sec 12 2 m 45 5 sec REV A B 22 Test the Alarm Package if e
16. Perkins 704 30 User s Handbook Genie part number 101840 Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST D PROCEDURES D 10 Calibrate the Platform Overload System if equipped Genie specifications require that this procedure be performed every 1000 hours of operation or yearly Yearly calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload System could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Perform this procedure with the machine on a firm level surface 1 Levelthe platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor REV B Determine the limit switch trigger point 4 Gently move the platform up and down by hand So it bounces approximately 2 5 to 5 cm Allow the platform to settle O Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off The platform will need to be moved up and down and allowed to settle in between adjustments There may
17. Section 4 e Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES REV B C 10 C 11 Replace the PCV Valve Replace the LPG Filter GM Models GM Models GM engine specifications require thatthis procedure be performed every 800 hours Replacement of the PCV valve at the scheduled maintenance interval is essential to good engine performance A malfunctioning PCV valve can restrict crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Openthe engine side turntable cover 2 Locate the PCV valve on top of the valve cover Remove the hose from the PCV valve 3 Remove the PCV valve from the valve cover Discard the valve 4 Install the new PCV valve and connect the hose PCV Valve Genie part number 65620 GM engine specifications require that this procedure be performed every 800 hours Replacement of the LPG filter at the scheduled maintenance interval is essential to good engine performance A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage ADANGER Explosion and fire hazard Engine fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Open the ground controls side turntable cover 2 Move the fuel select t
18. Type SAE 90 multipurpose hypoid gear oil API service classification GL5 CHECKLIST B PROCEDURES Turntable Rotate Drive Hub 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole a plug b drive hub 2 Ifnecessary add oil until the oil level is even with the bottom of the plug hole 3 Apply pipe thread sealant to the plug and install the plug in the drive hub Turntable rotate drive hub oil Capacity 32 fl oz 0 95 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES B 9 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage GM models The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department OR your local GM dealer GM models Low idle 1650 rpm High idle 2300 rpm Deutz models 1 Connecta tachometer to the engine Start the engine from the ground controls O
19. AWARNING Bodily injury hazard Safety decals are essential to safe machine operation Failure to replace all safety and instructional decals could create a situation resulting in death or serious injury If a turntable cover must be replaced be sure that all appropriate safety and instructional decals are applied to the new cover Crushing hazard The turntable cover could become unbalanced and fall if not properly supported and secured to an appropriate lifting device Alignment adjustments may be necessary when a new cover is installed Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures Engines 6 1 How to Remove the Flex Plate RPM Adjustment 1 Disconnect the wiring plug at the electronic Refer to Maintenance Procedure B 9 Check and Adjust the Engine RPM 6 2 Flex Plate 3 The flex plate couples the engine to the pump The 4 flex plate is bolted to the engine flywheel and has a cut out in the center for the pump coupler pump pump shaft coupler flex plate flywheel 0 185 inch gap Deutz Models 9 0 15 inch gap GM Models 0 3 inch gap Perkins Models 0oo000mm proportional controller located on the drive pump Diesel models Remove the fuel filter water separator retaining fasteners from the pump mounting plate Do not disconnect the fuel hoses Diesel models Remove the fuel filter water separator and lay it to the side Remove the medium a
20. AWARNING Bodily injury hazard An over inflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products This procedure does not need to be performed on machines equipped with the foam filled tire option To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge Add air as needed Tire specifications Pressure 100 psi 6 9 bar Genie S 80 and Genie S 85 Part No 77832 January 2004 REV B A 12 Test the Extendable Axles ADANGER Tip over hazard Do not raise or extend the boom unless both axles are fully extended If the axle extension system is not operating correctly the stability of the machine is compromised and it may tip over Be sure the axles are retracted before performing this procedure Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Start the engine from the ground controls Move and hold the function enable switch to either side and activate the boom up function Result The boom should raise to horizontal and then stop The boom should not raise above the limit switch unless both axles are extended Move and hold the function enable switch to either side an
21. Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the engine off and cooled 1 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 2 Locate the engine pivot plate anchor hole on the turntable 3 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Puton protective clothing and eye wear 5 Disconnect the hose from the coolant recovery tank at the radiator and drain the coolant recovery tank into a suitable container 6 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap 7 Openthe drain valve on the radiator and allow all the coolant to drain into a suitable container 8 After all the coolant has drained close the drain valve Connect the hose from the coolant recovery tank to the radiator 9 Openthe drain valve on the
22. D 6 Replace the Fuel Filter Deutz Models 2444444nn sn nnnnnnennen nennen 4 74 D 7 Replace the Fuel Hoses Deutz Models 24444snnssnnnnnnenn nennen 4 75 D 8 Clean the Engine Breather Assembly Perkins Models 4 77 D 9 Check the Engine Valve Clearances Perkins Models 4 77 D 10 Calibrate the Platform Overload System if equipped 4 78 D 11 Replace the Drive Hub Oil eeeee eos e aaa aaa nada aan 4 79 B Checklist E Procedures E 1 Testor Replace the Hydraulic Oil seeseseeeeeeeeneeeen 4 81 E 2 Change or Recondition the Engine Coolant Liquid cooled Models 4 83 E 3 Replace the Engine Breather Perkins Models 12 11111111 4 85 E 4 Grease the Steer Axle Wheel Bearings 2WD Models 4 85 E 5 Check the Fuel Injectors Perkins Models seeeeeeeese 4 87 PartNo 77832 Genie S 80 and Genie S 85 ix January 2004 TABLE OF CONTENTS Section5 Rev RepairProcedures Intr duction nein een eben ern 5 1 B Platform Controls 1 1 ALC 500Circuit Board ssssssssssssseseeeneneeeneenn nennen enne nnns 5 2 te JOYSICKS aic ott Ali w a RAWA AG AOS PRA 5 3 1 3 Lo PSP 5 7 1 4 Toggle Switches tie eerte teca ad 5 8 A PlatformComponents 2 1116 101 eiie eset Eid timebi
23. Service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position fully extend the boom and fully lower the platform 2 Remove the 2 bolts that are located on each side of the number 3 boom tube near the platform end of the number 2 boom tube BOOM COMPONENTS Place a 4 in x 4 in x 6 ft 10cm x 10 cm x 1 83 m block on top of the number 3 boom tube and place one end of the block against the weldment at the platform end of the boom Retract the boom until the number 2 boom tube is fully retracted into the number 1 boom tube The number 3 boom tube will remain extended 6 feet 1 83 m Remove the external snap rings from the extension cylinder pivot pin at the platform end Use a soft metal drift to remove the pin Remove the turntable end cover Support the rod end of the master cylinder with a lifting device Remove the pin retaining fastener from the master cylinder rod end pivot pin Place a rod through the pin and twist to remove the pin Use the platform level toggle switch with auxiliary power to relieve pressure on the master cylinder barrel end pivot pin 9 Lay the master cylinder down Protect the cylinder rod from damage Part No 77832 Genie S 80 a
24. engine off 1 Openthe engine side turntable cover and locate the fuel filter water separator 2 Loosen the vent plug located on the fuel filter water separator head a head bolt b vent plug c drain plug d filter bowl e separator head Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES 3 Loosenthe drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 4 Tighten the vent plug If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine See C 3 Heplace The Fuel Filter Water Separator Element Diesel Models for instructions on how to prime the fuel filter water A 19 REV B Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance checklists for continued scheduled maintenance 1 Performthefollowing maintenance procedures A 20 Check the Engine Fasteners separator Deutz Models 5 Clean up any fuel that may have spilled A 25 Greasethe Turntable Rotation 6 Startthe engine from the ground controls and Bearing and Rotate Gear check the fuel filter water separator and vent B 2 Check the Engine B
25. leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 Checklist B Procedures B 1 Check the Engine Oil Cooler and Cooling Fins Deutz Models Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns Engine oil cooler 1 Openthe latches from the engine side cover Remove the cover 2 Inspect the oil cooler for leaks and physical damage 3 Clean the oil cooler of debris and foreign material REVA Head cooling and blower fins 4 5 Inspect the fan blower fins for physical damage Clean the fan blower fins of debris and foreign material Using a flashlight inspect the head cooling passages and fins for physical damage or foreign material If needed clean the cylinder head cooling passages and fins of debris and foreign material 4 36 Genie S 80 and Genie S 85 Part No 77832 J
26. 2 Enginecoolant i 1 Compression ratio 17 5 1 Capacity 11 2 quarts 10 9 liters Compression pressure 300 to 500 psi 20 7 to 34 5 bar Alternator output 65A 12V DC Pressure psi or bar of lowest cylinder must be Batteries within 50 psi 3 45 bar of highest cylinder Type 12V DC Low idle 1600 rpm Size 13 x 613 16 x 93 8 inches High idle 2300 rpm 33 x 17 3 x 23 8 cm Governor centrifugal mechanical Quantity 2 Valve clearance cold Cold cranking ampere 1000A Intake 0 014 in Reserve capacity 25A rate 200 minutes 0 35 mm Fan belt deflection 3 8 in Exhaust 0 014 in 10 mm 0 35 mm Lubrication system Oil pressure 41 psi at 2300 rpm 2 8 bar Oil capacity 7 4 quarts including filter 7 liters Cil viscosity requirements 13 F to 68 F 25 C to 20 C 5W 20 5 F to 104 F 15 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Engine oil should have properties of API classification CC SE Part No 77832 Genie S 80 and Genie S 85 2 7 Section 2 Specifications January 2004 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Loke fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft Ibs 14 9 Nm 6 23 ft lbs 3
27. 4 Repeatstep 2 Install the fuel tank cap onto the fuel tank B 24 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test GM engine specifications require that this procedure be performed every 400 hours Periodic replacement of the spark plugs is esseniial to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off 1 Openthe engine side turntable cover 2 Tag and disconnect the plug wires from the spark plugs by grasping the spark plug boot Do not pull on the plug wire Blow out any debris around spark plugs Remove all the spark plugs from the engine Adjust the gap on each new spark plug o a R C Install the new spark plugs and torque to 22 ft Ibs 29 8 Nm 7 Connect the spark plug wires Be sure
28. C PROCEDURES Loosen the vent plug located on the fuel filter water separator head a head bolt b vent plug c drain plug d filter bowl e separator head Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel Loosen the head bolt Rotate the filter bowl counterclockwise and remove it from the element Rotate the filter element counterclockwise and remove it from the filter head and dispose of properly Install the bowl onto the new filter element Fuel filter water separator Genie part number 62433 PartNo 77832 Genie S 80 and Genie S 85 4 59 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES 8 Applyathin layer of clean diesel fuel onto the element gasket Install the filter bowl assembly onto the filter head Tighten the drain plug 9 Tighten the head bolt to 65 in Ibs 7 Nm 10 Tighten the vent plug 11 Clean up any diesel fuel that may have spilled during the installation procedure 12 Connect the fuel hose from the fuel tank to the fuel filter water separator Tighten the clamp Bleed the fuel system Before bleeding the system fill the fuel tank 13 Loosen the vent plug located on the fuel filter water separator head 14 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 15 Loosen the air vent sc
29. Horn A properly functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA B 15 Test the Foot Switch A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not
30. Oy 5 amp Part No 77832 Genie S 80 amp Genie S 85 5 43
31. Remove the switch from the engine block 3 Install the new switch and torque to specification 4 Connect the wires to the new switch Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a switch Oil temperature switch specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 13 16 inch Temperature switch point 300 F 149 C Oil pressure switch specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 11 16 inch Oil pressure switch point 7 psi 0 48 bar ENGINES 6 4 Coolant Temperature and Oil Pressure Switches Perkins Models The engine coolant temperature gauge optional is an electrical gauge The engine coolant temperature switch is a normally open switch and has limit contacts that are factory set The contacts will close at approximately 221 F 105 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine coolant temperature will be indicated on the gauge if equipped when the key is on and the red Emergency Stop Button is pulled out to the on position The engine oil pressure gauge optional is an electrical gauge The engine oil presure switch is a normally open switch and has limit contacts that are factory set The contacts will close at approximately 4 2 psi 0 3 bar When the contacts open the engine will sh
32. They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optionalfluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Genie specifications require additional equipment and special SPECIFICATIONS Drive pump Type bi directional variable displacement piston pump Flow rate 2300 rpm 30 3 gpm 114 7 L min Drive pressure maximum 4200 psi 290 bar Charge pump Type gerotor Displacement 0 85 cu in 13 9 cc Flow rate 2300 rpm 8 gpm 30 3 L min Charge pressure 2300 rpm 320 psi Neutral position 22 bar Function pump Type two section tandem gear pump Displacement Pump 1 inner 1 4 cu in 22 9 cc Flow rate 2300 rpm 12 7 gpm 48 L min Displacement Pump 2 outer 0 24 cu in 4 cc Flow rate 2300 rpm 2 25 gpm 8 5 L min Auxiliary pump i NIMA Type fixed displacement gear pump installation instructions for the approved optional fluids Consult Displacement static 0 151 cu in the Genie Industries Service 2 47 cc Department before use Part No 77832 Genie S 80 and Genie S 85 2 3 Section 2 Specifications January 2004 Z Z Z LL SPECIFICATIONS REV B Function manifold Functio
33. boom and remove the safety chock 8 Lowerthe boom to the stowed position 9 Checkto ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 ft Ibs 285 Nm eO O 18 4 30 Qi O 8 9090 14 gt 9 Bolt torque sequence CHECKLIST D PROCEDURES D 5 Clean the Fuel Pump Strainer Deutz Models Cleaning the fuel pump strainer is essential for good engine performance and service life A dirty or clogged strainer may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions or not operating the machine for extended periods of time may require that the strainer be cleaned more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Openthe engine side turntable cover and locate the fuel pump located next to the engine oil level dipstick 2 Tag disconnect and plug the fuel supply hose from the fuel pump 3 Remove the fuel pump cover retaining fastener Remove the cover Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST D PROCEDURES 4 Gen
34. completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information O Indicates that a specific result is expected after performing a series of steps Part No 77832 Genie S 80 and Genie S 85 5 1 Section 5 Repair Procedures January 2004 Platform Controls The platform control box contains one printed circuit board The ALC 500 circuit board inside the platform control box controls all proportional machine functions from the platform The joystick controllers at the platform controls utilize Hall Effect technology a
35. coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the engine off and cooled 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST E PROCEDURES 2 Locate the engine pivot plate anchor hole on the turntable 3 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Puton protective clothing and eye wear 5 Disconnect the hose from the coolant recovery tank at the radiator and drain the coolant recovery tank into a suitable container 6 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap 7 Openthe drain valve on the radiator and allow all the coolant to drain into a suitable container Coolant capacity Liquid cooled models GM 3 0L 12 quarts 11 4 liters Perkins 704 30 11 5 quarts 10 9 liters 8 After all the coolant has drained close the drain valve Co
36. drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump assembly from the machine Component damage hazard CAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Before installing the pump verify proper pump coupler spacing Refer to the appropriate flex plate installation instructions for your engine HYDRAULIC PUMPS How to Prime the Pump Component damage hazard Be CAUTION sure that the hydraulic tank shutoff valves if equipped are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple on the drive pump GM models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select toggle switch to the LPG position Deutz and Perkins models Disconnect the engine wiring harness from the fuel solenoid at the injector pump 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 300 psi 20 68 bar GM models Connect the LPG hose to the LPG tank and open the valve on the tank Deutz and Perkins models Connect the engine wiring harness to the fuel solenoid Sta
37. end of the boom One limit switch of each pair is used as a safety back up in case one of them becomes faulty The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated beyond the non steer wheels Machine Controls The Genie S 80 and Genie S 85 machines are equipped with operational controls which are found in two locations the ground controls located on the tank side of the machine and the platform controls located in the platform All lift and drive functions are available at the platform controls Only boom functions are available at the ground controls Ground controls are activated by holding the function enable toggle switch to either side then moving a boom function toggle switch in the direction indicated on the control panel decal This will determine which boom function will operate and its direction of travel Platform controls use toggle switches and boom function controllers joysticks to operate the boom functions The drive controller joystick regulates the drive pump displacement through the EDC in direct relation to the drive controller position A thumb rocker switch on the top of the drive controller is used for steering If the foot switch is pressed down for more than 2 minutes without activating a machine function the platform controls will be locked out To resume operating the machine normally release the foot switch and press down the foo
38. engine block and allow the coolant to drain into a suitable container After the fluid has drained close the drain valve CHECKLIST C PROCEDURES 10 Replace all coolant hoses and clamps 11 Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full Install the radiator cap 12 Fill the coolant recovery tank to the NoRMAL range Install the coolant recovery tank cap 13 Clean up any coolant that may have spilled during this procedure 14 Start the engine from the ground controls and let it run for 30 seconds Turn the engine off and inspect for leaks 15 Check the coolant level in the coolant recovery tank Add coolant if needed 16 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 17 Swing the engine pivot plate in towards the machine 18 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 19 Start the engine from the ground controls and let it run until it reaches normal operating temperature 20 Turn the engine off Allow the engine to cool 21 Check the coolant level in the coolant recovery tank Add coolant if needed Coolantcapacity GM 3 0L EFI Engine 12 quarts 11 4 liters PartNo 77832 Genie S 80 and Genie S 85
39. for 30 seconds Stop the engine 13 Check the oil filter and oil drain hose for leaks 14 Wait 15 minutes after stopping the engine and check the engine oil level on the dipstick Add oil if needed 15 Dispose of the used oil and filter properly Deutz F4L 913 Engine 14 3 quarts Oil capacity including filter 13 5 liters Cil viscosity requirements Below 77 F 25 C 5W 30 synthetic 13 F to 86 F 25 C to 30 C 10W 40 Above 4 F 20 C 15W 40 Engine oil should have minimum properties of API classification CD grade OR ACEA classification E1 96 CHECKLIST C PROCEDURES Perkins 704 30 Engine 7 4 quarts Oil capacity including filter 7 liters Cil viscosity requirements 13 F to 68 F 25 C to 20 C 5W 20 5 F to 104 F 15 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Engine oil should have minimum properties of API classification CC SE PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES C 7 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mecha
40. forward or reverse is accomplished by pressing down the foot switch in the platform and moving the drive controller joystick in the appropriate direction When activated the drive controller completes a circuit to the Electronic Displacement Controller EDC The EDC regulates drive pump displacement in direct relation to the drive controller position Limit switches There are two types of limit switches which are found in various locations on the machine drive speed limit switches and a drive enable limit Switch A drive speed limit switch performs two functions One function of a drive speed limit Switch is to limit the raised or extended drive speed to 0 68 miles per hour 1 1 km h when the boom is raised above horizontal OR when the primary boom is extended approximately 12 inches 30 5 cm The other function of a drive speed limit switch is to prevent the boom from being raised past 5 above horizontal OR extending the boom more than 12 inches 30 5 cm if the axles are not fully extended They also prevent the axles from being retracted when the boom is raised above horizontal or when the boom is extended more than 12 inches 30 5 cm REVA There are 2 pairs of drive speed limit switches One pair located at the boom pivot are used for boom up and down The other pair are used for boom extend and retract One switch is located at the platform end of the extension boom and other one is located inside the boom at the pivot
41. position l l engaged position CHECKLIST D PROCEDURES 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks lision h aoe AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Steer wheels 4WD models 7 Chock the non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer wheels 9 Lift the wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub disengaged position l l engaged position Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage
42. release it Result The travel alarm should sound when the drive controller is moved off center in either direction CHECKLIST B PROCEDURES B 23 Inspect the Fuel Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing fuel tank cap is essential for good engine performance and service life A dirty or clogged fuel tank cap may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap be inspected more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Remove the cap from the fuel tank 2 Checkfor proper venting When checking for positive fuel tank cap venting air should pass freely through the cap O Result Air should pass through the fuel tank cap Clean or replace the cap Part No 77832 Genie S 80 and Genie S 85 Section 4 e Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES REVA 3 Using a mild solvent carefully wash the cap B 25 venting system Dry using low pressure compressed air Replace the Spark Plugs GM Models
43. start 3 Do not press down the foot switch and attempt to start the engine O Result The engine should start 4 Do not press down the foot switch and attempt to operate the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions Result The machine functions should operate The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended CHECKLIST B PROCEDURES B 16 Test the Engine Idle Select Operation A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions only High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot Switch symbols should be used for normal machine operation This setting activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from the ground controls Move and hold the function enable toggle switch in the high idle rabbit symbol position O Result
44. steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position Perform this procedure with the boom in the stowed position 1 Startthe engine from the platform controls 2 Press down the foot switch CHECKLIST B PROCEDURES 3 Rotate the turntable until the boom moves past one of the the non steer wheels O Result The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown 4 Slowly move the drive control handle off center O Result The drive function should not operate 5 Rotate the turntable until the boom moves past the other non steer wheel Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 6 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center O Result The drive function should operate AWARNING Collision hazard Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved Blue Yellow Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES B 19 Test the Drive Bra
45. that each spark plug wire is attached to the correct spark plug GM3 0L EFI Engine Spark plug specifications Spark plug type AC Delco ACMR 43 LTS Spark plug gap 0 040 inch 1 01 mm Spark plug Genie part number 65622 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures Checklist C Procedures REV B C 1 Check the Engine Valve Clearances Deutz Models Information to perform this procedure is available in the Deutz 913Operation Manual Deutz part number 0297 7341 Deutz 913 Operation Manual Genie part number 62446 C 2 Replace the Fuel Filter Element Perkins Models Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often INJ TTJJ Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Open the engine side turntable cover and locate the fuel filter above the oil filter 2 Thoroughly clean the outside surf
46. the auxiliary power unit The batteries are charged through a common engine driven alternator A battery separator is used to charge the control system auxiliary power unit battery before charging the engine starting battery The engine and control system are protected by individual 15A circuit breakers that may be manually reset The hydraulic oil cooler and other machine options or accessories are protected by a 20A circuit breaker that may be manually reset The 20A circuit breaker receives power from the engine starting battery Part No 77832 Genie S 80 and Genie S 85 3 1 Section 3 Theory of Operation January 2004 THEORY OF OPERATION Boom Steer functions are accomplished by pressing down the foot switch when operating from the platform controls OR activating the function enable toggle switch when operating from the ground controls and activating the desired joystick controller or toggle switch When a toggle switch or a joystick controller is activated it sends voltage to the appropriate directional control valve These directional valves determine which direction the hydraulic fluid will travel The volume of hydraulic fluid is determined by either a proportional valve or flow regulator valve A proportional valve receives a variable voltage signal and delivers more hydraulic fluid as the voltage increases A flow regulator valve is a mechanical valve and delivers a predetermined amount of hydraulic fluid Drive
47. the engine from the ground controls 16 Inspect the filter housings and related components to be sure that there are no leaks Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES B 6 Confirm the Proper Brake Configuration Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure itis in the engaged position 2 Besurethe free wheel valve is closed clockwise disengaged position engaged position a drive pump b screwdriver c liftpump d free wheel valve The free wheel valve is located on the drive pump The free wheel valve should always remain closed REVA B 7 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products The t
48. to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform Remove the platform rotator and leveling slave cylinder See 2 3 How to Remove the Platform Rotator Remove the cable track See 4 1 How to Remove the Cable Track S 85 Remove the jib boom See 3 1 How to Remove the Jib Boom S 85 Remove the jib boom bell crank See 3 2 How to Remove the Jib Boom Bell Crank Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 6 Raise the boom to a horizontal position high enough that the boom lift cylinder rod end can clear the boom lift cylinder mounting boss 7 Remove the turntable end cover Remove the pin retaining fasteners from the master cylinder rod end pivot pin 9 Place a rod through the pin and twist to remove the pin Lower the rod end of the master cylinder 10 Remove the fasteners from the boom angle limit switches LS2RO and LS2RS mounted to the inside of both turntable riser side plates at the pivot end of the boom Do not disconnect the wiring 11 Remove the fasteners from the boom extend limit switch LS1RO mounted next to the boom extension cylinder at the pivot end of the boom Do not disconnect the wiring BOOM COMPONENTS 12 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWAR
49. watches and other jewelry 5 2 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV B 4 Attach a grounded wrist strap to the ground screw inside the platform control box Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5 Carefully disconnect the wire connectors from the circuit board 6 Remove the ALC 500 circuit board mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box PLATFORM CONTROLS 1 2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control If a joystick is disconnected or replaced it must be calibrated before that particular machine function will operate The joystick must be calibrated before the threshold max out or ramping can be set Perform this procedure with the engine off 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Press down the foot switch and select a joystick to calibrate 4 Move the joystick full stroke in either direction and hold for 5 seconds 5 Return the joystick to t
50. 1 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft Ibs 93 6 Nm 12 93 ft Ibs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft Ibs 233 2 Nm 24 208 ft Ibs 282 Nm SAE O ring Boss Port REVA Seal Lok fittings Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft Ibs 21 7 Nm 4 18 ft Ibs 24 4 Nm 6 35 ft Ibs 47 5 Nm 6 27 ft Ibs 36 6 Nm 8 60 ft Ibs 81 3 Nm 8 40 ft Ibs 54 2 Nm 10 105 ft Ibs 142 4 Nm 10 63 ft Ibs 85 4 Nm 12 140 ft Ibs 190 Nm 12 90 ft Ibs 122 Nm 16 210 ft Ibs
51. 284 7 Nm 16 120 ft Ibs 162 7 Nm 20 260 ft Ibs 352 5 Nm 20 140 ft Ibs 190 Nm 24 315 ft Ibs 427 1 Nm 24 165 ft Ibs 223 7 Nm Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 3 Theory of Operation REVA Power Source The Genie S 80 and Genie S 85 are powered by either a Gasoline LPG engine or one of two diesel engines The Gasoline LPG option uses a GM 3 0L EFI engine rated at 67 horsepower Q 2300 rpm The diesel engine options include a Deutz F4L 913 rated at 76 horsepower 2300 rpm and a Perkins 704 30 rated at 61 horsepower 2300 rpm Hydraulic System All machine functions are performed by the hydraulic system The hydraulic system is divided into three groups Boom and Steer Axle functions Oscillate functions and Drive functions Boom and Steer Axle functions are powered by the inner section of the dual section tandem gear pump rated at 12 7 gpm 48 L min at 2300 rpm When the engine is running this pump supplies hydraulic fluid under pressure to the function manifold and axle select manifold where the directional and flow control valves are located To protect from over pressurization of the Boom and Steer Axle system the pump is provided with a pressure relief valve set at 2900 psi 200 bar Oscillate functions are powered by the outer section of the dual section tandem gear pump rated at 2 25 gpm 8 5 L min at 2300 rpm When the engine is running this pump supplies h
52. 34 41 Nm 5 40 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV B MANIFOLDS l a i i E Oy 5 amp Part No 77832 Genie S 80 amp Genie S 85 5 41 Section 5 Repair Procedures MANIFOLDS January 2004 TEE Function Manifold Components View 1 continued REVB Index Schematic No Description Item Function Torque 21 Check valve sissisota Ur iss Blocks flow from auxiliary pump to function pump eese 35 40 ft Ibs 47 54 Nm 22 Priority flow regulator valve 3 5 gpm 13 2 L MIN M iners Steer circuit sirier ies 35 40 ft Ibs 47 54 Nm 23 Proportional solenoid valve W esae Boom up down circuit 35 40 ft Ibs 47 54 Nm 24 Solenoid valve 2 position 3 way tac Boom UP nee 10 12 ft lbs 14 16 Nm 25 Check valve sy sesioiicsesi semuri Y cursats Blocks flow from function pump to auxiliary pump eese 25 30 ft Ibs 34 41 Nm 26 Check valve ssssseeeee aii Hydraulic oil cooler bypass 25 30 ft Ibs 34 41 Nm 27 Check valve 22 0u01su10211 AA Boom up down circuit 8 10 ft Ibs 10 15 Nm 28 Needle valve ssss BB Platform level circuit
53. 4 Scheduled Maintenance Procedures REV B 3 Loosen the fuel filter with a filter wrench and drain the fuel into a suitable container Remove the fuel filter from the engine when the fuel flow has slowed or stopped a fuelfilter b oilfilter 4 Apply a thin layer of diesel fuel to the new fuel filter gasket Fuel filter Genie part number 75484 5 Install the new filter and tighten it securely by hand 6 Clean up any diesel fuel that might have spilled duringthe procedure 7 Usea permanent ink marker to write the date and number of hours from the hour meter on the filter 8 Install the fuel tank hose onto the inline fuel filter water separator head 9 Bleed the fuel system See C 3 Replace the Fuel Filter Water Separator Element Diesel Models CHECKLIST D PROCEDURES D 7 Replace the Fuel Hoses Deutz Models Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition JW 813 Explosion and fire hazard Engine fuels are combustible Replace the fuel hoses in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be sure the fuel hoses are routed the same way the original hoses were CAUTIO
54. 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES 7 Swingthe engine pivot plate in towards the machine 8 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Belt deflection 3 8 inch to 1 2 inch 9 mm to 12 mm Deutz models Perkins models 3 8 inch 9 mm Belts Genie part numbers Deutz engine belt 62431 Perkins engine belt 62423 REV A B 3 Replace the Engine Air Filter Element Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed a clamp b canister end cap c dust discharge valve Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA 2 Release the clamps from the end cap of the air filter canister Remove the end cap Remove the filter element 4 Clean the inside of the canister and the canister end cap w
55. 7832 Genie S 80 and Genie S 85 xiii January 2004 TABLE OF CONTENTS Section7 Rev Schematics INTPOCUCHION esi AA eee anne ebene 7 1 A Electrical Components before serial number 3577 sse 7 2 A Electrical Symbols Legend Rev A 7 4 A Hydraulic Symbols Legend Rev A nnns 7 5 A GM3 0LEngine Wiring Harness inisenisi enne nnns 7 7 A Electrical Schematic S 80 Deutz FAL 913 Models before serial number 3577 located at end of manual A Ground Control Box Wiring Diagram S 80 Deutz FAL 913 Models before serial number 3577 sss 7 8 A Platform Control Box Wiring Diagram S 80 Deutz FAL 913 Models before serial number 3577 sss 7 9 A Electrical Schematic S 80 Deutz FAL 913 Models after serial number 3576 sesssseee 7 10 A1 Electrical Schematic S 80 with Dual Battery Option Deutz FAL 913 Models after serial number 3576 sssssssseeees 7 12 A Electrical Schematic S 80 CE Models Deutz FAL 913 Models after serial number 3576 sssssssseees 7 14 A1 Ground Control Box Wiring Diagram S 80 Deutz FAL 913 Models after serial number 3576 sesssssseees 7 16 A Platform Control Box Wiring Diagram S 80 Deutz FAL 913 Models after serial number 3576 sse 7 17 A1 Ground Control Box Wiring Diagram S 80 CE Models Deutz FAL 913 Models after serial number 3576
56. 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B A 9 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank filter fittings hoses auxiliary power unit and turntable surface Hydraulic oil cooler Engine compartment hydraulic filters fittings hoses pumps and turntable surface All hydraulic cylinders All hydraulic manifolds Boom and jib boom if equipped Theunderside of the turntable The underside of the drive chassis Axles Ground area under the machine CHECKLIST A PROCEDURES A 10 Check the Hydraulic Filter Condition Indicators Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation The filter condition indicators will show when the hydraulic flow is bypassing a clogged filter If the filters are not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage There are three hydraulic filters located on the machine one tank return filter one medium pressure fil
57. Capacity 61 fl oz 1 8 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Drive Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor 3 Attach a suitable lifting device to the lifting eyes located near the drive motor 4 Removethe drive hub mounting bolts Carefully remove the turntable rotate drive hub assembly from the machine AWARNING Crushing hazard Theturntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device REV B 5 Removethe plug from the side of the drive hub Drain the oil from the hub into a suitable container a motor b drive hub c drive hub mounting bolts 6 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to 75 ft Ibs 101 7 Nm 7 Fillthe drive hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug
58. Deutz FAL 913 Models after serial number 3576 A Electrical Schematic S 85 GM 3 0L Models before serial number 3577 A Ground Control Box Wiring Diagram S 85 GM 3 0L Models before serial number 3577 A Platform Control Box Wiring Diagram S 85 GM 3 0L Models before serial number 3577 A Electrical Schematic S 85 GM 3 0L Models after serial number 3576 A1 Ground Control Box Wiring Diagram S 85 GM 3 0L Models after serial number 3576 A Platform Control Box Wiring Diagram S 85 GM 3 0L Models after serial number 3576 xvi Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 7 Rev A TABLE OF CONTENTS Schematics continued Electrical Schematic S 85 Perkins 704 30 Models before serial number 3577 located at end of manual Ground Control Box Wiring Diagram S 85 Perkins 704 30 Models before serial number 3577 sssssss 7 50 Platform Control Box Wiring Diagram S 85 Perkins 704 30 Models before serial number 3577 sssssssss 7 51 Electrical Schematic S 85 Perkins 704 30 Models before serial number 3577 sesaeeeeaaaaaeaaaaaacnaa 7 52 Ground Control Box Wiring Diagram S 85 Perkins 704 30 Models after serial number 3576
59. EV A 3 2 Jib Boom Bell Crank How to Remove the Jib Boom Bell Crank Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Support the rod end of the platform leveling slave cylinder Protect the cylinder rod from damage 3 Attach a strap from an overhead crane to the bell crank for support 4 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin JIB BOOM COMPONENTS S 85 5 Place a rod through the pin and twist to remove the pin Lower the rod end of the platform leveling slave cylinder Remove the pin retaining fasteners from the bell crank pivot pin Place a rod through the pin and twist to remove the pin Remove the bell crank from the boom AWARNING Crushing hazard The jib boom bell crank could become unbalanced and fall if not properly supported when removed from the machine Part No 77832 Genie S 80 and Genie S 85 5 15 Section 5 Repair Procedures January 2004 JIB BOOM COMPONENTS S 85 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting
60. Emergency Stop button at the platform controls to the off position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle O Result All boom functions should operate The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES B 13 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle O Result The platform should remain level at all times to within 5 degrees The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended REV A B 14 Test the
61. Emergency Stop button to the on position at the ground controls 9 Press down the foot switch and attempt to start the engine from the platform controls Result The engine should not start 10 Do not press down on the foot switch 11 Start the engine from the platform controls 12 Attempt to operate all machine functions Result All machine functions should not operate PartNo 77832 Genie S 80 and Genie S 85 4 17 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES 13 Press down the foot switch and activate each machine function Result All machine functions should operate through a full cycle 14 Push in the red Emergency Stop button to the off position at the platform controls O Result The engine should turn off and all functions should not operate As a safety feature selecting and operating the ground controls will override the platform controls including the red Emergency Stop button REV B A 15 Test the Auxiliary Power Operation Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component dam
62. Engine breather Perkins models E 4 Grease axle bearings 2WD models Perform every 3000 hours E 5 Fuel injectors Perkins models Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures Checklist A Procedures REV B A 1 Inspect the Operator s and Safety Manuals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Confirm that the storage container is present and in good condition 2 Confirm thatthe operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and m
63. Ground Control Override sssseseeeene 4 47 B 13 Test the Platform Self leveling sssseeeenne 4 48 Part No 77832 Genie S 80 and Genie S 85 vii January 2004 TABLE OF CONTENTS Section 4 Rev Scheduled Maintenance Procedures continued B 14 Te t the HOM iiir ene asien 4 48 B 15 Test the Foot WIEC was z een 4 49 B 16 Testthe Engine Idle Select Operation sssseeeeee 4 49 B 17 Test the Fuel Select Operation GM Models s sssn114221 4 50 B 18 Test the Drive Enable System eeueea oo ea aaa aaa aaa aaa awinn aaa 4 51 B 19 Test the Drive Brakes zaa a ne 4 52 B 20 Testthe Drive Speed Stowed Position seeueaee aa aaa aaa aaa sznaceh 4 53 B 21 Testthe Drive Speed Raised or Extended Position 4 53 B 22 Testthe Alarm Package if equipped seeeeeee aaa aaa aaa aaa einaicaca 4 54 B 23 Inspect the Fuel Tank Cap Venting System sssssssseees 4 55 B 24 Perform Hydraulic Oil Analysis esses 4 56 B 25 Replace the Spark Plugs GM Models seen 4 56 B Checklist C Procedures C 1 Check the Engine Valve Clearances Deutz Models 11 111 4 57 C 2 Replace the Fuel Filter Element Perkins Models ssssss 4 57 C 3 Replace the Fuel Filter Water
64. N Perform this procedure with the engine off and cooled 1 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST D PROCEDURES turntable Locate the engine pivot plate anchor hole on the Install the bolt that was just removed through the engine pivot plate and into the anchor hole REV B 5 Remove and replace all of the fuel hoses and clamps according to the following illustration to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Atthe fuel filter water separator disconnect the fuel hose to the fuel tank and drain the fuel tank into a suitable container See capacity specifications Fuel tank capacity nY TTJJ Explosion and fire hazard Fuel Injection systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them OO GG b b W b 33 gallons 124 9 liters 3 Y a Cig ER S
65. NING 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 13 Attach an overhead 5 ton 5000 kg crane to the center point of the boom 14 Attach a similar lifting device to the boom lift cylinder for support 15 Place support blocks under the boom lift cylinder across the turntable 16 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom lift cylinder could fall if not properly supported 17 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 18 Remove the pin retaining fastener from the boom pivot pin 19 Use a soft metal drift to remove the boom pivot pin Carefully remove the boom from the machine AWARNING Crushing hazard The boom could become unbalanced and fall if not properly supported by the overhead crane Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 BOOM COMPONENTS How to Disassemble the Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Extension Cylinders 1 Remove the boom See 4 2 How to Rem
66. ON Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A How to Repair the Cable Track Component damage hazard CAUTION The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries Service Parts Department part no 77896 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track BOOM COMPONENTS Lift up the hoses and cables and carefully insert the new 4 link section of cable track CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Connect the ends of the replacement cable track section to the existing cable track using the snap rings Install the rollers onto the new section of cable track Operate the boom extend retract function through a full cycle to ensure smooth operation of the new
67. Perkins models Low idle 1600 rpm High idle 2300 rpm REVA B 10 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control 3 Checkall machine function from the ground controls Result All machine functions should not operate 4 Turn the key switch to ground control 5 Checkall machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA B 11 Test the Emergency Stop A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting andoperating the gro
68. Result Low idle should be 1300 rpm Skip to step 10 if the low idle rpm is correct REVA 2 Remove the secondary idle adjustment screw cap from the secondary idle adjustment screw on the injection pump Loosen the locknut Deutz engine a primary idle adjustment screw b secondary idle adjustment screw 3 Turnthe secondary adjustment screw counterclockwise until the adjustment screw is loose Tighten the locknut Be sure the adjustment screw is loosened until there is no spring tension felt 4 Remove the primary idle adjustment screw cap from the primary idle adjustment screw on the injection pump Loosen the locknut 5 Adjustthe primary idle adjustment screw until low idle is 1250 rpm Tighten the locknut 6 Install the primary idle adjustment screw cap and tighten Do not over tighten Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA 7 Loosenthe secondary idle adjustment screw locknut 8 Adjustthe secondary adjustment screw until the low idle is 1300 rpm Tighten the locknut 9 Install the secondary idle adjustment screw cap and tighten Do not over tighten 10 Move the function enable rpm select toggle switch to the high idle rabbit symbol position O Result High idle should be 2300 rpm If the high idle is correct disregard adjustment step 11 11 Loosen the yoke lock nut Turn the
69. S SS EE i a ra Nutz 6j 2d B XJ e g ATI ZEN OOOO a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 6 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 7 Swingthe engine pivot plate in towards the machine 8 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 9 Bleed the fuel system See C 3 Replace the Fuel Filter Water Separator Element Diesel Models D 8 Clean the Engine Breather Assembly Perkins Models Information to perform this procedure is available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336 E Perkins 704 30 User s Handbook Genie part number 101840 CHECKLIST D PROCEDURES D 9 Check the Engine Valve Clearances Perkins Models Information to perform this procedure is available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336 E
70. Separator Element Diesel Models 4 59 C 4 Check the Starting Aid Perkins Models seuuaa nennen 4 60 C 5 Check the Specific Gravity of the Engine Coolant Liquid cooled Models 4 61 C 6 Replace the Engine Oil and Filter Deutz and Perkins Models 4 62 C 7 Grease the Platform Overload Mechanism if equipped 4 64 C 8 Testthe Platform Overload System if equipped sssss 4 64 C 9 Replace the Engine Coolant GM Models 22440424400n nennen 4 66 C 10 Replace the PCV Valve GM Models seem 4 68 C 11 Replace the LPG Filter GM Models eeeeuaa aaa aa aaa aaa aacinnaae 4 68 C 12 Replace the Distributor Cap and Rotor GM Models 11 1 4 69 Vili Genie S 80 and Genie S 85 Part No 77832 January 2004 a a iD n TABLE OF CONTENTS Section4 Rev Scheduled Maintenance Procedures continued B Checklist D Procedures D 1 Check the Boom Wear Pads onsite intis 4 70 D 2 Check the Extendable Axle Wear Pads eeesuaaaoe aaa aasazaacech 4 70 D 3 Checkthe Free wheel Configuration sssue eos a aaa aaa aaa aaa aeizaaccca 4 71 D 4 Check the Turntable Rotation Bearing Bolts ssssseesesss 4 72 D 5 Clean the Fuel Pump Strainer Deutz Models ssseeeesss 4 73
71. The engine rpm should change to high idle 3 Release the function enable toggle switch O Result The engine rpm should change to low idle Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Turn the key switch to platform controls At the platform controls move the engine idle select toggle switch to high idle rabbit symbol Do not press down the foot switch Result The engine rpm should change to high idle Move the engine idle select toggle switch to low idle turtle symbol Result The engine rpm should change to low idle Move the engine idle select toggle switch to foot Switch activated high idle rabbit and foot switch symbol Result The engine rpm should not change to high idle Press down the foot switch Result The engine rpm should change to high idle January 2004 REVA B 17 Test the Fuel Select Operation GM Models The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made whether the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating
72. able area for burnt chafed and pinched cables 11 Install the center turntable cover and fasteners 12 Lower the boom to the stowed position and turn the engine off PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES 13 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Cables on the boom and jib boom Jib boom platform rotate manifold S 85 Inside of the platform control box 14 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 15 Swing the engine pivot plate in towards the machine 16 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury REV B A 24 Check the Batteries Genie specifications require that this procedure be performed every 100 hours Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Bat
73. aces of the fuel filter assembly PartNo 77832 Genie S 80 and Genie S 85 Section 4 e Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES REV B 3 Hold the bottom cover of the filter element and 9 Putthe bottom cover under the new element and remove the element retaining screw hold the element squarely to the filter head 9 0 Fuel filter Ensure that the element is fitted in the center against the o ring in the filter head With the assembly in this position install the element retaining screw i Genie part number 62421 Bleed the fuel system 10 Loosen the vent plug on the side of the fuel A O injection pump Ped 11 Operate the priming lever of the fuel lift pump a element retaining screw until fuel free from air comes from the vent AR lug Tighten the vent plu c o ring plug lig plug Noa 12 Clean up any fuel that may have spilled during e lower seal f bottom cover this procedure 4 Lower the bottom cover of the filter 13 Operate the starter motor for intervals of 15 seconds until the engine starts Remove the element and dispose of properly 6 Clean the inside surfaces of the filter head and the bottom cover 7 Lightly lubricate the upper seal and the o ring with clean diesel fuel and install them into the filter head 8 Lightly lubricate the lower seal with clean diesel fuel and install it into the bottom cover It is important to al
74. age Perform this procedure with the engine off 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Simultaneously hold the auxiliary power toggle Switch on and activate each boom function toggle switch Result All boom functions should operate To conserve battery power test each function through a partial cycle The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended 3 Turn the key switch to platform control 4 18 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 4 Pull outthe red Emergency Stop button to the on position at the platform controls 5 Press down the foot switch and simultaneously hold the auxiliary power toggle switch on and activate each function controller or toggle switch O Result All boom and steer functions should operate Drive functions will not operate using auxiliary power The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended To conserve battery power test each function through a partial cycle 6 Startthe engine from the platform controls Press down the foot switch 8 Holdthe auxiliary power toggle switch in the on position O Result The engine should stop 9 Startthe engine from th
75. aintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Referto the Decals section in the Genie S 80 and Genie S 85 Operator s Manualand use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed Part No 77832 Genie S 80 and Genie S 85 4 7 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in anunsafe operating condition 1 Inspectthe entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Hydraulic oil cooler and fan Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Axle wear pads Tires and wheels Engineandrelated components Limit switches and horn Alarms and beacons if equipped Nuts bolts and other fasteners Platform entry mi
76. allation or the flex plate may become damaged 5 Install the pump and torque the pump mounting plate fasteners to 30 ft Ibs 41 Nm REVA 6 3 Oil Temperature and Oil Pressure Switches Deutz Models The engine oil temperature gauge optional is an electrical gauge The engine oil temperature switch is a normally open switch and has limit contacts that are factory set The contacts will close at approximately 300 F 149 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine oil temperature will be indicated on the gauge if equipped when the key is on and the red Emergency Stop Button is pulled out to the on position The engine oil pressure gauge optional is an electrical gauge The engine oil pressure switch is a normally open switch and has limit contacts that are factory set The contacts will close at approximately 7 psi 0 48 bar When the contacts open the engine will shut off to prevent damage Engine oil pressure will be indicated on the gauge if equipped when the engine is running How to Remove the Oil Temperature and Oil Pressure Switches Perform this procedure with the engine off 1 Remove the fasteners from the engine side cover remove the cover Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 2 Tag and disconnect the wiring from the desired switch
77. and the axles should extend The axle extend function will only work while the machine is driving The steer function will override the axle extend or the axle retract function 21 Activate the boom up down and boom extend retract functions O Result The boom up down and boom extend retract functions should operate through a full cycle Drive speed maximum Raised or extended position 0 68 mph 1 1 km h 40 ft 45 5 sec 12 2 m 45 5 sec Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES Drive Enable Limit Switch Proper drive enable system operation is essential to safe machine operation and workplace safety An improperly functioning drive enable system may allow the machine to be moved into an unsafe position When the boom is rotated past one of the non steer end wheels while the machine is moving the indicator light will turn on and the drive function will continue to operate until the drive control joystick is returnedto neutral The drive enable switch must be activated to reactivate the drive function and should inform the operator that the machine may move in the opposite direction that the drive and steer controls are moved When the boom is rotated past one of the non steer end wheels and the machine is not moving the indicator light will turn on and the drive function should not operate Perform this proce
78. anuary 2004 Section 4 Scheduled Maintenance Procedures REVA B 2 Check the Engine Belt Deutz and Perkins Models Maintaining the engine belt s is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener CHECKLIST B PROCEDURES 2 Locate the engine pivot plate anchor hole on the turntable 3 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Inspect the engine belt for Cracking Glazing Separation Breaks Perkins engine Deutz engine 5 Replace the belt if any damage is found 6 Removethe engine pivot plate retaining fastener from the engine pivot plate anchor hole PartNo 77832 Genie S 80 and Genie S 85 Section
79. any air that might be in the system PLATFORM COMPONENTS 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark CAUTION the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform Part No 77832 Genie S 80 and Genie S 85 5 11 Section 5 Repair Procedures je EA PLATFORM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator AWARNING 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 squir
80. ate shift from high to low speed 4 seconds Part No 77832 Genie S 80 amp Genie S 85 5 5 Section 5 Repair Procedures January 2004 PLATFORM CONTROLS How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Push in the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 8 times Result There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode 8 Start the engine from the platform controls and press down the foot switch 9 Select a boom funciion joystick to set the threshold REV B 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the joystick back to the neutral position Just before the function
81. ator hoses and connections 8 Removethe engine pivot plate retaining fastener from the engine pivot plate anchor hole Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 9 Swing the engine pivot plate in towards the machine 10 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury CHECKLIST A PROCEDURES A 22 Check the Alternator Belt GM Models Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist Maintaining the alternator belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Openthe engine side turntable cover Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES 2 Remove the engine pivot plate retaining fastener Swing
82. ay Service Deutz models Perform every 100 hours A 21 Inspect radiator Liquid cooled models A 22 Alternator belt GM models A 23 Electrical wiring A 24 Batteries A 25 Grease rotation bearing Perform after 150 hours A 26 Drive hub oil Perform every 200 hours filter GM models A 28 Replace fuel filter A 27 Replace engine oil and GM models B 18 Drive enable system B 19 Drive brakes B 20 Drive speed stowed B 21 Drive speed raised or extended B 22 Alarm package B 23 Inspect fuel tank cap venting system B 24 Hydraulic oil analysis Perform every 400 hours B 25 Replace spark plugs GM models Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures m s MAINTENANCE INSPECTION REPORT Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this sectio
83. be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds O Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds The platform will need to be moved up and down and allowed to settle in between adjustments Confirm the setting 5 Turn the key switch to platform control Start the engine from the platform controls 6 Lift the test weight off the platform floor using a suitable lifting device Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 7 Place the test weight back onto the center of the platform floor using a suitable lifting device O Result The alarm should be off The platform overload indicator light should be off at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light and alarm turn off 8 Add an additional 10 Ib 4 5 kg test weight to the original test weight to overload the platform O Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls There may be an approximate 2 second delay before the
84. cedure with the axles fully retracted 1 Remove the cover from the rear of the turntable to access the drive limit switches 2 Visually inspect both boom up drive limit switches LS2RO and LS2RS mounted to the turntable riser at the pivot end of the boom Inspect for the following Broken or missing roller or arm Loose or missing fasteners Loose wiring 3 Manually activate the boom up drive limit switch LS2RS which is located on the engine side of the turntable riser O Result The boom up drive limit switch arm LS2RS should move freely and spring return to center REV B 4 Startthe engine from the ground controls 5 Raise the boom to just above horizontal 6 Manually activate the boom up drive limit switch LS2RO which is located on the ground controls side of the turntable riser O Result The boom up drive limit switch arm LS2RO should move freely and spring return to center 7 Lowerthe boom to the stowed position 8 Visually inspect the boom extend drive limit switch LS1RS located inside the boom at the pivot end of the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loosewiring 9 Manually activate the boom extend drive limit switch LS1RS O Result The boom extend drive limit switch arm should move freely and spring return to center 10 Extend the boom approximately 12 inches 30 5 cm 1 Manually activate the boom extend drive limit
85. connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray REVA 6 Support the barrel end of the cylinder with a lifting device 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 8 Use a soft metal drift to remove the pin and lay the cylinder onto the ground 9 Attach a lifting strap from an overhead crane to the jib boom 10 Remove the pin retaining fastener from the jib boom pivot pin 11 Use a soft metal drift to remove the pin Remove the jib boom from the jib boom bell crank AWARNING Crushing hazard The jib boom could become unbalanced and fall if not properly supported by the overhead crane when removed from the machine 12 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 13 Slide both of the jib boom leveling arms off of the jib boom pivot pin 14 Attach a lifting strap from an overhead crane to the lug at the rod end of the jib boom lift cylinder 15 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the jib boom bell crank AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported by the overhead crane when removed from the machine Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures R
86. d activate the boom down function Result The boom should lower and return to the stowed position Move and hold the function enable switch to either side and activate the boom extend function Result The boom will extend approximately 1 foot 30 cm and then stop The boom should not extend farther unless both axles are extended Section 4 Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 6 Move and hold the function enable switch to either side and activate the boom retract function O Result The boom should retract 7 Turn the key switch to platform controls 8 Press down the foot switch and move the drive control handle in the forward direction and activate the axle extend function Result The machine will drive forward and the axles should extend The axle extend function will only work while the machine is moving The steer function will override the axle extend or the axle retract function 9 Turn the key switch to ground controls 10 At the ground controls hold the function enable Switch to either side and activate the boom up and boom down function Result The boom should raise and lower normally 11 At the ground controls move and hold the function enable switch to either side and activate the boom extend and boom retract function Result The boom should extend and retract normally Part No 77832 Genie S 80 and Genie S 85 4 15 Section 4 Scheduled Mainte
87. d bolts are tight 5 Inspect all welds for cracks 6 Inspect for exhaust leaks i e carbon buildup around seams and joints 7 Removethe engine pivot plate retaining fastener from the engine pivot plate anchor hole 8 Swingthe engine pivot plate in towards the machine 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury REVA B 5 Replace the Hydraulic Filters Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns Perform this procedure with the engine off Hydraulic return filter 1 Openthe ground controls side turntable cover and locate the hydraulic return filter mounted on the hydraulic tank 2 Place a suitable container under the hydraulic tank return filter 3 Remove the filter with an oil filter wrench 4 Apply a thin layer of fresh oil to the gasket of the new oil filter Hydraulic return filter Genie part number 61326
88. d rail or gate REV B Check entire machine for Cracks in welds or structural components Dents or damage to machine Compartment covers and latches Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened After you complete your inspection be sure that all compartment covers are in place and secured 4 8 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B CHECKLIST A PROCEDURES A 4 Deutz F4L 913 Engine 14 3 quarts Check the Engine Oil Level Oil capacity including filter 13 5 liters Cil viscosity requirements e WN Below 77 F 25 C 5W 30 Maintaining the proper engine oil level is essential synthetic to good engine performance and service life 2 a 7 Operating the machine with an improper oil level 13 F to 86 F 25 C to 30 C 10W 40 can damage engine components Above 4 F 20 C 15W 40 Check the oil level with the engine off 1 Check the engine oil dipstick GM models Result The oil level should be within the ADD and FULL marks on the dipstick Deutz models Result The oil level should be within the two marks on the dipstick Perkins models Result The oil level should be within the two notches on the dipstick GM3 0L EFI Engine 5 quarts Cil capacity including filter 4 7 liters Cil viscosity require
89. dure more often if dusty conditions exist Maintaining the radiator in good condition is essential for good engine performance Operating a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING P dily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Openthe engine side turntable cover REV B 2 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole on the turntable 4 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Inspectthe radiator for leaks and physical damage 6 Clean the radiator fins of debris and foreign materials 7 Inspect all radi
90. dure with the boom in the stowed position and the axles fully extended 1 Startthe engine from the ground controls and rotate the turntable to the left until the boom is past the left non steer wheel 2 Raise the boom far enough to access the boom storage cover fasteners Turn the engine off 3 Remove the boom storage cover mounting fasteners Remove the cover 5 9 REV B Locate the drive enable limit switch LS3 next to the hydraulic rotary coupler Visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loosewiring Manually activate the drive enable limit switch LS3 Result The drive enable limit switch arm should move freely and spring return to center Install the boom storage cover and install the mounting fasteners Start the engine from the ground controls and lower the boom to the stowed position Turn the key switch to platform controls 10 Press down the foot switch 1 Result The drive enable indicator light should be on Rotate the turntable so the boom is between the non steer wheels Result The drive enable indicator light should be off and drive function should operate 12 Rotate the turntable until the boom moves past one ofthe the non steer wheels Result The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown 4 22 Ge
91. e AWARNING T ushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine 5 16 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 4 1 Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom How to Remove the Cable Track When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Openthe platform control box 2 Tag and disconnect the foot switch wiring from the terminal strip inside the platform control box 3 Loosen the squeeze connector and remove the foot switch cable from the control box 4 Disconnect the wire connectors from the bottom of the platform control box When installing the wire connectors to the bottom of the platform control box match the color of the connectors to those on the control box to be sure they are installed in the correct location Boom Components 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly of
92. e condition Hydraulic Pumps 2 Tag disconnect and plug the hydraulic hoses from the function pump Cap the fittings on the pump AWARNING 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 3 Remove the pump mounting fasteners Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves if equipped and prime the pump after installing the pump See 8 2 How to Prime the Pump Part No 77832 Genie S 80 and Genie S 85 5 37 Section 5 Repair Procedures January 2004 HYDRAULIC PUMPS 8 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDO located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended W
93. e cotter pin from the castle nut Always replace the cotter pin with anew one when removing the castle nut or when checking the torque of the castle nut 7 Tighten the castle nut to 35 ft Ibs 47 Nm to seatthe bearings 8 Loosen the castle nut then torque the castle nut to 8 ft Ibs 11 Nm 9 Checkfor wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is side to side or up and down movement proceed to step 10 to replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced Result If there is no side to side or up and down movement grease the wheel bearings 10 Remove the castle nut Always replace the cotter pin with anew one when removing the castle nut or when checking the torque of the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub REV B 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the inner bearing 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle CAUTION Component damage
94. e ground controls 10 Hold the auxiliary power toggle switch in the on position O Result The engine should stop CHECKLIST A PROCEDURES A 16 Test the Tilt Sensor and Alarm The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate Select a level test area The tilt alarm should not be sounding prior to the test 1 Startthe engine from the platform controls 2 Openthe tank side turntable cover and locate the tilt sensor next to the ground control box 3 Press down on one side of the tilt sensor O Result The alarm located in the platform should sound Tip over hazard The alarm should AWARNING be audible at the ground controls If the alarm is not audible at the ground controls replace the alarm in the platform Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES A 17 Test the Limit Switches Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches have two functions To restrict drive speed when the boom is raised or extended and to prevent raising the boom past horizontal or extending the boom more than 12 inches 30 5 cm unless the axles are fully extended An improperly functioning drive limit Switch will allow the machine to operate in an unsafe position Perform this pro
95. e how long it takes the function to reach maximum speed This is the ramp rate 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease 11 While the joystick is activated set the ramp rate Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time Each time the drive enable toggle switch is momentarily moved the time will change in 1096 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 13 Return the joystick to the neutral position and wait for approximately 10 seconds Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Ramp rate factory settings Boom up down and turntable rotate should sound 6 times indicating that the accelerate 3 seconds machine is in ramp rate calibration mode decelerate 1 second 8 Start the engine from the platform controls and Boom extend retract press down the foot switch accelerate 4 seconds decelerate 1 second Drive accelerate 4 seconds decelerate to neutral 0 5 second decelerate change of direction 0 75 second decelerate coasting 1 second decelerate braking 1 second decelerate shift from low to high speed 1 second deceler
96. e models Title Part No Genie S 80 and Genie S 85 72062 Service Manual from serial number 966 to 3081 Copyright 2002 by Genie Industries 77832 Rev B1 January 2004 Genie and S are registered trademarks of Genie Industries in the USA and many other countries r 4 Printed on recycled paper Printed in U S A ii Genie S 80 and Genie S 85 PartNo 77832 January 2004 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 80 and Genie S 85 Operators Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance andrepair procedures are performed Do Not Perform Maintenance Unless M Youare trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Part No 77832 Genie S 80 and Genie S 85 iii Section 1 Safety Rules January 2004 SAFETY RULES 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 ofthe machine should be your top priority Read each procedu
97. eeeneneen nenne nennen nennen 4 11 A 8 Check the Hydraulic Oil Level seseeeeenennennns 4 12 A 9 Check for Hydraulic Leaks inisinia aaas 4 13 A 10 Check the Hydraulic Filter Condition Indicators sesessssss 4 13 A 11 Check the Tire Pressure ssssssssssseeeseeeeeneeeeeneeenn nennen nns 4 14 A 12 Test the Extendable Axles e eeeo see eee aaa anaa 4 15 A 13 Test the Oscillate Axle oooee ooo aaa aaa aaa nnns 4 16 A 14 Testthe Platform and Ground Controls ee sseaa aaa aa aaa aaaaaesnnae 4 17 A 15 Testthe Auxiliary Power Operation eeeeeeee aaa aaa aaa aaa asza cenna 4 18 A 16 Test the Tilt Sensor and Alarm eeeeeeee aaa aaa eee aaa aaa aaa aaaaaaacaa 4 19 A 17 Te tthe Limit Switches een 4 20 A 18 Drain the Fuel Filter Water Separator Diesel Models 4 23 A 19 Perform 30 Day Service usssnnssnsnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannn ran 4 24 vi Genie S 80 and Genie S 85 PartNo 77832 January 2004 TABLE OF CONTENTS Section4 Rev Scheduled Maintenance Procedures continued A 20 Check the Engine Fasteners Deutz Models 4 25 A 21 Inspectthe Radiator Liquid cooled Models sssessesssssssss 4 26 A 22 Check the Alternator Belt GM Models seseeee 4 27 A 23 Inspect the Electrical Wiring
98. elt plug for leaks Deutz and Perkins Models ADANGER Explosion and fire hazard If a fuel B 5 Replace the Hydraulic Filters leak is discovered keep any additional personnel from entering B 8 Check the Oil Level in the the area and do not operate the Drive Hubs a di R C 1 Check the Engine Valve immediately Clearances Deutz Models C 6 Replace the Engine Oil and Filter Deutz and Perkins Models D 4 Check the Turnable Rotation Bearing Bolts D 6 Replace the Fuel Filter Deutz Models D 9 Check the Engine Valve Clearances Perkins Models 4 24 Genie S 80 and Genie S 85 PartNo 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B A 20 Check the Engine Fasteners Deutz Models Engine specifications require that this one time procedure be performed after the first 40 hours of use Properly torqued engine fasteners are essential to good engine performance and operational safety Loose or improperly torqued fasteners can result in engine component damage and hazardous conditions 1 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener 2 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine CHECKLIST A PROCEDURES 3 Locate the engine pivot plate anchor hole on the turntable 4 Install the bolt that
99. emove all rings watches and other jewelry 6 Remove the platform control box mounting fasteners Lower the control box and set it aside Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal Part No 77832 Genie S 80 and Genie S 85 5 9 Section 5 Repair Procedures January 2004 PLATFORM COMPONENTS 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered to correct a malfunction bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom approximately 3 feet 1 m and place a struct
100. ervice life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often JW Tdi Explosion and fire hazard Engine fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Openthe ground controls side turntable cover and locate the fuel filter behind the ground control box 2 Turn the manual shutoff valve located at the fuel tank to the closed position if equipped 3 Atthe fuel filter tag and disconnect and plug the fuel supply hose that goes to the fuel tank Clean up and fuel that may have spilled CHECKLIST A PROCEDURES 4 Tagand disconnect and plug the fuel hose from the fuel filter to the fuel pump Remove the fuel filter 5 Install the new fuel fuel filter and connect the fuel hoses to the filter Fuel filter Genie part number 65626 6 Clean up any fuel that may have spilled during the installation procedure 7 Turnthe manual shutoff valve located at the fuel tank to the open position if equipped 8 Startthe machine from the ground controls and inspect the fuel filters and hoses for leaks 9 Properly dispose of the used fuel filter Explosion and fire hazard If a fuel ADANGER nwt
101. ey is on and the red Emergency Stop Button is pulled out to the on position The engine oil pressure gauge optional is an electrical gauge The engine ECM monitors the engine oil pressure and will shut the engine off when the oil pressure falls below 8 psi 0 55 bar to prevent damage How to Remove the Coolant Temperature and Oil Pressure Sending Units Perform this procedure with the engine off 1 Tagand disconnect the wiring from the desired sending unit Remove the sending unit from the engine block The coolant temperature sending unit is located at the thermostat housing The oil pressure switch is located on the oil filter side of the engine block near the flywheel end Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures SSS SEES REVA ENGINES 2 Install the new sending unit or switch and 6 6 torque to specification Timing Adjustment 3 Connect the wires to the new sending unit or switch The ignition timing is controlled by ACAUTION Burn hazard Contact with hot the engine ECM and can only be engine fluids or components may adjusted by re programming the cause severe burns engine ECM If timing adjustment or service is required please Always use pipe thread sealant contact Genie Industries Service when installing a sending unit or Department or your local GM switch dealer Coolant temperature sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex si
102. f to the side 6 S 80 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING 799 injury hazard Spraying 7 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 Tag disconnect and plug the hydraulic hoses from the platform leveling slave cylinder at the union and connect the hoses from the cylinder together using a connector AWARNING 799 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 S 85 8 Remove the hose and cable cover from the side of the jib boom Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate select manifold Cap the fittings on the manifold Part No 77832 Genie S 80 and Genie S 85 5 17 Section 5 Repair Procedures January 2004 BOOM COMPONENTS 10 Tag disconnect and plug the wiring from the jib boom platform rotate select manifold 11 Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pre
103. fer to Repair Procedure 4 2 How to Shim the Boom 1 Startthe engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad if itis less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag 4 Extendandretract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Boom wear pad specifications Upper and lower wear pads 7 16 inch minimum thickness 11mm Side wear pads 9 16 inch minimum thickness 14 3 mm REV B D 2 Check the Extendable Axle Wear Pads Maintaining the axle wear pads in good condition is essential to safe machine operation Wear pads are placed on axle tube surfaces to provice a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions If the wear pads are not worn below specification but are still within specification refer to Repair Procedure 16 1 How to Shim an Extendable Axle 1 Startthe engine from the platform controls and extend the axles 2 Measure each wear pad Replace the wear pad if itis less than specification If the wear
104. h part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N 2 no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 4 Scheduled Maintenance Procedures January 2004 ZA This page intentionally left blank 4 4 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn ho
105. hazard Do not apply excessive force or damage to the lip of the seal may occur 17 Place the outer bearing into the hub 18 Install the washer and castle nut 19 Torque the castle nut to 35 ft lbs 47 Nm to seat the bearings 20 Loosen the castle nut then torque the castle nut to 8 ft Ibs 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in place Always replace the cotter pin with anew one when removing the castle nut or when checking the torque of the castle nut 22 Install the dust cap Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B CHECKLIST E PROCEDURES 23 Install the tire and wheel assembly Torque the E 5 wheel lug nuts to 420 ft Ibs 569 5 Nm Check the Fuel Injectors _ 24 Center a lifting jack under the steer axle Perkins Models 25 Raise the machine approximately 6 inches 15 cm Remove the blocks from U Fo under the drive chassis N h i 26 Lower the machine Engine specifications require that this procedure be performed every 3000 hours or 18 months whichever comes first Information to perform this procedure is available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336 E Perkins 704 30 User s Handbook Genie part number 101840 PartNo 77832 Genie S 80 and Genie S 85 4 87 Section 4 Scheduled Maintenance Procedures January 2004 ZA This page intentio
106. he neutral position pause for a moment then move the joystick full stroke in the opposite direction Hold for 5 seconds and return the joystick to the neutral position O Result The alarm should sound indicating successful joystick calibration 6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch No machine fuction should operate while performing the joystick calibration procedure Part No 77832 Genie S 80 amp Genie S 85 5 3 Section 5 Repair Procedures January 2004 PLATFORM CONTROLS How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick controlled machine function Whenever a hydraulic cylinder drive motor or hydraulic pump is replaced the max out setting should be adjusted to maintain optimum performance The max out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Push in the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch Move and hold the drive enable toggle switch in the right position and pull out the red Emergenc
107. he platform end of the tank side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 18 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease type Multipurpose grease PartNo 77832 Genie S 80 and Genie S 85 4 31 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES A 26 Replace the Drive Hub Oil Specifications require that this procedure be performed after 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees REV B 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Install the plugs 5 Repeatthis procedure for each drive hub Drive hubs Capacity 61 fl oz 1 8 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Drive Hub When remov
108. he platform overload indicator light should be off at both the ground and platform controls 6 Add an additional 66 Ibs 30 kg of weight to overload the platform O Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 10 Calibrate the Platform Overload System There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds CHECKLIST C PROCEDURES 7 Carefully move the test weights to each remaining location in the platform O Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 10 Calibrate the Platform Overload System There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 8 Testall machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all mac
109. hen removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump REV A 2 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank ii open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosED position or 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 3 Tag disconnect and plug the hydraulic hoses from the drive and function pumps Cap the fittings on the pumps AWARNING 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 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 4 Support the pumps with a suitable lifting device and remove the two
110. high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz models Low idle 1300 rpm High idle 2300 rpm CHECKLIST B PROCEDURES Perkins models 1 Connecta tachometer to the engine Start the engine from the ground controls Result Low idle should be 1600 rpm Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm Perkins models solenoid boot yoke lock nut low idle adjustment screw low idle lock nut yoke high idle adjustment nut oooonqv Move the function enable rpm select toggle switch to the high idle rabbit symbol position Result High idle should be 2300 rpm PartNo 77832 Genie S 80 and Genie S 85 4 45 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle
111. hine functions from the ground controls O Result All ground control functions should not operate Machine functions should still operate with auxiliary power at the ground controls Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES 11 Lift the test weights off the platform floor using a suitable lifting device O Result The platform overload indicator light and alarm should turn off at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light and alarm turn off 12 Test all machine functions from the ground controls O Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls O Result All platform control functions should operate If the platform overload system is not operating properly see D 10 Calibrate the Platform Overload System REV B C 9 Replace the Engine Coolant GM Models GM engine specifications require that this procedure be performed every 800 hours Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently
112. hine operation An unsafe working condition exists if any function fails to operate properly or either red Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 2 Start the engine from the platform control 3 Press down the foot switch and extend the axles The axle extend function will only work while the machine is moving 4 Turn the key switch to ground controls Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch O Result All boom and platform functions should notoperate CHECKLIST A PROCEDURES 6 Hold the function enable switch to either side and activate each boom and platform function toggle switch O Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering The boom will not raise past horizontal and the boom will not extend more than 12 inches 30 5 cm unless both axles are fully extended 7 Push in the red Emergency Stop button to the off position at the ground controls Result The engine should turn off and all functions should not operate 8 Turn the key switch to platform control and pull out the red
113. ice life A dirty or worn cap and rotor may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the cap and rotor be replaced more often Perform this procedure with the engine off 1 Openthe engine side turntable cover 2 Locate the distributor above the oil filter 3 Tagand disconnect the coil and spark plug wires from the distributor cap 4 Removethe distributor cap retaining fasteners Remove the distributor cap 5 Remove the rotor from the distributor 6 Install the new rotor and distributor cap Tighten the distributor cap retaining fasteners Distributor cap and rotor Genie part numbers 65624 65625 Distributor cap Rotor 7 Install the coil and spark plug wires Be sure that each spark plug wire is in the correct location on the distributor cap attached to the correct spark plug Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 Checklist D Procedures D 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions If the wear pads are still within specification re
114. ight of machine Ses Serial Plate for weight of your machina Capacity maximum 600 Ibs 500 Ibs Platform dimensions 6 ft 8ft 6 foot platform 272 kg 227 kg Standard Optional Capacity maximum 500 Ibs 500 Ibs Length 72 in 96 in 8 foot platform 227 kg 227 kg 182 8 cm 243 8 cm Capacity maximum Width 30 in 36 in with foam filled tires and proper 750 Ibs N A 76 2 cm 91 4 cm counterweight configuration 340 kg N A Allowable side force maximum 150 Ibs 150 Ibs ANSI and CSA 667 N 667 N Allowable side force maximum 90 Ibs 90 Ibs CE 400 N 400 N Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 77832 Genie S 80 and Genie S 85 Section 2 Specifications January 2004 SPECIFICATIONS Tires and wheels Tire size 15 22 5 SAT 385 65 22 5 Tire ply rating 16 Overall tire diameter 43 5 in 110 5 cm Tire pressure 100 psi 6 9 bar Wheel diameter 22 5 in 57 cm Wheel width 11 75 in 29 8 cm Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft Ibs 569 4 Nm Lug nut torque lubricated 315 ft Ibs 427 Nm Fluid capacities Fuel tank 33 gallons 124 9 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters Drive hubs 61 fl oz 1 8 liters Turntable rotation drive hub 32 fl oz 0 95 liters REV A Performance Specifications D
115. ing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor 3 Attach a suitable lifting device to the lifting eyes located near the drive motor Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 4 Removethe drive hub mounting bolts Carefully remove the turntable rotate drive hub assembly from the machine AWARNING Crushing hazard Theturntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device 5 Remove the plug from the side of the drive hub Drain the oil from the hub into a suitable container a motor b drive hub c drive hub mounting bolts 6 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to 75 ft Ibs 101 7 Nm CHECKLIST A PROCEDURES 7 Fillthe drive hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug Install the plug 8 Adj
116. ing on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position high enough that the boom lift cylinder rod end can clear the boom lift cylinder mounting boss 2 Remove the center turntable cover fasteners Remove the cover 3 Place support blocks under the boom lift cylinder across the turntable side plates 4 Attach an overhead 5 ton 5000 kg crane to the boom for support Do not lift the boom Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures rmm B X M R r BOOM COMPONENTS 5 Support the rod end of the boom lift cylinder with an overhead crane or similar lifting device AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall when it is disconnected from the machine if not properly supported 6 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 2odily 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 7 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin and lower the
117. ires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 Check the pressure in each air filled tire Add air as necessary Tires and wheels Tire size 15 22 5 SAT 385 65 22 5 Pressure 100 psi 6 9 bar Tire ply rating 16 Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 433 9 Nm Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA B 8 Check the Oil Level in the Drive Hubs Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage DriveHubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees a drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealant to the plug s and install the plug s in the drive hub 5 Repeatthis procedure for each drive hub Drive huboil Capacity 61 fl oz 1 8 liters
118. ith a damp cloth 5 Install the the new air filter element Air filter element Genie part numbers Deutz models 62425 GM and Perkins models 62420 6 Install the end cap onto the canister Secure the clamps CHECKLIST B PROCEDURES B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING 2odily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of hot ACAUTION engine components Contact with hot engine components may cause severe burns 1 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a engine pivot plate anchor hole b engine pivot plate retaining fastener Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST B PROCEDURES 2 Locate the engine pivot plate anchor hole on the turntable 3 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Be sure that all nuts an
119. kes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 6 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions Perform this procedure with the boom in the stowed position 1 Mark atest line on the ground for reference Start the engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line REVA 4 Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test line 5 Measure the distance between the test line and your machine reference point Braking distance maximum High range on paved surface 3ft 90 cm The brakes must be able to hold the machine on any slope it is able to climb Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA B 20 Test the Drive Speed Stowed Position Proper drive function movement is essential to safe machine operation The drive functi
120. lant recovery tank Add coolant if needed E 3 Replace the Engine Air Breather Perkins Models Information to perform this procedure is available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336 E Perkins 704 30 User s Handbook Genie part number 101840 CHECKLIST E PROCEDURES E 4 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe non steer wheels Center a lifting jack under the steer axle 3 Raisethe machine approximately 6 inches 15 cm Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Checkfor wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST E PROCEDURES 6 Remove the dust cap from the hub and remove th
121. leveling arms ACAUTION Crushing hazard The platform rotator may become unbalanced and fall if not properly supported When installing the platform rotator fasteners torque the fasteners to specifications Torque specifications 1 8 center bolt grade 2 200 ft Ibs 271 Nm 1 8 center bolt grade 8 480 ft lbs 651 Nm 3 8 16 bolts 47 ft lbs 63 7 Nm Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Connecta clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom a top bleed valve b bottom bleed valve c clear hose d container 2 Move the platform rotate toggle switch to the left and then to the right through two platform rotation cycles continue holding the switch to the right until the platform is fully rotated to the right PLATFORM COMPONENTS 3 Open the top bleed valve but do not remove it 4 Move the platform rotate toggle switch to the left until the platform is fully rotated to the left Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 5 Connect the clear hose to the bottom bleed valve Open the bot
122. lift cylinder onto the blocks Protect the cylinder rod from damage AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall when it is disconnected from the machine if not properly supported January 2004 REVA 8 Remove the mounting fasteners from the barrel end cylinder pin retaining plates 9 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform and remove it from the machine AWARNING Crushing hazard The lift cylinder CAUTION could become unbalanced and fall if not properly supported Component damage hazard The cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 4 4 Extension Cylinders The extension cylinder consists of two cylinders that are fastened together The first cylinder extends and retracts the number 2 boom tube The second cylinder extends and retracts the number 3 boom tube The extension cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinders AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer
123. low the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel System there is probably a leak in the low pressure side of the system 4 58 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B C 3 Replace the Fuel Filter Water Separator Element Diesel Models Replacing the diesel fuel filter water separator element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Openthe engine side turntable cover and locate the fuel filter water separator The fuel filter water separator is located near the hydraulic pump 2 Disconnect and plug the fuel hose from the fuel tank at the fuel filter water separator head 3 7 CHECKLIST
124. lter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed 5 a clamp b cannister end cap c dust discharge valve 2 Release the clamps from the end cap of the air filter canister Remove the end cap Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B Remove the filter element 4 Clean the inside of the canister and the canister end cap with a damp cloth 5 Inspectthe filter element If needed blow from the inside out using low pressure dry compressed air or tap out dust taking care not to damage the element Install the filter element 7 Install the end cap onto the canister Secure the clamps Air filter element Genie part numbers Deutz models 62425 GM and Perkins models 62420 CHECKLIST A PROCEDURES A 7 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury ADANGER Explosion and fire hazard Engine fuels are combustible Inspect the machine in an open well ventilated area away from heaters spark
125. ments Below 0 F 17 8 C 5W 30 Above 0 F 17 8 C 10W 30 Only use engine oils labeled For Gasoline Engines by the American Petroleum Institute API Engine oil should have minimum properties of API classification CD grade OR ACEA classification E1 96 Perkins 704 30 Engine 7 4 quarts Oil capacity including filter 7 liters Cil viscosity requirements 13 F to 68 F 25 C to 20 C 5W 20 5 F to 104 F 15 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Engine oil should have minimum properties of API classification CC SE Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES A 5 Check the Engine Coolant Level Liquid cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap REV B A 6 Inspect the Engine Air Filter Maintaining the engine air fi
126. n relief pressure 2900 psi measured at PTEST port 200 bar Boom down relief pressure 2100 psi measured at PTEST port 145 bar Boom extend 2500 psi measured at PTEST port 172 bar Steer axle extend 3 5 gpm flow regulator 13 2 L min Oscillate relief pressure 950 psi 65 5 bar Drive manifold Hot oil relief pressure 280 psi 19 3 bar Brakes Brake release pressure 215 psi 14 8 bar Drive motors Displacement per revolution variable 0 9 to 2 7 cu in 2 speed motor 14 7 to 45 cc Hydraulic filters High pressure filter Beta 3 gt 200 High pressure filter 102 psi bypass pressure 7 bar Medium pressure filter Beta 3 gt 200 Medium pressure filter 51 psi bypass pressure 3 5 bar Hydraulic tank circuit 10 micron with return line filter 25 psi 1 7 bar bypass 2 4 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 2 Specifications REVA GM 3 0L EFI Engine Displacement 181 cu in 3 liters Number of cylinders 4 Bore amp stroke 4 x 3 6 inches 101 6 x 91 44 mm Horsepower Intermittent 67 Q 2300 rpm Continuous 60 2300 rpm Firing order 1 3 4 2 Low idle 1650 rpm High idle 2300 rpm Compression ratio 9 25 1 Compression pressure minimum 100 psi Pressure psi or bar of lowest cylinder 6 9 bar must be at least 75 of highest cylinder Valve clearances Zero lash 1 full turn Lubrication system SPECIFICATIONS Starter motor
127. n to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist C Rev B Y NR January 2004 Checklist D Rev B Y NR C 1 Valve clearances Deutz models C 2 Replace fuel filter Perkins models C 3 Replace filter separator Diesel models C 4 Starting aid Perkins models C 5 Engine coolant Liquid cooled models C 6 Engine oil and filter Deutz and Perkins models C 7 Grease platform overload if equipped C 8 Test platform overload if equipped Perform every 800 hours C 9 Engine coolant GM models C 10 PCV valve GM models C 11 LPG filter GM models C 12 Cap and rotor GM models D 1 Boom wear pads D 2 Axle wear pads D 3 Free wheel configuration D 4 Turntable rotation bearing bolts D 5 Fuel pump strainer Deutz models D 6 Replace fuel filter Deutz models D 7 Replace fuel hoses Deutz models D 8 Clean engine breather Perkins models D 9 Valve clearances Perkins models D 10 Calibrate platform overload if equipped Perform every 1500 hours D 11 Drive hub oil Checklist E Rev B E 1 Hydraulic oil E 2 Engine coolant Liquid cooled models E 3
128. nally left blank 4 88 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie S 80 and Genie S 85 Operator s Manual M Be sure that all necessary tools and parts are available and ready for use M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions MI Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boomin the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be
129. nance Procedures January 2004 CHECKLIST A PROCEDURES A 13 Test the Oscillate Axle Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over ADANGER Tip over hazard Failure to perform this procedure on a firm level surface will compromise the stability of the machine and could result in the machine tipping over 1 Start the engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb O Result The non steer tires should stay in firm contact with the ground If the chassis does not remain level during test see How to Adjust the Oscillate Limit Switches REV B How to Set Up the Directional Valve Linkage Perform this procedure on a firm level surface 1 Lowerthe boom to the stowed position 2 Use a bubble type level to be sure the surface the machine is on is completely level ADANGER Tip over hazard Failure to perform this proced
130. nd Genie S 85 5 25 Section 5 Repair Procedures January 2004 ee BOOM COMPONENTS REVA 10 Remove the external snap rings from the 15 Remove the trunnion pin retaining fastener and extension cylinder pivot pin at the pivot end of use a slide hammer to remove the pins the boom Use a soft metal drift to remove the pin through the access holes in the turntable riser 16 Support and slide the extension cylinder out of the pivot end of the boom AWARNING Crushing hazard The extension cylinder could become unbalanced and fall when it is removed from the machine if not properly supported 11 Using auxiliary power move the boom extend retract toggle switch in the extend direction and extend the extension cylinder out the pivot end of the boom approximately 1 foot 30 cm 12 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Note the length of the cylinder after removal The cylinder must be at the same length for AWARNING Bodily injury hazard Spraying installation 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 13 Attach a lifting strap from an overhead crane to the end of the extension cylinder and lift slightly to relieve the pressure on the trunnion pins 14 Remove the trunnion pin access covers from both sides of the number 1 boom tube at the
131. nd high pressure filters from the filter mounting bracket Do not disconnect the hydraulic hoses Remove the medium and high pressure filter bracket mounting fasteners Remove the bracket from the engine tray Support the drive pump assembly with an appropriate lifting device Remove all of the pump mounting plate to engine bell housing bolts Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Part No 77832 Genie S 80 and Genie S 85 5 29 Section 5 Repair Procedures January 2004 ENGINES How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump 2 Apply Loctite removable thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 30 ft Ibs 41 Nm 3 Install the coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between the coupler and pump end plate for your engine Pump coupler gap specification Deutz models 0 185 inch 4 7 mm GM models 0 15 inch 3 8 mm Perkins models 0 3 inch 7 6 mm 4 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 20 ft Ibs 27 Nm Component damage hazard Do CAUTION not force the drive pump during inst
132. nd require no adjustment The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls If a joystick error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 2 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion a ALC 500 circuit board b drive steer joystick controller c boom extend retract joystick controller d boom up down and turntable rotate left right joystick controller REV B 1 1 ALC 500 Circuit Board AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated See 1 2 How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted to the inside of the platform control box AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings
133. ne until the coolant has circulated the cooling system 3 Stopthe engine 4 Allow the engine to cool until the temperature of the coolant is below 140 F 60 C A CAUTION Burn hazard Beware of hot coolant Contact with hot coolant may cause severe burns CHECKLIST C PROCEDURES 5 Slowly remove the radiator filler cap Inspect the cap for wear Replace as necessary ACAUTION Burn hazard Allow any pressure to dissipate gradually before removing the radiator cap 6 Drain some coolant from the cooling system into a suitable container 7 Useacoolant hydrometer to check the temperature and specific gravity of the coolant 8 Adjust the strength of the coolant as necessary for your climate 9 Install the radiator filler cap Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST C PROCEDURES C 6 Replace the Engine Oil and Filter Deutz and Perkins Models Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Burn hazard Beware of hot engine ACAUTION parts and oil Contact with hot engine oil and o
134. ngs Boom up 89 to 93 seconds Boom down 90 to 94 seconds Boom extend 73 to 79 seconds Boom retract 79 to 84 seconds Turntable rotate 360 boom fully stowed 80 to 84 seconds 5 4 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV B How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 6 times Result There should be a pause and the alarm PLATFORM CONTROLS 9 Start a timer and simultaneously move the joystick in either direction full stroke Not
135. nie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 13 Slowly move the drive control handle off center O Result The drive function should not operate 14 Rotate the turntable until the boom moves past the other non steer wheel Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 15 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate AWARNING Collision hazard Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved 4 Yellow CHECKLIST A PROCEDURES A 18 Drain the Fuel Filter Water Separator Diesel Models Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Explosion and fire hazard Engine ADANGER e 1 fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the
136. nism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a mulit purpose grease REV B C 8 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine from the platform controls 2 Levelthe platform 3 Determine the maximum platform capacity Refer to the machine serial plate Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 4 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown O Result The platform overload indicator light should be off at both the ground and platform controls 5 Carefully move the test weight to each remaining location O Result T
137. nnect the hose from the coolant recovery tank to the radiator REV B 9 Openthe drain valve on the engine block and allow the coolant to drain into a suitable container After the fluid has drained close the drain valve 10 Replace all coolant hoses and clamps 11 Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full Install the radiator cap 12 Fill the coolant recovery tank to the NoRMAL range 13 Clean up any coolant that may have spilled during this procedure 14 Start the engine from the ground controls and let it run for 30 seconds Turn the engine off and inspect for leaks 15 Check the coolant level in the coolant recovery tank Add coolant if needed 16 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 17 Swing the engine pivot plate in towards the machine 18 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 19 Start the engine from the ground controls and let it run until it reaches normal operating temperature 20 Turn the engine off Allow the engine to cool 21 Check the coolant level in the coo
138. nnene 2 5 Deutz FAL 913 Engine Specifications sssaaa sonaa aea aa 2 6 Perkins 704 30 Engine Specifications sssseeeeene 2 7 Hydraulic Hose and Fitting Torque Specifications ssseeessss 2 8 Theory of Operation POWETSOUTCE E 3 1 Hydraulic System e cates ce cause 3 1 Electrical System uuu ea 3 1 Limit Switches em 3 2 Machine Controls CP 3 2 Part No 77832 Genie S 80 and Genie S 85 V January 2004 p R TABLE OF CONTENTS Section 4 Rev Scheduled Maintenance Procedures INTPOCUCHON esi 4 1 Pre Delivery Preparation a cuiii tree tcc O nen 4 3 Maintenance Inspection Report uuusenssssnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nennen 4 5 B Checklist A Procedures A 1 Inspect the Operator s and Safety Manuals sssseeee 4 7 A 2 Inspect the Decals and Placards sseeeenn 4 7 A 3 Inspect for Damage and Loose or Missing Parts 2 1 1111 4 8 A 4 Check the Engine Oil Level eesessesesseenmenennnmeeen nens 4 9 A 5 Check the Engine Coolant Level Liquid cooled Models 4 10 AG Inspect the Engine Air Filter eeeeeeseeeeeeeeceneeeeeene 4 10 A 7 Check for Fuel Leaks ssssssssssseseeeen
139. ntinuity zero Q terminal 1 to 3 4 5 and 6 no continuity infinite Q terminal 2 to 3 4 5 and 6 no continuity infinite Q terminal 3 to 4 5 and 6 no continuity infinite Q terminal 4 to 5 continuity zero Q Single pole terminal 4 to 6 no continuity double throw infinite Q SPDT terminal 5 to 6 no continuity Double pole infinite Q double throw DPDT 5 8 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures Platform Components REV A 2 1 7 Support and secure the platform to an Platform appropriate lifting device 8 Remove the platform mounting fasteners and How to Remove the Platform remove the platform from the machine Crushing hazard The platform AWARNING could become unstable and fall when it is removed from the 2 Remove the mounting fasteners from the power machine if not properly supported to platform outlet box bracket Lay the outlet box and bracket assembly off to the side 1 Remove the cable clamp from the top of the platform mounting weldment Remove the foot switch mounting fasteners Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals 5 Tagand disconnect the foot switch wiring from the foot switch Remove the cable from the back of the platform Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury R
140. od machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Openthe engine side turntable cover 2 Removethe engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine engine pivot plate anchor hole engine pivot plate retaining fastener o CHECKLIST A PROCEDURES 3 Locate the engine pivot plate anchor hole on the turntable 4 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine wiringharness Hydraulic manifold wiring 6 Openthe ground controls side turntable cover Inspect the following areas for burnt chafed corroded pinched and loose wires Inside of the ground control box Hydraulic manifold wiring 8 Startthe engine from the ground controls and raise the boom above the turntable covers 9 Remove the center turntable cover fasteners Remove the cover 10 Inspect the turnt
141. oggle switch to the LPG position atthe ground controls 3 Startthe engine from the ground controls 4 Close the valve on the LPG tank by turning it clockwise 5 Allow the engine to run until it dies to bleed off any LPG pressure left in the system Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 6 Slowly remove the LPG hose from the LPG filter Burn hazard Beware of escaping ACAUTION LPG gas or liquid Contact with LPG gas and or liquid may cause severe burns Loosen LPG connections very slowly to allow the LPG pressure to dissipate gradually Do not allow the LPG gas and or liquid squirt or spray 7 Remove the LPG filter from the LPG tank 8 Install the new LPG filter onto the tank and connect the LPG hose to the filter Be sure the arrow on the filter indicating flow direction is pointing towards the engine LPGFilter Genie part number 65627 9 Open the valve on the LPG tank fully by turning it counterclockwise 10 Start the engine from the ground controls and check for leaks An LPG detector may be necessary to locate LPG leaks CHECKLIST C PROCEDURES C 12 Replace the Distributor Cap and Rotor GM Models GM engine specifications require that this procedure be performed every 800 hours Replacement of the distributor cap and rotor at the scheduled maintenance interval is essential to good engine performance and serv
142. on should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions Perform this procedure with the boom in the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 4 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 5 Continue atfull speed and note the time when the machine reference point crosses the finish line Drive speed maximum Stowed position 3 3 mph 5 3 km h 40 ft 8 2 sec 12 2 m 8 2 sec CHECKLIST B PROCEDURES B 21 Test the Drive Speed Raised or Extended Position Proper drive function movement is esseniial to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet
143. ontinuity T RE E zero Q 7 red to white no continuity red infinite Q white black black to white no continuity Em infinite Q TOEIC Part No 77832 Genie S 80 amp Genie S 85 5 7 Section 5 Repair Procedures January 2004 PLATFORM CONTROLS 1 4 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching requires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the off position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed to check for continuity REV B Test Desired result Left position terminal 1 to 2 3 4 5 and6 no continuity infinite Q terminal 2 to 3 continuity zero Q terminal 2 to 4 5 and 6 no continuity infinite Q terminal 3 to 4 5 and 6 no continuity infinite Q terminal 4 to 5 and 6 no continuity infinite Q terminal 5 to 6 continuity zero Q There are no terminal combinations that will produce continuity Center position infinite Q Right position terminal 1 to 2 co
144. orms for three years 4 2 Genie S 80 and Genie S 85 Part No 77832 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie Genie Industries USA 18340 NE 76th Street PO Box 97030 Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after eac
145. ove the Boom 2 Remove the external snap rings from the extension cylinder pivot pin at the pivot end of the number 1 boom tube Use a soft metal drift to remove the pin 3 Remove and label the wear pads from the top side and bottom of the 1 boom tube at the platform end of the boom Pay careful attention to the location and quantity of shims used with each wear pad 4 Remove the two wear pad stop bolts from each side of the number 1 boom tube located on the outside 5 Attach a lifting strap from an overhead crane to the number 2 and number 3 boom tubes at the platform end of the boom for support REVA 6 Support and slide the number 2 and 3 boom tubes out of the number 1 boom tube Place the number 2 and 3 boom tubes on blocks for support AWARNING Crushing hazard The number 2 and 3 boom tubes could become unbalanced and fall when they are removed from the number 1 boom tube if they are not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing Tag and remove the wear pads from the top side and bottom of the number 2 boom tube at the platform end of the boom Remove the trunnion pin retaining fasteners at the base end of the number 2 boom tube Use a slide hammer to remove the trunnion pins Attach a lifting strap from an overhead crane to the number 3 boom tube at the platform end of the boom for support 10 Support and slide the numbe
146. ove the pin retaining fastener from the rod end pivot pin 8 Place a rod through the rod end pivot pin and twist to remove the pin 9 Remove the master cylinder from the machine AWARNING Crushing hazard The master cylinder could become unbalanced and fall if it is not properly supported by the lifting device when removed from the machine Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 Turntable Covers 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support and secure the open cover with an overhead crane or forklift Do not lift the cover AWARNING Crushing hazard Due to its heavy CAUTION weight do not attempt to support the cover by hand Component damage hazard Protect the cover from damage by using carpet or padding on the crane or forkliftforks 2 Remove the upper retaining clip from the gas strut 3 Gently pry the strut pivot socket off of the ball stud and lower the strut Protect the strut cylinder rod from damage AWARNING Crushing hazard The cover could fall if not properly supported when the strut is removed Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation REVA 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead 5 Carefully lift and remove the cover from the machine AWARNING
147. overload indicator light turns on and the alarm sounds 9 Testall machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls O Result All ground control functions should not operate If the platform overload system is notoperating properly repeat steps 1 through 4 CHECKLIST D PROCEDURES D 11 Replace the Drive Hub Oil Specifications require that this procedure be performed every 1500 hours or 12 months whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage DriveHubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs Part No 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST D PROCEDURES 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Install the plugs 5 Repeatthis procedure for each drive hub Drive hubs
148. p sparks flames and are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage NN Be sure that all tools and working areas Be sure any forklift overhead crane or d 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 e fasteners intended for one 7 time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time ey Be sure to properly dispose of old oil or o other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area 5 is properly ventilated and well lit NM iv Genie S 80 and Genie S 85 PartNo 77832 January 2004 Introduction Section 1 Rev Section 2 Rev Section 3 Rev A gt vu gt W gt gt gt gt gt gt gt Table of Contents Important Information beein ii Safety Rules General Safety Rules sse aaa aaa entrent nnns rennen iii Specifications Machine Specifications Josue iita tte A ee 2 1 Performance Specifications sssssssssssseseseeeeeeeene nennen 2 2 Hydraulic Specifications 1 nennt ete rette E w atta eae te ARR ad ERR EROS 2 3 GM 3 0L EFI Engine Specifications sssssseeseeeeneeee
149. pad is not less than specification shim as necessary to obtain zero clearance and zero drag 3 Extend and retract the axles through the entire range of motion to check for tight spots that may cause binding or scraping of the axle tubes Always maintain squareness between the outer and inner axle tubes Extendable axle wear pad specifications 1 2 inch 12 7 mm Bottom and side wear pads minimum thickness Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B D 3 Check the Free wheel Configuration Proper use ofthe free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge could result in death or serious injury and property damage Collision hazard Select a work site AWARNING that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h CAUTION Non steer wheels All models 1 Chockthe steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer wheels 3 Lift the wheels off the ground and then place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub T disengaged
150. pivot end of the boom 5 26 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the pivot end of the boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the master cylinder rod end pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 BOOM COMPONENTS 4 Remove the pin retaining fastener from the master cylinder barrel end pivot pin 5 Place a rod through the barel end pivot pin and twist to remove the pin 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 7 Rem
151. quipped The alarm package includes Travel alarm Descentalarm Flashingbeacons Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable rear cover Beacons are installed on both turntable covers The alarms and beacons will operate with the engine running or not running 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls O Result Both flashing beacons should be on and flashing 2 Move and hold the function enable toggle switch to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down 3 Turn the key switch to platform controls Result The flashing beacons should be on and flashing Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA 4 Press down the foot switch Move the boom controller to the down position hold for a moment and then release it Result The descent alarm should sound when the controller is held down 5 Press down the foot switch Move the drive controller off center hold for a moment and then release it Move the drive controller off center in the opposite direction hold for a moment and then
152. r 3 boom tube out of the number 2 boom tube Place the number 3 boom tube on blocks for support AWARNING Cushing hazard The number 3 boom tube could become unbalanced and fall when removed from the number 2 boom tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 5 22 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 11 Remove the external snap rings from the extension cylinder pivot pin at the platform end of the number 3 boom tube Use a soft metal drift to remove the pin 12 Support and slide the extension cylinder out of the pivot end of the number 3 boom tube Place the extension cylinder on blocks for support AWARNING Crushing hazard The extension cylinder could become unbalanced and fall when it is removed from the number 3 boom tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing BOOM COMPONENTS 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder AWARNING Body injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O r
153. r engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap 2 Pullthe oil drain hose out from underneath the engine 3 Remove the plug from the oil drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications 4 Install and tighten the plug into the oil drain hose REV B 5 Use an oil filter wrench to remove the oil filter j ABN T 0 i u M 3 a te ES ERI b zu RZ SL gt Deutz model a oilfiler cap b oilfilter c filter head d fuelfilter 6 Clean inside the filter head 7 Fillthe filter with clean engine oil 8 Apply athin layer of clean engine oil to the gasket of the new oil filter Install the filter and tighten it securely by hand Cil filter specification Genie part numbers Deutz F4L 913 Perkins 704 30 62430 62422 9 Clean up any oil that may have spilled during this procedure Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 11 Fill the engine with new oil per specifications and install the oil filler cap 12 Start the engine from the ground controls and allow the engine to run
154. re thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green usedto indicate operation ormaintenance information Workplace Safety Be sure to wear protective eye wear and e other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes W 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 to kee
155. rew located on top of the fuel injection pump 16 Operate the priming lever of the fuel lift pump until fuel free from air comes from the air vent SCrew 17 Tighten the air vent screw when air stops coming through the air vent 18 Clean up any diesel fuel that may have spilled during the bleeding procedure and dispose of properly 19 Start the engine from ground controls and check for leaks REV B C 4 Check the Starting Aid Perkins Models Information to perform this procedure is available in the Perkins 704 30 User s Handbook Perkins part number TPD 1336 E Perkins 704 30 User s Handbook Genie part number 101840 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B C 5 Check the Specific Gravity of the Engine Coolant Liquid cooled Models The quality of the engine coolant which is used can have a great effect on the efficiency and life of the cooling system Old or dirty engine coolant may cause the engine to perform poorly and continued use may cause engine damage Burn hazard Beware of hot engine ACAUTION parts and coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the machine on level ground Perform this procedure with the engine off 1 Puton protective clothing and eyewear 2 Operate the engine until itis warm enough to open the thermostat Continue to run the engi
156. rive speed maximum Stowed position 3 3 mph 5 3 km h 40 ft 8 2 sec 12 2 m 8 2 sec Raised or extended position 0 68 mph 1 1 km h 40 ft 43 sec Gradeability 12 2 m 43 sec Stowed position Boom function speeds maximum from platform controls 45 Jib boom up S 85 60 to 70 seconds Jib boom down S 85 40 to 50 seconds Boom up 89 to 93 seconds Boom down 90 to 94 seconds Boom extend 73 to 79 seconds Boom retract 79 to 84 seconds Turntable rotate 360 boom fully stowed 80 to 84 seconds Turntable rotate 360 boom raised or extended 210 to 240 seconds Platform rotate 160 8 to 12 seconds Platform level up 50 to 60 seconds Platform level down 40 to 50 seconds Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 2 Specifications REV B Hydraulic Specifications Hydraulic oil specifications Before serial number 3349 Hydraulic oil type Shell Donax TG Dexron III After serial number 3348 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150
157. rt the engine from the ground controls and check for hydraulic leaks Part No 77832 Genie S 80 and Genie S 85 5 39 Section 5 Repair Procedures January 2004 Manifolds 9 1 Function Manifold Components View 1 REV B The function manifold assembly is located on the tank side tray behind the ground control box Index Schematic No Description Item 1 Solenoid valve 3 position 4 way A 2 Check valve 30 psi 2 bar B 3 Check valve 30 psi 2 bar C 4 Solenoid valve 2 position 3 way D 5 Solenoid valve 3 position 4 way E 6 Relief valve 2500 psi 172 bar F 7 Solenoid valve 2 position 3 way CU 8 Check valve sssssseeee H ues 9 Differential sensing valve 10 Differential sensing valve J 11 Proportional solenoid valve K 12 Check valve sesinin en E uus 13 Check valve sseeseeeeee Mini 14 Solenoid valve 3 position 4 way N 15 Differential sensing valve Osee 16 Counterbalance valve P 17 Counterbalance valve Qin 18 Solenoid valve 2 position 3 way R 19 Solenoid valve 3 position 4 way S 20 Relief valve 2800 psi 193 bar
158. s flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 GM models Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise if equipped 2 Perform a visual inspection around the following areas GM models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and throttle body An LPG detector may be necessary to locate LPG leaks Fuel tank manual shutoff valve if equipped fuel pump fuel filter hoses and fittings and throttle body Diesel models Fuel tank manual shutoff valve if equipped hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors atomizers ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Part No 77832 Genie S 80 and Genie S 85 Section 4 e Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES REV B A 8 Hydraulic oil capacity specifications Check the Hydraulic Oil Level Hydraulic tank 45 gallons 170 liters Hydraulic system 55 gallons Maintaining the hydraulic oil at the proper level is including tank 208 liters essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of h
159. s tEn Eb aut 5 9 2 2 Platform Leveling Slave Cylinder sseeenee 5 10 2 3 Platform Rotalor ecce ee astute tees tute exec veut uud eu da Du ure ahi 5 11 A JibBoom Components S 85 Bell JID BOONTU rtt RE EEE EOS Fe exeo exe noU re TIERE 5 14 32 Jib Boom Bell rank un een 5 15 33 JibBoom Lift Cylinder zaa creto i a tnu Dee eere 5 16 Boom Components 41 Cable Track E 5 17 42 BOOM een TERA AEE 5 20 4 3 Boom Lift Cylinder uiia EA een 5 23 4 4 Extension Cylinders eeeeeeeeee enea aaa aaa aaa aaa nnns 5 25 4 5 Platform Leveling Master Cylinder eeeu esee aaa aaa aaa aaa azaaacecea 5 27 Turntable Covers b Turntable COVelS umawia nada ec O a AA ti eit A AE 5 28 Genie S 80 and Genie S 85 PartNo 77832 January 2004 DDD Ge TABLE OF CONTENTS Section 5 Rev Repair Procedures continued A Engines 6 1 RPM Adjustment ns anne 5 29 G2 FleXPlale ERR 5 29 6 3 Oil Temperature and Oil Pressure Switches Deutz Models 5 30 6 4 Coolant Temperature and Oil Pressure Switches Perkins Models 5 31 6 5 Coolant Temperature and Oil Pressure Sending Units GM Models 5 32 6 6 Timing Adjustment sssssssseeeenen enne mnes 5 33 A GroundControls 7 1 enliic M 5 34 4 2 POWOFr RELAY irr ced cese boe tees ote esee ee 5 35 7 3 Toggle Switches See 1 4 Toggle Switches
160. section of cable track Part No 77832 Genie S 80 and Genie S 85 5 19 Section 5 Repair Procedures January 2004 BOOM COMPONENTS 4 2 Boom How to Shim the Boom 1 Measure each side wear pad Replace the pad if it is less than 9 16 inch 14 3 mm thick If the pad is more than 9 16 inch 14 3 mm thick perform the following procedure 2 Measure each bottom and top wear pad Replace the pad if it is less than 7 16 inch 11 mm thick If the pad is more than 7 16 inch 11 mm thick perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 6 Tighten the mounting fasteners 7 Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the outer and inner boom tubes REVA How to Remove the Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued
161. serial number 3348 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use CHECKLIST E PROCEDURES E 2 Change or Recondition the Engine Coolant Liquid cooled Models Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage Extremely dirty conditions may require coolant to be changed more frequently Bodily injury hazard Beware of ACAUTION hot engine parts and
162. ssure to dissipate gradually Do not allow oil to squirt or spray All models 12 From the ground controls raise the boom to a horizontal position 13 Remove the fasteners from the drive speed limit switch bracket LS1RS mounted on the side of the boom at the platform end of the boom Do not remove the limit switch from the bracket 14 Remove the cotter pin from the upper cable track at the platform end of the boom Always replace the cotter pin with a new one 15 Remove the cable track guide fasteners from the cable track guides at the platform end of the boom Remove the cable track guides from the boom 16 Remove the cable clamp from the pivot end of the boom REVA 17 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 18 Attach a lifting strap from an overhead crane to the cable track 19 Remove the mounting fasteners that attach the lower cable track to the boom 20 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched CAUTI
163. step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information O Indicates that a specific result is expected after performing a series of steps Part No 77832 Genie S 80 and Genie S 85 4 1 Section 4 Scheduled Maintenance Procedures January 2004 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required
164. stops moving move the drive enable toggle switch to either side to set the threshold O Result The alarm should sound indicating a successful calibration 12 Repeat steps 9 through 11 for each boom joystick controlled machine function boom up down boom extend retract and turntable rotate 13 Return the joystick to the neutral position and wait for approximately 10 seconds Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time 5 6 Genie S 80 amp Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV B 1 3 Foot Switch How to Test the Foot Switch PLATFORM CONTROLS 4 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result Perform this procedure with the key switch in the off position red to black infinite Q 1 Remove the foot switch mounting fasteners red to white no continuity 2 Remove the cover plate from the bottom of the infinite Q foot switch to access the foot switch wire terminals black to white continuity zero Q 3 Do not press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity qe Z Xo Test Desired result red to black c
165. switch LS1RO located at the platform end of the boom Result The boom extend drive limit switch arm should move freely and spring return to center 12 Fully retract the boom 13 Turn the key switch to platform controls Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 14 Press down the foot switch and slowly move the drive controller off center Result The machine should move at normal drive speeds 15 Raise the boom to just above horizontal Result The boom should raise to horizontal and stop The axle extend retract indicator light should be on The boom should not raise above the limit switches unless both axles are extended 16 Slowly move the drive controller off center Result The machine should move at a reduced drive speed 17 Lower the boom to the stowed position then extend the boom approximately 12 inches 30 5 cm Result The boom should extend to approximately 12 inches 30 5 cm and stop The axle extend retract indicator light should be on The boom should not extend past the limit Switches unless both axles are extended 18 Slowly move the drive controller off center Result The machine should move at a reduced drive speed 19 Fully retract the boom CHECKLIST A PROCEDURES 20 Slowly move the drive controller off center and activate the axle extend function Result The machine should drive
166. t or spray 3 S 85 Support the jib boom leveling arms and the platform mounting weldment with an appropriate lifting device Do not apply any lifting pressure Remove the mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator AWARNING Crushing hazard The platform 5 mounting weldment could become unbalanced and fall if not properly supported when removed from the machine Support the platform rotator with an appropriate lifting device Do not apply any lifting pressure S 80 6 Support the rod end of the platform leveling slave cylinder Protect the cylinder rod from damage Remove the pivot pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 8 January 2004 REVA Use a soft metal drift to remove both pivot pins Remove the platform rotator from the machine ACAUTION C yshing hazard The platform rotator may become unbalanced and fall if not properly supported S 85 6 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins Support the jib boom leveling arms Use a soft metal drift to drive both pins out then remove the platform rotator from the machine ACAUTION POTY injury hazard The jib boom 9 leveling arms may fall if not properly supported Lower the jib boom
167. t switch Washing electronic components is not suggested Instead use compressed air to remove debris Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure AWARNING as presented and scheduled could result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boomin the stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and
168. temperature 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle 4 Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REVA 5 Move the fuel select toggle switch to LPG 6 Startthe engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running B 18 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the boom is past the non steering wheels drive movement is stopped and the indicator light turns on The drive enable switch must be held to either side to reactivate the drive function and should alert the operator that the machine may move in the opposite direction that the drive and
169. ter and one high pressure filter The tank return and high pressure filter have a condition indicator on them The medium pressure filter does not have a filter condition indicator 1 Start the engine from the platform controls 2 Change the engine idle to high rpm rabbit symbol PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES TankReturn Filter 3 Openthe ground control side turntable cover and inspect the filter condition indicator gauge a filter condition indicator gauge Result The needle on the gauge should be operating in the green area If the needle is in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See B 5 Replace the Hyaraulic Filters High PressureFilter The high pressure filter is located to the left of the medium pressure filter below the hydraulic pumps A filter condition indicator is located on the top of the high pressure filter 4 Openthe engine side turntable cover and Inspect the filter condition indicator O Result The filter condition indicators should be operating with the plungers in the green area If the indicator displays the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See B 5 Replace the Hyaraulic Filters REV B A 11 Check the Tire Pressure
170. teries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure thatthe battery cable connections are secure and free of corrosion 3 Be sure that the battery hold down brackets are in place and secure Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B 4 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer O Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced 5 Check the battery acid level of each cell If needed replenish with distilled water to the bottom of each battery fill tube Do not overfill 6 Install the battery vent caps Applying a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables CHECKLIST A PROCEDURES A 25 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on t
171. terminal no 87 N O Control Relay Schematic 5 94 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 7 2 Power Relay AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry The power relay is mounted on the backside of the ground control box How to Test the Power Relay AWARNING Electrocution hazard Disconnect the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 12 to 16Q 2 large posts no continuity infinite Q Any small post to any large post no continuity infinite Q GROUND CONTROLS 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 2 large posts continuity zero Q a solenoid activate coil terminal small post b high amp power contact terminal large post Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 GROUND CONTROLS 7 3 Toggle Switches See 1 4 Toggle Switches 7 4 Terminal Strip How to Remove a Terminal Strip Section AWARNING Electrocution hazard Contact with elec
172. the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks REVA 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin Attach a lifting strap from an overhead crane to the lug at the rod end of the jib boom lift cylinder Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machin
173. the engine pivot plate out away from the machine o a engine pivot plate anchor hole b engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole on the turntable 4 Install the bolt that was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Inspect the alternator belt for Cracking Glazing Separation Breaks 6 Replace the belt if any damage is found ue 0 REV B 7 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 8 Swingthe engine pivot plate in towards the machine 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Belt deflection GM models 1 2 inch 12 mm Alternator belt Genie part number 65621 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B A 23 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 100 hours Maintaining electrical wiring in good condition is essential to safe operation and go
174. the two hydraulic shutoff valves located at the hydraulic tank if equipped ii open closed CAUTION Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or 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 3 Remove the drain plug from the hydraulic tank 4 Completely drain the tank into a suitable container See capacity specifications Hydraulic oil capacity Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST E PROCEDURES 6 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 7 Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 8 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 9 Supportthe hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device
175. tly clean the fuel strainer with clean diesel fuel or a mild solvent 5 Install the fuel strainer and pump cover onto the fuel pump Install and tighten the fuel pump cover retaining fastener Install the fuel supply hose to the fuel pump 7 Startthe engine from the ground controls and inspect the fuel pump and fuel supply hose for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately REV B D 6 Replace the Fuel Filter Deutz Models Replacing the diesel fuel filter water separator is essential to good engine performance and service life A dirty or clogged filter water separator may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter water separator be replaced more often ADANGER Explosion and fire hazard Engine fuels are combustible Replace the fuel filter water separator in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Tag disconnect and plug the fuel hose from the fuel tank at the inline fuel filter water separator head 2 Place a suitable container beneath the fuel filter Genie S 80 and Genie S 85 Part No 77832 January 2004 Section
176. to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure Z JE BE Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year To account for repeated procedures the Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six month or every 500 hours A B C Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report 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 f
177. tom bleed valve but do not remove it Hold the platform rotate toggle switch to the right until the platform is fully rotated to the right Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of 7 the platform during rotation Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled Rotate the platform full right then full left and inspect the bleed valves for leaks Part No 77832 Genie S 80 and Genie S 85 5 13 Section 5 Repair Procedures January 2004 Jib Boom Components S 85 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Remove the cable cover from the side of the jib boom 4 Supportthe jib boom with a lifting device 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic
178. trically charged circuits could cause death or serious injury Remove all rings watches and other jewelry 1 Label the wiring from the terminal strip section to be removed 2 Use a small flat blade screwdriver to push in and release the wire from the terminal strip 3 Locate the removal tab on the bottom or top of the terminal strip section 4 Use a small flat blade screwdriver to gently pry up on the tab of the terminal strip section and remove it REVA 5 36 Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A 8 1 Function Pump How to Remove the Function Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank ii open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in the closed position or 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 th
179. und controls will override the platform controls including the platform red Emergency Stop button 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from ground controls 3 Push in the red Emergency Stop button at the ground controls to the off position Result The engine should shut off and no machine functions should operate 4 Pull outthe red Emergency Stop button to the on position at the ground controls 5 Turn the key switch to platform control and start the engine from platform controls 6 Pushin the red Emergency Stop button at the platform controls to the off position Result The engine should shut off and no machine functions should operate The red Emergency Stop button at the ground controls will stop all machine operation even if the key Switch is turned to platform control CHECKLIST B PROCEDURES B 12 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button at the platform controls is in the on or OFF position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the red
180. ure capable of supporting it under the platform REVA 3 Lower the boom until the platform is resting on the structure just enough to support the platform Do not rest the entire weight of the boom on the structure 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the end of the boom tubes and connect them together using a connector Cap the fittings on the cylinder AWARNING 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 5 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 6 Remove the external retaining ring from the barrel end pivot pin 7 Usea soft metal drift to drive the rod end pivot pin out 8 Use a soft metal drift and drive the barrel end pin out 9 Carefully pull the cylinder out of the boom Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 5 Repair Procedures REV A How to Bleed the Slave Cylinder Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the boom to a horizontal position 2 Move the platform level toggle switch up and down through two complete platform leveling cycles to remove
181. ure on a firm level surface will compromise the stability of the machine and could result in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover from the non steer end of the machine 5 Disconnect the linkage clevis yoke from the axle 6 Place a bubble type level on the turntable rotate bearing plate at the non steer end Check to be sure the drive chassis is completely level 7 Tolevel the drive chassis start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the axle 10 Install the shoulder bolt and nut 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Result The measurements should be equal If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B A 14 Test the Platform and Ground Controls Testing the machine functions and the red Emergency Stop buttons for malfunctions is essential for safe mac
182. ust turntable rotation gear backlash Refer to Repair Procedure 11 1 How to Adjust the Turntable Rotation Gear Backlash Turntable rotate drive hub Oil capacity 32 fl oz 0 95 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 77832 Genie S 80 and Genie S 85 Section 4 e Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES REV B A 27 4 Install the plug into the drain hose and tighten Replace the Engine Oil and 5 Place a suitable container under the oil filter Filter GM Models 6 Use an oil filter wrench and remove the filter 7 Applyathin layer of fresh oil to the gasket of the new oil filter Install the filter and tighten it securely by hand GM engine specifications require thatthis procedure be performed Oil filter every 200 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 200 hour interval Burn hazard Beware of hot engine ACAUTION parts and oil Contact with hot engine oil and or engine parts may cause se
183. ut off to prevent damage Engine oil pressure will be indicated on the gauge if equipped when the engine is running How to Remove the Coolant Temperature and Oil Pressure Switches Perform this procedure with the engine off 1 Tagand disconnect the wiring from the desired switch Remove the switch from the engine block Part No 77832 Genie S 80 and Genie S 85 Section 5 Repair Procedures January 2004 ENGINES 2 Install the new switch and torque to specification 3 Connect the wires to the new switch A CAUTION Burn hazard Contact with hot engine fluids or components may cause severe burns Always use pipe thread sealant when installing a switch Coolant temperature switch unit specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 7 8 inch Temperature switch point 221 F 105 C Oil pressure switch specifications Torque 8 10 ft Ibs 11 14 Nm Hex size 7 8 inch Oil pressure switch point 4 2 psi 0 3 bar REVA 6 5 Coolant Temperature and Oil Pressure Sending Units GM Models The engine coolant temperature gauge optional is an electrical gauge The engine ECM monitors the engine coolant temperature and will shut the engine off when the coolant temperature reaches approximately 230 F 110 C to prevent damage The engine will not start until the temperature drops below the switch point Engine coolant temperature will be indicated on the gauge if equipped when the k
184. ve clearance cold Intake 0 006 in 0 15 mm Exhaust 0 006 in 0 15 mm Lubrication system Oil pressure 40 to 60 psi 2 75 to 4 14 bar Oil capacity 14 3 quarts including filter 13 5 liters Oil viscosity requirements Below 77 F 25 C 5W 30 synthetic 13 F to 86 F 25 C to 30 C 10W 40 Above 4 F 20 C 15W 40 Engine oil should have properties of API classification CD grade OR ACEA classification E1 96 REV B Injection system Injection pump make IMSA Injection pump pressure 8702 psi 600 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Alternator output 55A 12V DC Batteries Type 12V DC Size 13 x 613 16 x 93 8 inches 33 x 17 3 x 23 8 cm Quantity 2 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9to 12 mm Genie S 80 and Genie S 85 PartNo 77832 January 2004 REV B Perkins 704 30 Engine Section 2 Specifications E o X L H H W Z Injection system SPECIFICATIONS Displacement 183 cu in Injection pump make Zexel PFR KX 3 liters Injection pump pressure 2755 psi Number of cylinders 4 190 bar Bore and stroke 3 82 x 3 94 inches _ lnlector opening pressure 3626 psi 97 x 100 mm abe Horsepower 61 2300 rpm Fuel requirement diesel number 2 D Firing order 1 3 4
185. vere burns 1 Openthe engine side turntable cover and remove the oil filler cap 2 Pullthe oil drain hose out from underneath the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications Genie part number 65623 8 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fill the engine with new oil per specifications and install the filler cap See capacity specifications 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 11 Check the oil filter and oil drain hose for leaks 12 Check the engine oil level dipstick Add oil if needed 13 Clean up any oil that may have spilled Properly dispose of the oil and filter GM 3 0L EFI Engine 5 quarts Oil capacity including filter 4 7 liters Cil viscosity requirements Below O F 17 8 C 5W 30 Above 0 F 17 8 C 10W 30 Only use engine oils labeled For Gasoline Engines by the American Petroleum Institure API Genie S 80 and Genie S 85 Part No 77832 January 2004 Section 4 Scheduled Maintenance Procedures REV B A 28 Replace the Fuel Filter GM Models GM engine specifications require thatthis procedure be performed every 200 hours Replacing the gasoline fuel filter is essential to good engine performance and s
186. w to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Checklist A Rev B Y N R Checklist B Rev A A 1 Manuals A 2 Decals and placards A 3 Damage and loose or missing parts A 4 Engine oil level A 5 Engine coolant level Liquid cooled models A 6 Air filter A 7 Fuelleaks A 8 Hydraulic oil level A 9 Hydraulic leaks A 10 Hydraulic filter condition indicators B 1 Engine oil cooler and fins Deutz models B 2 Engine belt Deutz and Perkins models B 3 Replace air filter B 4 Exhaust system B 5 Replace hydraulic filters B 6 Brake configuration B 7 Tires and wheels B 8 Drive hub oil level B 9 Engine RPM B 10 Key switch A 11 Tire pressure B 11 Emergency Stop A 12 Extendable axles B 12 Ground control override A 13 Oscillate axle B 13 Platform self leveling A 14 Platform and ground controls A 15 Auxiliary power A 16 Tilt sensor and alarm A 17 Limit switches B 14 Horn B 15 Foot switch B 16 Engine idle select B 17 Fuel select GM models A 18 Drain filter separator Diesel models Perform after 40 hours A 20 Engine fasteners A 19 30 D
187. was just removed through the engine pivot plate and into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Tighten all valve cover retaining fasteners Torque to 108 in Ibs 12 Nm 6 Tighten all air intake pipe clamps Torque to 108 in Ibs 12 Nm 7 Tighten all intake manifold retaining fasteners Torque to 17 ft Ibs 23 Nm 8 Tighten all exhaust manifold retaining fasteners Torque to 30 ft Ibs 40 Nm 9 Tighten all engine mounting fasteners Torque engine to bracket mounting fasteners to 54 ft Ibs 73 Nm and bracket to engine pivot plate mounting fasteners to 175 ft Ibs 237 Nm 10 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole 11 Swing the engine pivot plate in towards the machine 12 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury PartNo 77832 Genie S 80 and Genie S 85 Section 4 Scheduled Maintenance Procedures January 2004 CHECKLIST A PROCEDURES A 21 Inspect the Radiator Liquid cooled Models Engine specifications require that this procedure be performed every 100 hours Perform this proce
188. y Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode REV B 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the machine function time with the table below and determine whether the function time needs to increase or decrease 11 While the joystick is activated adjust the max out setting to achieve the proper function cycle time Momentarily move the drive enable toggle Switch in the right direction to increase the time or momentarily move the drive enable toggle Switch in the left direction to decrease the time Each time the drive enable toggle Switch is momentarily moved the time will change in 2 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 13 Return the joystick to the neutral position and wait for approximately 10 seconds O Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Function speeds factory setti
189. ydraulic fluid under pressure to the oscillate control valve To protect from over pressurization of the Oscillate System the pump is provided with a pressure relief valve set at 950 psi 65 5 bar Drive functions are powered by a bi directional variable output piston pump rated at 0 to 30 3 gpm O to 114 7 L min at 2300 rpm Two internal 3625 psi 250 bar relief valves are used to prevent over pressurization of the closed loop drive system Theory Of Operation The boom lift cylinder boom extend cylinder platform leveling slave cylinder platform rotator turntable rotate motor and jib boom cylinder S 85 models incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure A regeneration circuit is used to increase the performance of the primary boom extension function This circuit transfers hydraulic fluid from one end of the primary cylinder into the other end when the cylinder is extending The auxiliary pump is a single section gear pump with a static displacement of 0 151 cu in 2 47 cc The auxiliary pump provides hydraulic fluid under pressure in the event of a main power loss The auxiliary pump should only be used at short intervals as to not drain the battery or overheat the pump Electrical System Two identical 12V DC batteries are used for this system One of the batteries is used for engine starting purposes only The other battery is used to power the control system and
190. ydraulic system problems Perform this procedure with the boom in the stowed position 1 Visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge 2 Addoilas needed Hydraulic oil specifications Before serial number 3349 Hydraulic oil type Shell Donax TG Dexron III After serial number 3348 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Genie S 80 and Genie S
191. ze 9 16 inch Temperature switch point 230 F 110 C Oil pressure sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 11 16 inch Oil pressure switch point 8 psi 0 55 bar Part No 77832 Genie S 80 and Genie S 85 5 33 Section 5 Repair Procedures January 2004 Ground Controls 7 1 Control Relays 87 Relays used for single function switching are single pole double throw SPDT relays 86 87a 85 How to Test a Single Pole Double 30 Throw Relay AWARNING Electrocution hazard Contact with terminal no 87a N C electrically charged circuits could terminal no 85 coil negative result in death or serious injury an no common erminal no 86 coil positive Remove all rings watches and other jewelry 1 Tag and disconnect all the wiring from the relay to be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a and 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a and 30 no continuity infinite Q terminal 87 to 30 continuity zero Q

S-80/S-85 Service Manual

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