Home

Service Manual - Genie Industries

1. i RED 7 46 6 2 LS POWER O GANWHTT 45 GENERATOR OPTION i i GRN BLK E H RED R8 44 GRNIBLK D 8 RD BKW2 DUMP VALVES ewierowo Bue onam e aoma Rxs i TURNTABLE ROT HIGH Gi G2 WHT RED 26A i CABLE OG BK ORG BLK 1 41 OG BK 2ISM PULSE PICKUP i 7 WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH i BLU RED 1 39 BU RD BU RD S P LP 5 eluwnti 38 BuwTSP GAS i BUBKEH BLUBLK1 37 BUBKD B STEER LEFT WHTIBLK 254 BUE mun STEER RIGHT BLK 22 BLKRED1 35 BKROSP RPM mes CABLE BLKWHTA 38 Glow PLUG i 6 BK 3 ISM 33 gt BLKS P START WIRD _ WHT RED 82 WT RD OB BRAKE i i WTIBK E H WHTIBLK 1 31 ED C _ RED 5 WHT 1 30 EDC ROMTER 29 RDBKEH REDBIK
2. gt T lt z o m n ej NT E 4 Q i S a ey eye SOEUR ij ES Rr ee ee T CCP TE A e de eee w ee P TAE T pegs Sag eee ee IZA DD E RAEE wiwa awa Sg 1 ro ul gt Ow z JZZ id E x2z Sa S 1 4 PEN 4 x lo ow c cz 9 x g AE B Ws a oz oo us m zu ii 24 mo zi cO Bu Rx I I i 1 I 1 366 o gt E x x lt 1 I Ld E 85 I ui I E SO ou o 29 i ogli I lt 2 8 9 of ORI 55 52 FEE g I ttt 4 RS SE es EM 5 o a 95 6 Oo Spel ey O 8 Or 5 88 A 5 m 85 a SE GP EI 9 1 4 I 3a I e I na
3. CASE DRAINS T N LO N T lt 2 5 5 m amp 5 m z O m 21 c Cd 1 1 S 9 I 5 I gt of fe I tr I T i lt xz ze i E 4 J x c QH a FO I M cz 1 bees bolo x FO Ai ZZ 2 z 8 E zd a u gt I fe i uu a 1 I 8 og I 1 Af 1 i 1 1 1 I 1 1 gb x x i E Za Oe 48 28 I c DE I o 5 8 amp 9 5 2 amp lt lt 2 rr ro E E a I z i c ou Of ii POWAZNE 1 c a I I o Ou al i B Eo U I 5 st I E ace 4 1 T mm T i 4
4. WHT BLK 45 z L o NT eav ORG RED 42 Y WHT RED 6 ORG RED 16 ORG 14 ORG BLK 15 GRN 43 NO O USE 100 OHM RES FOR 4WD AND 150 OHM RES FOR 2WD NOTE RESISTOR IS MOUNTED TO EXT RET CONTROLLER 6 12 Genie 5 80 amp Genie 5 85 Part No 52270 NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION Service Manual Electrical Schematic Diesel Models Section 6 Schematics HIGH RPM ENGINE SPEED O l b N D l Lo FUNCTION ENABLE SUXRER 5 ES CHIGHEREM gt HIGH IDLE RELAY E BLK RED 1 go o O HIGH IDLE CUTOUT d RELAY BLK RED R4 E H 7 o 52 OFF 9 r GENERATOR amp ON GRN WHT 1 GRN WHT 4 E
5. 68 89 82 Ll 29 BB 28 ee O 11 Y 5 2 d R 05122222 2 25 12 8 ASC 3 lt gt ar suu A i Z W 3 DG OE sy SZ Part No 52270 Genie S 80 8 Genie S 85 7 41 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect O to 5000 psi 0 to 345 bar pressure gauge to the test port item 27 on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the boom retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 26 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure System relief valve specifications How to Adjust the Boom Down Relief Valve Perform this procedure with
6. 25 30 ft lbs 34 41 Nm 2 Flow divider combiner valve AF Controls flow to flow divider combiner valves 6 and 7 25 30 ft lbs 34 41 Nm 3 Relief valve 250 psi 17 2 bar AG Charge pressure circuit 10 12 ft lbs 14 16 Nm 4 Check valve pilot to close Works in conjunction with Index no 12 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm 5 Orifice plug 0 052 inch 1 32 mm Al Steer end drive motor circuit 6 Flow divider combiner valve AJ Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 7 Flow divider combiner valve AK Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 8 Orifice 0 070 in 1 78 mm AL Non steer end drive motor circuit 9 Orifice 0 070 in 1 78 mm AM Equalizes pressure on both sides of flow divider combiner valve Index no 2 10 Shuttle valve position way AN Charge pressure circuit that gets hot oil out of low pressure side of drive pump 15 18 ft lbs 20 24 Nm 11 Diagnostic Testing 12 Check val
7. Mb n o JL DOE EL a e x E 8o m Z ORG 1 P WHT 6 BRM6 s a I zd EREEEEREEE WHT 7 BRN 7 MEER ag LEEF i 2 1560205 i AEAN A A eo RED WHT E RED WHT 1 4 NN HIGH 22 DO 8 Low sz X T 56 amp Lu 2 BLK 3 o BLK WHT 3 m BLK 4 EXTEND a BLK WHT p RETRACT BLK WHT 4 g 1 BLK RED 4 ka BLK RED 4 o EL BLK RED 3 EL WHT RED 3 D c Z WHT BLK 3 EN WHT 3 5 WHT x X WHT 4 ee ROTATE 8 4 T E HH 15 WHT BLK 4 ME g o E qt 9 2 B WHT RED 4 1 1 14 A I m E RED 4 LE RED BLK I PRIMARY BOOM amp I I N DOWN E RED BLK 4 EFLEEB een 5 1 RED WHT 4 z a e E x RED 3 B RED BLK 3 pe e a E E RED WHT 3 07 co Oz E ORG 3 PLATFORM LEVEL LDOWN ORG BLK 3 ORG FE 2 E 27 ORG 4 gt TUP ORG BLK gt PLATFORM LEVEL DOWN ORG BLK 4 iD NE E m ORG RED 4 a i Fr ORG RED 3 ie M E 92 A 2 E EG GRN 3 oz JIB BOOM A DOWN GRN BLK 3 GRN ia gp 2 GRN 4 ae JIB BOOM GRNBLK DOWN Je GRN BLK 4 2 x R RIGHT RIGHT PLATFORM PLATFORM ROTATE LEFT ROTATE LEFT 8 1 B
8. 4 29 C 3 Check the Turntable Rotation Bearing Bolts 4 30 C 4 Check the Free wheel Configuration 4 30 C 5 Grease the Turntable Rotation Bearing and Rotate 4 32 C 6 Replace the Torque Hub 4 32 C 7 Replace the Hydraulic Tank 4 34 C 8 Replace the Drive Loop Hydraulic 4 34 C 9 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models 4 35 C 10 Replace the Gasoline Fuel Filter Gasoline LPG Models 4 36 C 11 Replace the PCV Valve Gasoline LPG Models 4 37 C 12 Replace the Spark Plugs Gasoline LPG Models 4 37 C 13 Check and Adjust the Air LPG Mixture Gasoline LPG Models 4 38 C 14 Check and Adjust the Ignition Timing Gasoline LPG Models 4 39 C 15 Check the Engine Valve Clearances Deutz Diesel Models 4 39 C 16 Check the Turntable Rotation Gear Backlash 4 39 D 1 Test or Replace the Hydraulic 4 40 D 2 Change or Recondition the Engine Coolant Gasoline LPG Models 4 40 D 3 Change the Fuel Lines 222244 00 000 nennen nen
9. 11 13 ft lbs 15 18 Nm 29 Check valve BB Differential sensing circuit Platform rotate right 11 13 ft lbs 15 18 Nm 30 Priority flow regulator valve CC Sleerinig iie 10 12 ft lbs 14 16 Nm 5 gpm 18 9 l min 31 Solenoid valve Poppet DD Platform rotate left Jib boom up 25 30 ft lbs 34 41 Nm 32 Solenoid valve Poppet EE Platform rotate right Jib boom down 25 30 ft lbs 34 41 Nm 33 Flow regulator valve 0 6 gpm 2 27 l min EF au Platform rotate 10 12 ft lbs 14 16 Nm 34 Counterbalance valve GG Platform level up 35 40 ft lbs 47 54 Nm 35 Counterbalance valve HH Platform level down 35 40 ft lbs 47 54 Nm 36 Check valve pepe Boom extend retract circuit 11 13 ft lbs 15 18 Nm Plug Torque Specifications Description Hex size Torque SAE No 6 1 4 18 ft lbs 24 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm 7 40 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS
10. SS SS MANIFOLDS 10 8 Valve Adjustments 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold 2 Start the engine from the platform controls Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the charge pressure relief valve and remove the cap item 1 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turnthe engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 54 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee MANIFOLDS This page intentionally left blank Part No 52270 Genie S 80 amp Genie S 85 7 55 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 9 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Directional valve 2 position 2 way AE High speed divider bypass N C Pilot to
11. 4 eI B al et LS J E 5 REOS f 4 szl BIE c gs i ay iS n cum I ES Guj ra Cen TH amp du u Te ds gg 4 iz C F te E g id I H 6 SSeS SSS Sel 41 CASE DRAINS Genie S 80 amp Genie S 85 6 21 Part No 52270 Section 6 Schematics 4WD Hydraulic Schematic Service Manual PLATFORM ROTATE JIB BOOM
12. 52270 Genie 5 80 amp Genie 5 85 5 49 Section 5 Troubleshooting Flow Charts Service Manual Second Edition SSS SSS CHART 19 Disconnect wires to 0 or turntable rotate right infinite directional valve coil ohms item A and test the resistance of the valve coil See Repair Section Continued from the previous page Replace turntable rotate right directional valve coil item A 2 5 to 3 5 ohms function Move function enable operates Replace defective directional valve switch to either side and hold the turntable rotate left right toggle switch at the ground controls in the right direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick 2900 Exchange flow regulator function disconnect coupling on psi valve item J with a like operates Replace defective flow the boom function valve item Check regulator valve manifold and start the turntable rotate right engine Move the function function enable switch to either side and hold the turntable rotate right toggle switch at the ground controls in the right direction and check the pressure function inoperative Repair turntable rotation motor OR function manifold may have an internal defect Consult Genie Industries Service Department less than 2900 PSI
13. BLK WHT 8A BLK 7A RED 1A RED BLK 2A RED WHT 3A WHT BLK 5A gt ba WHT 4A e R J GBN 17A GBN BLK 18A GRN WHT 19A 9 a pe eJ ORG BLK 15A BLK RED 9A WHT RED 6A BLK 33A BLK RED 35A BLU RED 39A RED 20A BLU WHT 37A RED R1 30 A FEE N HdE 9 358 sees N ORG RED 16 TB16D_ LABEL DESCRIPTION B P1 EMERGENCY STOP BUTTON REDS KS1 KEY SWITCH RED HS TB4AC eT TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH ORGIRED 4 TS11 ENGINE FUEL SELECT SWITCH TS12 FUNCTION ENABLE TS13 PLATFORM ROTATE SWITCH AU cj TS14 PLATFORM LEVEL SWITCH RED TB20C 7515 BOOM EXTEND RETRACT SWITCH 18208 zku TS16 PRIMARY BOOM UP DOWN SWITCH 17 7517 TURNTABLE ROTATE SWITCH L CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER ORG 13 E H Re RESISTOR 14 OHM BOOM FUNCTIONS R3 RESISTOR 10 OHM BOOM FUNCTIONS Gi VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE HYD OIL COOLER SECTION A A OPTION RELAY
14. 35 40 ft Ibs 47 54 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Part No 52270 Genie S 80 amp Genie S 85 7 45 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 4 Chassis Jack Manifold Components The chassis jack manifold is mounted next to the drive manifold at the non steer end Index Schematic No Description Item Function Torque 1 Check valve MM Hydraulic limit switch circuit 35 40 ft lbs 47 54 Nm 2 Relief valve 350 psi 24 1 bar NN Chassis jack auto retract circuit 25 30 ft lbs 34 41 Nm 3 Counterbalance valve OO Non steer end chassis jack circuit 35 40 ft lbs 47 54 Nm 4 Counterbalance valve Steer end chassis jack circuit 35 40 ft lbs 47 54 Nm O 23 Plug Torque Specifications Description Hex size Torque 2 SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee MANIFOLDS 10 5 Axle Extend Dump Manifold Components The axle extend dump manifold is mounted to the tan
15. 12V Activate footswitch and more boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage TP7 Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department CHART 16 Repair open in blk wire circuit from TB7 to boom extend function directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot boom extend retract function toggle switch TS19 on ground control panel OR repair open in blk wire circuit from TS19 to TB7 OR consult Genie Industries Service Department Repair open in blk wire from TP7 to TB7 Repair open in power supply circuit from TP24 to BP1 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 16 Disconnect wires to 0 boom extend directional infinite valve coil item C and ohms PA lae test the resistance of the it bs C valve coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom extend toggle switch at the ground controls in t
16. Result The machine functions should not operate 6 Turn the key switch to the orr position O Result The engine should stop and no functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds B 14 Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons are essential for safe machine operation An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for ground and platform personnel As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button 1 Start the engine from the ground controls 2 Push down the Emergency Stop button to the OFF position Result The engine should shut off and no machine functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Start the engine from the platform controls Push down the Emergency Stop button to the position Result The engine should shut off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance
17. m lu o 1 2 3 4 5 6 7 8 9 10 a a a za mg ap 5 7 orc s x 9 5 o RED BLK 1 e 6 TILT ALARM ORG 14 ORG BLK 15 GRN 43 O USE 100 OHM RES FOR 4WD AND 150 OHM RES FOR 2WD NOTE RESISTOR IS MOUNTED TO EXT RET CONTROLLER O 6 18 Genie S 80 amp Genie S 85 Part No 52270 Section 6 Schematics Service Manual Second Edition ra M Hc Part No 52270 Genie S 80 amp Genie S 85 6 19 Service Manual Second Edition Section 6 Schematics Hydraulic Symbols Legend 2 Pressure gauge A Filter Fixed displacement pump Bi directional variable displacement pump d Bi directional motor 2 2 speed bi directional motor Om Pump prime mover engine or motor Cylinder Accumulator Satt 0 035 Orifice with size A Variable orifice or shut off valve n x Check valve E A Relief valve Priority flow divider olf Wy ul Solenoid operated dump valve L L ree Differential sensing valve Solenoid operated propo
18. 1 A Lif x i M a me al RZE I 5 i I EE ze i 43 o 25 uj 9 Qu gg z a TZ I Ba I Ix 1 4 Ti 4 oz E 2 lt 1 om SS Z Z W HR 0 ZG Z co z 5 S sys BE T Z E TN I z I Y x i i pp Z gt M qnl Da 21 I 1 a 1 o lt gt i LR DEI 88 1 I Z 1 I SE 5 1 T SET 8 SE RH E 5 RH f 5 ej 38 20 w 20 I Ou p84 l o Ee 88 la i a le sf I i 2 p dla I tr LL 2 x I i oc I I I 9 i I I 9 gt ME I oz s 2 2 EO Ss I x 52 46 45 8600 1 zz Op Ave D PE WRC NN e n 12 SE z B 13 ul o P k H BN a 3 2 4 J Tegel 2 z Sa gt J o th z 52 22 Ag Soe ESD wq 5 28 2 5 x gt gt 7 I fa 5 SES 5 lt 200 uo ZEG Ea oe ZIA ER I 5 AYSE ee L x I
19. 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0 03V DC voltage reading 9 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage setting in step 6 11 Be sure that the boom is in the stowed position then drive the machine and observe how the engine rpm reacts to drive control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C potentiometer will cause the engine to stall The C potentiometer adjustment is a compromise between engine stability surging and engine rpm droop 12 Disconnect the volt meter Part No 52270 Genie S 80 amp Genie S 85 7 7 Section 7 Repair Procedures PLATFORM CONTROLS 13 Raise the boom above horizontal 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer to o
20. 610 7 ohms function Exchange platform level operates up and down directional valves items V and X and activate the platform level up function function inoperative function operates Exchange platform level up and down counterbalance valves items GG and HH and activate the platform level up function function inoperative Install a 0 to 3000 0 to 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level up function 2600 psi or more less than 2600 psi function Exchange platform level operates flow regulator valve item W with a like valve item FF and activate the platform level up function function inoperative Test master cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department Replace the platform level up directional valve coil item V Replace the defective directional valve Replace the defective counterbalance valve Check for mechanical restrictions keeping platform level up function from operating OR replace slave cylinder OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second
21. 7 48 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee MANIFOLDS 10 6 Steer Manifold Components The steer manifold is mounted underneath the function manifold Index Schematic No Description Item Function Torque 1 3 position 4 way solenoid valve VV Steer 30 35 in lbs 3 4 2 Check valve WW Priority flow regulator circuit 10 12 ft lbs 14 16 Nm 3 Orifice plug 0 025 inch 0 635 mm XX Priority flow regulator circuit 4 Priority flow regulator valve 3 5 13 2 l min YY Regulates flow to axle extend dump manifold 10 12 ft lbs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft Ibs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Part No 52270 Genie S 80 amp Genie S 85 7 49 Section 7 Repair Procedures Service Manual Second Edition SS SS MANIFOLDS How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications 3 position 4 way solenoid valve 5 70 schematic item VV 7 50 Geni
22. E I I a x 1 Wows 5 gt Xx I 1 o 1 1 I o aa c LB dap 250 i Leh BEDS 1 55 I 1 c e I i ro x ES EI o I a 5 82 tr I H us o I a o 5 w 0 p ox R gt 2 gt lex Faj G E I a x i T I i e m I I 05 TO JEN k RES dod I I Genie 5 80 amp Genie 5 85 6 22 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie 5 80 amp Genie 5 85 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the follo
23. RU ZB R N X 2 pivot plate retaining bolts b engine pivot plate 5 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container 6 After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator 7 Openthe drain valve on the engine block and allow the coolant to drain into a container After the fluid is drained close the drain valve 8 Replace all coolant hoses and clamps 9 Pour the proper coolant mixture anti freeze and water for your climate into the radiator until it is full TABLE D PROCEDURES 10 Disconnect the hose coupler at the fan end from the tube that is connected to the water pump and hold it until coolant starts to come out of the open hose Then immediately reconnect the hose a tube connected to water pump b hose coupler 11 Fill the radiator and then fill the coolant recovery tank to the NoRMAL range 12 Clean up any coolant spilled during this procedure 13 Start the engine from the ground controls run it for 30 seconds and then turn it off 14 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed 15 Start the engine from the ground controls and run it until reaching normal operating temperature 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine Coolant capacity 11 5
24. Replace ignition start module OR consult Genie Industries Service Department Crank engine and check ov voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Disconnect wht 24 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 24 wire from water temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained yes no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on 12V ignition start module and check voltage at terminal 4 Test auxiliary power toggle switches TS1 and TS9 See Repair Section Chart 2B Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Ford service manual for troubleshooting low oil pressure Check coolant level OR replace water temperature sending unit OR refer to Ford service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department Part No 52270 Genie S 8
25. 1 2 3 4 5 6 7 8 9 10 da ge e 2 a 5 t RED BLK 1 o r m m 4 E 8 58 O e c c Du E Part No 52270 Genie 5 80 8 Genie 5 85 6 11 Service Manual Second Edition SSS Platform Control Box Wiring Diagram Gasoline LPG Models Section 6 Schematics a 23 7 E o z m f zo Zaz cue org x 19 GRN WHT a a GENERATOR 45 GRN WHT 1 5 SPARE 44 GRN BLK 1 m HORN 43 GRN 1 5 TURN ROT HI 42 ORG RED 1 x 41 m 40 ul LP 39 BLU RED 1 ra GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOWPLGOPT 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD AWD 29 RED WHT 1 28 AUX PWR 27 RED 1 PWR TO ES 26 BLK F S PWR START 25 RED F S t PWR CONT 24 WHT FSS PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 OPTION WIRE 21 WHT 20 JIB VALVE 19 GRN WHT 3 m PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 PLAT
26. 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 A 3 Inspect for Damage 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 an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable rotation motors and torque hubs Axle components Boom components and wear pads Dents or damage to machine Tires and wheels Engine and related components Limit switches Alarms horn and beacon if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Cracks welds or structural components Compartment covers and latches 4 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 4 Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine componen
27. ar suu A N 2789 2 5 DG Q9 S gt LIN ON Part No 52270 Genie S 80 amp Genie S 85 7 39 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS Function Manifold Components continued Index Schematic No Description Item Function Torque 20 Check valve m hn T Differential sensing circuit platform level down 11 13 ft Ibs 15 18 Nm 21 Proportional solenoid valve Uses Turntable rotate left right 10 12 ft lbs 14 16 Nm 22 Solenoid valve Poppet Platform level up 25 30 ft lbs 34 41 Nm 23 Flow regulator valve 0 6 gpm 2 27 l min W Platform level circuit 10 12 ft lbs 14 16 Nm 24 Solenoid valve Poppet Platform level down 25 30 ft lbs 34 41 Nm 25 Differential sensing valve bap Meters flow to functions 10 12 ft lbs 14 16 Nm 26 Relief valve 2900 psi 200 bar Z ge System 35 40 ft lbs 47 54 Nm 27 Diagnostic nipple Testing 28 Check valve Differential sensing circuit Platform rotate left
28. inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 2596 less than dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification may vary depending on application of bolt Part No 52270 Genie S 80 amp Genie S 85 2 9 Section 2 Specifications Service Manual Second Edition us This page intentionally left blank 2 10 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There ar
29. no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on 12V ignition start module and check voltage at terminal 4 Test auxiliary power toggle switches TS1 and TS9 See Repair Section Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Deutz service manual for troubleshooting low oil pressure Check oil level OR replace engine temperature sending unit OR refer to Deutz service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure to check LPG fuel level Disconnect LPG supply line from LPG tank and bleed pressure from line With keyswitch on and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select switch 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position check voltage at TB39 12V With keyswitch on and both Emergency Stop bu
30. 1 000 2 6 Hydraulic Hose and Fitting Torque 2 8 Bolt Torque Specifications 2 9 Scheduled Maintenance Inspections eet et eee e eft EA 3 1 Table incipe aaa Dd 3 2 Rape EE 3 3 teas 3 5 Table Disses 3 6 Maintenance Inspection 3 7 Scheduled Maintenance Procedures cidit tata tta CERE 4 1 A 1 Inspect the 4 2 2 Inspect the Decals and 4 2 Inspect for Damage Loose or Missing 4 2 A 4 Check the Engine Oil Level 4 3 A 5 Check the Engine Coolant Level Gasoline LPG Models 4 3 6 Check for Fuel 4 222 1 01 aaa nnne eniin nens 4 3 A 7 Check the Hydraulic Oil 4 4 A 8 Check for Hydraulic 4 4 Part No 52270 Genie S 80 amp Genie S 85 v Service Manual Second Edition n HaT TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire Pressure 4 5 A 10
31. 6 21 AWD Hydraulic Schematic 6 22 Part No 52270 Genie S 80 amp Genie S 85 ix Service Manual Second Edition n HaT TABLE OF CONTENTS Section Seven Repair Procedures Ene 7 1 Platform Controls 1 1 Joystick 7 2 1 2 Horsepower Limiter Board 2 2044400 7 6 1 3 7 8 1 4 3BOSISIOIS et ot eid e enden edi 7 9 1 5 Toggle 440 402440 0 1 00 anawa aaa 7 9 1 6 Control RelayS x eos cei eR ERE RR EXE PO Rada 7 10 Platform Components 2 1 Lieu t tmm 7 11 2 2 Platform Leveling Slave Cylinder 7 11 2 3 Platform Rotator iie e S OO eed b t ts 7 12 Jib Boom Components S 85 Models 3 1 Jib Boom 5 85 Models 444 0000 0 7 15 3 2 Jib Boom Lift Cylinder 5 85 Models 7 16 3 3 Jib Boom Platform Rotate Manifold Components 5 85 Models 7 17 Boom Components 451 Boom Gable Track ege ect intere expen rp os 7 18 4 2 weim a ue un Imi E UL A 7 20 4 3 Lift 7 22 4 4 Extension Cylinders 02 40 aaa ii daa nnne nennen 7 23 4 5 Platform Leveling Master Cylinder 2 222404 7 24 Turntable Covers 5 1
32. Check voltage at TP23 W 12V Repair open in blk wire circuit from platform Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department circuit from key switch to TB22 OR Replace the platform controls contact at the key switch Repair open in blk 2 wire circuit from TB22 TP22 Repair open in blk wire from TP22 to Emergency Stop button P2 Check if Emergency Stop button internal cam yes is activating the contact no Replace the platform Emergency Stop button Repair open in red wire with diode from Emergency Stop button to TP23 Replace contact on Emergency Stop button P2 Part No 52270 Genie S 80 amp Genie S 85 5 31 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 14 Boom Up Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in up direction and check voltage on red wht wire on boom up down proportional valve coil item R 12V or more Continued on the next page Move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in the up direction and check voltage at TB3 With th
33. O o H op 58 zx 9 1 I 25 I 4 4 SUW LE nil SE 5 ER i Lam A C DOE Y 21 s i m I EE E I z I I Pa Po als Ta l 3 Mz 4 A PS SEL H I IZ La E ot 7 51 1 S BH 58 BH BH 2 I pt DONDE o gt 1 E 58 a pae organs a eee 4 m pu i I as 1 8 1 I o o I J GC W le m zd E 6 I AE E 82 95 B LLLI s az 5 PE Josa _ 55 LJ IS ui 5 5 5 8 5 5 8 D az A 8 5 Lt p pe 2 81 p do ag 55 uz zl 1 ze JE OCL NE I Z a c UNS 2 gt u 5 XE os I a J 59 2 x OED i 3 I m 0Q w 1 2 ane tt eset Aol 411 AZA uj u I i 8 48771 5 e Ga pa E Gut x pope eae m amp I 8 5 I i 8 ae o 82 a 1 1 1 gt 1 E ip 256 decr eee uS o oo lt gt gt lt
34. Second Edition Platform Control Box Wiring Diagram Diesel Models Section 6 Schematics SSS BLK 22 WHT 23 BLK 26 BLK WHT 34 2 NC LP WHT 1 H P L GRN TO GRD BLU BLK 37 BLU 36 WHT BLK 31 WHT 30 WHT RED 32 BLK RED 35 BLU RED 13 BLK 33 GRN 25 BLU WHT 12 RED 10 H P L bod RED WHT 29 BLK WHT 8 BLK 7 BLK RED 9 RED 27 GRN 17 JIB cu REI CR13 TOUT LAY GRN BLK 18 GRN WHT 19 RED 1 RED WHT 3 RED BLK 42 D2 WHT BLK 5 WH
35. Troubleshooting Flow Charts Move the function enable switch to either side and hold the add turntable rotate left right toggle switch TS18 on ground panel in the right direction and check voltage at TB4 With key switch in platform position and both Emergency Stop 12V or buttons pulled out to More ON position activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the right direction and check voltage TB4 12V Activate footswitch and more turntable rotate left right proportional controller BP1 on platform control panel in the right direction and check voltage TP4 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department CHART 19 Repair open in wht wire circuit from TB4 to turntable rotate right function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS18 on ground control panel OR repair open in wht wire circuit from TS18 to TB4 OR consult Genie Industries Service Department Repair open in wht blk wire from TP4 to TB4 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to
36. position momentary 13037 Microswitch Control Inc TNT SZ pane 2 Vacuum switch 22278 Peterson Industrial 1501 E ien ees 1 Part No 52270 Genie S 80 amp Genie S 85 6 3 Section 6 Schematics Service Manual Second Edition Electrical Symbols Legend LXrg ouo Wire color with cable number TB20 Terminal TB Terminal base TP Terminal platform Quick disconnect terminal BLK 21 21 T circuits connect at terminal T circuits connect Connection no terminal Circuits crossing no connection Diode Battery 15AMP a Circuit breaker Solenoid or relay coil TILT ALARM Horn nol Light U 07 Resistor AE Tilt sensor gt Spark plug Glow plug 181 NO Limit switch normally open held closed 17 ym Ground supression circuit 5 S LHM NC NO Ls3 s g Limit switch Ag NC 1 Limit switch normally closed held open VAC Vacuum switch O N 1590 Oil pressure switch normally closed Auxiliary pump 4 Water temperature switch normally open ON ISIM Foot switch PLAT KSI GRND Key switch HORN Horn but
37. valves OR function manifold may have an internal defect Consult Genie Industries Service Department Replace the platform level down directional valve coil item X Check for mechanical restrictions keeping platform level down function from operating OR replace slave cylinder OR replace Replace the defective directional valve Replace the defective counterbalance valve slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Rotate Left Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS14 in the left direction and check voltage at grn wht wire at TP19 at the platform controls 12V With keyswitch turned to 0V Check voltage on center 0V platform control and terminal of TS5 both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page Chart 23 Repair open
38. 0 PWR FS 26 BLK F S PWR START 25 RED FS 2 PWR CONT 24 WHT H P L NE PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 D 5 lt 20 a 20 JIB VALVE 19 GRN WHT 3 E m Li PLAT ROT R 18 GRN BLK 3 KJ m E E PLAT ROT L 17 GRN 3 i u PLAT LVL F C 16 ORG RED 3 X V PLAT LVL DN 15 ORG BLK 3 O JIB BOOM OPTION PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 8 o CR13 2 DRV ENA 12 BLU WHT 3 wa SEC BOOM DN 11 BLU BLK 3 RELAY SEC BOOM UP 10 BLU 3 z EXT RET F C 9 BLK RED 3 OIGE RETRACT BLK WHT 3 860g EXTEND 7 BLK 3 Tu EO ag TURNJEXT FC 6 WHT RED 3 Sx a TURN ROT R 5 WHT BLK 3 p1R alo2 TURN ROT L 4 WHT 3 PRIMARY FC RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY 1 RED 3 amp 5 00019 u z a Flooo gu Li E zd v uta E 5 1 213 4 5 6 7 8 910 Sd n a o a x T o ka I m ka a RED BLK 1 s g 59 Ke ES 50 2 Part No 52270 Genie S 80 amp Genie S 85 6 17 Service Manual
39. 24 WARNING SENDER RoWTEH wHr2 28 WHTSP KEYSWITCH POWER BLK CRS BLK2 22 BLK S P POWER TO PLAT WHT CR2 WHTEH 21 WHTOB WHTSP IGNITION POWER 20 12V SUPPLY GANWHTS 19 GRWISR JIB VALVE GENBLK4 _ GRNWBLK 3 18 GRBKDB PLATFORM ROTATE RIGHT GAN 17 GHNSP PLATFORM ROTATE LEFT CABLE ORG RED R8__ ORG RED 3 16 OGIRD D B OGIRD 8 P PLATFORM LEVEL 1 ORGIELK4 _ ORG BLK3 15 OG BKD B OG BKS P _ PLATFORM LEVEL DOWN ORG 4 ORG 3 14 ORG D amp ORGSP PLATFORM LEVEL UP WHT amp BLUREDG 13 DRIVE ENABLE LIGHT WHT ER BLUWHT 3 12 DRIVE ENABLE BLUBLKA _ BLUBLKS 11 BUBKSP SEC BOOM DN BLU BLUS 10 BLUSP SEC BOOMUP BLK RED 4 BLK RED 3 9 BK RD S P EXT RET BLKWHT4 _ BLKWHTG 8 BKWTDB BAWTSP BOOMRETRACT BLKS 7 BLKD BIKSP BOOM EXTEND CABLE WIR WHTRED3 6 WTRDSP TURN ROT FC waraka _ WHTBLK3 5 WIIBKDS WUBKSP TURNTABLE ROTATE LEFT 2 WHT 4 WHT 3 4 WHTD B WHT S P TURNTABLE ROTATE RIGHT RWA RED WHT 3 3 RD WT S P PRIMARY BOOM F C REDBLK4 _ REDIBLKG _ 2 RDBKDB RDIBKSP PRIMARY BOOM DOWN RED 4 RED 3 1 RED D B REDSP PRIMARY BOOM UP D C B A ORGIBLK 158 imm FEE ORGIRED 168 ORG 148 2 KIE GRNBLK 44B i AE GRNIBLK 198 RED WHT 29B e BLK R1487 BLK WHT 8B 5 10 BRN GROUND CABLE 1 5 WHT2IB 3 gt WHTIBLK SB 2 ae BLU 36B worse 4 8 BLUBLK 37B REDI
40. 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Move the function enable switch to either side and activate the turntable rotate left function Continued from the previous page 250 psi or more Exchange turntable rotate left and right function counterbalance valves Operates items LL and KK Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate left function from operating OR replace shuttle valve item JJ OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 47 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 19 Turntable With key switch in Move the function Repair open in wht red i ground position and enable switch to either wire circuit from TB6 to Rotate Right both Emergency Stop side and hold the 4 6 turntable rotate left right Function buttons pulled out to the turntable rotate toggle proportional valve coil switch TS18 on ground panel in the right direction and check voltage at TB6 ON position move the function enable switch to Inoperative either side and hold the B Il oth turntable rotate toggle e sure all other switch TS18 on ground functions operate p
41. 287 Genie part number 33907 D 10 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 Block the non steering wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts then remove the tire and wheel assembly TABLE D PROCEDURES 5 Check for 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 6 Remove the dust cap from the hub then remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 foot pounds 47 Nm to seat the bearings 8 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 9 Check for 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 bearing
42. Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the open position Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Install a 0 to 5000 PSI 345 bar pressure gauge on the function manifold Start engine move the function enable toggle switch to either side and hold the boom retract function toggle switch and check the hydraulic pressure less than 2600 psi Adjust the function manifold system relief valve item Z all the way in clockwise counting the number of turns Move the function enable switch to either side and hold the boom retract toggle switch and recheck the pressure Check steer functions Check the function pump see Repair section Replace the function pump steering inoperative Chart 11 Troubleshoot each function individually or consult Genie Industries Service Department Move the function enable switch to either side and hold the boom retract switch and readjust the relief pressure to 2900 psi 197 bar Repair or replace differential sensing valve item Y OR repair or replace flow regulator valve item CC OR manifold has an internal defect consult Genie Industries Service Department Replace the relief valve item Z OR manifold has an internal defect Consult the Genie Industries Service Department Part No 52270 Genie S 80 amp Geni
43. LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 o DRV ENA 12 BLU WHT 3 SEC BOOM 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 8 5 N TURN ROT 6 WHT RED 3 Qk TURN ROT R 5 WHT BLK 3 NE TURN ROT L 4 WHT 3 PRIMARY F C 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 _ PRIMARY UP 1 RED 3 A mw 1 Gi lt 7 E zi S z 5 3 112 3 456 7 8 9000 a M zo m 9 22 O 7 orc 5 RED BLK 1 o m m T 5 Q TILT ALARM BLU RED 39 BLU WHT 38 WHT 1 H P L BRN TO GRD BLU BLK 37 WHT BLK 31 WHT 30 WHT RED 32 BLK RED 35 BLU RED 13 BLK 33 BLU WHT 12 RED 10 H P L 966 RED WHT 29 BLK WHT 8 BLK RED 9 GRN 17 GRN BLK 18 GRN WHT 19 RED 1 RED WHT 3 REDIBUK MO
44. RED WHT 23 E H RELAY LEVEL SENSOR TP23 TP43 GRN 1 TB23 CRS GRN SERVICE HORN P3 H HORN D 2 BLK 2 TB22 TB43 Ux CR5 NO BLK R5 E H RELAY SERVICE HORN TP22 KS1 PLAT GRND P1 RED ORG BLK 1 TB41 H2 20 O WHT R17 E H HYDRAULIC OIL NO CR17 ORG R17 E H TEMP SWITCH WHT 21 E H 510 0 RED E H ORG BLK 41 E H RED 25 AMP o a RED 20 E H ALTERNATOR REGULATOR COOLING FAN OPTION Part No 52270 Genie S 80 amp Genie S 85 6 7 Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models CN LO BRN 2 bc e E 3 BLU RED 3 WHS o 3 SZ 3 e BRN 5 1 WHT 1 A RED 5 BLK 5 gt oi S ui Ea E amp DRIVE ENABLE BLU WHT 3 m 5 8 20 A 31 ca E WHT BLK 1 Fy WHT BLK 31 E H n c g a m A WHT RED 1 B WHT RED 32 E H m 5 5 m E BLU BLK 1 B BLU BLK 37 E H BLU 1 BLU 36 E H
45. Service Manual Second Edition RED 7 46 REDH27 WHT 21 L S POWER GRWF4 GENWHTA GEN OPTION GRN BLK E H RED R8 44 GRN BLK D B RD BK 2 DUMP VALVES GRN CR5 GRN 1 43 HORN BLK 7 ORG RED 1 42 BK WT 8 4 BLK 6 TURNTABLE ROT HIGH CABLE OG BK ORG BLK 1 41 OG BK 2ISM PULSE PICKUP 7 WHT 6 ORG 1 40 WHTI LIMIT SWITCH BLUREDH 39 BURDGR7 BURDSP LP BU WT CRE BLU WHT 1 38 IBU WT S P GAS BUBKEH _ BLUBLK1 37 BLBKDB STEER LEFT BLUEH BLU T 36 BLUD B STEER RIGHT BLKRED 35 BLKREDGR4 BKRDSP RPM CABLE BLK WHT 1 34 GLOW PLUG 6 BKS ISM 1 __ BLKSP START WIRD EH WHIREDi WI RDDS BRAKE WTBKEH wieka 31 EDC z RED S WHT 1 30 EDC RDWEEH RWA 29 2WD AWD ROBKEH _ REDIBLK1 _ 28 TILT ALARM CABLE RED EH RED 1 z7 RoMiSM REDSR AUX PWR 5 WT RD E H 26 WT RDSP WATER TEMP SENDER WT BK E H 25 WT BK S P OIL PRESSURE SENDER 1018 WHTEH
46. less than 2100 PSI Reset boom down relief valve item E pressure see Repair Section OR replace boom down relief valve OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 15 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 16 Boom Extend Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend toggle switch TS19 on ground panel in extend direction and check voltage on blk red wire on boom extend retract proportional valve coil item P 12V or more Continued on the next page Move the function enable switch to either side and hold the boom extend toggle switch M TS19 on ground panel in the extend direction and check voltage at TB9 With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage at TP9 Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust cont
47. 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 Tag disconnect and plug all the hydraulic hoses from the jib boom manifold Bodily injury hazard Spraying AWARNING 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 10 Attach a lifting strap from an overhead crane to the jib boom 11 Remove the pin retaining fastener from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the primary boom AWARNING Crushing hazard If the overhead crane is not properly attached the jib boom may become unbalanced and fall when it is 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 Support the rod end of the jib boom lift cylinder with a lifting device 15 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the jib boom mounting weldment AWARNING Crushing hazard If the overhead crane is not properly attached the jib boom lift cylinder may become unbalanced and fall when it is removed from the
48. on ground pane in the i retract direction and check voltage on blk red wire on boom extend retract proportional valve coil item P 12V or more Continued on the next page Chart 17 Move the function enable switch to either side and hold the boom extend retract toggle switch 7519 on the ground panel in the retract direction and check voltage at TB9 With keyswitch in 9 to 10V platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage at TP9 Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item P OR repair open in brown ground wire circuit to valve coil Repair open in blk red wire from TP9 to TB9 Repair open in power supply circuit from TP24 to BP1 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Part No 52270 Genie S 80 amp Genie S 85 5 41 Section 5 Troubleshooting Flow Charts ECSS CDS CD DOLL CHART 17 Continued from the previous page With key switch in ground position and both
49. plate mounting bolts to 34 ft lbs 46 Nm Cheek and Adust ihe Engine MEM 2 Install the coupler onto the pump shaft with the set screw toward the pump Leave a 1 2 inch 12 7 mm gap between the coupler and pump 6 2 end plate ite Flex Plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm The flex plate acts as a coupler between the l engine and the pump It is bolted to the engine ACAUTION Component damage hazard Do flywheel and has a splined center to drive not i the vitis PA the pump installation or the flex plate teet may become damaged 9 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm 6 3 Oil Temperature and Pressure Gauges B pump The oil temperature gauge is an electrical gauge pump shaft 5 ns c coupler The sending unit has limit contacts that are factory d flex plate with raised spline set The contacts will close at 3009 F 1479 C e we When the contacts close the engine will shut off to le prevent damage and will not start until the temperature drops below the contact point How to Remove the Flex Plate Temperature will be indicated when the key is on 1 Disconnect the wiring plug at the electronic and the Emergency Stop Button is pulled out to the displacement controller EDC located on ON position nedrive pump ACAUTION Component damage hazard 2 Support the drive pump with
50. steer manifold OR repair open in brown ground wire circuit to steer right valve coil Replace steer right directional valve coil item VV OR repair open in brown ground wire circuit to steer right valve coil Repair open in blu blk 37 wire circuit from drive controller DP1 to TP37 then to TB37 5 72 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 30 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer right function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer right function regulator valve item CC OR consult Genie Industries Service less than 2900 PSI Department Continued from the previous page Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 73 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 31 All Drive Functions inoperative All Other Functions Operate Normally Be sure the rpm toggle switch is in the footswitch activated high idle position Be sure the hydraulic tank shut off valves are in the oPEN position Be sure machine is not in the free wheel configurati
51. the voltage at the white wire on the choke while cranking the engine Check automatic choke for proper adjustment or internal damage good With keyswitch on and both Emergency Stop buttons pulled out to the ON position check voltage at red wht 23 wire on vacuum switch 12V Remove the blk wire with diode from terminal 86 on CR3 hold the start switch to either side and crank the engine over for 15 seconds and check voltage at red blk wire on vacuum switch reconnect blk wire after test 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position disconnect wires from vacuum switch and connect the wires together Check the voltage at terminal 86 on CR6 12V Continued on the next page Repair open in white 21 wire circuit from the ignition coil plug to the automatic choke Adjust or replace automatic choke OR consult Genie Industries Service Department Repair open in red wht 23 wire circuit from TB23 to vacuum switch Turn machine off See bad Repair section for how the test the vacuum switch ok bad Check vacuum line for restrictions or damage ok See Ford service manual to troubleshoot low manifold vacuum Repair open in red blk wire circuit from vacuum switch to CR6 Replace vacuum switch Replace vacuum line Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troublesh
52. write to the technical publications team in care of Genie Industries PO Box 97030 Redmond WA 98073 0069 U S A If you have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 425 556 8649 Genie Europe Office Telephone 44 01636 605030 Office FaxFax 44 01636 611090 Parts Telephone 44 01636 605002 Parts Fax 44 01636 611091 Genie Industries Copyright 1998 by Genie Industries Second Edition First Printing July 1998 Genie and S are Registered Trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 oy Printed on recycled paper Printed in U S A ii Genie S 80 8 Genie S 85 Part No 52270 Service Manual Second Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie S 80 amp Genie S 85 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are 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 a
53. 28 to 34 38 to 46 M 10 x 16 8 8 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition 1 J Een Section 2 Specifications SPECIFICATIONS Bolt tightening specifications continued torque torque ft lbs Nm torque torque Bolt description size grade ft lbs Nm thermostat housing screw 37 to 44 50 to 60 Idler pulley V belt pulley bolt 271032 361044 Plug M 38 x 1 5 M 10 x 25 8 8 Oil thermostat housing bolts 5 5 to 7 7 5109 Idler pulley for toothed belt 3010 36 41to4g M 6x 35 Torx 8 8 M 10 x 50 8 8 Oil thermostat housing bolts 5 5 to 7 7 5109 pump bolts 15 to 18 201024 6 80 Torx 8 8 M 8 x 35 Torx Oil thermostat housing bolts 14 to 16 19 to 22 Oil filter bracket bolts 7108 9to11 M 86 x 105 Torx 8 8 M 8 x 20 Torx 8 8 Valve plunger housing bolts 14 to 16 19 to 22 Oil intake housing bolts 151018 20024 8 30 Torx 8 8 8 x 75 Torx Alternator nuts M 5 3 4 Fuel pump bolts 15 to 18 201024 Fuel bracket bolts M 8 x 20 8 8 15 20 Injection pump bolts 15 to 18 201024 Adapter housing bolts 70077 9510105 Injector cap nut 30 to 37 40to50 12 35 10 9 12 75 10 9 Injector fastening bolt 15 to 18 20 to 24 JISPSIBBI second step tightening tightening Injection line 10to12 13 5 to 16
54. 3 liters Number of cylinders 4 3 781 x 3 126 inches 96 04 x 79 4 mm Bore amp stroke Horsepower 63 4000 rpm Firing order 1 3 4 2 Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Governor electronic Compression ratio 9 41 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure operating temp 2000 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 5 quarts including filter 4 7 liters Cil viscosity requirements Temperature below 60 F 15 5 C 5W 30 10 F to 90 F 23 C to 32 C 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C Temperature above 20W 40 or 20W 50 20 F 6 6 C Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear protection Units ship with 10W 40 SG CC Service Manual Second Edition 1 M P 1 Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 170A Current draw maximum load 200A Current draw minimum 140A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Brush spring tensio
55. 4 31 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 5 Grease the Turntable Rotation Bearing and Rotate Gear Yearly 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 the 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 13 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 C 6 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Select the torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest point Remove both plugs and drain the oil Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs and then
56. 80 Models 6 Support the rod end of the platform leveling slave cylinder 7 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin Part No 52270 Genie S 80 amp Genie S 85 7 13 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Move the platform rotate switch to the right then the left through two platform rotation cycles then hold the switch to the RIGHT position until the platform is fully rotated to the right 2 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 3 Open the top bleed valve on the rotator but do not remove it a top bleed valve b bottom bleed valve C clear hose d container 4 Hold the platform rotate switch to the LEFT position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then close the bleed valve Crushing hazard Keep clear of AWARNING the platform during rotation 5 Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve 6 Hold the platform rotate switch to the RIGHT position until the platform is fully rotated Continue holding the switch until air stops coming out of th
57. A terminal on the controller printed circuit board Connect the black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 Setthe hi range Press down the foot switch fully retract the boom then move the control handle all the way to the left or right Adjust the voltage to 5 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch extend the boom 3 feet then move the control handle all the way to the left or right Adjust the voltage to 4 5V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Engine should be at normal operating temperature 10 Fully retract the boom then start a timer and record how long it takes the turntable to rotate through a complete circle Adjust the max out trimpot to achieve a 70 to 80 second cycle time 11 Extend the boom then start a timer and record how long it takes the turntable to rotate through a complete circle Adjust
58. Check voltage at oV terminal 30 on CR3 12V Check voltage at oV terminal 486 on CR3 12V no continuit Check continuity from ground to brown wire on terminal 485 of CR3 continuity Check voltage to ov terminal 87 on CR3 12V Check voltage at terminal 1 red wht wire on electronic governor 12V Check voltage at terminal 1 red wht wire on governor actuator 12V Check continuity fom terminal 6 on precision continuit governor to blu blk terminal 42 on governor actuator full continuity Continued on the next page Repair open in wht wire circuit from CR2 terminal 487 to CR3 30 Repair open in rd blk R6 wire circuit from vacuumn switch to CR6 to CR7 to terminal 86 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace relay Repair open in red wht wire circuit from terminal 87 on CR3 to terminal 1 on electronic governor Repair open in red wht wire circuit from electronic governor terminal 5 to governor actuator terminal 1 Repair open in blu blk wire circuit from governor actuator to electronic governor 5 20 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts SSS CHART 6 Check voltage on red Repair open in red wht wht wire on governor wire from governor actuator controller to governor actuator Continued from the p
59. ES Table C C 1 Check the Boom Wear Pads C 2 Check the Extendable Axle Wear Pads C 3 Check the Turntable Rotation Bearing Bolts o MI C 4 Check the Free wheel Configuration 5 Grease the Turntable Rotation Bearing and Rotate Gear C 6 Replace the Torque Hub Oil C 7 Replace the Hydraulic Tank Filter C 8 Replace the Drive Loop Hydraulic Filter C 9 Replace the Diesel Fuel Filter Water Separator X 2 Deutz Diesel Models A C 10 Replace the Gasoline Fuel Filter Gasoline LPG Models C 11 Replace the PCV Valve FA Gasoline LPG Models C 12 Replace the Spark Plugs Gasoline LPG Models Part No 52270 Genie S 80 amp Genie S 85 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Table C continued Tools are required New parts required Warm engine required Cold Dealer engine service required suggested C 13 Check and Adjust the Air LPG Mixture Gasoline LPG Models C 14 and Adjust the Ignition Timing Gasoline LPG Models E C 15 Check the Engine Valve Clearances Deutz Diesel Models LSS C 16 Check the Turntable Rotation Gear Backlash ra ra ra Table D D 1 Test or Replace the Hydraulic Oil D 2 Change or Recondition the Engine Coolant Gasoline LPG Models D 3 Change the Fuel Lines EHE D 4 Check the Engine Valve Clearance Gasoline LPG Mode
60. Edition Section 4 Scheduled Maintenance Procedures B 2 Check the Radiator Gasoline LPG Models 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 Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant may cause severe burns 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator 2 Inspect the radiator for leaks and physical damage 3 Clean the radiator fins of debris and foreign materials TABLE B PROCEDURES B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel 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 Do not inspect while the engine AWARNING is running Remove the key to se
61. Genie S 80 amp Genie S 85 7 37 Section 7 Repair Procedures Service Manual Second Edition Manifolds 10 1 Function Manifold Components The function manifold is located on the tank side tray behind the ground control box Index Schematic No Description Item 1 position 4 way DOS valve D 2 position 4 way DOS valve Bonon 3 position 4 way valve 4 Check valve pilot operated BRR 5 Relief valve 2100 psi 145 bar E ss 6 Relief valve 2500 psi 172 bar Eun 7 Solenoid valve poppet 8 Flow regulator valve 1 5 5 7 l min 9 Flow regulator valve 1 5 5 7 l min 10 Flow regulator valve 1 5 5 7 l min Jesi 11 Flow regulator valve 0 2 gpm 0 78 l min Kies 12 Flow regulator valve 1 5 5 7 l min Essi 13 2 position 2 way directional valve M 14 Check valve Nae 15 Check valve scel Qus 16 Proportional solenoid valve Pane 17 Check valve 2 Qua 18 Proportional solenoid valve pi eus 19 Check This list continues Please turn the page Function Torque 30 35 in lbs 3 4 Nm 30 35
62. HORN T D 9 tr _ 8 WHT WHT R17 E H 7 O HYDRAULIC OIL 55 6 gt TEMP SWITCH lt a 6 B E Rze z 1 OF ORGAIZ EH zy COOLING FAN m DAE OPTION amp ORG BLK 1 ORG BLK 41 E H a Q a r ft I id R gt i NE Ig i m HN E rig 8184 884 17 4 5 amp E 8 RED FE RED 20 E H CN LO N Part No 52270 Genie S 80 amp Genie S 85 6 13 Section 6 Schematics Service Manual Electrical Schematic Diesel Models N LO N BRN 2 m e n e yv ad BLU RED 3 WHS EA 8 m WHT 1 RED 5 BLK S o 8 i S T Ew 5 DRIVE ENABLE E BLU WHT 3 E 5 8 x gt E WHT BLK 1 Fr W
63. LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH 7818 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH CBI CIRCUIT BREAKER CONTROLS 154 CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER R2 RESISTOR 14 OHM BOOM FUNCTIONS RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE TS10 TS19 TS15 TS16 TS17 O O 518 EE TS14 uem SE CR18 PLATFORI LEVEL CUTOUT CR17 COOLING FAN RELAY SECTION A A Service Manual Second Edition RP ssw n2 YI ZZ Ground Control Box Legend Diesel Models GE VR CABLE 2 W O RED 7 27A JE 218 GR WT 4 GRN WHT 1 RED 6 GRN BLK EH GRN BLK D B RB 87A GRN R5 GRN 1 BLK 6 ORG RED 1 HE BLK7 OG BK EH ORG BLK 1 OG BK 2ISM WHT 6 ORG 1 WHT 7 BLU RED 1 BU RD CR7 BUIRD S P BUWT CRE IBLU WHT 1 BU WT S P BU BK E H BLU BLK 1 BL BK D B BLU EH BLU 1 BLU D B BLK RED 1 BK RD S P BLKAWHT 1 BLK 3 ISM BLK 1 BLK S P WT RD E H WHTIRED 1 WTIRD D B WT BK E H W
64. Oil cooler and fins Diesel B 4 Exhaust system B 5 Battery B 6 Hydraulic tank filter C 14 Ignition timing Gas LP C 15 Valves Deutz Diesel C 16 Turntable backlash Checklist D YN R B 7 Electrical wiring Refer to Table D B 8 Tires and wheels D 1 Hydraulic oil B 9 Brake configuration 0 2 Engine coolant Gas LPGI B 10 Torque hub oil level D 3 Change fuel lines B 11 ldle mixture Gas LPG D 4 Valves Gas LPG B 12 Engine RPM D 5 Compression Gas LPG B 13 Key switch D 6 PCV hoses Gas LPG B 14 Emergency Stop D 7 Fuel injection Diesel B 15 Ground control override D 8 Toothed belt Diesel B 16 Platform leveling D 9 Timing belt Gas LPG B 17 Horn D 10 Wheel bearings Part No 52270 Genie S 80 amp Genie S 85 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition gt gt gt ZZL This page intentionally left blank 3 8 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey 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 annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure
65. PR Power relay Resistor Terminal base location dide Terminal platform location Ric seen es Toggle switch Vacuum switch Part No 52270 Genie S 80 amp Genie S 85 6 5 Section 6 Schematics Service Manual Second Edition Eee es 6 6 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Section 6 Schematics Electrical Schematic Gasoline LPG Models NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION BLK RED 1 HIGH RPM ENGINE SPEED TS4 OPTION TP35 I 9 _ GENERATOR m e FUNCTION ENABLE HIGH RPM BLK RED 4 HIGH IDLE RELAY GRN WHT 1 TB35 RED WHT E Hj BLU BLK E H s o NC N BLK RED R4 E H e GOVERNOR ACTUATOR ELECTRONIC GOVERNOR 3 EN CR3 FB FLASHING BEACONS RED WHT 23 E H PRECISION GOVERNOR RELAY RED BLK R6 E H FUEL RELAY FUEL RELAY CR6 CR7 GRN WHT 4 GENERATOR TP39 BLU RED 1 TB45 TB39 OPTION BLU RED R7 E H BLU WHT 1 NO BLU WHT R6 E H LPG SOLENOID ANTI DIESEL VALVE TP38 GAS FUEL ORG RED 1 TB38 CR6 CR7 NO BLU WHT R6 E H
66. PR Repair open from TB27 to PR1 OR repair open in brown ground wire circuit to PR1 OR replace PR Repair open in red power supply wire from keyswitch KS1 to auxiliary toggle switch TS10 12V or more Repair open in red 27 wire from TS10 to TB27 OR replace TS10 5 82 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 37 Check continuity from Replace negative cable negative terminal on from auxiliary pump to auxiliary power unit to ground ground Continued from the previous page Replace auxiliary pump motor Part No 52270 Genie S 80 amp Genie S 85 5 83 Section 5 Troubleshooting Flow Charts Service Manual Second Edition E This page intentionally left blank 5 84 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 6 Schematics Observe and Obey M Troubleshooting and 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 Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the appropriate Genie S 80 and Genie S 85 Operator s Manual Be sure that all necessary tools and t
67. Platform Raised or Extended 5 80 36 Drive Enable System Is Malfunctioning 5 81 37 Auxiliary Functions Inoperative 2 5 82 Schematics HMO CU Ct lonis cao ro eei eeu 6 1 Electrical Components ns aa aa eee eue tees ech 6 2 Electrical Symblos 6 4 Abbreviation Legends e nee tee ete Ente E n dex E ce Dr ede 6 5 Electrical Schematic Gasoline LPG Models esses 6 7 Ground Control Box Legend Gasoline LPG Models 6 9 Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Platform Control Box Legend Gasoline LPG Models 6 11 Platform Control Box Wiring Diagram Gasoline LPG Models 6 12 Electrical Schematic Deutz Diesel 6 13 Ground Control Box Legend Deutz Diesel Models 6 15 Ground Control Box Wiring Diagram Deutz Diesel Models 6 16 Platform Control Box Legend Deutz Diesel Models 6 17 Platform Control Box Wiring Diagram Deutz Diesel Models 6 18 Hydraulic Symbols Legend 6 20 2WD Hydraulic Schematic iiir ter tcr den peer
68. Procedures B 15 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 Emergency Stop button on the platform controls is in the on or position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform Emergency Stop button to the orr position 2 Startthe engine from the ground controls 3 Operate each boom function through partial cycle Result All boom functions should operate B 16 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 is 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 Start the engine from the ground controls then extend the axles and lower the boom into the stowed position 2 Adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle Result The platform should remain leve
69. Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES 5 Install the new spark plugs then connect the 2 Loosen the high idle mixture adjustment wires Be sure that each spark plug wire is lock nut attached to the correct spark plug Spark plug specifications Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Spark plug torque 5 to 10 foot pounds 7 to 14 Nm C 13 Check and Adjust the Air LPG high idle mixture Mixture Gasoline LPG Models 2 Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance Load the system by pressing the boom retract switch then move the function enable toggle switch to the high idle rabbit symbol position 4 Adjust the high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer 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 The engine rpm needs to be preset for gasoline fuel operation before adjusting the LPG idle mixture Refer to B 12 Check and Adjust the Engine RPM The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start
70. Section 5 Troubleshooting Flow Charts Service Manual Second Edition SSS SSS CHART 5 Hold the start switch to Check continuity from y Repair open in brown either side and check ground to brown wire at ground wire circuit to the voltage at blu wht wire fuel pump fuel pump on the fuel pump Continued from the previous page continuity Repair open in blu wht wire from anti diesel solenoid to fuel pump OR replace fuel pump 0 or infinite ohms Check resistance of anti diesel valve Replace anti diesel valve 24 to 25 ohms less than 7 psi Install a pressure gauge Replace fuel pump OR to the fuel pump Hold check anti diesel and start switch to either fuel valve for defects side and observe the pressure on the gauge more than 7 psi Reconnect starter and see Ford service manual for carburetor troubleshooting OR consult Genie Industries Service Department 5 18 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle inoperative Gasoline LPG Models If high idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If high idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding Be sure high idle can be a
71. Turntable Covers 7 26 Deutz Engine F4L 1011F 6 1 BBPN Agjustment ucc m e Ped tem Ede ie c ER Beer d e 7 27 6 27 ePi te 7 27 6 3 Oil Temperature Oil Pressure 7 27 Ford LRG 423 Engine PA GQovernorACtUaltor ae ERE EE 7 28 7 2 Choke Adjustments 7 29 X Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition TABLE OF CONTENTS Section Seven Repair Procedures Ford LRG 423 Engine continued 7 3 TIMING 7 30 7 4 Carburetor 7 30 7 5 eer erre re iR 7 30 7 Flex Plate oie teet adie dees 7 30 7 7 Water Temperature and Oil Pressure 7 31 7 82 eiie net rere Ut eee ian 7 32 Ground Controls 921 Gontrol Bielays ot eie tim ve p ibus ibis 7 33 8 2 Toggle Switches See 1 5 Toggle Switches 7 33 8 3 Wago9 Componerits niei ct pene ttt ne si hr etg Me E en E ed 7 33 8 4 lt ts 7 33 825 eh
72. activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the boom to fully raise Adjust the max out trimpot to achieve a 85 to 95 second cycle time 11 Start a timer and record how long it takes for the boom to fully lower Adjust the dual range trimpot to achieve an 85 to 95 second cycle time If the function cycle time is not achievable check the relief valve pressure See 10 2 Valve Adjustments Function Manifold 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltage reading 15 Start the engine PLATFORM CONTROLS 16 Start a timer and simultaneously move the control handle all the way to the up position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate turn the trimpot to obtain a 3 to 4 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 3 5V DC 8 5V DC 85 to 95 seconds Boom up hi range Cycle time 6 2V DC 85 to 95 seconds Boom down lo range Cycle time Ramp rate 3 to 4 seconds Turntable Rotation C
73. allow the boom functions to operate How to Set Up the Hydraulic Limit Switch Linkage Adjustment of the hydraulic limit switch linkage is only necessary when the switch or linkage has been replaced or the axle wear pads are worn or have been replaced 1 Install the hydraulic switch and connect the hydraulic hoses 2 Install the linkage rod and leave the lock nut loose locknut linkage rod spring valve actuator limit switch valve OooOooo 0mm Use the lift jack to raise the machine Extend the axles completely then lower the machine 5 Turn the linkage rod clockwise until it completely compresses the valve actuator Then turn the linkage rod counterclockwise 1 8 inch 3 2 mm Raise the machine 7 Extend and retract both axles through 2 cycles and check boom functions If the boom will not raise past the drive limit switch with both axles extended readjust the hydraulic limit switches as necessary Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures Non steering Axle Components 16 1 Drive Motor How to Remove a Drive Motor Component damage hazard ACAUTION Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer Component damage hazard The ACAUTION work area and surfaces where this procedure will be performed must be clean and free of debris t
74. 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 boom is horizontal 2 Place support blocks under the cylinder across the turntable 3 Attach an overhead 5 ton 4536 kg crane to the boom Do not lift the boom 4 Support the balance point of the boom lift cylinder with an overhead crane or similar lifting device Crushing hazard If the overhead AWARNING crane is not properly attached the lift cylinder may become unbalanced and fall when it is disconnected from the machine Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 6 Remove the pin retaining fastener from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin then lower the lift cylinder onto the blocks Protect the cylinder rod from damage Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if it is not properly supported 7 Remove the mounting fasteners from the barrel end cylinder pin
75. from TB24 temperature sender no continuity Repair short in wht wire circuit from ignition start module to TB24 OR consult Genie Industries Service Department 0 or Turn the machine off infinite Replace the fuel and isolate the fuel ohms solenoid solenoid Check the resistance of the solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel system 5 12 Genie S 80 amp Genie S 85 Part No 52270 Continued from the Service Manual Second Edition E Hold start switch and check voltage at wht 21 wire on terminal 87 of CR2 Check voltage at red wire on terminal 30 of CR2 Hold the start switch to either side and check voltage at terminal 86 of CR2 12V Check continuity from ground to terminal 85 on CR2 good Continued on the next page Section 5 Troubleshooting Flow Charts Repair open in wht 21 wire from CR2 to fuel solenoid Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Hold the start switch to either side and check 12V voltage at terminal 9 on the ignition start module oV Check voltage at terminal 6 and 7 on ignition start module 12V Check continuity from ground to brown wire at continuity terminal 5 on ignition start module continuity Replace the ignition start module OR consult Genie Industries Service Department Repair open in brown ground w
76. in lbs 3 4 Nm 30 35 in lbs 3 4 Nm 11 13 ft lbs 15 18 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 35 40 ft lbs 47 54 Nm Turntable rotate left right Boom up down Boom extend retract Boom extend retract circuit prevents overflowing the proportional valve 10 12 ft lbs 14 16 Nm Boom up down circuit prevents overflowing the proportional valve 10 12 ft lbs 14 16 Nm Turntable rotate left right prevents overflowing the proportional valve 10 12 ft lbs 14 6 Nm Hydraulic limit switch circuit 10 12 ft lbs 14 16 Nm Bleeds off differential sensing valves to tank 10 12 ft lbs 14 6 Nm 25 30 ft lbs 34 41 Nm Hydraulic limit switch circuit Differential sensing circuit boom extend retract 11 13 ft lbs 15 18 Nm Differential sensing circuit boom up down 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm Boom extend retract Differential sensing circuit turntable rotate left right 11 13 ft lbs 15 18 Nm 10 12 ft lbs 14 16 Nm Boom up down Differential sensing circuit platform level up 11 13 ft lbs 15 18 Nm 7 38 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS 68 89 82 Ll 29 BB 28 ee O 11 Y 5 13 d R 05122222 2 25 12 PB NADE 3
77. injury hazard Spraying AWARNING 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 rod 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 pivot end of the boom 15 Remove the trunnion pin retaining fastener and use a slide hammer to remove the pins 16 Support and slide the extension cylinder out of the pivot end of the boom Crushing hazard The extension AWARNING cylinder may become unbalanced and fall when it is removed from the boom if it is not properly supported and attached to the overhead crane Note the length of the cylinder after removal The cylinder must be at the same length for installation 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base 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 Hydrau
78. install the plugs 5 Repeat steps 1 through 4 for all the other drive torque hubs Oil capacity per hub non steer outside 50 fl oz 1 48 liters non steer inside 4 fl oz 0 11 liters steer end 4WD models 44 fl oz 1 3 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures TABLE C PROCEDURES Turntable Rotate Torque Hub 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 1 Secure the turntable from rotating with the turntable rotation lock pin 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters Install the brake and motor onto the torque hub 7 Fillthe 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 plugs and then install the plugs 8 Adjust turntable rotation gear backlash See Repair Procedure 12 1 How to Adjust the unlocked locked Turntable Rotation Gear Backlash 2 Remove the motor brake mounting bolts and then remove the motor and brake from the torque hub and set them to the side Oil capacity 44 fluid ounces 1 3 liters Turntable rotate torque hub Component damage hazard ACAUTION Hoses can be damaged if they are i Type SAE 90 multipurpose hypoid gear oil API kinked or pi
79. less than specification If the wear 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 boom tubes Bottom and side wear pads 7 16 inch 11 mm Boom wear pad specifications Upper and lower wear pads 9 16 inch 14 3 mm Side wear pads 11 16 inch 17 5 mm Part No 52270 Genie S 80 amp Genie S 85 4 29 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 3 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 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 part no 33484 2 sure that each turntable mounting bolt is torqued in sequence to 210 foot pounds 285 Newton meters 1 1 10 000 a 18 9 Q Bo
80. machine Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition eee JIB BOOM COMPONENTS S 85 MODELS 3 2 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses the fittings on the Jib Boom Lift Cylinder cylinder S 85 Models m AWARNING iniury hazard Spraying hydraulic oil can penetrate and How to Remove the Jib Boom burn skin Loosen hydraulic Lift Cylinder connections very slowly to allow the oil pressure to dissipate Perform this procedure with the gradually Do not allow oil to boom in the stowed position squirt or spray When removing a hose assembly 3 Remove the pin retaining fasteners from the jib or fitting the O ring on the fitting boom lift cylinder rod end pivot pin Do not and or hose end must be replaced remove the pin and then torqued to specification during installation 4 Use a soft metal drift to tap the jib boom lift Refer to Section Two Hydraulic cylinder rod end pivot pin half way out Then Hose and Fitting Torque lower one of the leveling arms to the ground Specifications Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 1 Raise the jib boom slightly and place blocks P under the platform mounting weldment Then 5 Support the jib boom lift cylinder with a lifting lower the jib boom until the platform is resting device on the just enough to support
81. normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage on red wht wire on boom up down proportional valve coil item R 12V or more Continued on the next page Move the function enable switch to either side and hold the boom down toggle switch am TS17 on ground panel in the down direction and check voltage at TB3 With the keyswitch in 6 to 7V the platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP1 on platform control panel in down direction and check voltage at TP3 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Chart 15 Repair open in red wht wire circuit from TB3 to boom up down proportional valve coil item R OR repair open in brown ground wire circuit to valve coil Repair open in power supply circuit from TP24 to BP1 OR repair open Repair open in red wht wire from TP3 to TB3 in brown ground wire circuit from ground to BP1 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts CHAR
82. or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosEp 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 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying AWARNING 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 Hydraulic Pumps 3 Remove the pump mounting bolts Carefully remove the pump Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 9 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC 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 Se
83. position then extend the boom 3 feet 91 cm 14 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended All models 1 foot per second 0 31 meter per second a extend drive limit switch 151 b cable track 4 Startthe engine from the ground controls and extend the axles 5 Raise the boom until the boom extend limit switch is accessible 6 Extend the boom approximately 3 feet 0 9 m 7 Manually activate the boom extend drive limit switch Result The boom extend drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 8 Turn the keyswitch to platform control 9 Start the engine from the platform controls and fully retract the boom 10 Slowly move the drive control handle off center O Result The machine should move at normal drive speeds 11 Raise the boom to just above horizontal Part No 52270 Genie S 80 amp Genie S 85 4 9 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine operation and workplace safety The drive enable limit switch stops the drive function when the boom is rotated past a non steer tire and alerts the operator that the machine may drive in the opposite direction that the drive and s
84. resistance of the valve coil See Repair Section Continued from the previous page Replace turntable rotate left directional valve coil item A 2 5 to 3 5 ohms function Move function enable operates Replace defective directional valve switch to either side and hold the turntable rotate left right toggle switch at the ground controls in the left direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure gauge at the quick 2900 Exchange flow regulator function disconnect coupling on psi valve item J with a like operates Replace defective flow the boom function valve item 1 Check regulator valve manifold and start the turntable rotate left engine Move the function function enable switch to either side and hold the turntable rotate left toggle switch at the ground controls in the left direction and check the pressure function inoperative Repair turntable rotation motor OR function manifold may have an internal defect Consult Genie Industries Service Department less than 2900 PSI Continued on the next page 5 46 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts SSS SSS SSS CHART 18 Plumb 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure
85. rotate the hub until the plugs are located one on top and the other at 90 degrees 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 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 and then install it in the torque hub 5 Repeat this procedure for each drive torque hub Steer end 4WD models Torque hub oil Non steer end 50 fl oz 1 48 liters 44 fl oz 1 3 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES Turntable Rotate Torque 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 torque hub b plug 2 If necessary add oil until the oil level is even with the bottom of the side plug hole 3 Apply pipe thread sealant to the plug and then install it in the torque hub Turntable rotate torque hub oil 44 fluid ounces 1 3 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models Complet
86. the boom in the stowed position 1 Connect a O to 5000 psi 0 to 345 bar pressure gauge to the test port item 27 on the function manifold 2 Startthe engine from the ground controls Hold the function enable switch to either side and activate and hold the boom down switch with the boom fully lowered Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 5 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure Boom down relief valve specifications Pressure 2100 psi 145 bar Pressure 2900 psi 200 bar 7 42 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to the test port item 27 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the extend switch with the boom fully extended Observe the pressure reading on the pressure gauge 4 Turn the en
87. the lo range trimpot to achieve a 85 to 95 second cycle time 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the left or right Record the maximum voltage reading 15 Start the engine 7 4 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 16 Start a timer and simultaneously move the control handle all the way to the left or right Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate Turn the trimpot to obtain 5 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Turntable rotation specifications Threshold 3 5V DC Turntable rotation hi range boom retracted 5 5V DC Cycle time 70 to 80 seconds lo range boom extended 4 5V DC Cycle time 85 to 95 seconds Ramp rate 5 seconds Boom Extend Retract Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition wit
88. the machine 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts Then remove the tire and wheel assembly Remove the dust cap cotter pin and slotted nut Pull the hub off the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Part No 52270 Genie S 80 amp Genie S 85 7 65 Section 7 Repair Procedures Service Manual Second Edition 2WD STEERING AXLE COMPONENTS How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle Component damage Do not ACAUTION apply excessive force or damage to the lip of the seal may occur 5 Place the outer bearing into the hub Install the washer and slotted nut 7 Tighten the slotted nut to 35 foot pounds 47 Nm to seat the bearing 8 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 420 foot pounds 569 5 Nm 13 2 St
89. the tilt sensor to the turntable side plate at the pivot end ofthe Result After a 1 5 second delay the alarm in puami the platform should sound Broken or missing roller or roller head Tip over hazard The alarm should Missing fasteners AWARNING be audible at the ground controls Loose wiring If the alarm is not audible at the ground controls replace the alarm a fueltank b til sensor c ground control box a turntable riser b boom A 14 c boom drive limit switch LS2 Test the Limit Switches Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised or extended An improperly functioning drive limit switch will allow the machine to operate at an unsafe drive speed 1 Remove the cover from the rear of the turntable to access the drive limit switch 4 8 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 3 Visually inspect the boom extend drive limit switch located on the end of the cable track on the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loose wiring TABLE A PROCEDURES 12 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 13 Lower the boom to the stowed
90. the wear pads at the platform end of the number 1 boom tube Pay careful attention to the location and amount of shims used with each wear pad 5 Remove the two wear pad stop bolts from each side of the number 1 boom tube located on the outside 6 Support the number 2 and 3 boom tubes with a lifting strap attached to an overhead crane at the platform end of the boom 7 Support and slide the number 2 and 3 boom tubes out of the number 1 boom tube Place the 2 and 3 boom tubes on blocks for support Crushing hazard The number 2 AWARNING and 3 boom tubes may 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 Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 8 Remove and label the wear pads from the top side of the number 2 boom tube at the platform end of the boom 9 Remove the trunnion cap mounting fasteners at the base of the number 2 boom tube Then use slide hammer to remove the trunnion caps 10 Carefully rotate the the base end of the extension cylinder until the pin mounting bore is in a vertical position 11 Support the number 3 boom tube with a lifting strap attached to an overhead crane at the platform end of the boom 12 Support and slide the number 3 boom t
91. them 4 Block the non steering wheels and then center a lifting jack of ample capacity under the steering axle 5 Raise the machine 6 inches 15 2 cm and place blocks under the chassis for support 6 Remove the lug nuts then remove the tire and wheel assembly 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the torque hub and then remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support the yoke torque hub assembly with a lifting jack Secure the yoke torque hub assembly to the lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out 13 Remove the yoke torque hub assembly from the machine Crushing hazard The yoke hub AWARNING assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly secured and supported by the lifting jack Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 14 Place the yoke torque hub assembly on a flat surface with the torque hub facing down 15 Remove the torque hub mounting fasteners that attach the yoke to the torque hub Remove the yoke weldment from the torque hub Replace the thrust washer
92. to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing 11 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter condition indicator How to Remove the Hydraulic Tank Component damage hazard ACAUTION 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 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 11 1 How to Remove the Fuel Tank Part No 52270 Genie S 80 amp Genie S 85 7 59 Section 7 Repair Procedures Service Manual Second Edition FUEL AND HYDRAULIC TANKS 2 Close the two hydraulic shutoff valves located at the hydraulic tank open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosEp 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 Remove the drain plug from the hydrauli
93. toggle switch to the high idle rabbit symbol position at the ground controls O Result High idle should be 2300 rpm If high idle rpm is correct disregard adjustment step 4 Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 4 Loosen the yoke lock nut then 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 Deutz Diesel models Low idle 1500 rpm High idle 2300 rpm B 13 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 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 Check any machine function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check any machine function from the platform controls
94. voltage reading 15 Start the engine 16 Start a timer and simultaneously move the control handle all the way to the ExrEND position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Set the ramp rate turn the trimpot to obtain a 3 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom extend retract specifications Threshold 3 5V DC 9 75V DC 70 to 80 seconds Boom extend Max out Cycle time Boom retract Dual lo range 9 2V DC Cycle time 85 to 95 seconds Ramp rate 3 seconds 1 2 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure See Maintenance Procedure B 12 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5
95. when installing the yoke torque hub assembly onto the axle Torque specifications Lug nut dry 420 ft lbs 569 5 Nm lubricated 320 ft lbs 433 9 Nm Torque hub mounting bolts dry 120 ft lbs 163 Nm lubricated 90 ft lbs 122 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm lubricated 56 ft lbs 76 Nm 4WD STEERING AXLE COMPONENTS 14 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure 13 2 How to Remove a Steering Cylinder 14 3 Tie Rod Cylinder How to Remove the Tie Rod Cylinder This procedure is the same as the 2WD procedure See Repair Procedure 13 3 How to Remove the Tie Rod Cylinder How to Perform the Toe in Adjustment This procedure is the same as the 2WD procedure See Repair Procedure 13 3 How to Perform the Toe in Adjustment Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition Extendable Axle Components 15 1 Extendable Axles The extendable axles are used to widen the foot print of the drive chassis for stability How to Shim the Extendable Axle Measure each wear pad Replace the wear 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 1 Extend the axle 2 Remove the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zer
96. 0 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures TABLE C PROCEDURES C 11 2 Remove the hose from the PCV valve then Replace the PCV Valve remove the valve Gasoline LPG Models Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning PCV valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve a PCV valve x TT 3 Install the new PCV valve Connect the hoses UIT 4 Swing the engine pivot plate back to its original W position and replace the two retaining bolts C 12 Replace the Spark Plugs Gasoline LPG Models Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may a pivot plate retaining bolts result in component damage b engine pivot plate Perform this procedure with the engine off Label then disconnect the plug wires from the spark plugs by grasping the molded boot Do not pull on the plug wire 2 Blow out any debris around spark plugs 3 Remove all the spark plugs from the engine 4 Adjust the gap on each new spark plug Part No 52270 Genie S 80 amp Genie S 85 4 37
97. 0 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 3 Engine Cranks Over But Will Not Start Deutz Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the diesel fuel shut off valve is in the on position Be sure that the battery is fully charged Hold the start switch to 1855 either side and check 11V battery voltage while engine is cranking 11V or more Check if engine over temperature sending signal post has continuity to ground no continuity Disable the starter by removing the blk wire at sy the starter solenoid Hold the start switch to either side and check the voltage at positive terminal on fuel solenoid Continued on the next page continuit Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if oil cooler hot and or engine block feels excessively hot Check engine oil level OR oil cooler fins for clogging OR check engine fan belts OR see Deutz service manual for troubleshooting an overheating engine not hot Remove wht wire from continuity Replace temperature temperature sending switch sending unit unit check continuity to ground on sending unit no continuity continuity Repair short in wht wire circuit from TB24 to Remove wht wire
98. 01 1 Relay 12V DC continuous 27155 70 902 1 BH uses Resistor 1000 25 watt 4WD 27116 aii RH25 100R 1 1 1500 25 watt 2WD 34798 Dale e eee RH25 150R 1 1 B2 Resistor 140 25 watt 46678 te RH25 14R 1 1 Resistor 100 25 watt 27287 Dalee RH25 10R 1 1 TS1 TS10 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc 2NT1 8 ee 2 TS2 6 9 11 19 TB testes Toggle switch SPDT position momentary 13037 Microswitch Control Inc INTIEZ aiz area 6 TS8 TS20 Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc 2 ICT Toggle switch DPDT position maintained 13038 Microswitch Control Inc ONT VT inis 1 TS5 7 14 16 17 18 19 Toggle switch DPDT position momentary 16397 Microswitch Control Inc ONT THF 7 TS3 TS12 Gas LPG Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc 2N TA I iiie 2 TS3 TS12 Diesel Toggle switch SPDT
99. 1 RED 7 BLK 7 BLK 6 RED 6 p FUEL PUMP CE PLATFORM LEVEL EJ es AE A iv 5 gt F 9 LS1 DISABLE OPTION TP33 LIFT DUMP VALVE AXLE DUMP VALVE BLK 1 I TS2 ENGINE RED RED TP25 TP21 FS RED BLK BLK START WHT AUXILIARY POWER TP24 TP27 TS11 ENGINE START BLK IGN START MODULE 2 TACHOMETER 1 START RELAY START INPUT 4 Aux ON 5 GROUND 6 BATTERY 8 KEY BYPASS 9 IGN FUEL ON 1d ENG FAULT TB33 TB44 WATER TEMP TB24 WHT 24 E H SENDER OIL PRESSURE SENDER WHT Z HOUR METER TS10 I POWER AUXILIARY RED TB27 CR2 CR2 No TB21 AUTOMATIC CHOKE gt gt WHT 21 E H COIL gt lt IGNITION SYSTEM gt WATER TEMP 2 IGNITION MODULE PULSE GENERATOR CR1 BLK R1 E H CR1 NO RED 27 E H STARTER MOTOR AUXILIARY POWER RED 1 Hi RED TP28 RELAY AUXILIARY PUMP RED BLK 1 TB28 NO CR19 AUXILIARY RESISTOR RED BLK 28 E H WHT 2
100. 20 to CB1 to CR1 to CR2 Hold start switch and check voltage at 12V terminal 9 on ignition start module oV Check voltage at terminal 6 on ignition start module 12V Check continuity from ground wire at terminal 5 on start lockout module to ground continuity Consult Genie Industries Service Department Repair open in blk wire from terminal 86 on CR2 to terminal 9 on ignition start module Repair open in power supply wires from CB1 to CR1 to CR2 to terminal 6 on ignition start module Repair open in brown ground wire to start lockout module Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 2 Check continuity f ie Repai inb eck continuity from continui epair open in brown Continued from the ground to terminal 85 ground wire circuit to previous page on CR2 CR2 continuity If weak spark still exists consult Ford engine service manual for troubleshooting engine with weak spark OR consult Genie Industries Service Part No 52270 Genie S 80 amp Genie S 85 5 7 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2A Engine Cranks Over But Will Not Start Gasoline LPG Models or Engine Runs While Cranking Then Dies Perform these tests in gasoline mode only Hold the start switch to either side and check
101. 266 kg 729 cm Ground clearance 11 in 11 in Tire pressure 100 psi 27 9 cm 27 9 cm 6 89 bar Operational dimensions Wheel diameter 221 2 in 57 cm Maximum platform height 80 ft 85 ft 5 244m 259m Wheel width 113 in 29 8 cm Maximum horizontal reach 71 ft 11 in 76 ft 11 in Wheel lugs 10 3 4 16 21 9 m 23 4m Lug nut torque dry bolts 420 ft lbs Maximum turntable tailswing 3 ft 81 2 in 3 ft 81 2 in 569 4 Nm 113 113 Lug nut torque lubricated bolts 320 ft lbs Wheelbase 9 ft 9 ft 433 9 Nm zm SM Fluid capacities Turning radius inside 5 ft 4 in 5 ft 4 in Fuel tank 30 gallons axles extended 1 6 m 1 6 m 114 liters Turning radius outside 11 ft 7 in 11 ft 7 in LPG tank 33 5 pounds axles extended 3 5m 3 5m 15 2 kg Turntable rotation continuous continuous Hydraulic tank 45 gallons 170 liters Platform rotation 160 160 Hydraulic system 55 gallons Maximum capacity 600 Ibs 500 Ibs including tank 208 liters 212288 PE d Drive torque hubs 50 fl oz Maximum capacity 500 Ibs 500 Ibs 1 63 liters 8 foot platform 227 kg 227kg Turntable rotation 44 fl oz Maximum allowable 150 lbs 150 Ibs torque hub 1 3 liters side force ANSI and CSA 68 kg 68 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 52270 Genie S 80 amp Genie S 85 Section 2 Specifications SPECIFICATIONS Performance Specifications Drive speeds m
102. 5 Troubleshooting Flow Charts Service Manual Second Edition 2 Continued from the previous page Hold the start switch to Repair open in blu wht either side and check 38 wire circuit from voltage at blu wht wire CR6 to anti diesel valve on anti diesel valve on engine carburetor Hold the start switch to Check continuity from Repair open in brown either side and check brown ground wire on ground wire circuit to voltage at blu wht 38 fuel pump to ground fuel pump wire on fuel pump continuity Repair open in blu wht 38 wire circuit from anti diesel valve to fuel pump Hold the start switch to Reconnect the two wires either side does engine to vacuum switch and start check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for troubleshooting fuel pump and or carburetor OR Consult Genie Industries Service Go to chart 2B Department 5 10 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Runs While Cranking Then Dies Hold start switch to either side and check voltage at terminal 2 on ignition start module 6 to 7V While cranking engine for 15 seconds check continuity to ground on yes terminal 10 ignition start module 5 continuity maintained no Check voltage at 12V terminal 4 on ignition start module
103. 5 RPM 35 BLK RED 1 Plane GLOW PLUG 34 BLK WHT 1 a START 33 BLK 1 mE BRAKE 32 WHT RED 1 golf E D C 31 WHT BLK 1 ED C WHT 1 OL 2WD AWD 29 RED WHT 1 a 910 O Z6 Blo 44 O 28 AUX PWR 27 RED 1 o Osa PWR TOFS 26 BLK FS PWR START 25 RED FS e PWR CONT 24 WHT 1 K PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 5 O0O x OPTION 21 WHT Poo 20 JIB VALVE 19 GRN WHT 3 m GZ PLAT ROT 18 GRN BLK 3 ay PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 zz PLAT LVL DN 15 ORG BLK 3 ul xl l ly 8 PLAT LVL UP 14 oRG 3 59 DRV ENA LT 13 BLU RED 3 o DRV ENA 12 BLUWHT 3 SEC BOOM DN 11 BLU BLK 3 Lockout SEC BOOM UP 10 BLU 3 RELAY EXT RET F C 9 BLK RED 3 O 6E RETRACT 8 BLK WHT 3 I 8lo EXTEND 7 BLK 3 ay 0 lt 0 TURN EXT 6 WHT RED 3 Os a TURN ROT R 5 WHT BLK 3 TURN ROT L 4 WHT 3 D1R abd PRIMARY F C RED WHT 3 s PRIMARY DN 2 RED BLK 3 x n OOO OU PRIMARY UP 1 RED 3 4 E 5 Ee ag a E a i
104. 5 in the up direction and check voltage at the grn wire on the jib boom up directional valve item DD 12V With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to theon osition activate the footswitch and the jib boom toggle switch TS6 in the up direction and check voltage at TB17 12V Continued on the next page Move the function enable switch to either side and activate the jib 12V boom toggle switch TS15 in the up direction and check voltage at TB17 Repair open in red power wire circuit from keyswitch to TS15 OR toggle switch 515 Activate the footswitch 12V and the jib boom toggle switch TS6 in the up direction and check voltage at TP17 With the keyswitch turned to platform 12V control and both Emergency Stop buttons pulled out to the on position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 Check the voltage at terminal 30 CR13 P 12V Check the voltage at ov terminal 87a on CR13 12V Repair open in red wire from terminal 87a on CR13 to TS6 OR consult Genie Industries Service Department Chart 25 Repair open in grn wire from TB17 to jib boom up directional valve OR repair open in brown ground wire circuit to directional valve Repair open in grn wire from TP17 to TB17 Repair open in grn wire from TS6 to
105. 5 torque angles ft lb N ist 2nd Air intake manifold bolts 15 to 18 20 to 24 gt n M 8 x 30 8 8 Main bearing bolts 37 50 60 45 Air intake manifold 3 hole 15 to 18 20 to 24 Big end bolts 22 30 60 60 flange bolts M 8 x 35 Torx 8 8 Flywheel bolts 22 30 60 30 Exhaust manifold bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Cylinder head step 1 22 30 studs step 2 59 80 Starter fastening bolts 28 to 34 38 to 46 step 3 118 160 120 NA M 10 x 28 8 8 Camshaft central bolt 22 30 150 NA Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Crankshaft central bolt 96 130 210 NA Oil pan bolts 15 to 18 20 to 24 M 8 x 16 Torx 8 8 Oil drain bolts 37 to 44 50 to 60 Part No 52270 Genie S 80 amp Genie S 85 2 7 Section 2 Specifications Service Manual Second Edition eee SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok O ring face seal fittings and hose ends Machines that utilize Parker Seal Lok O ring face seal hoses and fittings require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE Dash Installing Size into 4 Aluminum Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure that the face seal O ring is seated and replaced anytime the seal has been broken retained properly The O ring cannot be re used if the fitting
106. 63 Floyd Bell Inc XB 09 630 Q 1 m ORO Alarm chime tone 45462 Floyd Bell Inc CH 09 525 Q 1 Hourmeter 19506 ENM Corporation T40A4508 1 imis Contact Keyswitch N O 45081 Telemecanique ZB2 BE101 2 ET LED Red 12V DC 32335 Arctolectric Corp LE177C39007 1 161 2 3 Contact Limit switch NCZELOr tete A iets 194915 Telemecanique XESP2051 3 Level sensor Level sensor 4 5 44586 Power Comp of Midwest 1536 2 1 Bil P2 uud Contact 29732 Telemecanique ZB2 BE102 4 This list continues the next page 6 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 6 Schematics r ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number BS aiias Contact N O 45081 Telemecanique ZB2 BE1
107. 7 32 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 8 1 Control Relays See 1 6 Control Relays 8 2 Toggle Switches See 1 5 Toggle Switches 8 3 Wago Components How to Remove a Wago Component AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and should be used when removing a Wago9 component This screwdriver is located in the operator s manual storage box in the platform 1 Label the wiring from the component to be removed 2 Locate the removal tab on the bottom or top side of the component 3 Usea small narrow flat blade screwdriver to push in and release the wire from the component 4 Use the small narrow flat blade screwdriver to gently pry up on the tab of the component and remove it Ground Controls 8 4 Resistors How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces voltage to all the boom function switches at the ground controls Refer to the schematic legends for resistor locations and values 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connectthe leads from an ohmmeter to each end or wiring of the resistor b
108. 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 9 Tag disconnect and plug the axle extension cylinder hydraulic hoses at the tee next to the chassis lift jack Bodily injury hazard Spraying AWARNING 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 4WD Models Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying AWARNING 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 10 Remove the drive motor access covers from both sides of the axle 11 Tag disconnect and plug the hydraulic hoses from the axle extension cylinder 12 Steer end Remove the external snap ring from the axle extension cylinder pivot pin Use a soft metal drift to remove the pin Non steer end Remove the cotter pin from the clevis pin Use a soft metal drift to remove the pin Always use a new cotter pin when installing a clevis pin 13 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressu
109. 9 5 Nm 4 46 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 80 amp Genie S 85 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution h
110. ABLE TS14 PLATFORM ROTATE SWITCH TS15 JIB BOOM UP DOWN SWITCH TS16 PLATFORM LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH 7818 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH CBI CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER R2 RESISTOR 14 OHM BOOM FUNCTIONS RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE G1 G3 P1 KS1 TS10 ONCO ojo NO NO ONCO olo o HM TS19 TS17 TS12 TS15 TS18 TS11 5 o O s 1516 TS14 CB1 CB2 000 1 U CR18 PLAT LEVEL DISABLE OPTION CR17 COOLING FAN RELAY SECTION A A Ground Control Box Legend Gasoline LPG Models gt RED 7 46 27A e 218 GRN WHT4 GRNWHT 1 45 GRN BLK E H RED 6 44 GRN BLK D B R8 87A GRN RS 43 BLK 7 ORG RED 1___ 42 BLK 6 CABLE ORGBLKEH ORG BLK 1 41 ORG BLK ZISM 7 WHT 6 ORG 1 40 WHT T BLU RED 1 39 BLURED CR7 BLU RED SP IBLUWHT CRG BLU WHT 1 38 IBLU WHT S P 2 BLU BLK 1 37 BUBK D B BLU EH B
111. ASS IGN FUELON 10 ENG FAULT CR1 CR2 CR3 CR4 START IGNITION RPM RPM RELAY RELAY CUTOUT RELAY RELAY CR5 HORN RELAY CR6 FUEL CUTOUT RELAY CR7 FUEL CUTOUT RELAY CR8 DUMP VALVE RELAY ENGINE HARNESS L S POWER GENERATOR OPTION DUMP VALVES HORN TURNTABLE ROT HIGH PULSE PICKUP LIMIT SWITCH LP GAS STEER LEFT STEER RIGHT RPM GLOW PLUG START BRAKE ED C ED C 2WD 4WD TILT ALARM AUXILIARY POWER WATER TEMP SENDER OIL PRESSURE SENDER WARNING SENDER KEYSWITCH POWER POWER TO PLATFORM IGNITION POWER 12V BATT SUPPLY JIB VALVE PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL F C PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LIGHT DRIVE ENABLE SECONDARY BOOM DOWN SECONDARY BOOM UP EXT RET FC BOOM RETRACT BOOM EXTEND TURNTABLE ROTATE TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT PRIMARY BOOM PRIMARY BOOM DOWN PRIMARY BOOM UP Part No 52270 Genie S 80 amp Genie S 85 Section 6 Schematics Ground Control Box Wiring Diagram Gasoline LPG Models STACKED CONTACTS BRN GROUND WHT RED 26A WHT 21A WHT BLK 25A BLK 22A WHT 29A b NO NO RED 278
112. AWARNING as presented and scheduled may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Key switch in the orr 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 information and step by step instructions Symbols Legend Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a step Part No 52270 Genie S 80 amp Genie S 85 4 1 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table A Procedures A 1 Inspect the Manuals Maintaini
113. BLK 2B 4 WHT RED 328 RED 1B e 10 BRN GROUND SSS nuces LE TACHOMETER IGN START BLK 33D LO s smarneur MODULE RED 27B LO 4 aux o CABLE BRN GRD EST 4 LC s RED R2430 5 6 BATTERY 7 KEY PWR 8 KEYBYPASS a2 9 IGN FUEL ON LO o rar RED46 ISM PE CH WHT 9 ISM RED WHT R3 E H RED CBi BLK 338 cmon 7 2 al 4 BLK 1 ISM EJ BLK R1 E H WHT21D BLK D B BLU WHTERG AH BLKKRS A H BLU WHTRRG EH BLU RED amp R7 EH RED BLK 44A 6 7 8 d BLU WHT 38D RED BLK amp RG E H BLK 7B BLU RED 398 RED BLK 2B 6 10 Genie S 80 amp Genie S 85 Part No 52270 Section 6 Schematics Service Manual Second Edition n Platform Control Box Legend Gasoline LPG Models o 2 5 a o g T _ ks 9 m 55 L Bo of Su 5 ug O 7 amp 8 z2 9 sr e z t roo O O zs J plo o Tm GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 HORN 43 GRN 1 TURN 42 ORG RED 1 2 4 a ojo 40 Ou LP 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 O gt STEER RIGHT 36 BLU 1 g O00 5
114. BLK4 2 ADBKDB RD BKSP _ PRI BOOM DOWN G RED RED 1 RED DB REDSP PRI BOOM UP iy GENTIA D C A ORGIBLK 158 ORG RED 168 i i ORG 14B GRN 17B 1 ORGIBLK 15A GRNIBLI A4B GRN BLK 18B O REDWHT 208 BLAWHTSB BRN GROUND ara CABLE e nm 3 m WHT 4B BLU BLK 37B i WHT RED 6A REDIELK ZB WHTRED 328 AED IB BAN GROUND BLK A1486 O J saRTAELAY ZEE onama monowereR IGN START BLKWHT 34A Buen saarneur MODULE RED 27B 6 AUX ON RED 20A CABLE aes P LO s encuvo RED R2430 LO 6 earreny RED RI 30 gt s xeveveass C s ward LC vo ena ORG REDH16 TB16D RED 6 ISM v v BLK RED R4 E H E MH ISM BLK RED 35B 18 RED CB1 1 RED 6 LABEL DESCRIPTION 1 2 4 RED 44 TB44C_ INI H P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH m BLESTASM i 59 AUXILIARY SWITCH REDA 4 TS10 ENGINE START SWITCH i TS11 ENGINE FUEL SELECT SWITCH 1 WHT 21D i 812 FUNCTION ENABLE m BLK D B BLK RS AH 7813 PLATFORM ROTATE SWITCH 7514 PLATFORM LEVEL SWITCH 25AMP_ t I 7515 BOOM EXTEND RETRACT SWITCH m i 5 BE a Gene TES HARNESS CB1 CIRCUI
115. CATIONS Function manifold Function relief 2900 psi valve pressure 200 bar Boom down 2300 psi relief valve pressure 158 6 bar Boom extend 2500 psi 172 bar Maximum drive pressure 3500 psi Steer axle extend 5 gallons per minute 241 3 bar flow regulator 18 9 liters per minute Charge pressure Steer regulator 3 5 gallons per minute neutral position 290 psi 20 bar 13 2 liters per minute drive position 250 psi 17 bar Auxiliary pump Medium pressure filter 3 micron Type fixed displacement gear pump Medium pressure filter 50 psi bypass 2 34 a Displacement static 0 152 cu in 2 5 CC Drive manifold Displacement 1 4 gallons per minute Brake 250 psi 5 3 liters per minute relief pressure 17 2 bar P Auxiliary pump 2500 psi Steer end drive motors 4WD models relief pressure 172 bar Displacement 1 52 cu in per revolution 25 cc Non steer end drive motors Displacement per revolution variable 0 16 to 2 8 cu in 4WD 2 speed motor 2 62 to 45 9 cc Displacement per revolution variable 1 12 to 2 8 cu in 2WD 18 4 to 45 9 cc Function pump Type pressure balanced gear Displacement static 1 14 cu in 19 cc Displacement 2500 rpm 0 to 12 3 gallons per minute 0 to 46 6 liters per minute Hydraulic tank circuit 10 micron with 25 psi return line filter 1 7 bar bypass Part No 52270 Genie S 80 amp Genie S 85 2 3 Section 2 Specifications SPECIFICATIONS Ford Engine LRG 423 Displacement 140 cu in 2
116. Continued on the next page 5 50 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 19 Plumb a 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Move the function enable switch to either side and activate the turntable rotate right function Continued from the previous page 250 psi or more Exchange turntable rotate right and left function counterbalance valves Operates items LL and KK Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item JJ OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 51 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 20 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Remove both hydraulic Replace the hoses from the manifold yes counterbalance valves ports PL1 amp PL2 Plug on function manifold the hoses and cap the items GG amp HH manifold fittings Move the fu
117. Controls 1 1 Joystick Controllers Maintaining joystick controllers at the proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion eee Platform control box horsepower limiter board terminals drive proportional controller extend retract proportional controller boom proportional controller 0 8 Boom Up Down Controller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry turntable rotate proportional controller 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine Open the platform control box lid and locate the boom up down controller terminal D2 directional output terminal A proportional output terminal ground terminal positive terminal R activates max out range terminal D1 direc
118. Cylinder front cover bolt M 6 10 to 12 13 to 16 Camshaft thrust plate bolt M 6 6 to 9 8 to 12 Inner timing belt cover 15 to 22 20 to 30 Carburetor to spacer stud M 8 7 5 to 15 10 to 20 stud M 8 Carburetor spacer to 10 to 14 14 to 19 Outer timing belt cover 6 to 9 8 to 12 manifold bolt M 8 bolt M 6 Crankshaft damper 92 to 122 125 to 165 bolt M 14 Cylinder head bolt M 12 torque in sequence first step 50 to 60 68 to 81 second step 80 to 90 108 to 122 Bolt torque specifications torque torque Bolt description size ft lbs Nm Exhaust manifold to cylinder head bolt or nut M 10 torque in sequence first step 14 to 19 19 to 26 second step 35 to 50 47 to 68 Flywheel to crankshaft 54 to 64 73 to 87 bolt M 10 Intake manifold to 15 to 22 20 to 30 cylinder head bolt or nut M 8 Oil pressure sending unit to block 8 to 18 11 to 24 Oil pan drain plug to pan M 14 15 to 25 20 to 34 Part No 52270 Genie S 80 amp Genie S 85 2 5 Section 2 Specifications SPECIFICATIONS Deutz Engine F4L 1011F Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold 166 7 cu in 2 782 liters 4 3 58 x 4 13 inches 91 x 105 mm 56 3000 rpm 1 3 4 2 18 5 1 362 to 435 psi 25 to 30 bar 1300 rpm 2300 rpm centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubricatio
119. Department Chart 28 Check for mechanical restrictions keeping axle extend function from operating OR replace counterbalance valve item OO OR repair or replace axle extension cylinder OR control valve may have an internal defect Check for mechanical restrictions keeping axle from extending or retracting OR replace counterbalance valve item OO OR repair or replace axle extension cylinder OR control valve may have an internal defect Repair or replace function pump Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 29 Steer Left Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in left direction and check voltage at the controller terminal with the blu wire attached controller DP1 in left direction and check voltage on TB36 Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate fo
120. ELAY CR3 RPM CUTOUT RELAY I 1 1 LS POWER GEN OPTION DUMP VALVE S HORN TURN ROT HI PULSE PICKUP LIMIT SWITCH LP GAS STEER LEFT STEER RIGHT RPM GLOW PLUG START BRAKE E D C ED C 2WD 4WD TILT ALARM AUX PWR TEMP SENDER OIL PRESSURE SENDER WARNING SENDER KEYSWITCH POWER POWER TO PLATFORM IGNITION POWER 12V BATT SUPPLY JIB VALVE PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT PLATFORM LEVEL F C PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LIGHT DRIVE ENABLE SEC BOOM DOWN SEC BOOM UP EXTIRET BOOM RETRACT BOOM EXTEND TURNTABLE ROTATE FC TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT PRIMARY BOOM FC PRIMARY BOOM DOWN PRIMARY BOOM UP Part No 52270 Genie 5 80 8 Genie 5 85 Section 6 Schematics Service Manual Second Edition eee Ground Control Box Wiring Diagram Diesel Models STACKED CONTACTS
121. Edition Section 4 Scheduled Maintenance Procedures Gasoline LPG a carburetor b fuel filter c hose from the fuel filter to the fuel pump d hose from the fuel pump to the fuel tank not shown 3 Clean up any fuel that may have spilled during this procedure 4 Startthe engine from the ground controls then inspect the fuel filter and hoses for leaks TABLE D PROCEDURES D 4 Check the Engine Valve Clearance Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 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 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES D 6 2 Disconnect the hose from the PCV valve then Clean the PCV Hoses and disconnect the hose from the engine Fittings Gasoline LPG Models Maintaining PCV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the c
122. Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform level toggle switch TS16 in the down direction and check the voltage at org blk wire on platform level down function directional valve item X Continued on the next page 12V or more Chart 22 With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform level toggle switch TS16 in the down direction and check the voltage at TB15 Repair open in org blk wire from TB15 to platform level down directional valve coil item X OR repair open in brown ground wire circuit to valve coil With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform level toggle Switch TS7 in the down direction and check the voltage at TB15 Troubleshoot platform level toggle switches TS16 and TS7 on ground and platform control panels OR repair open in red power wire circuit to TS16 and TS7 OR repair open in org blk wire circuit from TS16 and TS7 to TB15 OR consult Genie Industries Servic
123. Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend retract toggle switch TS19 on ground panel in the retract direction and check voltage on blk wht wire on boom function directional valve coil item C 12V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either 12V or side and hold the boom more extend retract toggle switch TS19 on the ground panel in the retract direction and check voltage at TB8 With key switch in platform position and both Emergency Stop 12V or buttons pulled out to More ON position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage TB8 12V or Activate footswitch and more boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage TP8 Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Repair open in blk wire circuit from TB8 to boom retract function directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot boom extend retract function toggle switch TS19 on
124. Genie Industries Ted il Rr Genie 5 80 5 85 ED Service Manual Second Edition First Printing Part No 52270 Introduction Service Manual Second Edition Genie 80 Genie 5 85 Important Read understand and obey the safety rules and operating instructions in the appropriate Genie S 80 amp Genie S 85 Operator s Manual before attempting any maintenance or repair procedure This service manual covers the Genie S 80 and Genie S 85 2WD and 4WD models This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at a Genie dealer service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other manuals Please
125. H S GENERATOR O OPTION p p n m E BLK WHT 1 8 p GLOW ENGINE PLUG A p GLOW 3 PLUG E BLK WHT 34 E H a ENGINE GLOW PLUG OPTION Ew Ta ga is ga a 8 E WHT E BLK 1 RH RR 2 HOUR METER e able jJ E ENGINE START ziaes SEE Sg OIL PRESSURE a 2589 06 l5 SENDER o4 a ENGINE 9 oldie oo Wier EL _ 08 WATER TEMP BLK SENDER 2 o a B WHT 21 E H FUEL SOLENOID N a 5 MD INED PIED RN RED BLK7 BLK6 6 amp CE PLATFORM LEVEL my eo xm ite DISABLE OPTION gt 5 zo a NO Y i m E QS tb S ORG RED 1 LIFT DUMP VALVE AXLE DUMP VALVE z o a LE BLK R1 E H ro pm E EJ STARTER MOTOR 1 i5 e RU E M AUXILIARY Pe E a E lz PUMP RED RED 27 E H AUXILIARY POWER A zi RED 1 RELAY a 2 t p 1 E y AUXILIARY PUMP aa I I x X 7 AUXILIARY RESISTOR 5 RELAY Lu FLASHING BEACONS m z NENA x E RED BLK 1 RED BLK 28 E H 1 A g 8 s n RED WHT 2 RED WHT 23 E H _ LEVEL SENSOR x 2 E m z m a tr 3 gt E a a 4 21 GRN GRN 1 GRN o SERVICE HORN o RELAY z 89 N BLK 2 e BLK R5 SERVICE
126. HT BLK 1 WHT 1 RIW 1 RED BLK 1 RED EH RED 1 RD 4 ISM RED S P WT RD E H WT RD S P WTIBK E H WTIBK S P WT 10 ISM WHT EH WHT EH WHT 2 WHT S P BLK 2 BLK CR5 BLK S P WHT EH RED R17 WHT 43A WHT SP DB RED EH RED S P GRN WHT 3 GRN BLK 4 GRN BLK 3 GR BK D B GR BK S P GRN 4 GRN 3 GRN D B GRN S P ORG RED R6 ORG RED 3 OGIRD D B OG RD S P ORG BLK 4 ORG BLK 3 OG BK D B OG BK S P ORG 4 ORG 3 ORG D B ORG S P WHT 5 BLUJRED 3 WHT E H BLUMWHT 3 BLK 5 BLU BLK 3 BU BK D B BU BK S P BLU 3 BLU D B BLU S P BLK RED 4 BLK RED 3 BK RD S P BLKIWHT 4 BLK WHT 3 BK WT D B BKWT S P BLK 4 BLK 3 BLK D B 8R8 BLK S P WIR 4 WHT RED 3 WT RD S P WHT BLK 4 WHT BLK 8 WT BK D B WT BK S P WHT 4 WHT 3 WHT D B WHT S P RED WHT 3 RDM S P RED BLK 4 RED BLK 3 RD BKD B 8R8 RD BK S P RED 4 RED 3 RED D B RED S P D B A DIODE BLOCKS START RELAY TACHOMETER START INPUT AUX ON GROUND BATTERY KEY PWR KEY BYPASS IGN FUEL ON ENG FAULT IGN START MODULE 9 CR2 FUEL R
127. HT BLK 31 E H w EG 9 WHT RED 1 WHT RED 32 E H g C lt BLU BLK 1 Pd BLU BLK 37 E H BLU 1 BLU 36 E H n AW all a O E cg cc NZ ES E S 8o m ORG 1 P WHT 6 BRN 6 E E esiste se E WHT 7 c BRN 7 uke 49 2 lt 22 16520 I a B m RED WHT E RED WHT 1 E aa HIGH 55 LOW oo 1 ir 55 L nj 88 i a n c BLK 3 BLK WHT 3 B m 5 BLK 4 R EXTEND BLK WHT BOOM 4 RETRACT NL BLK WHT 4 oi d Eg EMEN E 2 B BLK RED 4 n R E BLK RED 3 E WHT RED 3 wo E WHT BLK 3 WHT 3 i WHT 4 hi WHT 4 p u RIGHT ik WHT BLK TURNTABLE ROTATE 8 m LEFT BET WHT BLK 4 T 5 BEDDER p E z oah 9 WHT RED 4 U a 1 14 A m E RED 4 UP RED BLK PRIMARY BOOM amp n DOWN E RED BLK 4 z BELFER z p Yf FZZ he x RED WHT 4 I M a a RED 3 RED BLK 3 Bog RED WHT 3 gt gt 5 ERE E ORG 3 UP PLATFORM LEVEL x R LDOWN ORG BLK 3 5 ORG B UP PLATFORM LEVEL ORGIBER i DOWN ORG BLK 4 7 m pam l pue 1 ORG RED 4 E a amp ORG RED 3 bru e 52 m Ee n e c JIB BOOM GRN BLK 3 5 GRN 4 2 gt GRN 4 A E UP JIB BOO
128. LU 1 36 BLU D B BLKIRED 1 35 BLK RED S P CABLE BLKIWHT t 34 6 BLI 3 ISM BLK 1 BLK CR8 BLK S P WHT RED EH WHT RED 1 32 WHT RED D B WHT BLK EH WHT BLK 1 31 RED 5 WHT 1 30 RED WHT E H REDWHT1 29 RED BLKE H __ RED BLK 1 28 CABLE RED 1 27 RED 4 1SM_ RED S P 5 WHT RED E H 26 WHT RD S P WHT BLK E H 25 WHT BK S P WT 10 ISM WHT EH 24 RED WHTEH WHT2 23 WHT S P BLK CRS BLK 2 22 BLK S P WHT CR2 RED R17 21 WHT 43A WHT SP DB RED E H 20 RED S P GRN WHT 3 19 GRN WT S P GRN BLK 4 GRN BLK 3 18 GRN BLK D B GR BLK S P GRN 4 GRN 3 17 GRN D B GRN S P CABLE ORGIRED R18_ ORGIRED 3 16 ORG RD D B ORG RD S P H ORGIBLK 4 ORG BLK 3 15 ORG BLK D B ORG BK S P ORG 4 ORG 3 14 ORG D B ORG S P WHT 5 BLU RED 3 13 WHT EH BLUWHT 3 12 BLK 5 BLU BLK 3 11 BLUBLK D B __ BLUBLK S P BLU 3 BLU D B BLU S P BLKIRED 4 BLKIRED 3 9 BLK RD S P BLKIWHT 4 BLKIWHT 3 8 BLKWHT D B BLKWT S P BLK 3 7 BLK D B GRB BLK S P WHT RED 4 WHTIRED 3 6 WHT RD S P CABLE WHT BLK 3 5 WHTBLK D B WHT BK S P 2 WHT 4 WHT 3 4 WHT D B WHT S P RED WHT 4 RED WHT 3 3 RD WHT S P RED BLK 4 RED BLK 3 2 RD BLK D B amp R8 RD BLK S P RED 4 RED 3 1 RED D B RED S P D c B A DIODE BLOCKS CABLE 3 O 1 STARTRELAY 2 TACHOMETER IGN START O STARTINPUT MODULE O 4 aux on GROUND 6 BATTERY 7 KEY PWR CABLE O 4 key BYP
129. M 4 DOWN GRN BLK 4 5 x RIGHT P RIGHT L PLATFORM ROTATE PLATFORM ROTATE w LEFT 1 E ir 2 BRN GRNWHT GRN WHT 3 2 tr RED Z JIB VALVES E Z 185 i568 I kis Eie 1350 BATT DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE TRAVEL ALARM STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH MOTOR STROKE BOOM FUNCTION DUMP CUT OUT RELAY COIL BOOM EXTEND BOOM RETRACT EXTEND RETRACT FLOW CONTROL TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL FLOW CONTROL PLATFORM ROTATE LEFT JIB UP PLATFORM ROTATE RIGHT JIB DOWN Genie S 80 amp Genie S 85 6 14 Part No 52270 Section 6 Schematics TS12 TS13 G1 G2 P1 KS1 ONCO NO NO ONCO olo 0151534 61H29 LABEL DESCRIPTION EMERGENCY STOP BUTTON KS1 KEY SWITCH TS10 AUXILIARY SWITCH 1811 ENGINE START SWITCH 7612 ENGINE GLOW PLUG OPTION TS13 FUNCTION ENABLE TSi4 PLATFORM ROTATE SWITCH 7515 OPTION JIB BOOM UP DOWN SWITCH TSi6 PLATFORM
130. RN GRN WHT GRN WHT 3 o 2 9 RED JIB VALVES LFT DRV SELECTOR OPTION GROUND DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE TRAVEL ALARM STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH MOTOR STROKE BOOM FUNCTION DUMP CUT OUT RELAY COIL BOOM EXTEND BOOM RETRACT BOOM EXT RET FLOW CONTROL TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLAT LEVEL F C PLATFORM ROTATE LEFT JIB UP PLATFORM ROTATE RIGHT JIB DOWN Genie S 80 amp Genie S 85 6 8 Part No 52270 Service Manual Second Edition Section 6 Schematics STACKED CONTACTS HOLSISZH AHYTIXNY 6 H0 LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS10 AUXILIARY SWITCH TS11 ENGINE START SWITCH TS12 ENGINE FUEL SELECT SWITCH TS13 FUNCTION EN
131. S 11 Check the oil filter and the oil pan drain plug for leaks 12 Swing the engine pivot plate back to its original position and replace the two pivot plate retaining bolts 13 Check the engine oil level dipstick Add oil if needed Ford LRG 423 Engine 5 quarts Oil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 C 10W 40 or 10W 50 above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often 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 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 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come o
132. S 80 amp Genie S 85 5 71 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 30 Steer Right Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in right direction and check voltage on TB37 12V or more With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in the right direction and check voltage on blu blk 437 wire on steer right directional valve coil item VV on steer manifold 12V or more Disconnect wires to 0 or steer right directional infinite valve coil item VV on ohms steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP1 in the right direction and check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil on
133. Second Edition EXTENDABLE AXLE COMPONENTS 5 Remove the pin retaining fasteners from the axle extension cylinder pivot pins Use a soft metal drift to remove the pins 6 Remove the cylinder from the machine AWARNING Crushing hazard The axle extension cylinder may become unbalanced and fall if it is not properly supported when it is removed from the axle 15 2 Drive Chassis Lift Jacks The drive chassis lift jacks are used to lift the drive chassis for axle extension The lift jacks should not be used to support the machine during maintenance or repair procedures How to Remove a Chassis Lift Jack 1 Remove the drive chassis cover 2 Tag disconnect and plug the chassis lift jack hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 Attach a strap from an overhead crane to the cylinder 4 Remove the chassis lift jack mounting fasteners then remove the lift jack cylinder from the machine Crushing hazard The chassis lift AWARNING jack cylinder may become unbalanced and fall if it is not properly attached to the overhead crane when it is removed from the machine 15 3 Hydraulic Limit Switches The hydraulic limit switches are 2 position 2 way valves The switches sense full axle extension and
134. T 4 lt ORG RED 42 WHT RED 6 ORG RED 16 Q E n a x e 20 D orga 19 GRN WHT a a GENERATOR 45 GRN WHT 1 5 SPARE 44 GRN BLK 1 HORN 43 GRN 1 5 TURN ROT HI 42 ORG RED 1 x 41 m 40 Q L P 39 BLU RED 1 a GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD 4WD 29 RED WHT 1 28 AUX PWR 27 RED 1 PWR TO ES 26 BLK FS PWR START 25 RED FS PWR CONT 24 WHT FS PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 OPTION WIRE 21 WHT 20 JIB VALVE 19 GRN WHT 3 m PLAT ROT R 18 GRN BLK 3 2 PLAT ROT L 17 GRN 3 L PLAT LVL 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 o DRV ENA 12 BLUWHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 TURN 6 WHT RED 3 Oe TURN ROT R 5 3 O TURN ROT L WHT 3 PRIMARY F C 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 m ui lt O 3 m
135. T 15 Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage on red blk 2 wire on boom function directional valve coil item B 12V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage at TB2 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP1 on platform control panel in down direction and check voltage TB2 Activate footswitch and boom function controller BP1 on platform control panel in down direction and check voltage TP2 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more Repair open in red blk 2 wire circuit from TB2 to boom down function directional valve coil item B OR repair open in brown ground wire circuit to valve coil Troubleshoot boom down function toggle switch TS17 on ground co
136. T BREAKER CONTROLS 15A H H i CB2 CIRCUIT BREAKER ENGINE 15A ORG 1 i HM HOUR METER BLK 22D RED BLK 2B R2 RESISTOR 14 OHM BOOM FUNCTIONS R a GRN 43D BLK 7B i R3 RESISTOR 10 OHM BOOM FUNCTIONS Gt VOLT METER GAGE HYD OIL COOLER T G2 OIL PRESSURE GAGE OPTION RELAY OIL TEMP GAGE SECTION 6 16 Genie 5 80 amp Genie 5 85 Part No 52270 Section 6 Schematics Service Manual Second Edition n ny Platform Control Box Legend Diesel Models gt 18 o gt o S 7 5 E o ZE 0126 56 oo gt A a O 8141914 Fr E c I a ake O o ga O O 45 GRN WHT 1 44 GRN BLK 1 HORN 43 GRN 1 Ol TURN ROT HI 42 ORG RED 1 41 a ojo 40 LP 39 BLU RED 1 GAS 38 BLU WHT 1 c STEER LEFT 37 BLU BLK 1 O gt STEER RIGHT 36 BLU 1 35 BLK RED 1 m GR GLOW PLUG 34 BLK WHT 1 go START 33 BLK 1 ols o BRAKE 32 WHT RED 1 80 E D C 31 WHT BLK 1 E D C 30 wHT 1 QE 2WD 4WD 29 RED WHT 1 a o9 EJ O oq AUX PWR 27 RED 1 amp
137. TP17 OR replace jib boom toggle switch TS6 Repair open in red wire from BP1 to CR13 OR repair open in brown ground wire circuit to CR13 Replace CR13 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 25 Activate footswitch and jib boom toggle switch TS6 in the up direction and check voltage on the red and black wires at the jib platform rotate select valves item AP Continued from the previous page Replace CR13 Install a 0 to 5000 psi 0 Exchange jib boom to 345 bar pressure platform rotate select gauge at the quick i valves item AP disconnect coupling on Activate footswitch and the function manifold jib boom up function and activate the jib boom up function function operate Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom up function from Operating OR repair or replace jib boom cylinder OR replace valve 0 035 orifice may less than 2900 psi be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department function Exchange jib boom operate counterbalance valves and activate jib boom up function Replace defective counterbalance valve function inoperative Consult Genie Industries Service Department 5 64 Genie S 80 amp Genie S 85 P
138. Test the Extendable Axles 4 5 A 11 Test the Platform and Ground 4 6 A 12 Test the Auxiliary Power 4 7 A 13 Test the Tilt 4 7 A 14 Test the Limit 4 8 A 15 Replace the Engine Oil and Filter Gasoline LPG Models 4 11 A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models 4 12 A 17 Replace the Engine Air 4 13 B 1 Check the Engine 4 14 B 2 Check the Radiator Gasoline LPG 4 15 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 15 B 4 Check the Exhaust System 4 16 B 5 Check the Battery 4 17 B 6 Check the Hydraulic Tank Filter Condition 4 17 B 7 Inspect the Electrical 0 4 18 B 8 Inspect the Tires and Wheels including lug nut torque 4 18 B 9 Confirm the Proper Brake Configuration sess 4 19 B 10 Check the Oil Level in the Torque 4 19 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 20 B 12 Check and Adju
139. 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 Boom 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 Open the platform control box and remove the platform control box mounting fasteners 2 Separate the footswitch quick disconnect then lower the platform control box and lay it off to the side 3 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located near the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying AWARNING 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 4 Tag disconnect and plug the hydraulic hoses from the from the platform leveling cylinder at the union and connect the hoses from the cylinder together using a connector Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressu
140. V Check the voltage at ov terminal 87a on CR13 12V Repair open in red wire from terminal 87a on CR13 to TS6 OR consult Genie Industries Service Department Chart 26 Repair open in grn blk wire from TB18 to jib boom down directional valve OR repair open in brown ground wire circuit to directional valve Repair open in grn blk wire from TP18 to TB18 Repair open in grn blk wire from TS6 to TP18 OR replace jib boom toggle switch TS6 Repair open in red wire from BP1 to CR13 OR repair open in brown ground wire circuit to CR13 Replace CR13 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 26 Activate footswitch and Continued from the jib boom toggle switch previous page TS6 in the down direction and check voltage on the red and black wires at the jib platform rotate select valves item AP Replace CR13 Install a 0 to 5000 psi 0 Exchange jib boom r to 345 bar pressure platform rotate select function gauge at the quick i valves item AP operates disconnect coupling on Activate footswitch and the function manifold jib boom down function and activate the jib boom down function Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib cylinder OR replace c
141. V DC output Gasoline LPG models Perform this procedure in gasoline mode 7 6 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition ECCE Z P RT z ZA Remove the fasteners from the platform control box lid Open the control box lid and locate the horsepower limiter board Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Platform control box a horsepower limiter board Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal 12V DC or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller 1 o6 8 9 S v e 2 Horsepower limiter board a A potentiometer maximum voltage output to the controller in the stowed position b potentiometer maximum voltage output to the drive controller in the boom raised position C potentiometer reaction rate how fast the voltage output reacts to the change in engine rpm Section 7 Repair Procedures PLATFORM CONTROLS 4 Startthe engine from the platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol
142. ace the retaining ring Air filters Genie part numbers Ford LRG 423 Engine 27916 Deutz F4L 1011F Engine 27916 Part No 52270 Genie S 80 amp Genie S 85 4 13 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table B Procedures B 1 5 Check the engine belt for proper tension Check the Engine Belt 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 Do ot inspect while the engine is running Remove the key to secure from operation ACAUTION Beware of hot engine components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the front engine access cover mounting fasteners 2 Remove the front engine access cover mounting fasteners 3 All models Inspect the engine belt for Cracking Glazing Separation Breaks 4 Replace belt if any damage is found Belt deflection Deutz Diesel models 9 mm to 12 mm Deutz Diesel engine Ford LRG 423 engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required 3 8 inch to 1 2 inch 4 14 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second
143. acing the drive loop hydraulic filter is essential to 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 ACAUTION Beware of hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted on the engine near the main pump 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing Remove the filter element from the housing 4 Inspect the housing seal and replace it if necessary 5 Install the new filter Genie part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 6 Startthe engine from the ground controls 7 Inspect the filter assembly to be sure that there are no leaks 8 Clean up any oil that may have spilled Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 9 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models Replacing the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause
144. ads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Single pole double throw SPDT Double pole double throw DPDT Test Left position PLATFORM CONTROLS Right 9009 Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 continuity zero terminal 2 to 4 5 amp 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 amp 6 no continuity terminal 5 to 6 Center position Right position continuity There are no terminal combinations that will produce continuity infinite Q terminal 1 to 2 continuity zero terminal 1 to 3 4 5 amp 6 no continuity infinite Q terminal 2 to 3 4 5 amp 6 no continuity terminal 3 to 4 5 amp 6 no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity Part No 52270 Genie S 80 amp Genie S 85 7 9 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 1 6 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and
145. after warming the engine to normal operating temperature Beware of hot engine parts and oil ACAUTION Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover TABLE A PROCEDURES 2 Place a suitable container under the engine pivot plate directly below the oil pan drain plug a engine pivot plate b pivot plate retaining bolts c oildrain hose 3 Remove the plug from the oil pan and allow all of the oil from the engine to drain into a suitable container See capacity specifications below 4 Install the plug into the oil pan Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter 6 Use an oil filter wrench and remove the filter 7 Apply a thin layer of oil to the new oil filter gasket Genie part no 28656 Then install the filter and tighten it securely by hand 8 Use a 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 above 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURE
146. all other functions operate normally Be sure machine is in the stowed position Be sure that the chassis lift jacks operate properly This procedure is written for the non steer end axle If the steer end axle is inoperative repeat procedure and substitute steer for non steer Start the engine and raise the non steer end of the machine with the non steer end lift jack While holding the lift jack control handle in the down direction activate and hold the axle extend control handle Does the axle extend While holding the lift jack control handle in the down direction activate and hold the axle retract control handle Does the axle retract Axle extend retract function is operating correctly While holding the lift jack control handle in the down direction activate and hold the axle retract control handle Does the axle retract Install a 0 to 5000 345 bar pressure gauge onto the test port on the function manifold Start the engine and while holding the lift jack control handle in the down direction activate and hold the axle extend control handle and check the pressure Test the function pump See Repair Section Replace counterbalance valve item OO in chassis jack manifold OR replace flow regulator item UU in axle dump manifold OR repair or replace non steer axle cylinder OR chassis jack manifold or control valve may have an internal defect Consult Genie Industries Service
147. alve in function manifold item M OR replace axle dump valve NE o mp manifo replace S0 PSI hydraulic limit switches OR consult Genie Industries Service Department Replace lift dump valve in function manifold item M OR Consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 29 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 12 Ground Controls Inoperative Platform Controls Operate Normally no Does the engine start from the ground controls Be sure all other functions operate normally including the platform controls With both Emergency Stop buttons pulled out to the ON position check voltage at red wire on the input side of the ground controls contact of the key switch KS1 the red wire checked should originate from the Emergency Stop button 12V With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to theon position check voltage at red wire at the output side of the ground controls contact on the key switch 12V Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch Start the engine from the ground controls Move the function enable toggle switch to either side and check the voltage on the center terminal of the platform rotate toggle switch TS14 Repair open in red wire circuit f
148. an appropriate Do not crank the engine with lifting device Then remove all of the pump the over temperature light on mounting plate to engine bell housing bolts The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 7 psi 0 48 bar When the contacts close the engine will shut off to 4 Remove the flex plate mounting fasteners prevent damage Oil pressure will be indicated then remove the flex plate from the flywheel when the engine is running 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on Part No 52270 Genie S 80 amp Genie S 85 7 27 Section 7 Repair Procedures Service Manual Second Edition Ford LRG 423 Engine 7 1 Governor actuator and linkage a clevis yoke Governor Actuator b linkage rod c carburetor d throttle plate shaft How to Set Up the Governor e governor actuator z f actuator shaft Actuator and Linkage g actuator arm Adjustment of the governor 4 Position the linkage rod so that the throttle is in actuator is only necessary when the idle position Then adjust the clevis yoke on the governor actuator or the the linkage rod to obtain the proper length linkage has been replaced Install the yoke onto the actuator arm 1 Connectthe linkage rod to the throttle plate 5 With the throttle in the idle position a
149. anel in the right normally direction and check voltage on wht red wire on turntable rotate left right proportional valve coil item U With keyswitch in 4 to 6 Repair open in wht red platform position and wire from TP6 to TB6 both Emergency Stop buttons pulled out to the position activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the right direction and check voltage at TP6 item U OR repair open in brown ground wire circuit to valve coil Activate footswitch and 12V or more check voltage at terminal on BP1 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1 Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Continued on the next page 5 48 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the right direction and check voltage on wht wire on boom function directional valve coil item A 12V or more Continued on the next page Section 5
150. art No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 2 Press down the footswitch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 3 Do not press down the footswitch and start the engine 4 Do not press down the footswitch Check 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 B 19 Test the Engine Idle Select 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 Drive functions do not operate at low idle High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Start the engine from the grou
151. art No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Down Function Inoperative S 85 Models Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the jib boom toggle switch TS15 in the down direction and check voltage at the grn blk wire on the jib boom down directional valve item EE 12V With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the ON osition activate the footswitch and the jib boom toggle switch TS6 in the down direction and check voltage at TB18 12V Continued on the next page Move the function enable switch to either side and activate the jib yoy boom toggle switch TS15 in the down direction and check voltage at TB18 Repair open in red power wire circuit from keyswitch to TS15 OR toggle switch 515 Activate the footswitch 12V and the jib boom toggle switch TS6 in the down direction and check voltage at TP18 With the keyswitch turned to platform 12V control and both Emergency Stop buttons pulled out to the on position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 Check the voltage at terminal 30 CR13 P 12
152. ashing beacon should be on and flashing 2 Move 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 switch is held down 3 Turn the key switch to platform control O Result The flashing beacon should be on and flashing 4 Press down the foot switch Move the boom control handle to the pown position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down TABLE B PROCEDURES 5 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 25 Check the Hydraulic Limit Switch Linkage 1 Remove the drive chassis steer end cover 2 Extend and retract the axle through 2 cycles and visually inspect the the linkage for damage Be sure the valve actuator is functioning properly 3 Be sure the lock nut is properly tightened 4 Repeat procedure for the non steer end axle dod lock nut linkage rod spring valve actuator limit switch valve If the linkage is not func
153. at starter cable to starter cable Repair or replace starter or starter solenoid 5 4 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Cranks With the keyswich n turned to ground Over But Will paid ota Not Start Emergency Stop buttons pulled out to the on Gasoline LPG position hold start switch to either side and Models check battery voltage while engine is cranking Be sure to check the engine oil level and fill as needed more than 11V Check if engine coolant temperature sending continuit Be sure to check fuel levels and engine coolant level unit signal post has continuity to ground Be sure the gasoline shut off valve is in the ON Or OPEN position Be sure that automatic choke is not sticking closed Perform following tests in gasoline mode only Be sure that the water temperature gauge does not show an overheated condition no continuity good spark Remove 1 spark plug and ground spark plug body Crank engine and observe spark weak or no spark Continued on the next page Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if radiator and or hot engine block feels excessively hot not hot Remove wht wire from temperature sending unit check continuity
154. ative 5 52 21 Platform Level Up Function Inoperative 5 53 22 Platform Level Down Function Inoperative 5 55 23 Platform Rotate Left Function Inoperative 5 57 24 Platform Rotate Right Function Inoperative 4 5 60 25 Jib Boom Up Inoperative 5 85 Models 5 63 Viii Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section Five Section Six TABLE OF CONTENTS Troubleshooting Flow Charts continued 26 Jib Boom Down Inoperative 5 85 Models 5 65 27 Drive Chassis Jack Function Inoperative 5 67 28 Axle Extend Retract Inoperative 5 69 29 Steer Left Function Inoperative sss 5 70 30 Steer Right Function Inoperative 2 5 72 31 All Drive Functions Inoperative All Other Functions Operate Normally 5 74 32 Drive Forward Or Reverse Function Inoperative 5 77 33 Traction Function Inoperative 0 0224 40000 5 78 34 Machine Will Not Drive At Full 5 79 35 Machine Drives At Full Speed With
155. aximum 2WD 4WD Drive speed stowed 3 8 mph 3 1 mph Gasoline LPG models 6 1 km h 4 9 km h 40 ft 7 2 40 ft 8 8 sec 12 2 m 7 2 sec 12 2 m 8 8 sec Drive speed stowed 3 3 mph 3 mph Deutz Diesel models 5 3 km h 4 8 km h 40 8 3 sec 40 ft 9 1 sec 12 2 m 8 3 sec12 2 m 9 1 sec Drive speed 0 6 mph 0 6 mph raised or extended 1 0 km h 1 0 km h all models 40 ft 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Service Manual Second Edition Boom function speeds maximum from platform controls Jib boom up 60 to 70 seconds Jib boom down 40 to 50 seconds Boom up 90 to 120 seconds Boom down 90 to 120 seconds Boom extend 70 to 85 seconds Boom retract 85 to 95 seconds Turntable rotate 360 boom fully retracted 80 to 120 seconds Turntable rotate 360 boom extended 210 to 240 seconds Platform rotate 160 8 to 12 seconds Gradeability boom stowed 2WD 4WD Platform level up 50 to 60 seconds Rough terrain 30 38 Platform level down 40 to 50 seconds 2 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron equivalent Drive pump Type bi directional variable displacement piston pump Displacement 2500 rpm 0 to 30 3 gallons per minute 0 to 114 7 liters per minute SPECIFI
156. azard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING 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 Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 52270 Genie S 80 amp Genie S 85 5 1 Section 5 Troubleshooting Flow Charts Service Manual Second Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction Identify Troubles
157. bends and cracked welds Check each lug nut for proper torque 4 Check the pressure in each air filled tire Tires and wheels Tire size 15 22 5 SAT Tire ply rating 16 Tire pressure 100 psi 6 89 bar 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 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 9 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 torque hub disconnect cap to be sure it is in the engaged position mo brake disengage position arf mj I brake engage position 2 sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the bottom of the drive pump drive pump b free wheel valve c pump screwdriver The free wheel valve should always remain closed TABLE B PROCEDURES B 10 Check the Oil Level in the Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Drive the machine to
158. board Activate the footswitch and check the voltage on the org blk 4 1wire on the alterator Repair open in org blk 7108V 41 wire from alternator to TB41 to TP41 to terminal 3 on horsepower limiter ov board Repair or replace alternator 5 74 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Activate the footswitch and hold the drive joystick in the full Continued from the previous page forward position and check the voltage at terminal 6 on the drive joystick controller 9 to 12V Connect the positve lead from a voltmeter to terminal 4 on the joystick and the negative lead to terminal 5 on the joystick Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the 4 and 5 terminals on the drive joystick controller Connect the positve lead from a voltmeter to terminal 5 on the joystick and the negative lead to terminal 4 on the joystick Activate the footswitch and hold the drive joystick in the full reverse position and check the voltage across the 5 and 4 terminals on the drive joystick controller 2V Continued on the next page CHART 31 Repair open in wire from terminal 10 on horsepower limiter board to terminal 6 on the drive joystick no Check continuity from continuity terminal 3 on drive joystick t
159. brake Then remove the hydraulic fitting and the bleed valve 3 Loosen the wheel lug nuts Do not remove them 4 Center a lifting jack of ample capacity under the non steering axle Raise the machine and place blocks under the drive chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place second lifting jack under the torque hub for support and secure the torque hub to the lifting jack Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition NON STEERING AXLE COMPONENTS 7 Remove the torque hub mounting bolts that attach the torque hub to the axle Remove the torque hub Crushing hazard The torque AWARNING hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack Torque specifications 569 5 Nm 433 9 Nm 163 Nm 122 Nm Lug nut dry 420 ft lbs lubricated 320 ft lbs Torque hub mounting bolts dry 120 ft lbs lubricated 90 ft lbs Drive motor mounting bolts dry 75 ft lbs lubricated 56 ft lbs 102 Nm 76 Nm Genie S 80 amp Genie S 85 Part No 52270 Distributed By E Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
160. btain the correct raised drive speed of 1 foot per second 0 31 m per second Turn the B potentiometer counterclockwise to increase voltage or clockwise to decrease voltage 16 Close the platform control box lid and install the fasteners Drive speed specifications Stowed position Gasoline LPG models Deutz Diesel models distance 40 ft 12 m 2WD 4WD 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec 40 f 6 8 sec 40 ft 9 1 sec 12 2 m 6 8 sec 12 2 m 9 1 sec Boom raised or distance 40 ft 12 m Service Manual Second Edition 2 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 Do not use the color of the connector as a guide for these tests Use the actual wire color to identify which wire to use for testing Test Desired result red to black continuity zero red to white no continuity infinite black to white no continuity Do not use the color of the connector as a guide for these tests Use the actual wire color extended 1 foot per second to identif y which wire to use for All models 30 5 cm per second testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for 1 3 continuity Foot Switch Test Desired result How to Test the Foot Switch red to black n
161. c tank 4 Completely drain the tank into a suitable container See capacity specifications 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 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 straps from the hydraulic tank 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING may become unbalanced and fall if itis not properly supported and secured to the overhead crane 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 a thread sealant on the threads 14 Install the drain plug using a 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 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfi
162. check voltage at TB1 With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP1 on platform control panel in up direction and check voltage TB1 Activate footswitch and boom function controller BP1 on platform control panel in up direction and check voltage TP1 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 14 Repair open in red 1 wire circuit from TB1 to boom up function directional valve coil item B OR repair open in brown ground wire circuit to valve coil Troubleshoot boom up function toggle switch TS17 on ground control panel OR repair open in red 1 wire circuit from TS17 to TB1 OR consult Genie Industries Service Department Repair open in red wire from TP1 to TB1 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 52270 Genie 5 80 amp Genie 5 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 14 Disconnect wires to 0 boom up directional infinite valve coil item B and ohms 1 test the resistance of the item B valve
163. chieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Chart 6 Check voltage at center terminal on rpm select Repair open in power supply circuit to center terminal of switch Start engine and move the rpm select to high idle rabbit symbol for switch TS4 and TS13 following tests Check voltage at blk red wire 12V on rpm select switch TS4 and TS13 Replace rpm select toggle switch 12V Check voltage at TB35 M Repair open in blk red wire circuit from toggle switch to TP35 to TB35 12V Check voltage at terminal 85 blk red on CR4 Repair open in blk red wire circuit from TB35 to CR4 12V no Check continuity from continuit ground to the brown wire on terminal 486 of 4 Repair open brown ground wire circuit to terminal 86 continuity Check voltage at oV Repair open in white terminal 30 on CR4 21 power wire from terminal 87 on CR2 to CR3 to CR4 12V Check voltage at 12V terminal 87A on CR4 Replace relay Repair short in blk red Check voltage at 12V wire to terminal 7 terminal 7 on electronic governor precision governor Continued on the next page Part No 52270 Genie S 80 amp Genie S 85 5 19 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 6 Continued from the previous page
164. coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms 7 function Move function enable operates switch to either side and hold the boom up toggle switch at the ground controls in the up direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either side and hold the boom up toggle switch at the ground controls in the up direction and check the pressure less than 2600 PSI Exchange flow regulator function valve item I with a like operates valve item H Check boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect Consult Genie Industries Service Department 5 34 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Boom Down Function Inoperative Be sure all other functions operate
165. component damage Extremely dirty conditions may require that the filter be replaced more often 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 Turn the manual fuel shutoff valve located at the fuel tank to the cLosep position 2 Remove the fuel filter with a filter wrench a oilfilter b fuel filter water separator Prime the Fuel Pump 3 Fill the new filter Genie part no 29560 with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filter gasket TABLE C PROCEDURES Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure Turn the manual fuel shutoff valve located at the fuel tank to the oPEN position Start the engine from the ground controls then inspect the fuel filter for leaks 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 52270 Genie S 80 amp Genie S 85 4 35 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 10 Replace the Gasoline Fuel Filter Gasoline LPG Models Replacing the gasoline fuel filter is essential to good engine pe
166. cure from operation A CAUTION Beware of hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Remove the fasteners from the engine side cover then remove the cover 2 Inspect the oil cooler for leaks and physical damage e QUA E oil cooler b cylinder head cooling fins c fan blower fins 3 Clean the oil cooler of debris and foreign material Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES Cooling and Fan Blower Fins 4 Inspect the fan blower fins for physical damage 5 Clean the fan blower fins of debris and foreign material 6 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 7 Clean the cylinder head cooling passages of debris and foreign material B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Do not inspect while the engine AWARNING is running Remove the key to secure from operation Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine
167. d to be performed on machines equipped with the foam filled tire option An over inflated tire can explode AWARNING and may cause death or serious injury 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 and add air as needed Tire specifications Tire size 15 22 5 SAT Pressure 100 psi 6 89 bar A 10 Test the Extendable Axles Tip over hazard Do not raise or extend the boom unless both axles are 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 1 Start the engine from the ground controls TABLE A PROCEDURES 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 Hold the function enable switch to either side and activate the boom down function Result The boom should lower and return to the stowed position Hold the function enable switch to either side and activate the boom extend function Result The boom should extend no more than 6 inches 15 cm and then stop The boom should not extend beyond the limit switch unless both axles a
168. d check voltage on the red and black wires at terminal 87 on CR14 12V Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red and black wires at the jib platform rotate select valves item AP 12V Test the resistance of the valve coils Continued on the next page Service Manual Second Edition Replace the jib delay capacitor OR repair open in brown ground wire from capacitor to ground Repair open in red wire from jib delay capacitor to CR14 Replace relay CR14 OR repair open in power supply from P2 to CR14 OR repair open in brown ground wire to CR14 Repair open in cable containing red and black wires from CR14 to jib boom platform rotate select valves Replace defective valve coil Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 23 Check continuity from i Repair open in brown LT me brown ground wires on ground wire circuit to p page valve coils to ground valve coils function Exchange jib boom operate Repair open in brown platform rotate select ground wire circuit to valves item AP valve coils Activate footswitch and platform rotate left function function inoperative Repair or replace platform rotator OR 0 030 orifice fittings in jib manifold are plugged OR jib manifold may hav
169. d on the drive pump Be sure the drive speed select switch is on high range machine on level surface symbol With the boom in the stowed position check continuity from TB40 to ground With the boom in the stowed position check terminal 6 on horsepower limiter board for continuity to ground Re adjust or replace horsepower limiter board OR check for misalignment of limit switches LS1 and LS2 OR consult Genie Industries Service Department no continuity no continuity Chart 34 Repair short to ground in wht wires to limit switches LS1 and LS2 OR repair or replace boom lift drive limit switch or boom extend limit switch Repair short to ground in orange wire from 40 to TP40 to terminal 6 on horsepower limiter circuit board Part No 52270 Genie S 80 amp Genie S 85 5 79 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 35 Machine Drives At Full Speed With Platform Raised or Extended Be sure boom drive limit switch is being activated by the cam on the boom when the boom is raised Be sure that the boom extend drive limit switch is not being held down or being activated when the boom is extended Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Extend the boom past the drive limit switch and check continuity from ground to terminal 6 on the horsepower limiter board Test limi
170. e Department 12V or more Troubleshoot platform level toggle switch TS16 on ground control panel OR repair open in red power wire circuit to TS16 OR repair open in org blk wire circuit from TS16 to TB15 OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 55 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 22 0 or infinite ohms Disconnect the wires from the platform level down directional valve Continued from the previous page coil item X and test the resistance of the valve coil 610 7 ohms function Exchange platform level operates down and up directional valves items X and V and activate the platform level down function function inoperative function Exchange platform level operates down and up counterbalance valves items GG and HH and activate the platform level down function function inoperative Install a 0 to 3000 0 to 207 bar pressure gauge at the quick disconnect coupling on the function manifold and activate the platform level down function 2600 psi or more less than 2600 psi function Exchange platform level operates flow regulator valve item W with a like valve item FF and activate the platform level down function function inoperative Test master cylinder see Chart 20 OR repair or replace slave cylinder or slave cylinder counterbalance
171. e platform control box mounting fasteners Then lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal 4 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING may become unstable and fall if it is not properly supported 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 Platform Leveling Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 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 slightly and place blocks under the platform Lower the boom until the platform is resting on the blocks just enou
172. e S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee This page intentionally left blank Part No 52270 Genie S 80 amp Genie S 85 7 51 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 7 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 250 psi 17 2 bar ZZ Charge pressure circuit 10 12 ft lbs 14 16 Nm 4 Flow divider combiner valve AB Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 3 Orifice 0 070 in 1 78 mm AC Drive circuit 2 Shuttle valve position way AD Charge pressure circuit that gets hot oil out of low pressure side of drive pump 15 18 ft lbs 20 24 Nm 5 DiaQnOStic Mtn Testing Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 52 Genie S 80 amp Genie S 85 Part No 52270 Section 7 Repair Procedures Service Manual Second Edition
173. e S 85 5 27 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 11A All Lift Functions Inoperative Steer and Drive Functions Operational Be sure that both axles are fully extended With the boom in the stowed position and both axles fully extended start the less than 12V engine and check the voltage at the lift dump valve item G on the function manifold 12V or more 0 or Disconnect wires to infinite valve coil and testthe ohms resistance of the valve coil 6 to 7 ohms With the boom in the less than stowed position and 12V both axles fully extended start the engine and check the voltage at the axle dump valve item SS on the axle dump manifold 12V or more 0 Disconnect wires to infinite valve coil and test the 5 resistance of the valve coil 6 to 7 ohms Continued on the next page 12V or more Start the engine and check the voltage at TB46 less than 12V 12V or Start the engine and more check the voltage at the wht wire on the alternator less than 12V Repair or replace alternator Replace the lift dump valve coil item G Repair open in wht wire from lift dump valve item G to axle dump valve item SS Replace the axle dump valve coil item SS Repair open in red wire from TB46 to LS1 through blk wire to TB42 through blk wire to LS2 through red wire to l
174. e an internal defect Consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 59 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 24 Platform Rotate Right Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS14 in the right direction and check voltage at grn wht wire at TP19 at the platform controls 12 Repair open in grn wht wire from TS14 to TB19 to TP19 OR test toggle switch See Repair Section With keyswitch turned to 0V Check voltage on center 0V platform control and terminal of TS5 both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page 12V With keyswitch turned to joy platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at TP19 Activate footswitch and 12V platform rotate toggle switch TS5 in the right direction and check voltage at the grn wht wire
175. e bleed valve Then 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 left and inspect the bleed valves for leaks 7 14 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures Jib Boom Components S 85 Models 3 1 Jib Boom S 85 Models 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 Support the jib boom with a lifting device 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 6 Support the barrel end of the cylinder with a
176. e drain hose 5 Use an oil wrench and remove the oil filter a engine oil level dipstick b fuel filter C filter 6 Applyathin layer of oil to the new filter gasket Genie part no 49924 Then install the filter and tighten it securely by hand 7 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filter 8 Fill the engine with new oil per specifications and install the oil filler cap 9 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and oil drain hose for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine FAL 1011F Cil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011F Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures C 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 contin
177. e engine running should immediately kill the engine Lift the red auxiliary motor pump switch cover hold operates auxiliary switch and listen for sound of auxiliary pump motor operating motor does not operate With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position activate the auxiliary pump toggle switch and check the voltage on the red cable on the auxiliary power unit 12V Continued on the next page Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the pressure port of the auxiliary 2000 psi pump and hold the auxiliary power toggle switch and note the pressure less than 2000 psi Check for a positive connection between good electric motor and the pump by removing the pump from the motor but leave all the hoses connected Visually check coupling connection bad Replace the auxiliary power unit Test PR1 See Repair bad Procedure 8 5 good Activate the auxiliary 12V or pump toggle switch and more check the voltage at TB27 oV Activate the auxiliary pump toggle switch and check the voltage at the center terminal of TS10 Reconnect pressure line and check battery condition There is possibly not enough battery capacity to operate both aux pump and function valves Repair or replace pump OR replace relief valve Consult Genie Industries Service Department Replace
178. e four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 forms for three years Part No 52270 Genie S 80 amp Genie S 85 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Maintenance Tables Warm Cold Dealer Table A Tools are New parts engine engine service required required required required suggested A 1 Inspect the Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts A 4 Check the Engine Oil Level A 5 Check t
179. e in the system 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 ACAUTION 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 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee PLATFORM COMPONENTS 2 5 80 models Tag disconnect and plug the 8 Use a soft metal drift to drive both pins out then hydraulic hoses from the platform rotator remove the platform rotator from the machine manifold Cap the fittings on the rotator AARNE Crushing hazard The platform AWARNING Bodily injury hazard Spraying rotator may become unbalanced h
180. e information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 B 12 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 Gasoline LPG Models Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Disconnect the blue black wire from the governor actuator 2 Connect an rpm gauge to the engine then start the engine from the ground controls O Result Carburetor low idle should be 900 rpm Skip to step 4 if the low idle rpm is correct 3 Turn the idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm a carburetor b adjustment screw 4 Turn the engine off and reconnect the blue black wire to the governor actuator 5 Startthe engine from the ground controls O Result Electronic governor low idle should be 1600 rpm 4 20 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 6 Move the function enable toggle switch to the high idle rabbit symbol position at the ground controls Result High idle should be 2500 rpm 7 T
181. e keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP 1 on platform control panel in up direction and check voltage at TP3 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in red wht wire circuit from TB3 to boom up down proportional valve coil item R OR repair open in brown ground wire circuit to valve coil 8 to 9V Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 5 32 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in up direction and check voltage on red 1 wire on boom up down directional valve coil item B 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts MN Move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in up direction and
182. e sealant will help eliminate corrosion on the battery terminals and cables TABLE B PROCEDURES B 6 Check the Hydraulic Tank Filter Condition Indicator Maintaining the hydraulic tank filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Startthe engine from the platform controls 2 Move the engine speed control switch to high idle rabbit symbol 3 Inspectthe filter condition indicator a filter condition indicator b filter c hydraulic tank O Result The filter should be operating with the plunger in the green area If the display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See C 7 Heplace the Hyaraulic Tank Filter Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 7 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocutio
183. e side of the switch to the other OR replace start toggle switch TS11 Repair blk wire circuit from start switch TS11 to TB33 Repair blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1 to CR2 then to terminal 46 to on ignition start module Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 1 Hold the start switch to Check ground wire to T the either side and check terminal 5 on ignition Repair open in ground previous pages voltage at terminal 1 on start module ME ignition start module Consult Genie Industries Service Department Hold the start switch to Repair open in blk wire either side and check from terminal 1 on voltage at terminal 86 ignition start module to Repair open in red wire circuit from battery to CB1 to CR1 terminal 30 Check voltage at terminal 30 on CR1 Hold the start switch to Check brown ground Repair open in brown either side and check wire to terminal 85 on ground wire circuit to voltage at terminal 87 Replace relay Hold the start switch to Repair open in blk wire either side and check circuit from CR1 to voltage at the black wire starter solenoid on the starter solenoid Repair open in battery Check voltage
184. e testis 7 34 Hydraulic Pumps 9 1 PUMP Gitta o etae tee eae FAA 7 35 952 iDrive PUMP zen kd a tee ese ee een tee 7 35 Manifolds 10 1 Function Manifold 0 1 7 38 10 2 Valve Adjustments Function 7 42 10 3 Turntable Rotation Manifold Components 7 45 10 4 Chassis Jack Manifold Components 7 46 10 5 Axle Extend Dump Manifold Components seen 7 47 10 6 Steer Manifold Components 7 46 10 7 2WD Drive Manifold Components 2 20 0 7 52 10 8 Valve Adjustments 2WD Drive Manifold 7 54 10 9 4WD Drive Manifold Components 400 7 56 10 10 Valve Adjustments 4WD Drive 7 58 Fuel and Hydraulic Tanks MARA FUST ANE tree ee eene eer ties 7 59 11 2 Hydraulic 7 59 Part No 52270 Genie S 80 amp Genie S 85 Xi Service Manual Second Edition 41 TABLE OF CONTENTS Section Seven Repair Procedures continued Turntable Rotation Components 12 1 Rotation Hydraulic MOTOT tren n ete etis 7 62 2WD Steering Axle Components 1341 Yoke and Hub ui e oed eee 7 65 13 2 Steering ena ge tret e qc ge a d ded 7 66 13 3 he Rod Cylinder iecit e
185. eering Cylinders How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod cylinder maintains equal movement of the tires 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 Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 2 4WD Models Remove the hose bracket mounting fastener on the steer cylinder barrel end pivot pin 3 Remove the pin retaining fasteners from the steer cylinder pivot pins Then remove the pivot pin from each end of the steering cylinder 4 Remove the steering cylinder from the machine 7 66 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 13 3 Tie Rod Cylinder How to Remove the Tie Rod Cylinder 1 Tag disconnect and plug the hydraulic hoses from the tie rod cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydra
186. eing tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor Part No 52270 Genie S 80 amp Genie S 85 7 33 Section 7 Repair Procedures Service Manual Second Edition GROUND CONTROLS 8 5 Power Relay Electrocution hazard Contact with AWARNING 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 Electrocution hazard Disconnect AWARNING 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 160 no continuity infinite 2 large posts no continuity infinite Any small post to any large post 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 amp power contact terminal large post b solenoid activate coil terminal small post Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 9 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and
187. er axle should extend smoothly free of ae n Level Control Disable Function hesitation The platform level function will not 11 Return the chassis jack control handle to the operate when the boom is raised neutral position or extenced past the drive speed O Result The lift jack cylinder should fully retract nS when the control handle is returned to neutral Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 11 6 Start the engine from the platform controls Test the Platform and 4 mea not press down on the footswitch Ground Controls 8 Attempt to operate all machine functions Testing the machine functions and the Emergency Result All machine functions should not Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or 9 either Emergency Stop button fails to stop all the machine functions and shut off the engine Each operate Press down on the footswitch and activate each machine function function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pull out the Emergency Stop button at the ground controls to the on position Start the engine from the ground controls Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All bo
188. est equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Retum to Perform Service problem repair Solved Part No 52270 Genie S 80 amp Genie S 85 6 1 Section 6 Schematics Service Manual Second Edition TT Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number BAT Battery 1000 CCA 12V DC 30143 Troja sates es C31 XH 2 1 BP isis Joystick controller Single axis 24495 OEM Controls 54 6883 1 BP2 s Joystick controller Dual axis 40613 OEM Controls EJS5M10089 1 CB2 Circuit breake
189. g bolt 8 Tighten the jam nut against the tie rod cylinder 9 Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Toe in specification 0 1 8 inch 6 35 mm Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition 4WD Steering Axle Components 14 1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may require periodic replacement The yoke must be removed before the torque hub can be removed 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 pin retaining fasteners from both the steering cylinder and the tie rod cylinder pivot pins Remove the pins oscillate cylinder king pin torque hub yoke clevis pin tie rod cylinder steer cylinder Q7 o0ooO0c0oonmfn 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittngs on the drive motor Bodily injury hazard Spraying AWARNING 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 Loosen the wheel lug nuts Do not remove
190. gh to support the platform Do not rest the entire weight of the boom on the blocks Part No 52270 Genie S 80 amp Genie S 85 7 11 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold 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 Pull the slave cylinder hoses through the platform rotator 6 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 7 Remove the external retaining ring from the barrel end pivot pin 8 Use a soft metal drift to drive the rod end pivot pin out 9 Use a soft metal drift and drive the barrel end pin out 10 Carefully pull the cylinder out of the boom Component damage hazard ACAUTION Hoses can be damaged if they are kinked or pinched 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 switch up and down through two platform leveling cycles to remove any air that might b
191. gine off Use a wrench to hold the relief valve and remove the cap item 6 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and recheck relief valve pressure Boom extend relief valve specifications Pressure 2300 psi 159 bar MANIFOLDS How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions boom up down extend retract and turntable rotate use a variable position proportional valve and a three position directional valve Example one position for boom up one position for neutral and one position for boom down The platform rotate function uses a three position valve The platform level uses a three position and a two position valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 10 1 Function Manifold in this section 1 Push the button on the end of the valve in inch 6 mm 2 Hold the function enable switch to either side and move the ground control function switch for the function being overridden to operate function AWARNING Collision hazard Impact with moving boom components may cause death or serious i
192. ground control panel OR repair open in blkAwht wire circuit from TS19 to TB8 OR consult Genie Industries Service Department Repair open in wire from TP8 to TB8 Repair open in power supply circuit from TP24 to BP1 to BP2 OR repair open in brown ground wire circuit from ground to BP2 5 42 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Disconnect wires to 0 boom retract directional infinite valve coil item C and ohms 2 test the resistance of the it bs C valve coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom extend retract toggle switch at the ground controls in the retract direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from retracting disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Move the Genie Industries Service function enable switch to Department either side and hold the boom extend retract toggle switch at the ground controls i
193. h a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls Do not start the engine PLATFORM CONTROLS 3 Open the platform control box lid and locate the boom extend retract controller m ZE 7 Ua ramp rate adjustable trimpot dual lo range adjustable trimpot terminal R activates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot a b f 9 i j Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the max out Press down the foot switch then move the control handle all the way to the EXTEND position Adjust the
194. hat could get into the hydraulic system and cause severe component damage Dealer service is 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 Remove the fasteners from drive chassis cover at the non steer end Remove the cover 2 Remove the drive motor access covers from both sides of the axle 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying AWARNING 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 4 Remove the drive motor mounting fasteners 5 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine Torque specifications 75 ft lbs 102 Nm Drive motor mounting bolts 16 2 Torque Hub How to Remove a Drive Torque 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 Remove the drive motor See 16 1 How to Remove a Drive Motor 2 Tag disconnect and plug the hydraulic hose from the
195. he extend direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from extending disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Move the Genie Industries Service function enable switch to Department either side and hold the boom extend toggle switch at the ground controls in the extend direction and check the pressure less than 2300 PSI function Exchange flow regulator operates valve item H with a like valve item 1 Check boom extend function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department 5 40 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Boom Retract Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend retract toggle switch TS19
196. he Engine Coolant Level Gasoline LPG Models A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Test the Extendable Axles A 11 Test the Platform and Ground Controls A 12 Test the Auxiliary Power Operation A 13 Test the Tilt Sensor A 14 Test the Limit Switches 3 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Table A continued Section 3 Scheduled Maintenance Inspections Tools required New parts required MAINTENANCE TABLES Warm Cold Dealer engine engine service required required suggested Every 100 hours perform the following three engine maintenance procedures A 15 Replace the Engine Oil and Filter U Gasoline LPG Models A 16 Drain the Fuel Filter Water Separator s Deutz Diesel Models A 17 Replace the Engine Air Filter o Table B B 1 Check the Engine Belt B 2 Check the Radiator Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins U Deutz Diesel Models A B 4 Check the Exhaust System B 5 Check the Battery o B 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires and Wheels m including lug nut torque N B 9 Confirm the Proper Brake Configuration B 10 Check the Oil Level in the Torque Hubs B 11 Check and Adjust
197. he alternator AWARNING Electrocution hazard Contact with electrically charged 3 Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar circuits may cause death or serious injury Remove all rings watches and other jewelry 4 Connect the wiring and start the engine from the ground controls Check for hydraulic leaks Part No 52270 Genie S 80 amp Genie S 85 7 61 Section 7 Repair Procedures Service Manual Second Edition Turntable Rotation Components 12 1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor 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 I Unlocked position CELI LJ H Bann Locked position 2 Tag disconnect and plug the hydraulic hoses from the motor brake and manifold AWARNING 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 motor brake mounting fasteners then remove the motor fr
198. he guide 13 Remove the hose and cable clamp at the platform end of the cable track 14 Attach a lifting strap from an overhead crane to the cable track 15 Remove the cotter pin and clevis pin from the upper cable track at the platform end 16 Remove the cable track mounting fasteners that attach the lower cable track to the boom 17 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING may become unbalanced and fall if it is not properly attached to the overhead crane Component damage hazard ACAUTION Cables and hoses can be damaged if they are kinked or pinched How to Repair the Boom Cable Track Component damage hazard ACAUTION 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 46677 The kit includes a 4 link section of cable track fasteners other miscellaneous parts and detailed instructions 1 Remove the boom cable track See 4 1 How to Remove the Boom Cable Track 2 Visually inspect the cable track and determine which 4 link section needs to be replaced BOOM COMPONENTS 3 Drill out the 4 spot welds on each side of the cable track using a 17 64 drill bit Repeat this step for the other end of the 4 link section of cable track Component damage hazard ACAUTION Cables and hoses can be damaged if the dr
199. hoot discovered symptoms problem still exists Return to Perform service repair problem solved 5 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the on position Be sure the circuit breakers are not tripped Be sure the battery is fully charged Check battery voltage 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to the on position check the voltage at the center terminal on the start toggle switch TS11 12V Hold the start toggle switch to either side and check the voltage at either side terminal on start switch 12V Hold the start switch to either side and check voltage at terminal TB33 12V Hold the start switch to either side and check voltage at terminal 3 on ignition start module 12V Hold the start switch to either side and check voltage at terminal 6 on the ignition start module Continued on the next page less than 12V Chart 1 Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch emergency stop button and 2 repair open Repair open in jumper wire from on
200. i _ 28 TILT ALARM p i CABLE RED EH RED 1 27 RD amp 41SM 9 RED S P AUXILIARY POWER RED 278 5 WI RD ER 26 WIRDSP WATER TEMP SENDER i WT BK EH 25 WTBK OIL PRESSURE SENDER WARNING SENDER RDWLEH WHT2 28 WATS KEYSWITCH PWR BLK CRS BLK2 22 BLK S P PWR TO PLAT i RED 1A i WHT GR2 WHT E H 21 WHT D B WHT S P IGNITION PWR i l l RED BLK 2A RED EH 20 RED S P 12V BATT SUPPLY i GANWHTS 19 GRWTSP JIBVALVE GAN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLAT ROT RIGHT RED WHT 3A GAN 4 GRN 3 17 GAN DB GRNS PLAT ROT LEFT i vi z ORGREDAR ORGREDS 16 oGRDDB__ OGRDSR PLAT LEVELFC 1 ORG BLK 4 ORG BLK 3 15 OG BKD B OG BK S P PLAT LEVEL DOWN i AA WHTS 15 DRIVE ENABLE LIGHT C NR BLUWHTS 12 DRIVE ENABLE BLUBLK4 BLUBLK3 n BUBKSR SEC BOOM DOWN WATA BLU 4 BLU 3 10 BLU S P SEC BOOM UP i 4 BLK RED 4 BLK RED 3 9 BK RD S P EXT RET z BLKWHT lt BLKWHTS BKWIDB _ BKWTSP BOOMRETRACT He 9 BLK 4 BLK 3 7 BLK S P BOOM EXTEND i WA WMTREDS 6 WTRDSP TURN ROT FC WHTBLK4 wHrBLka 5 WIBKD B _ WTBKS P TURN ROTATE LEFT 2 WHT 4 WHT 3 WHTOB WHT SP TURN ROTATE RIGHT i RDWTSE PRLBOOMFC RED
201. ift dump valve item G OR replace LS1 or LS2 Repair open in wht wire from alternator to TB21 to TB46 5 28 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 11A 12V or Check voltage at the more Repair open in red power supply wire from CB2 to Emergency Stop With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at the center terminal of the function enable toggle switch TS12 Continued from the previous page output side of CB2 button to the keyswitch to the function enable toggle switch TS12 Repair open from battery to CB2 OR reset or replace CB2 12V or more Hold the function enable toggle switch to either side and check the voltage at the center terminal of each function toggle switch Repair open in red power supply wire from function enable toggle switch TS12 to each function toggle switch 12V or more less than Plumb 0 to 500 PSI 350 PSI 34 5 bar pressure gauge into the hose from the axle limit switches to the function manifold Start engine and check the hydraulic pressure less than 350 psi Adjust the axle limit switch relief valve 350 psi Adjust relief valve to 350 item NN all the way in psi 34 5 bar clockwise counting the number of turns and check the pressure Replace directional v
202. iie ttem ralio 7 67 4WD Steering Axle Components 14 1 Yoko and HUD ERE E RR ER EAS ERES 7 68 14 2 Steering Cylinders 7 69 74 3 ioco or trt e Rae 7 69 Extendable Axle Components 15 1 Extendable Axles 2 1102 7 70 15 2 Drive Chassis Lift 2204200 0 eene 7 72 15 3 Hydraulic Limit Switches sss 7 72 Non steering Axle Components 1657 Drive Motor rrr e essem PY 7 73 16 2 Torque AUD ue wysadzi NA eae tee ene eee nee ee eed 7 73 Xii Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition This page intentionally left blank Part No 52270 Genie S 80 amp Genie S 85 xiii Service Manual Second Edition Section 2 Specifications Specifications Machine Specifications Platform dimensions 6 ft 8 ft Standard Optional Stowed dimensions S 80 S 85 Length 72 in 96 in Length 36 ft 8 in 40 ft 7 in 182 8 cm 243 8 cm iem 124m width 30 in 36 in Width axles retracted 7811 2 7 ft 111 2 in 76 2cm em 2 4 m 24m Tires and wheels Width axles extended 10 ft 10 ft Tire size 15 22 5 SAT En om Tire ply rating 16 Height 9 ft 2 in 9ft2in contact area 71 sq in Weight 33 380 lbs 35 860 Ib s Overall tire diameter 113 in 15 141 kg 16
203. ill bit comes in contact with them Protect the hoses and cables with a block of wood to prevent drilling into the hoses and cables 4 Remove the retaining fasteners from upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched 8 Connectthe ends of the replacement cable track section to the existing cable track using the fasteners provided in the kit Do not overtighten the fasteners Component damage hazard ACAUTION Over tightening the fasteners will result in the cable track not rotating and may bind during operation Be sure that the fasteners are installed from the inside out so the nuts are on the outside of the cable track Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 9 Install the black rollers onto the new section of cable track 10 Install cable track onto the machine and operate the boom extend retract function through a ful
204. in grn wht wire from TS14 to TB19 to TP19 OR test toggle switch See Repair Section Repair open in red power wire circuit through controllers and function toggle switches to TS5 12V With keyswitch turned to joy platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at TP19 Repair open in grn wht wire from TP19 to jib delay capacitor Activate footswitch and 12V platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire on TS5 Repair open in grn wht wire from TS5 to TP19 Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Part No 52270 Genie S 80 amp Genie S 85 5 57 Section 5 Troubleshooting Flow Charts RR ee SSS SSS SS SS CHART 23 Continued from the previous page With keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the red wire at the jib delay capacitor 12 Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red wire at terminal 86 on CR14 12V Activate footswitch and platform rotate toggle switch TS5 in the left direction an
205. ing Axle Components 13 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the pin retaining fasteners from both the steering cylinder and the tie rod cylinder pivot pins Use a soft metal drift to remove the pins tie rod cylinder axle yoke pivot pin yoke hub clevis pin 0 steering cylinder 2 Loosen the wheel lug nuts Do not remove them 3 Block the non steering wheels and then center a lifting jack of ample capacity under the steering axle 4 Raise the machine 6 inches 15 cm and place blocks under the chassis for support 5 Remove the lug nuts Then remove the tire and wheel assembly 9 Remove the pin retaining fasteners from the yoke pivot pins Support the yoke hub assembly with a lifting jack Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out Remove the yoke from the machine AWARNING Crushing hazard The yoke hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly secured and supported by the lifting jack Torque specifications Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft lbs 433 9 Nm How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them Block the non steering wheels and place a lifting jack of ample capacity under the steering axle Raise
206. ing bolts and then use a lifting device to remove the torque hub from the machine Part No 52270 Genie S 80 amp Genie S 85 7 63 Section 7 Repair Procedures Service Manual Second Edition eee TURNTABLE ROTATION COMPONENTS How to Adjust the 6 Rotate the torque hub pivot plate away from the turntable until it contacts the adjustment bolt Turntable Rotation Gear Backlash Then tighten the mounting fasteners on the The turntable rotation torque hub is mounted ona torque hub pivot plate adjustable plate that controls the gap between the 7 Rotate the turntable through an entire rotation rotation motor gear and the turntable bearing Check for tight spots that could cause binding Be sure to check the backlash Readjust if necessary with the machine on a flat level surface 1 Loosen the mounting fasteners on the torque hub pivot plate a pivot plate mounting bolts b adjustment bolt with lock nut c torque hub pivot plate 2 Push the torque hub pivot plate towards the turntable as far as possible this will push the rotation gear into the rotation bearing 3 Loosen the lock nut on the adjustment bolt 4 Turn the adjustment bolt clockwise until it contacts the pivot plate 5 Turn the adjustment bolt 1 2 turn counterclockwise Then tighten the lock nut on the adjustment bolt 7 64 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 2WD Steer
207. ion and recheck the valve pressure 7 Turnthe engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 58 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 11 1 Fuel Tank How to Remove the Fuel Tank 6 Explosion hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion hazard When transferring fuel connect a grounding wire between the machine and pump or container Turn the manual fuel shutoff valve to the CLOSED position Remove the tank side turntable cover See 5 1 How to Remove a Turntable Cover Gasoline LPG models Disconnect drain and plug the fuel hose Deutz Diesel models Disconnect drain and plug the supply and return fuel lines Cap the fuel return fitting on the fuel tank Remove the retaining fasteners from the fuel tank hold down straps Remove the straps from the fuel tank Support the fuel tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane Remove the fuel tank from the machine AWARNING Crushing hazard The fuel tank may become unbalanced and fall if it is not properly supported and secured
208. ire circuit to CR2 CHART 3 Repair open in blk wire from terminal 86 on CR2 to terminal 9 on the ignition start module Repair open in power supply wires to terminal 6 and 7 on ignition start module Repair open in brown ground wire circuit to terminal 5 on ignition start module Part No 52270 Genie S 80 amp Genie S 85 5 13 Section 5 Troubleshooting Flow Charts CHART 3 Crank engine and check gy voltage at terminal 2 on ignition start module Continued from the previous page 7V While cranking engine for 15 seconds check continuity to ground on yes terminal 10 on ignition start module Is continuity maintained no Check voltage at 12V terminal 4 on ignition start module Replace ignition start module OR consult Genie Industries Service Department Service Manual Second Edition SSS Crank engine and check ov voltage at org blk 41 wire on alternator 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Disconnect wht 24 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 24 wire from engine temperature sender and check continuity to ground on signal post of sender while cranking the engine 15 continuity maintained yes
209. ivated If the boom does not stop raising when the boom limit switch is activated see 15 3 How to Set up the Hydraulic Limit Switches Lower the boom to the stowed position Retract the steer axle and extend the non steer axle Raise the boom Result The boom should stop raising when the boom drive limit switch is activated If the boom does not stop raising when the boom limit switch is activated see 15 3 How to Set up the Hydraulic Limit Switches Lower the boom to the stowed position Extend the steer axle Raise the boom Result The boom should operate through the complete range of motion 4 10 Genie 5 80 8 Genie 5 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 15 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require that this procedure be performed every 100 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 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 100 hour interval Perform this procedure
210. k tray underneath the function manifold Index Schematic No Description Item Function Torque 1 Check valve Blocks flow back to pump 85 90 ft lbs 115 122 Nm 2 Relief valve 200 psi 13 8 bar RR Chassis jack relief circuit when boom is raised or extended 25 30 ft lbs 34 41 Nm 3 Solenoid valve pilot operated SS Allows chassis jacks to lift chassis when boom is in stowed position 25 30 ft lbs 34 41 Nm 4 Check Prevents flow from chassis jacks through auxiliary pump 25 30 ft lbs 34 41 Nm 5 Flow regulator 0 3 1 14 l min UU Regulates flow to steer manifold 10 12 ft lbs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 2 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Part No 52270 Genie S 80 amp Genie S 85 7 47 Section 7 Repair Procedures Service Manual Second Edition SS SS MANIFOLDS How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Normally open poppet valve 6 40 schematic item SS
211. l cycle to ensure smooth operation of the new section of cable track 4 2 Boom How to Shim the Boom 1 Measure each upper and lower 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 side wear pad Replace the pad if it is less than 11 16 inch 17 5 mm thick If the pad is more than 11 16 inch 17 5 mm thick perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners 5 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 may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes How to Remove the Boom AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause 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 to specification during installation Refer to Section Two Hydraulic Hose a
212. l at all times to within 5 degrees TABLE B PROCEDURES B 17 Test the Horn A functional 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 control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the horn button at the platform controls O Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn B 18 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 The engine should not start if the foot switch is pressed down 1 Turn the keyswitch to platform controls and pull out the Emergency Stop button to the oN position at both the ground and platform controls P
213. lic Hose and Fitting Torque Specifications 1 Raise the boom until the master cylinder rod end pivot pin is accessible 7 24 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 7 10 BOOM COMPONENTS 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 Bodily injury hazard Spraying AWARNING 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 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 5 Place a rod through the barell 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 Remove the pin retaining fastener from the rod end pivot pin 8 Place a rod through the barell end pivot pin and twist to remove the pin Crushing hazard The master AWARNING cylinder will fall if the overhead crane is not properly attached Part No 52270 Genie S 80 amp Genie S 85 7 25 Section 7 Repair Procedures Service Manual Second Edition Turntable Covers 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support the ope
214. lic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then 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 Hydraulic oil specifications Hydraulic oil type Dexron equivalent Tank capacity 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters A 8 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 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 Engine compartment fittings hoses pumps filter and turntable surface All hydraulic cylinders All hydraulic manifolds Boom underside of the turntable The underside of the drive chassis Ground area under the machine Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 9 Check the Tire Pressure This procedure does not nee
215. lift jack and check the pressure less than 2900 psi Replace counterbalance valve item OO in chassis jack manifold OR replace axle dump solenoid valve item SS OR repair or replace non steer end lift jack OR chassis jack manifold or control valve may have an internal defect Consult Genie Industries Service Department Chart 27 Repair open in brown ground wire circuit to axle dump valve coil item SS Replace the axle dump valve coil item SS Check for mechanical restrictions keeping non steer end lift jack from operating OR replace counterbalance valve item OO in chassis jack manifold OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 67 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 27 Start the engine and Repair open in red wire zm the check the voltage at from TB46 to LS1 p page TB46 through blk wire to TB42 through blk wire to LS2 through red wire to axle dump valve item SS OR replace LS1 or LS2 Start the engine and Repair open in wht wire check the voltage at the from alternator to TB21 wht wire on the to TB46 OR replace alternator diodes at TB46 Repair or replace alternator 5 68 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Axle Extend Retract Function Inoperative Be sure
216. ll 18 Clean up any oil that may have spilled and open the hydraulic tank valves Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank Always use pipe thread sealant when installing the drain plug Use only Dexron equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters Hydraulic fluid Dexron equivalent Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures FUEL AND HYDRAULIC TANKS How to Prime the Pump Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLoSED position Component damage hazard Be ACAUTION sure that the hydraulic tank shutoff valves are in the oPEN position before priming the pump The i 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 Em 59 hp EE fp or LR 1 Connect 1 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump a manual fuel shutoff valve 2 Gasoline LPG models Disconnect the electrical connector at the ignition coils The ignition coils are located above t
217. ls D 5 Check the Engine Cylinder Compression Gasoline LPG Models E 3 D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models 0 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models D 8 Check the Toothed Belt Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LPG Models Ed D 10 Grease the Steer Axle Wheel Bearings 2WD Models ra ra ra ra ra 3 6 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be rmed Daily Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives an 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 remove from service R repaired Com
218. lt torque sequence 3 Lower the boom to the stowed position 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Nm 24 167999 90g 12 0 O 17 O o 25 300 29 c P 14 00 92 5 10 19 62 Bolt torque sequence C 4 Check the Free wheel Configuration Proper use of the 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 may cause death or serious injury and property damage Collision hazard Select a work AWARNING site that is firm and level Non steering wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 1065 9072 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and then place jack stands under the drive chassis for support Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub disengage position engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by
219. lu blk wire from terminal 46 on electronic governor and restart engine engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor engine goes to high idle Isolate the ground and platform rpm toggle switches TS4 and TS13 check individually and replace defective switch Repair open in wht wire circuit from terminal 87 on CR2 to CR4 terminal 30 Replace relay Repair open in blk red wire circuit from CR4 terminal 87A to electronic governor terminal 7 Repair open in brown wire circuit from ignition module to electronic governor Recheck throttle linkage see Repair section OR check and or replace governor actuator OR see Ford service manual for carburetor troubleshooting 5 22 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle inoperative Deutz Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground Start engine switch rpm select switch to high idle rabbit symbol and solenoid pulls in check if 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red wire on rom select switch TS4 and TS13 12 Check voltage at TB35 ov 12V Check voltage at oV te
220. ments Checklist A YN R Refer to Table A A 1 Manuals A 2 Decals and placards A 3 Damage loose or missing parts A 4 Engine oil level A 5 Engine coolant Gas LPG A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Extendable axles A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter Gas LPG Models A 16 Drain filter separator Deutz Diesel A 17 Replace air filter Checklist B Y R B 18 Foot switch B 19Engine idle select B 20 Fuel select Gas LPG B 21Drive enable system B 22Drive brakes B 23Drive speed stowed B 24 Alarm package B 25 Hydraulic limit switch linkage B 26 Hydraulic oil analysis Perform every 500 hours B 27 dest engine oil dest filter Deutz Diesel Checklist C Y NR Refer to Table C C 1 Boom wear pads C 2 Extendable axle wear pads C 3Turntable bearing bolts C 4 Free wheel configuration C 5 Grease rotation bearing C 6 Torque hub oil C 7 Hydraulic tank filter C 8 Drive loop hydraulic filter C 9 Fuel filter Deutz Diesel C 10 Fuel filter Gas LPG C 11 PCV valve Gas LPG Refer to Table B C 12 Spark plugs Gas LPG B 1 Engine belt C 13 Air LPG mixture B 2 Engine radiator Gas LP B 3
221. n cover with an overhead crane or forklift Do not lift it Crushing hazard Due to its heavy AWARNING weight do not attempt to support the cover by hand Component damage hazard ACAUTION Protect the cover from damage byusing carpet or padding on the crane or fork lift forks 2 Remove the upper and lower retaining clips from the gas strut 3 Gently pry the strut pivot sockets off of the ball studs and remove the strut Protect the strut cylinder rod from damage Mark the locationof the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 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 Crushing hazard The turntable AWARNING cover may become unbalanced and fall if it is not properly supported and secured to a appropriate lifting device AWARNING If a turntable cover must be replaced be sure that all appropriate safety and instructional decals are applied to the new cover Alignment adjustments may be necessary when a new cover is installed 7 26 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures Deutz Engine F4L 1011F 6 1 How to Install the Flex Plate RPM Adjustment 1 Install the flex plate onto the flywheel with the oo raised spline towards the pump Torque the flex Refer to Maintenance Procedures B 12
222. n 64 ounces 18 Newtons Bolt torque through brush 45 to 84 inch pounds 5 08 to 9 5 Nm Brush mounting 15 to 20 foot pounds bolt torque 20 to 27 Nm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fuel pump Electronic solenoid 7 psi 0 48 bar Ignition System Spark plug type Motorcraft AWSF 52C Spark plug gap 0 042 to 0 046 inches 1 07 to 1 18 mm Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 2 Specifications SSS SPECIFICATIONS Engine coolant Oil pan to block M 6 10 to 13 5 14 to 18 Capacity 111 2 quarts Oil filter insert to block 21 to 26 28 to 35 10 9 liters Rocker arm cover to 7 to 10 9 to 13 Alternator cylinder head M 6 Output 95A 14 5V Spark plug to cylinder 7 to 15 9 to 20 head M 14 Bolt torque specifications torque torque Temperature sending 8 to 18 11 to 24 Bolt description size ft lbs Nm unit to block M 14 Timing belt tensioner 29 to 40 40 to 55 Water jacket drain plug to block 12 to 18 16 to 24 pivot bolt M 10 Water pump to block bolt M 8 15 to 22 20 to 30 Timing belt tensioner 25 to 29 35 to 40 adjusting bolt M 8 Water outlet connection 15 to 22 20 to 30 bolt M 8 Camshaft gear bolt M 12 52 to 66 70 to 90
223. n hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Engine compartment electrical panel Gasoline LPG models Engine wiring harness Inside of the ground control box Turntable manifold wiring 2 Start the engine from the ground controls then extend the axles and raise the boom above the turntable covers 3 Inspect the turntable area for burnt chafed and pinched cables 4 Lower the boom into the stowed position and turn the engine off 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Boom to platform cable harness Inside of the platform control box Jib boom cable cover 5 85 models B 8 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 A r inflated tire can AWARNING 0 0 explode and may cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage
224. n system Oil pressure 26 to 87 psi 1 8 to 6 0 bar Oil capacity 11 quarts including filter 10 5 liters Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SG or CD SG grades Units ship with 10W 40 SG CC Injection system Injection pump make OMAP Service Manual Second Edition 1 M P 1 Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Alternator output 55A 14V Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9to 12 mm Bolt tightening specifications torque torque Bolt description size grade ft lbs Nm Camshaft thrust bearing bolt 15 to 18 20 to 24 M 8 x 35 8 8 Rocker arm bolts 15 to 18 20 to 24 M 8 x 45 8 8 Rocker arm set screw nut 15 to 18 20 to 24 Cylinder head cover 6 to 7 8 to 10 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Blower carrier bolts 15 to 18 20 to 24 M 8 x 50 Torx 8 8 V belt pulley bolts
225. n the retract direction and check the pressure less than 2900 PSI function Exchange flow regulator operates valve item H with a like valve item 1 Check boom extend function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department CHART 17 Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 18 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop ON position move the function enable switch to either side and hold the turntable rotate toggle switch TS18 on ground panel in the left direction and check voltage on wht red wire on turntable rotate left right proportional valve coil item U 12V or more Continued on the next page buttons pulled out to the 0V Move the function enable switch to either side and hold the turntable rotate toggle switch TS18 on ground panel in the left direction and check voltage at TB6 With keyswitch in platform position and both Emergency Stop buttons pulled out to the position activate footswitch and turntable rotate left right proportional controller BP 1 on platfo
226. nched purpose hypoid 9 service classification GL5 e motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 3 Remove the torque hub mounting bolts and then use a lifting device to remove the torque hub from the machine Part No 52270 Genie S 80 amp Genie S 85 4 33 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE C PROCEDURES C 7 Replace the Hydraulic Tank Filter Replacement of the hydraulic tank filter 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 Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Perform this procedure with the engine off 1 Remove the filter with an oil filter wrench 2 Apply athin layer of oil to the new oil filter gasket 3 Install the new filter Genie part no 46014 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 5 Start the engine from the ground controls 6 Inspect the filter and related components to be sure that there are no leaks C 8 Replace the Drive Loop Hydraulic Filter Repl
227. nction enable switch to either side and activate the boom up function and check to see if platform levels Plumb a 0 to 5000 psi Check for mechanical 0 to 345 bar pressure restrictions OR replace gauge into master the slave cylinder cylinder rod end counterbalance valves hydraulic hose hose connected to port PL2 using a tee fitting Activate boom up function and check the pressure less than 2000 PSI Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch at a time Continually monitor the pressure gauge during boom up Do not allow the pressure to exceed 2500 PSI Repair or replace the master cylinder 2000 PSI or more Repair or replace the slave cylinder 5 52 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform level toggle switch TS16 in the up direction and check the voltage at org wire on platform level up function directional valve item V 12V or more Continued on the next page With the keyswitch turned to ground con
228. nd 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 Boom Cable Track S 85 Models Remove the jib boom See 3 1 How to Remove the Jib Boom Raise the boom to a horizontal position Remove the turntable end cover Tag disconnect and plug the hydraulic hoses from the master 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 pressure to dissipate gradually Do not allow oil to squirt or spray 7 20 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 7 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Place a rod through the pin and twist to remove the pin 8 Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring 9 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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
229. nd controls Then move the function enable toggle switch to the high idle rabbit symbol position and hold in the ON position Result The engine should change to high idle Release the function enable toggle switch Result The engine should return to low idle Turn the key switch to platform controls o At the platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle 6 Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change to high idle B 20 Test the Fuel Select Operation Gasoline LPG 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 when 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 temperature 1 Move the fuel select switch to gasoli
230. nd drive controller in forward direction and check voltage at terminal 2 on drive controller DP 1 12V or more Repair open from terminal 4 on DP1 to center terminal on TS9 OR refer to Chart 31 OR consult Genie Industries Service Department Hold the drive enable switch TS9 to either side and activate the footswitch and drive forward function Will unit drive Repair open in blu wht wire from drive enable toggle switch TS9 to TP12 to TB12 OR replace drive enable toggle switch TS9 Activate limit switch by hand and check continuity from TB30 to TB12 no continuity Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Chart 36 Repair open in power supply circuit from TP24 The machine is operating correctly If machine does not operate gerer consult Genie Industries Service Department Replace drive enable limit switch contact OR replace drive enable limit switch LS3 Part No 52270 Genie S 80 amp Genie S 85 5 81 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 37 Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and the Emergency Stop buttons are pulled out to the on position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with th
231. nd the shaft then tighten the lock nut actuator arm at a 110 degree angle to the linkage rotate the clevis yoke on the linkage rod two turns counterclockwise to pre load the spring Tighten the lock nut on the linkage rod 2 Fasten the lock nut and clevis yoke to the linkage rod Do not tighten the lock nut against the clevis yoke 3 Loosen the fastener on the actuator arm Rotate the actuator arm until it is at a 110 degree angle to the linkage rod Then tighten the actuator arm fastener 7 28 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 6 Manually pull the actuator arm through a full cycle to be sure that the linkage moves freely Be sure that the linkage activates the throttle shaft to approximately half throttle ACAUTION Component damage hazard If the throttle linkage is improperly adjusted and allowed to reach full throttle the engine will over rev and cause component damage The linkage must be free of friction and obstruction Do not let it rub against the engine brackets or hoses FORD LRG 423 ENGINE 7 2 Choke Adjustments This engine is equipped with an electrically heated automatic choke The choke has a poppet valve to enhance cold starting ability on LPG fuel Choke adjustments are affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates Automatic Choke with Poppet Val
232. ne and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 4 24 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 2 Start the 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 Emergency Stop switch in to the OFF position 5 Move the fuel select switch to LPG 6 Restart the 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 21 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 to either side to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functi
233. nen 4 42 D 4 Check the Engine Valve Clearance Gasoline LPG Models 4 43 D 5 Check the Engine Cylinder Compression Gasoline LPG Models 4 43 D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models 4 44 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 44 D 8 Check the Toothed Belt Deutz Diesel Models 4 45 D 9 Replace the Timing Belt Gasoline LPG Models 4 45 D 10 Grease the Steer Axle Wheel Bearings 2WD Models 4 45 Part No 52270 Genie S 80 amp Genie S 85 vii Service Manual Second Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts Introd ction ssia Ee c Lente Mente eee Lay 5 1 1 Engine Will Not Crank Over 5 3 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 5 5 2A Engine Cranks Over But Will Not Start OR Engine Runs While Cranking Then Dies Gasoline LPG 5 8 2B Engine Runs While Cranking Then 1 800 0 5 11 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 12 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models 5 15 5 Engine Will Not Start On Ga
234. ng Flow Charts Chart 5 Eng ine Will With keyswitch on and Replace fuel select both Emergency Stop switch Not Start On buttons pulled out to the ON position check Gasoli ne voltage at gasoline side But Will Start blu wht wire of fuel select switch On LPG 12 Gasoline LPG Models With keyswitch on and Repair open in blu wht both Emergency Stop wire circuit from fuel buttons pulled out to the select switch to Be sure fuel select ON position check TP38 to TB38 switch is switched voltage at TB38 to gasoline 12V Be sure to check gasoline fuel level With keyswitch on and Repair open in blu wht both Emergency Stop wire circuit from TB38 to Be sure that engine buttons pulled out to the terminal 30 on CR6 ON position check choke is operating voltage at terminal 30 properly on CRG 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR6 while cranking Repair open in red blk wire circuit from vacuum Switch to CR6 12V Check continuity from ground to brown wire at terminal 85 on CR6 Repair open in brown ground wire circuit to terminal 85 on CR6 continuity Hold the start switch to Repair open in blu wht either side and check wire circuit from CR6 voltage at blu wht wire terminal 87 on anti diesel valve on to anti diesel valve OR carburetor replace CR6 12V Continued on the next page Part No 52270 Genie S 80 amp Genie S 85 5 17
235. ng 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 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manual 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 maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Refer to the Decals section in the appropriate Genie S 80 amp Genie S 85 Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place
236. njury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition SS SS MANIFOLDS How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 12V 8 60 schematic items P R and U 3 position 4 way directional valve 10V 3 20 schematic items A B and C Normally open poppet valve 6 40 schematic item G V X DD and EE 7 44 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures SSS SS Se 10 3 MANIFOLDS Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable Index No Schematic Description Item Function Torque Shuttle valve 2 position way di sius Turntable rotation brake release 10 13 ft lbs 14 18 Nm Counterbalance valve KK Turntable rotate right 35 40 ft lbs 47 54 Nm Counterbalance valve EE su Turntable rotate left
237. ntrol panel OR repair open in red blk 42 wire circuit from TS16 to TB2 OR consult Genie Industries Service Department Repair open in red blk wire from TP2 to TB2 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts SSS Disconnect wires to 0 boom down directional infinite valve coil item B and ohms OT x test the resistance of the ite in B valve coil See Repair Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates switch to either side and hold the boom down toggle switch at the ground controls in the down direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either side and hold the boom down toggle switch at the ground controls in the down direction and check the pressure
238. o clearance and zero drag 4 Use around punch to align the shim to the wear pad Install the mounting fasteners 5 Extend and retract the axle through an entire cycle Check for tight spots that could cause binding or scraping of the axle tubes Always maintain squareness between the inner and outer axle tubes How to Remove the Inner Axle 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 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 Extend the axle to be removed Remove the drive chassis cover Loosen the wheel lug nuts Do not remove them Block the wheels on the opposite end of the machine and then center a lifting jack under the axle to be removed Raise the machine 15 inches 88 cm and place blocks under the chassis for support Remove the lug nuts then remove the tire and wheel assembly Non steer end proceed to step 10 Steer end 7 Remove the pin retaining fasteners from the rod end pivot pin of the steer cylinder and the tie rod cylinder Remove the pins Remove the steer cylinder mounting lug from the inner axle 7 70 Genie S 80 amp Genie S
239. o continuity infinite 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from red to white no continuity the platform toe board black to white continuity zero 7 8 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 1 4 Resistors The resistors are used on 4WD machines to maintain low range drive speed The resistors are located in the platform control box Refer to the schematic legends for resistor locations and values How to Test the Resistors 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connectthe leads from an ohmmeter to each end or wiring of the resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor 1 5 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 orr position Tag and disconnect all wiring from the toggle switch to be tested 2 Connectthe le
240. o ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department no Check continuity from continuity terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 75 Section 5 Troubleshooting Flow Charts CHART 31 Continued from the previous page Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the wht 12 wire and the wht blk 31 wire on EDC Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department Service Manual Second Edition With the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS9 to either side and check the voltage across the wht 1H2 wire and the wht blk 310n EDC Connect the positve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS9 to either side and hold the negative lead from the vol
241. om and platform functions should not operate Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering O Result All machine functions should operate through a full cycle 10 Push in the Emergency Stop button to the position at the platform controls O Result No function should operate the engine should stop As a safety feature selecting and operating the ground controls will override the platform controls including the Emergency Stop button Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 12 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 damage 1 Turn the key switch to ground control and pull out the Emergency St
242. om the brake motor brake mounting bolts motor brake torque hub mounting bolts torque hub plug 7 62 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee TURNTABLE ROTATION COMPONENTS How to Remove the Turntable 4 Remove the plug from the side of the torque Rotation Brake or Torque Hub hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting 1 Secure the turntable from rotating with the bolts to 180 foot pounds 244 Newton meters turntable rotation lock pin Install the brake and motor onto the torque hub 7 Fillthe 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 plugs and then install the plugs 8 Adjust turntable rotation gear backlash See Repair Procedure 12 1 How to Adjust the Turntable Rotation Gear Backlash unlocked locked Turntable rotate torque hub 2 Remove the motor brake mounting bolts and Capacity 44 fluid ounces then remove the motor and brake from the 1 3 liters torque hub and set them to the side Type SAE 90 multipurpose hypoid gear oil API Component damage hazard service classification GL5 ACAUTION Hoses can be damaged if they are kinked or pinched motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake O AGUO 3 Remove the torque hub mount
243. on With the keyswitch less turned to platform than control and both 12V Emergency Stop buttons pulled out to the ON position activate the footswitch and check the voltage at terminal 2 on the drive joystick DP1 12V or more With the keyswitch ha turned to platform 12V control and both Emergency Stop buttons pulled out to theon position activate the footswitch and check the voltage at terminal 1 on the horsepower limiter circuit board 12V or more Activate the footswitch and hold the drive joystick in the full forward position and check the voltage at terminal 10 on the horsepower limiter board 9 to 12V Continued on the next page Check continuity of Repair open in power brown ground wire from continuity supply circuit from TP24 terminal 3 on DP1 to to terminal 2 on drive ground joystick DP1 no continuity Repair open in brown ground wire circuit from ground to DP1 Check continuity of brown ground wire from terminal 42 on the horsepower limiter circuit board to ground Repair open in power supply circuit from TP24 continuit to terminal 1 on the horsepower limiter circuit board no continuity Repair open in brown ground wire circuit from ground to terminal 2 on the horsepower limiter circuit board Activate the footswitch 7 to 8V Replace horsepower and check the voltage at limiter board terminal 3 on the horsepower limiter
244. on TS5 oV Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Repair open in red power wire circuit through controllers and function toggle switches to TS5 Repair open in grn wht wire from TP19 to jib delay capacitor Repair open in grn wht wire from TS5 to TP19 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts S CHART 24 With keyswitch turned to Replace the jib delay 21 Tom the platform control and capacitor OR repair previous page both Emergency Stop open in brown ground buttons pulled out to the wire from capacitor to on position activate ground footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the red wire at the jib delay capacitor 12V Activate footswitch and Repair open in red wire platform rotate toggle from jib delay capacitor switch TS5 in the right to CR14 direction and check voltage on the red wire at terminal 86 on CR14 12V Activate footswitch and Replace relay CR14 OR platform rotate toggle repair open in power switch TS5 in the right supply from P2 to CR14 direction and check OR repair open in brown voltage on the red and ground wire to CR14 black wires at terminal 87 on CR14 12V Activate footswitch and Repair open in cable platform rotate toggle containing red and black Switch TS5 in the right
245. onic displacement controller EDC located on the drive pump 4 Remove the mounting fasteners from the regulator mounting bracket then pull the bracket up past the bell housing Secure the bracket before continuing 5 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 6 Carefully pull the pump away from the engine and secure it from moving 7 Remove the flex plate mounting fasteners then remove the flex plate from the fly wheel 7 30 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 4 inch 6 35 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do ACAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm FORD LRG 423 ENGINE 7 7 Water Temperature and Oil Pressure Gauges The water temperature gauge is an electrical gauge The sending unit has limit con
246. oning drive enable system may allow the machine to be moved into an unsafe position 1 Startthe engine from the platform controls TABLE B PROCEDURES Rotate the turntable to the right until the boom is past the right non steering wheel Result The drive enable indicator light should turn on Slowly move the drive control handle off center Result The drive function should not operate Hold the drive enable toggle switch to either side and slowly move the drive control handle off center LLI Always use the color coded ACAUTION direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Result The drive function should operate Rotate the turntable to the left until the boom is past the left non steering wheel Result The drive enable indicator light should come on Repeat steps 3 and 4 Part No 52270 Genie S 80 amp Genie S 85 4 25 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 22 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational Be sure that the machine is not in AWARNING free wheel or pa
247. ontroller Adjustments Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platform controls Do not start the engine Part No 52270 Genie S 80 amp Genie S 85 7 3 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 3 Open the platform control box lid and locate the turntable rotation controller Refer to the platform control box illustration page 7 2 Lo Fo eo J terminal D2 directional output terminal A proportional output terminal ground terminal positive terminal activates max out range terminal D1 directional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connect the red lead from a volt meter to the
248. ooting Flow Charts With keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the ON position crank the Continued from the previous page engine and check voltage at center terminal on fuel select switch TS12 in ground control box 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage on gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both Emergency Stop buttons pulled out to the on position crank engine and check voltage at terminal TB38 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank engine and check voltage at blu wht wire at terminal 30 on CR6 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank the engine and check voltage at terminal 87 on CRG 12V Continued on the next page CHART 2A Repair open in red power wire circuit with diode to fuel select toggle switch TS12 Replace toggle switch Repair open in blu wht wire circuit from toggle TS12 toggle switch to TB38 Repair open in blu wht wire circuit from TB38 to terminal 430 on CR6 Check brown ground Repair open in brown wire on terminal 85 of ground wire circuit to CR6 no goo CR6 good Replace CR6 Part No 52270 Genie S 80 amp Genie S 85 5 9 Section
249. op button to the oN position at the ground controls 2 Liftthe red auxiliary power switch cover 3 Simultaneously hold the auxiliary power switch ON and activate each boom function toggle switch To conserve battery power test each function through a partial cycle Result All boom functions should operate TABLE A PROCEDURES 4 Turn the key switch to platform control 5 Pull out the Emergency Stop button to the on position at the platform controls then press down the foot switch 6 Liftthe red auxiliary power switch cover 7 Simultaneously hold the auxiliary power switch ON and activate each function control handle or toggle switch To conserve battery power test each function through a partial cycle O Result All boom and steer functions should operate Drive functions should not operate with auxiliary power A 13 Test the Tilt Sensor 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 Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition aS H Z ZKZ TABLE A PROCEDURES 2 Open the tank side turntable cover and press 2 Visually inspect the drive limit switch mounted down on one side of
250. or hose end has been tightened beyond finger tight Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight The O rings used in the Parker Seal Lok fittings and hose ends are a custom size O ring They 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table are not a standard SAE size above O ring They are available in the 6 Operate all machine functions and inspect the ig fel OMEN hoses and fittings and related components to Genie part no 49612 be sure that there are no leaks 2 Lubricate the O ring before installation 2 8 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 2 Specifications SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts lt gt SAE Grade 8 Bolts Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 32 49 6 68 8 1 4 inch 20 96 11 144 16 28 120 14 168 19 5 16 inch 18 17 23 25 34 24 19 28 25 34 3 8 inch 16 30 41 45 61 24 35 48 50 68 7 16 inch 14 50 68 70 95 20 55 75 80 109 1 2 inch 13 75 102 110 149 20 90 122 120 163 9 16 inch 12 110 149 150 204 18 120 163 170 231 5 8 inch 11 150 204 220 298 18 170 231 240 326 3 4 inch 10 260 353 380 515 16 300 407 420 570
251. osition 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 If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition D 2 Change or Recondition the Engine Coolant Gasoline LPG 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 Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Puton protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container 3 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator drain valve AG
252. oss solenoid terminals should be approximately 0 3 ohms solenoid Check if 2 speed binds Repair open in blk red wire circuit from CR3 to CR4 Repair open in brown ground wire circuit to terminal 85 on CR4 Repair open in wht wire circuit from CR2 to CR3 to CR4 Replace CR4 relay OR repair open in blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Check linkage or replace solenoid 5 24 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Low Idle Inoperative Deutz Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At the platform controls start the engine and move the rpm select switch TS4 to maintained low idle turtle symbol Check voltage at blk red wire on rpm select switch Check voltage at the blk red wire on the 2 speed solenoid Check if 2 speed solenoid moves in and out freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department moves freely Chart 9 Isolate the platform and ground rpm switches TS4 and TS13 check individually and replace defective switch Replace CR4 relay solenoid binds Check linkage or replace
253. other jewelry Direct Connection Relay 1 Label and then 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 without resistor 85 to 950 terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a amp 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 amp 30 no continuity infinite Q terminal 87 to 30 continuity zero Q 87 5 or g terminal no 87a terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O OooOooom Control Relay Schematic without resistor 85 87 87a G 0 86 30 Control Relay Schematic with resistor Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 2 1 Platform How to Remove the Platform 1 Separate the foot switch quick disconnect plug 2 Support the platform with a appropriate lifting device 3 Open the platform control box and remove th
254. otswitch and steer rocker switch on drive controller DP1 in left direction and check voltage on blu 36 wire on steer left directional valve coil item VV on steer manifold Repair open in blu 36 wire circuit that runs from TB36 to steer left directional valve coil on steer manifold 12V or more Disconnect wires to Oor Replace steer left steer left directional infinite directional valve coil valve coil item VV on ohms item VV OR repair steer manifold and test open in brown ground the resistance of the wire to steer left valve valve coil coil 5 to 6 ohms Continued on the next page Repair open in blu 36 wire circuit from drive controller DP1 to TP36 then to TB36 5 70 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts N CHART 29 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer left function regulator valve item CC OR consult Genie Industries Service less than 2900 PSI Department Continued from the previous page Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department Part No 52270 Genie
255. ounterbalance less than 2900 psi valve OR 0 035 orifice may be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department function Exchange jib boom operates counterbalance valves and activate jib boom down function Replace defective counterbalance valve function inoperative Consult Genie Industries Service Department 5 66 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Drive Chassis Jack Function Inoperative Be sure all other functions operate normally Be sure machine is in the stowed position This procedure is written for the non steer end lift jack If the steer end lift jack is inoperative repeat procedure and substitute steer for non steer With the boom in the stowed position and both axles fully extended start the 12V or more engine and check the voltage at the axle dump valve item SS on the axle dump manifold oV Continued on the next page no continui Check continuity from brown ground wire on coil to ground continuity Oor infinite ohms Disconnect wires to valve coil and test the resistance of the valve coil 6 to 7 ohms Install a 0 to 5000 345 bar pressure gauge onto the test port on the function manifold 2900 psi Start the engine and operate the non steer end chassis
256. pivot plate away from the machine to access the exhaust system one EE a engine pivot plate b pivot plate retaining bolts 2 All models Be sure that all nuts and bolts are tight 3 Inspect all welds for cracks A Inspect for exhaust leaks i e carbon buildup around seams and joints Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 5 Check the Battery 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 Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry AWARNING Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Besure that the battery cable connections are free of corrosion 3 sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity with a hydrometer 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors and a corrosion preventativ
257. pplicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 52270 Genie S 80 amp Genie S 85 iii Section 1 Safety Rules Service Manual Second Edition 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 of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following y Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of A CAUTION P a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information other protective clothing if the situation G Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes 3j Be aware of potential crushing hazards zl Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and read
258. quarts 10 9 liters Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE D PROCEDURES D 3 Change the Fuel Lines Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel line may cause an unsafe operating condition Engine fuels are combustible Replace the fuel lines 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 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them zy G NG U A Ll Am CALLE 2 l 3 P Cal FA 4 E O 9 Deutz Diesel models 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 4 42 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second
259. r 24018 c cte 45 700 IG1 P10 2 CR1 through CR8 Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 COS 8 CR13 14 17 18 and 19 Relay SPDT 12V DC 19274 Potter Brumfield VF4 45F11 CO5 5 Diode Diode 6 amp 200 PIV 45782 Motorola MOTMR752 36 DP tue Joystick controller Drive 20424 OEM Controls 1159 01386 1 FEB pocz Flashing beacon 20189 ECCO Electronic Controls 6400 2 ES1 42 Footswitch 13482 Linemaster Switch Corp 632 8 iiie 1 cop Gauge Voltage 30789 annt enn 392 502 aid 1 32 4 ieu Gauge Oil Pressure 30786 VDO aed eene 350 516 ee 1 COE Gauge Water Temp 30787 VDO zi sie aia dee 310 502 nes 1 uunc Alarm Warble tone 19270 Floyd Bell Inc MW 09 616 Q 1 H2 ates Horn 12V DC 130 GB 19145 Sparton Engineered Prod 7431 24823 5 1 issus Alarm intermittent 189
260. r pressure and extremely hot Use caution when removing cap and adding fluids A 6 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 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 Gasoline LPG Models 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor Gasoline tank manual shutoff valve fuel pump solenoid shutoff valve hoses and fittings and carburetor Deutz Diesel models Fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 7 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydrau
261. rankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses a carburetor to valve cover hose b PCV valve PCV valve to carburetor hose 3 Disconnect the hose from the carburetor then disconnect the hose from the valve cover TuS UI 4 Clean the hoses with a mild cleaning solvent NY 5 Dry both hoses and inspect them for cracks and damage Replace the hoses if they are damaged D 7 Check the Fuel Injection Pump and Injectors Deutz Diesel a pivot plate retaining bolts b engine pivot plate Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz number 0297 7195 Genie part number 52229 4 44 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Operation Manual Deutz number 0297 4706 EN Genie part number 29790 D 9 Replace the Timing Belt Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194
262. re extended Hold the function enable switch to either side and activate the boom retract function Result The boom should retract At the extendable axle controls located at the non steer end of the machine activate the steer axle drive chassis lift jack cylinder Result The cylinder should extend and the drive chassis should raise smoothly free of hesitation Continue holding the chassis jack in the extended position and activate the steer axle EXTEND control handle to extend the steer axle Result The cylinder should extend and the steer axle should extend smoothly free of hesitation Return the chassis jack control handle to the neutral position Result The lift jack cylinder should fully retract when the control handle is returned to neutral Activate the non steer axle drive chassis lift jack cylinder Result The cylinder should extend and the drive chassis should raise smoothly free of hesitation Part No 52270 Genie S 80 amp Genie S 85 4 5 Section 4 Scheduled Maintenance Procedures SSS ZK SS TABLE A PROCEDURES Service Manual Second Edition 10 Continue holding the chassis jack in the 5 Push in the Emergency Stop button to the extended position and activate the non steer position RN PATENN Gonto Hie onto Result No function should operate the engine should stop Result The cylinder should extend and the Machines equipped with Platform non ste
263. re to dissipate gradually Do not allow oil to squirt or spray 5 8 85 Models Remove the hose and cable cover from the side of the jib boom 6 S 85 Models Remove the jib rotate manifold mounting fasteners Do not disconnect any of the hoses 7 S 85 Models Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 8 Raise the boom to a horizontal position 9 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring 10 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables out of the channel 11 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track may become unbalanced and fall when it is removed from the machine Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 12 Remove the mounting fasteners from the large cable track guide at the platform end of the cable track Remove t
264. re to dissipate gradually Do not allow oil to squirt or spray EXTENDABLE AXLE COMPONENTS 14 Attach a strap from a lifting device to the inner axle for support 15 Use a soft metal drift to remember to remove the axle extension cylinder pivot pin 16 Remove the lock plate from the top side of the inner axle Then remove the lower wear pads Pay careful attention to the location and number of shims used when removing the wear pads 17 Carefully pull the inner axle out of the outer axle tube Crushing hazard The inner axle AWARNING may become unbalanced and fall if itis not properly supported when it is removed from the outer axle tube How to Remove the Axle Extension Cylinder 1 Steer end Remove the yoke and hub assembly See 13 1 or 14 1 How to Hemove the Yoke and Hub Non steer end Remove the torque hub See 16 2 How to Remove a Drive Torque Hub 2 Non steer end Remove the drive motor access covers at both ends of the axle 3 Tag disconnect and plug the axle extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 4 Supportthe axle extension cylinder with a lifting device Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual
265. retaining plates 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform until it is out Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if it is not properly supported Component damage hazard The ACAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them BOOM COMPONENTS 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 This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause death or serious injury and significant component damage Dealer 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 and fully extend the boom 2 Remove the 2 bolts that are located on each side of the number 3 boom tube near the pla
266. revious page Turn machine off 0 or remove both wires infinite from governor actuator ohms and check resistance across governor actuator terminals Replace governor actuator 210 3 ohms Reconnect governor Repair open in brown wires and restart engine wire circuit from ignition and check voltage at coil plug to electronic electronic governor governor terminal 3 and 4 brown wires See Maintenance section for governor adjustments OR replace electronic governor Part No 52270 Genie S 80 amp Genie S 85 5 21 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 7 Engine Low Idle inoperative Gasoline LPG Models If low idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Start engine and switch rpm select to low idle 12V turtle symbol Check voltage at terminal 86 blk rd wire on 12V EX IN Check voltage at OV terminal 30 Check voltage at terminal 87A on CR4 12V Check voltage at terminal 7 on electronic governor 12V Check voltage at electronic governor terminal 3 and 4 brown wires 12V Turn machine off remove b
267. rformance 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 AA y 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 a fuel filter Perform this procedure with the b hose from the fuel pump to engine off the fuel filter 1 Remove the 2 bolts from under the engine pivot 3 Install the new fuel filter Genie part 33971 plate Swing the engine pivot plate away from into the fitting on the carburetor the machine to access the fuel filter located near the carburetor 4 Connectthe fuel hose to the filter 5 Clean up any fuel that may have spilled during the installation procedure 6 Startthe machine from the ground controls then inspect the fuel filter and hose for leaks If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 7 Swing the engine pivot plate back to its original position and replace the two retaining bolts a pivot plate retaining bolts b engine pivot plate 2 Disconnect the fuel hose from the filter then remove the filter from the fitting 4 36 Genie 5 80 amp Genie 5 85 Part No 5227
268. rm control panel in the left direction and check voltage at TP6 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to turntable rotate left right proportional valve coil item U OR repair open in brown ground wire circuit to valve coil 4 to 6V Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 5 44 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the left direction and check voltage on wht blk wire on boom function directional valve coil item A 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the left direction and check voltage at TB5 With key switch in platform position and both Emergency Stop buttons p
269. rminal 430 on CR3 12V Check voltage to oV terminal 486 on CR3 12V no continuit Check continuity from ground to brown wire at terminal 85 on CR3 continuity Check voltage to oV terminal 87 on CR3 12V Continued on the next page Chart 8 Check high idle adjustment see Maintenance section OR see Deutz workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal o rpm select switch Repair open in circuit supplying 12V to center f oV terminal of switch 12V Replace toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 Repair open in wht wire circuit from terminal 87 on CR2 to terminal 86 on CR3 Repair open in brown ground wire circuit to terminal 85 on CR3 Replace CR3 relay Part No 52270 Genie S 80 amp Genie S 85 5 23 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 8 Continued from the previous page Check voltage at oV terminal 86 on CR4 12V Check continuity from bad ground to brown wire at terminal 85 on CR4 good Check voltage to oV terminal 30 on CR4 12V Check voltage at the blk red wire on the 2 speed solenoid 12V solenoid moves in and out freely moves freely Replace 2 speed solenoid Note resistance acr
270. roller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item P OR repair open in brown ground wire circuit to valve coil Repair open in blk red wire from TP9 to TB9 Repair open in power supply circuit from TP24 to BP1 to BP2 OR repair open in brown ground wire circuit from ground to BP2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend retract toggle switch TS19 on ground panel in the extend direction and check voltage on blk wire on boom function directional valve coil item C 12V or more Continued on the next page Section 5 Troubleshooting Flow Charts MNS Move the function enable switch to either 12V or side and hold the boom more extend toggle switch TS19 on ground panel in the extend direction and check voltage at TB7 With key switch in platform position and both Emergency Stop 12V or buttons pulled out to More ON position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage TB7
271. rom key switch to function enable toggle switch to each function toggle switch 12V Troubleshoot each function individually Repair open in red wire circuit from emergency stop button to the key switch Check if key switch internal cam is activating Replace key switch contact for ground ground contact controls no Replace key switch 1 U 5 30 Genie 5 80 8 Genie 5 85 Part No 52270 Section 5 Troubleshooting Flow Charts Chart 13 Service Manual Second Edition Platform start from yes n engine Test or replace foot the platform controls platform controls then switch see Repair Controls B te foot Section OR repair open switch and check in wht wire circuit from pili 2 voltage at TP24 foot switch to TP24 roun Controls a no Operate Repair open in wht wire circuit from TP24 to Normal ly function toggle switches and function controllers Be sure all cables from chassis oV through the cable Check voltage at TB22 Repair open in red wire track are in good condition with no kinks or abrasions 12V ov Check voltage at TP22 12V Check voltage at blk wire on input side of platform Emergency Stop button contact P2 12V With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on position check the voltage on the output side of the platform Emergency Stop button contact 12V
272. rtial free wheel configuration Refer to B 9 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line the ground for reference 2 Start the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Braking paved surface 2WD 4WD Stopping distance 3 to 5 ft 2 to 3 ft 0 9t01 5m 0 6t00 9m The brakes must be able to hold the machine on any slope it is able to climb B 23 Test the Drive Speed Stowed Position Proper drive function movement is essential 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 12 2 m apart 2 Sta
273. rtional valve Solenoid operated 2 pos 3 way directional valve 9 M duo E Pilot operated flow control valve Solenoid operated 2 pos 4 way directional valve Solenoid operated 3 pos 4 way directional valve DO1 d 2 pos 3 way shuttle valve mom E 3 pos 4 way directional valve Sequencing valve gt lt d Unloader valve Pressure compensating valve Genie S 80 amp Genie S 85 Part No 52270 Section 6 Schematics 2WD Hydraulic Schematic Service Manual
274. rtthe engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch then lower the boom into the stowed position 4 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 5 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 6 Continue at full speed and note the time when the machine reference point crosses the finish line Drive speed stowed position 2WD 4WD Gasoline LPG models 40 ft 7 2 40 ft 8 8 sec 12 2 m 7 2 sec 12 2 m 8 8 sec 40 f 8 3 sec 40 ft 9 1 sec 12 2 m 8 3 sec 12 2 m 9 1 sec Deutz Diesel models Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 24 Test the Alarm Package Optional Equipment The alarm package includes Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the Emergency Stop button to the on position at both the ground and platform controls O Result The fl
275. rvice Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The ACAUTION 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 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 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition HYDRAULIC PUMPS 2 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The ACAUTION 777 3 engine must not be started with the hydraulic tank shutoff valves in the cLosEp 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 Tag and disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps ACAUTION Bodily injury hazard Spraying 6 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very
276. s with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced O Result If there is no side to side or up and down movement grease the wheel bearings 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear 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 Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition e SS SSS SS TABLE D PROCEDURES 16 Slide the hub onto the yoke spindle Component damage Do not ACAUTION 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 slotted nut 19 Tighten the slotted nut to 35 foot pounds 47 Nm to seat the bearings 20 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in 22 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 420 foot pounds 56
277. slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Support the pump with a lifting device and remove the two drive pump mounting fasteners Carefully pull the drive pump out until the pump coupler separates from the flex plate Remove the drive pump from the machine Component damage hazard ACAUTION 5 Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Disconnect the electrical connector at the ignition coils The ignition coils are located above the alternator AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLoSED position a manual fuel shutoff valve Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar Gasoline LPG models Connect the ignition coil wiring and start the engine from the ground controls Check for hydraulic leaks Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee This page intentionally left blank Part No 52270
278. solenoid Part No 52270 Genie S 80 amp Genie S 85 5 25 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 10 All Functions inoperative Engine Starts and Runs Check hydraulic Fill with Dexron fluid level equivalent hydraulic fluid Check pump suction line closed shutoff valves In the with valves closed it open position the valve may have damaged one handles should be or both pumps Please parallel with hose contact the Genie Industries Service Department Do the pumps feel If engine has been excessively hot Open valves and start the engine Check all machine functions for correct operation Disconnect ignition coil Troubleshoot connector plug from inoperative boom ignition coils On Deutz functions and diesel models hold inoperative drive manual fuel shutoff lever functions separately to the closed position clockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing spline drive at rear of main pump spline does not turn Engine to pump flex plate coupling 15 defective OR main pump is defective Consult Genie Industries Service Department 5 26 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Functions Operational
279. soline But Will Start On LPG Gasoline EPG Models re e e action fa 5 17 6 Engine High Idle Inoperative Gasoline LPG 5 19 7 Engine Low Idle Inoperative Gasoline LPG Models 5 22 8 Engine High Idle Inoperative Deutz Diesel Models 5 23 9 Engine Low Idle Inoperative Deutz Diesel Models 5 25 10 All Functions Inoperative Engine Starts and Runs 5 26 11 AllLift and Steer Functions Inoperative Drive Functions Operational 5 27 11A All Lift Functions Inoperative Steer and Drive Functions Operational 5 28 12 Ground Controls Inoperative Platform Controls Operate Normally 5 30 13 Platform Controls Inoperative Ground Controls Operate Normally 5 31 14 Up Function 5 32 15 Down Function Inoperative eeeese eee eee aaa aaa aaa 5 35 16 Extend Function 5 38 17 Boom Retract Function Inoperative 5 41 18 Turntable Rotate Left Function Inoperative 5 44 19 Turntable Rotate Right Function Inoperative 5 48 20 AllPlatform Leveling Functions Inoper
280. st the Engine RPM sse 4 20 B 13 Test the Key 02242204 dia 4 22 B 14 Test the Emergency Stop Switches 4 22 B 15 Test the Ground Control Override 2 4 23 B 16 Test the Platform Self leveling sese 4 23 Testthe Horri ee ntt p tre ei rhe EAR 4 23 B 18 Test the Foot Switch 4 23 B 19 Test the Engine Idle 4 24 B 20 Test the Fuel Select Operation Gasoline LPG Models 4 24 B 21 Test the Drive Enable 4 25 B 22 Test the Drive Brakes 4 00 4 26 B 23 Test the Drive Speed Stowed 4 26 vi Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 24 Test the Alarm Package Optional 4 27 B 25 Check the Hydraulic Limit Switch 4 27 B 26 Perform Hydraulic Oil Analysis sse 4 27 B 27 Replace the Engine Oil and Filter Deutz Diesel Models 4 28 C 1 Check the Boom Wear 4 29 C 2 Check the Extendable Axle Wear Pads
281. t or spray 10 Attach an overhead 5 ton 4536 kg crane to the center point of the boom 11 Attach a similar lifting device to the lift cylinder 12 Place support blocks under the lift cylinder across the turntable 13 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift AWARNING cylinder will fall unless it is properly supported 14 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 15 Remove the pin retaining fastener from the boom pivot pin 16 Remove the boom pivot pin with a soft metal drift then carefully remove the boom from the machine Crushing hazard If the overhead AWARNING crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine 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 Cylinder 1 Remove the boom See 4 2 How to Remove the Boom 2 Place blocks under the extension cylinder for support 3 Remove the external snap rings from the extension cylinder barrel end pivot pin at the pivot end of the number 1 boom tube Use a soft metal drift to remove the pin 4 Remove and label all of
282. t switches See procedure A 14 in the Maintenance Section Repair open from wht wires at TB40 to drive limit switches LS1 and LS2 then from brown ground wires to ground Replace horsepower limiter board OR re adjust horsepower limiter board OR consult Genie Industries Service Department Repair open in org wire circuit from TB40 to TP40 to terminal 6 on horsepower limiter circuit board Replace defective limit switch contact OR replace limit switch Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Drive Enable System Is Malfunctioning Be sure the boom is in the stowed position With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the non steer tires activate footswitch and drive controller in forward direction Will unit drive yes With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the steer end tires activate footswitch and drive controller in forward direction Will unit drive yes Check for continuity from TB30 to TB12 no continuity Repair open from TB30 through red wire to LS3 then from LS3 through blk wire to TB12 With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch a
283. tacts that are factory set The contacts will close at 230 F 109 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 Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the ON position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 423 ENGINE 7 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING om 1 Connect the leads from an ohmmeter or continuity tester to the common and normally open terminals Result There should be no continuity infinite Q 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Component damage hazard A CAUTION Do not short the vacuum switch terminals to ground
284. taining proper backlash of the turntable bearing is essential to safe machine operation Improper backlash could result in an unsafe operating condition and component damage See 12 1 How to Adjust the Turntable Rotation Gear Backlash Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition Table D Procedures D 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 often The machine uses Dexron equivalent hydraulic oil 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 1 Remove the hydraulic tank See Repair Procedure 11 2 How to Remove the Hyaraulic Tank The pump needs to primed before starting the engine See Repair Procedure 11 2 How to Hemove the Hydraulic Tank Component damage hazard Be ACAUTION sure that the hydraulic tank shutoff valves are in the oPEN p
285. teer control handle is moved 1 Atthe ground controls start the engine and rotate the boom between the steer and non steer tires Turn the engine off 2 Visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring a turntable b drive enable limit switch LS3 c turntable rotation bearing 3 Manually activate the drive enable limit switch Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard 4 Startthe engine from the platform controls Result The drive enable indicator light should be on Rotate the turntable so the boom is between the non steer tires Rotate the turntable to the left until the boom is past the left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable toggle switch is activated Rotate the turntable to the right until the boom is past the right non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable toggle switch is activated Axle Extension Hydraulic Limit Switch 1 O o U Start the engine from the ground controls and lower the boom to the stowed position Extend the steer axle Raise the boom Result The boom should stop raising when the boom drive limit switch is act
286. tform end of the number 2 boom tube 3 Place a 4 in x 4 in x 6 ft 183 cm 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 4 Retract the boom until the number 2 boom tube is fully retracted into the number booom 1 tube The number 3 boom tube will remain extended 6 feet 183 cm Part No 52270 Genie S 80 amp Genie S 85 7 23 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 5 Remove the external snap rings from the extension cylinder rod end pin at the platform end Use a soft metal drift to remove the pin 6 Remove the turntable end cover 7 Support the rod end of the master cylinder with a lifting device 8 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 9 Lay the master cylinder down Protect the cylinder rod from damage 10 Remove the external snap rings from the extension cylinder rod end pivot pin at the pivot end of the boom Use a soft metal drift to remove the pin through the access holes in the turntable riser 11 Activate auxiliary power and move the boom extend toggle switch in the ExrEND direction and extend the extension cylinder out the pivot end of the boom approximately 3 feet 0 9m 12 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily
287. tha 6 Remove the pin retaining fastener from the jib platform boon lift cylinder barrel end pivot pin Use a Do not rest the entire weight of the soft metal drift to remove the barrel end pin boom on the blocks 7 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine Crushing hazard The jib boom lift AWARNING cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported 7 16 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures eee JIB BOOM COMPONENTS 5 85 MODELS 3 3 Jib Boom Platform Rotate Manifold Components S 85 Models 1 2 position way valve AP Platform rotate jib boom select 8 10 ft lbs 11 14 Nm Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specification 2 position 3 way valve 5 90 schematic item AP Part No 52270 Genie S 80 amp Genie S 85 7 17 Section 7 Repair Procedures Service Manual Second Edition Boom Components 4 1 Boom Cable Track
288. the Engine Idle Mixture Gasoline LPG Models Part No 52270 Genie S 80 amp Genie S 85 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES 1 Wi Cold Deal Table B continued Tools are New parts bonis engine Rem required required required required suggested B 12 Check and Adjust the Engine RPM B 13 Test the Key Switch B 14 Test the Emergency Stop Buttons B 15 Test the Ground Control Override B 16 Test the Platform Self leveling B 17 Test the Horn B 18 Test the Foot Switch B 19 Test the Engine Idle Select B 20 Test the Fuel Select Operation Gasoline LPG Models Yt B 21 Test the Drive Enable System B 22 Test the Drive Brakes B 23 Test the Drive Speed Stowed Position B 24 Test the Alarm Package n Optional Equipment XR B 25 Check the Hydraulic Limit Switch Linkage 26 Perform Hydraulic Anaysis See D 1 Test or Replace the Hydraulic Oil 3 4 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition ee Table B continued Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES Warm Cold Dealer engine engine service required required suggested Every 500 hours perform the following engine maintenance procedure B 27 Replace the Engine Oil and Filter Deutz Diesel Models AN
289. the engine from the ground controls Preliminary setting is 1 4 inch of threads showing Measure from top of lock nut to top of adjustment Screw If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 6 Move the function enable toggle switch to the low idle turtle symbol position and adjust the low idle screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 a low idle mixture adjustment screw Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 3 4 turns C 14 Check and Adjust the Ignition Timing Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 TABLE C PROCEDURES C 15 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz Number 0297 7195 Genie part number 52229 C 16 Check the Turntable Rotation Gear Backlash The turntable rotation torque hub is mounted on an adjustable plate that controls the gap between the rotation motor gear and the turntable bearing Main
290. tional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot a b f 9 i J Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 7 2 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures 7 Set the hi range Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 8 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Set the lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjust the voltage to 6 2V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Start the engine and move the engine idle control switch to foot switch
291. tioning correctly see 15 3 How to Set Up the Hydraulic Limit Switch Linkage B 26 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil Part No 52270 Genie S 80 amp Genie S 85 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 27 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Perform this procedure more often if dusty conditions exist 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 Perform this procedure after warming the engine to normal operating temperature Beware of hot engine parts and oil ACAUTION Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located above the dipstick 2 Pull the end of the drain hose out from under 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 to the right 4 Install the plug into th
292. tmeter onto the blu wht wire on TS9 and check the voltage Connect the positve lead from a voltmeter to terminal 5 on the joystick and with the footswitch activated and the drive joystick in the full forward position hold the negative lead of the voltmeter onto the center terminal of the drive enable toggle switch TS9 and check the voltage 2V Replace drive enable toggle switch TS9 Repair open in wht wire from terminal 4 on drive joystick to TS9 to TP30 to TB30 through drive enable limit switch LS3 to TB12 to wht 12 wire on EDC quick disconnect plug Repair open in blu wht wire from TS9 to TP12 to TB12 Repair open in wire from terminal 4 from drive joystick DP1 to drive enable toggle switch TS9 OR replace drive joystick controller OR consult Genie Industries Service Department 5 76 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 32 Drive Forward Disconnect Helse voltage readings different Pf wire connector from the rive controller drive pump start engine move the drive Fu nction controller to full forward Inoperative position and note the voltage across the wht 12 and the wht blk 31 Be all other wire terminals on the functions operate EDC Reverse the volt i i meter leads and move Ho including the drive controller to full drive in opposite re
293. to ground on temperature sending unit no continuity Remove wht wire from TB24 and check continuity to ground no continuity Repair short in wht wire circuit from terminal 10 on ignition start module to TB24 OR consult Genie Industries Service Department Go to Chart 2A continuit continuit Chart 2 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual for troubleshooting an overheating engine Replace temperature switch sender Repair short in wht wire circuit from TB24 to temperature sender Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts S CHART 2 Continued from the previous page Disable starter by removing blk wire atthe 12V starter solenoid hold the start switch to either side and check voltage at the white wire on the ignition coil plug less than 12V Hold the start switch to 12V either side and check voltage at wht 21 on terminal 87 of CR2 oV Check voltage at red wire on terminal 30 of CR2 12V Hold the start switch to either side and check voltage at terminal 86 of CR2 12V Continued on the next page Service Manual Second Edition See Ford service manual for troubleshooting ignition system Repair open in wht 21 wire from CR2 to ignition coil Repair open in red wire circuit from battery to TB
294. ton normally open P1 A Emergency Stop button normally closed Relay contact normally open Relay panel contactor CES RIES CDE EI Horsepower limiter board DP1 ey oo o A Single axis drive controller 16 LHM 3 Time delay relay 783 an Az m Toggle switch SPDT Naj Toggle switch DPDT JH9IH BP2 PWM Single axis proportional controller START RELAY TACHOMETER START INPUT AUX ON GROUND BATTERY KEY PWR KEY BYPASS IGN FUEL ON ENG FAULT o x o o s o v Ignition start module BP1 RENDER EELA Dual axis Ramp up and down proportional controller Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 6 Schematics _ Abbreviation Legend LABEL DESCRIPTION nies Battery BP oce Proportional controller OB Circuit breaker Control relay DP uices Drive proportional controller Flashing beacon BO sso Foot switch cr Gauge Horn or Alarm Hour meter Keyswitch LED 2 Limit switch Power switch
295. trol and both Emergency Stop buttons pulled out to the on position move the function enable switch to either side and activate the platform level toggle switch TS16 in the up direction and check the voltage at TB14 With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform level toggle switch TS7 in the up direction and check the voltage at TB14 Troubleshoot platform level toggle switch TS16 on ground control panel OR repair open in red power wire circuit to TS16 OR repair open in org wire circuit from TS16 to TB14 OR consult Genie Industries Service Department 12V or more Chart 21 Repair open in org wire from TB14 to platform level up directional valve coil item V OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches TS16 and TS7 on ground and platform control panels OR repair open in red power wire circuit to TS16 and TS7 OR repair open in org wire circuit from TS16 and TS7 to TB14 OR consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 21 0 or infinite ohms Disconnect the wires from the platform level up directional valve coil Continued from the previous page item V and test the resistance of the valve coil
296. ts Check the oil level with the engine off 1 Check the oil dipstick Add oil as needed Result The oil level should be in the safe zone Ford LRG 423 Engine 5 quarts Oil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 C 10W 40 or 10W 50 above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Deutz Engine F4L 1011F Oil capacity including filter 11 quarts 10 5 liters Deutz Engine FAL 1011F Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE SF CC or SF CD grades TABLE A PROCEDURES A 5 Check the Engine Coolant Level Gasoline LPG 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 1 Check the fluid level in the coolant recovery tank Add fluid as needed O Result The fluid level should be in the NORMAL range AWARNING Fluids in the radiator are unde
297. ttons pulled out to the ON position check voltage at terminal 30 on CR7 12V Crank engine for 15 seconds and check voltage at terminal 86 12V Check continuity from bad ground to brown wire on terminal 85 on CR7 good Continued on the next page Chart 4 Replace fuel select switch Repair open in blu red wire circuit from fuel select switch to TP39 to TB39 Repair open in blu red wire circuit from TB39 to terminal 30 on CR7 Repair open in red blk wire circuit from vacuum Switch to CR6 to CR7 Repair open in brown ground wire circuit to terminal 85 on CR7 Part No 52270 Genie S 80 amp Genie S 85 5 15 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 4 Hold the start switch to either side and check voltage at terminal 87 CR7 Continued from the Replace CR7 relay previous page Hold the start switch to Repair open in blu red either side and check wire circuit from CR7 voltage at blu red wire terminal 87 to LPG on LPG solenoid solenoid 12V 0 or infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 9 to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department 5 16 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooti
298. turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands llisi Fai AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage Steer wheels 4WD models 7 Chock the non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 9072 kg under the drive chassis between the non steer tires 9 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the torque hubs by turning over the torque hub disconnect caps on each steer wheel hub disengage position pM engage position 11 Manually rotate each steer wheel O Result Each steer wheel should rotate with minimum effort TABLE C PROCEDURES 12 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the bottom of the drive pump a drive pump b free wheel valve c lift pump d screwdriver The free wheel valve should always remain closed Part No 52270 Genie S 80 amp Genie S 85
299. ube out of the number 2 boom tube Place the number 3 boom tube on blocks for support Crushing hazard The number 3 AWARNING boom tube may become unbalanced and fall when it is removed from the number 2 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 13 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the number 3 boom tube Use a soft metal drift to remove the pin 14 Support and slide the extension cylinder out of the base end of the number 3 boom tube Place the extension cylinder on blocks for support Crushing hazard The extension AWARNING cylinder may become unbalanced and fall when it is removed from the number 3 boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 15 Remove and label all of the wear pads from the extension cylinder Pay careful attention to the location of each wear pad 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the
300. ued 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 see Repair Procedure 4 2 How to Shim the Boom 1 Start the 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 not less than specification shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom tubes Always maintain squareness between the outer and inner Table C Procedures C 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 see Repair Procedure 15 1 How to Shim the Extendable Axles 1 Start the engine from the ground controls and extend the axles 2 Measure each wear pad Replace the wear pad if itis
301. ulic 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 2 Support the tie rod cylinder with a lifting jack 3 Remove the pin retaining fasteners then remove the pivot pin from each end of the tie rod cylinder 4 Remove the tie rod cylinder Crushing hazard The tie rod ACAUTION cylinder may become unbalanced and fall if it is not properly supported and secured to the lifting jack when it is removed from the machine How to Perform the Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position 1 Straighten the steer wheels 2WD STEERING AXLE COMPONENTS 2 Measure the steer tires front to front and back to back using a measuring fixture 3 Center a lifting jack of ample capacity under the steering axle then raise the machine 4 Loosen the jam nut on the adjustable end of the tie rod cylinder 5 Remove the pin retaining fasteners then remove the pivot pin from the adjustable end of the tie rod cylinder 6 Slide the tie rod cylinder off of the yoke and adjust it by turning the end One half turn on the adjustable end equals approximately 1 4 inch 6 4 mm change in the front and rear measurements 7 Slide the tie rod cylinder onto the yoke Install the pivot pin then install the retainin
302. ulled out to the ON position activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TB5 Activate footswitch and turntable rotate left right proportional controller BP1 on platform control panel in the left direction and check voltage TP5 Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 18 Repair open in wht blk wire circuit from TB5 to turntable rotate left function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS18 on ground control panel OR repair open in wht blk wire circuit from TS18 to TB5 OR consult Genie Industries Service Department Repair open in wht blk wire from TP5 to TBS Repair open in power supply circuit from TP24 to BP1 OR repair open in brown ground wire circuit from ground to 52270 Genie 5 80 amp Genie 5 85 5 45 Section 5 Troubleshooting Flow Charts Service Manual Second Edition SSS SSS CHART 18 Disconnect wires to 0 or turntable rotate left infinite directional valve coil ohms item A and test the
303. urn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from the electronic governor located on the engine side bulkhead then remove the back panel from the governor 9 Restart the engine turn the low or high speed trimpot screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do not adjust any trimpot other than specified in this procedure LJ B MUONO 2 calc s 00 a low idle adjustment b high idle adjustment 10 Apply a drop of silicone to the top of the trimpot screw Apply a bead of silicone to the surface of the back panel prior to re assembly 11 Re assemble the governor and recheck low and high idle Gasoline LPG models Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm TABLE B PROCEDURES Deutz Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1500 rpm Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the rpm solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 3 Move the function enable
304. ut Immediately tighten the drain plug a fuel filter b drain plug 4 12 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 2 Clean up any fuel that may have spilled If the fuel filter is completely drained you must prime the fuel filter water separator before starting the engine Refer to C 9 in this section Replace The Diesel Fuel Filter Water Separator for instructions on how to prime the fuel filter water separator 3 Start the engine from the ground controls and check the fuel filter water separator for leaks TABLE A PROCEDURES A 17 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 hours 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 Remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter retaining fastener then remove the filter 4 Clean the inside of the canister and the gasket with a damp cloth 5 Insert the new filter and replace the mounting fastener 6 Replace the end cap on the canister then repl
305. ve AO Works in conjunction with Index no 4 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 56 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS lt gt c NZ 2 KD Part No 52270 Genie S 80 amp Genie S 85 7 57 Section 7 Repair Procedures Service Manual Second Edition SS SS MANIFOLDS 10 10 Valve Adjustments 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold 2 Start the engine from the platform controls Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the charge pressure relief valve and remove the cap index 3 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restart the engine Drive the machine in either direct
306. ve The choke functions in both gasoline and LPG mode The choke butterfly may be adjusted to fully closed rich position for colder climates and the poppet valve will provide a flow path during LPG fueled operation Part No 52270 Genie S 80 amp Genie S 85 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 423 ENGINE 7 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 7 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 7 5 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM 7 6 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump OO pump pump shaft coupler flex plate with raised spline flywheel 1 4 inch gap a b f Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner 2 Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnect the wiring plug at the electr
307. verse position and direction of note the voltage malfunction voltage readings the same 0 or infinite ohms Check the resistance of the Replace the EDC m 20 to 24 ohms Adjust the drive pum Defective Sundstrand null neutral Consult no improvement drive pump contact Genie Industries Service Sundstrand authorized Department repair facility symptoms improve Re adjust drive joystick controller OR if problem still persists consult Genie Industries Service Department Part No 52270 Genie S 80 amp Genie S 85 5 77 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 33 Traction Any type of traction Function UE aaa Inoperative MER Be sure all other functions operate normally 5 78 Genie 5 80 amp Genie 5 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the machine is not raised above or extended beyond the drive limit switches Be sure the boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position Be sure that the boom extend drive limit switch arm is being held down when the boom is retracted Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Be sure the free wheel valve is close
308. voltage to 9 75V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Part No 52270 Genie S 80 amp Genie S 85 7 5 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 8 Set the dual lo range Press down the foot switch then move the control handle all the way to the RETRACT position Adjust the voltage to 9 2V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal AWARNING operating temperature 10 Start a timer and record how long it takes for the boom to fully extend Adjust the max out trimpot to achieve a 70 to 80 second cycle time 11 Start a timer and record how long it takes for the boom to fully retract Adjust the dual range trimpot to achieve an 85 to 95 second cycle time AWARNING If the function cycle time is not achievable check the relief valve pressure See 10 2 Valve Adjustments Function Manifold 12 Turn the engine off and re connect the volt meter 13 Pull out the Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the ExrEND position Record the maximum
309. wing configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr 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 completed Then to re assemble perform the disassembly steps in reverse order General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved Symbols Legend Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious personal injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 52270 Genie S 80 amp Genie S 85 7 1 Section 7 Repair Procedures Service Manual Second Edition Platform
310. wires from CR14 to jib direction and check boom platform rotate voltage on the red and select valves black wires at the jib platform rotate select valves item AP 12V Oor infinite Test the resistance of ohms Replace defective valve the valve coils coil 5 5 to 6 5 ohms Continued on the next page Part No 52270 Genie S 80 amp Genie S 85 5 61 Section 5 Troubleshooting Flow Charts Service Manual Second Edition N CHART 24 Check continuity from i Repair open in brown LT me brown ground wires on ground wire circuit to p page valve coils to ground valve coils function Exchange jib boom operate Repair open in brown platform rotate select ground wire circuit to valves item AP valve coils Activate footswitch and platform rotate right function function inoperative Repair or replace platform rotator OR 0 030 orifice fitting in jib manifold are plugged OR jib manifold may have an internal defect Consult Genie Industries Service Department 5 62 Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Up Function Inoperative S 85 Models Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the jib boom toggle switch TS1
311. y 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 am sure that your workshop or work area is properly ventilated and well lit 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 any forklift overhead crane PAN Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose old oil or ue other fluids Use an approved container Please be environmentally safe iv Genie S 80 amp Genie S 85 Part No 52270 Service Manual Second Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Information ees iie eir LL Lee evened eee d La dnd li Safety Rules General Safety lii Specifications Machine Specifications nei ioo decet hr Be x e o Fs E ts EU ax Ron 2 1 Performance Specifications 2 2 Hydraulic Specifications 2 3 Ford LRG 423 Engine Specifications 4 000000 2 4 Deutz F4L 1011F Engine Specifications
312. ydraulic oil can penetrate and and fall if it is not properly burn skin Loosen hydraulic supported connections very slowly to allow the oil pressure to dissipate 5 85 Models gradually Do not allow oil to squirt 6 Remove the pin retaining fasteners from the jib or spray boom and jib boom leveling arms to platform S 85 models Tag disconnect and plug the rotator pivot pins Do not remove the pins hydraulic hoses from the V1 and V2 ports on 7 Support the jib boom and leveling arms platform rotator manifold Cap the fittings on the manifold 8 Use soft metal drift to drive both pins out then sm SE remove the platform rotator from the machine odily injury hazard Sprayin AWARNING 5 717 hydraulic oil can penetrate and Crushing hazard The platform bs skin 5 hydraulic AWARNING rotator may become unbalanced connections very slowly to allow and fall if it is not properly the oil pressure to dissipate supported gradually Do not allow oil to squirt or spray 3 Support the platform mounting weldment but do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform AWARNING mounting weldment may become unbalanced and fall if it is not properly supported 5 Support the platform rotator Do not apply any lifting pressure S

Service Manual - Genie Industries

Contents

Download Pdf Manuals

Related Search

Related Contents