Genie S85 Service Manual

Part No. 72062

Rev A2

October 2008

Service ManualRefer to inside cover for additional serial number information

(from serial number 966 to 3081)

Genie S-80 & Genie S-85 Part No. 72062

Third Edition First Printing

ii

Introduction

Copyright 1998 by Genie Industries

Third Edition: First Printing, February 2001

"Genie" and "S" are Registered Trademarksof Genie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

ImportantRead, understand and obey the safety rules andoperating instructions in the Genie S-80 &Genie S-85 Operator's Manual before attemptingany maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at a Genie dealer service center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore product specifications are subjectto change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-97030 U.S.A.

If you have any questions, please contact GenieIndustries.

Contact us:http://www.genielift.come-mail: [email protected]

Part No. 72062 Genie S-80 & Genie S-85


iii

Safety RulesSection 1 Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-80 & Genie S-85Operator's Manual will result in death or seriousinjury.Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturers instructions and safety rules- employers safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.



SAFETY RULES

iv

Section 1 - Safety Rules

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbolused to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.Redused to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.Orangeused to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.Yellow with safety alert symbolused to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.Yellow without safety alertsymbolused to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.Greenused to indicate operationor maintenance information.

Workplace SafetyBe sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Be sure to keep sparks, flames andlighted tobacco away from flammableand combustible materials like battery

gases and engine fuels. Always have an approvedfire extinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.



Table of Contents

v

IntroductionImportant Information ...................................................................................................... ii

Section One Safety RulesGeneral Safety Rules..................................................................................................... iii

Section Two SpecificationsMachine Specifications ............................................................................................. 2 - 1Performance Specifications ...................................................................................... 2 - 2Hydraulic Specifications ............................................................................................ 2 - 3Ford LRG 425 EFI Engine Specifications ................................................................. 2 - 4Deutz F4L 1011F Engine Specifications ................................................................... 2 - 5Perkins 704-30 Engine Specifications....................................................................... 2 - 6Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 7

Section Three Theory of OperationPower Source ........................................................................................................... 3 - 1Hydraulic System...................................................................................................... 3 - 1Electrical System ...................................................................................................... 3 - 1Limit Switches ........................................................................................................... 3 - 2Machine Controls ...................................................................................................... 3 - 2



TABLE OF CONTENTS

vi

Section Four Scheduled Maintenance ProceduresIntroduction ............................................................................................................... 4 - 1Maintenance Inspection Report ................................................................................ 4 - 3A-1 Inspect the Operators' and Safety Manuals .................................................... 4 - 5A-2 Inspect the Decals and Placards ..................................................................... 4 - 5A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6A-4 Check the Engine Oil Level ............................................................................. 4 - 7A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8A-6 Check for Fuel Leaks ...................................................................................... 4 - 8A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10A-9 Check the Tire Pressure ............................................................................... 4 - 10A-10 Test the Extendable Axles ............................................................................ 4 - 11A-11 Test the Platform and Ground Controls ......................................................... 4 - 12A-12 Test the Auxiliary Power Operation ............................................................... 4 - 13A-13 Test the Tilt Sensor ....................................................................................... 4 - 14A-14 Test the Limit Switches ................................................................................. 4 - 14A-15 Drain the Fuel Filter/Water Separator - Diesel Models .................................. 4 - 17A-16 Inspect the Engine Air Filter .......................................................................... 4 - 19A-17 Perform 30 Day Service ................................................................................ 4 - 20A-18 Inspect the Radiator - Liquid Cooled Models ................................................. 4 - 20A-19 Check the Battery ......................................................................................... 4 - 21A-20 Replace the Engine Oil and Filter - Ford Models ........................................... 4 - 22A-21 Inspect the Electrical Wiring .......................................................................... 4 - 24A-22 Check the Oil Cooler and Cooling Fins - Deutz Models ................................ 4 - 25A-23 Check the Engine Belt - Ford and Perkins Models ........................................ 4 - 26A-24 Replace the Fuel Filters - Ford Models ......................................................... 4 - 28



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Section Four Scheduled Maintenance Procedures, continuedB-1 Check the Exhaust System ........................................................................... 4 - 30B-2 Check the Hydraulic Tank Return Filter Condition Indicator .......................... 4 - 31B-3 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 32B-4 Confirm the Proper Brake Configuration ....................................................... 4 - 33B-5 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34B-6 Check and Adjust the Engine RPM ............................................................... 4 - 36B-7 Test the Key Switch ...................................................................................... 4 - 37B-8 Test the Emergency Stop Buttons ................................................................. 4 - 38B-9 Test the Ground Control Override ................................................................. 4 - 38B-10 Test the Platform Self-leveling ...................................................................... 4 - 39B-11 Test the Horn ................................................................................................ 4 - 39B-12 Test the Foot Switch ..................................................................................... 4 - 40B-13 Test the Engine Idle Select Operation ........................................................... 4 - 40B-14 Test the Fuel Select Operation - Ford Models ............................................... 4 - 41B-15 Test the Drive Enable System ....................................................................... 4 - 42B-16 Test the Drive Brakes ................................................................................... 4 - 43B-17 Test the Drive Speed - Stowed Position ........................................................ 4 - 44B-18 Test the Drive Speed - Raised or Extended Position .................................... 4 - 45B-19 Test the Alarm Package (if equipped) ........................................................... 4 - 46B-20 Perform Hydraulic Oil Analysis ...................................................................... 4 - 47B-21 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 47B-22 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 48B-23 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 49B-24 Replace the Engine Air Filter Element ........................................................... 4 - 50B-25 Replace the Spark Plugs - Ford Models ........................................................ 4 - 51



Section Four Scheduled Maintenance Procedures, continuedC-1 Check the Engine Belt - Deutz Models .......................................................... 4 - 52C-2 Check the Engine Valve Clearances - Deutz Models .................................... 4 - 53C-3 Replace the Fuel Filter/Water Separator Element - Perkins Models .............. 4 - 53C-4 Replace the Fuel Filter Element - Perkins Models ......................................... 4 - 55C-5 Replace the Engine Oil and Filter - Perkins Models ...................................... 4 - 56C-6 Check the Starting Aid - Perkins Models ....................................................... 4 - 57C-7 Check the Specific Gravity of Engine Coolant - Liquid Cooled Models .......... 4 - 58C-8 Replace the PCV Valve - Ford Models .......................................................... 4 - 59D-1 Check the Boom Wear Pads ......................................................................... 4 - 60D-2 Check the Extendable Axle Wear Pads ........................................................ 4 - 60D-3 Check the Free-wheel Configuration ............................................................. 4 - 61D-4 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62D-5 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 63D-6 Replace the Drive Hub Oil ............................................................................. 4 - 64D-7 Replace the Engine Oil and Filter - Deutz Models ......................................... 4 - 65D-8 Clean the Fuel Pump Strainer - Deutz Models .............................................. 4 - 67D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz & Perkins Models ... 4 - 68D-10 Replace the Fuel Hoses - Deutz Models ....................................................... 4 - 69D-11 Check the Engine Valve Clearances - Perkins Models ................................. 4 - 70D-12 Clean the Engine Breather Assembly - Perkins Models ................................ 4 - 70E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 71E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 73E-3 Change the Fuel Hoses - Ford Models ......................................................... 4 - 74E-4 Replace the Engine Air Breather - Perkins Models ....................................... 4 - 76E-5 Grease the Steer Axle Wheel Bearings - 2WD Models ................................. 4 - 76E-6 Check the Fuel Injectors - Perkins Models .................................................... 4 - 78

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Section Five Troubleshooting Flow ChartsIntroduction ............................................................................................................... 5 - 1Fault Code Chart ...................................................................................................... 5 - 31 Engine Will Not Crank Over ............................................................................ 5 - 82 Engine Cranks Over But Will Not Start - Ford Models ................................... 5 - 102A Engine Runs While Cranking Then Dies - Ford Models ................................ 5 - 123 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 134 Engine Will Not Start On LPG, But Will Start On Gasoline -

Ford Models .................................................................................................. 5 - 165 Engine Will Not Start On Gasoline, But Will Start On LPG -

Ford Models .................................................................................................. 5 - 186 Engine High Idle Inoperative - Ford Models .................................................. 5 - 197 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 208 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 219 Engine Low Idle Inoperative - Diesel Models................................................. 5 - 2310 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 2411 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 2512 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 2613 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 2714 Boom Up Function Inoperative ...................................................................... 5 - 2815 Boom Down Function Inoperative ................................................................. 5 - 3116 Boom Extend Function Inoperative ............................................................... 5 - 3417 Boom Retract Function Inoperative ............................................................... 5 - 3718 Turntable Rotate Left Function Inoperative ................................................... 5 - 3919 Turntable Rotate Right Function Inoperative ................................................. 5 - 43

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x

Section Five Troubleshooting Flow Charts, continued20 All Platform Leveling Functions Inoperative .................................................. 5 - 4721 Platform Level Up Function Inoperative ........................................................ 5 - 4822 Platform Level Down Function Inoperative .................................................... 5 - 5023 Platform Rotate Left Function Inoperative ..................................................... 5 - 5224 Platform Rotate Right Function Inoperative ................................................... 5 - 5425 Jib Boom Up Inoperative, S-85 Models ......................................................... 5 - 5626 Jib Boom Down Inoperative, S-85 Models .................................................... 5 - 5827 Drive Chassis Jack Function Inoperative ...................................................... 5 - 6028 Axle Extend/Retract Inoperative .................................................................... 5 - 6229 Steer Left Function Inoperative ..................................................................... 5 - 6330 Steer Right Function Inoperative ................................................................... 5 - 6531 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 6732 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 7033 Traction Function Inoperative ........................................................................ 5 - 7134 Machine Will Not Drive At Full Speed............................................................ 5 - 7235 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 7336 Drive Enable System Is Malfunctioning ......................................................... 5 - 7437 Auxiliary Functions Inoperative ..................................................................... 5 - 75



Section Six SchematicsIntroduction ............................................................................................................... 6 - 1Electrical Components .............................................................................................. 6 - 2Electrical Symbols Legend ....................................................................................... 6 - 4Abbreviation Legend ................................................................................................. 6 - 5Engine Wire Harness - Ford Models ......................................................................... 6 - 7Electrical Schematic - Ford Models .......................................................................... 6 - 8Ground Control Box Wiring Diagram - Ford Models ................................................ 6 - 10Platform Control Box Wiring Diagram - Ford Models .............................................. 6 - 11Electrical Schematic - Deutz Models ...................................................................... 6 - 12Ground Control Box Wiring Diagram - Deutz Models .............................................. 6 - 14Platform Control Box Wiring Diagram - Deutz Models ............................................ 6 - 15Electrical Schematic - Perkins Models .................................................................... 6 - 16Ground Control Box Wiring Diagram - Perkins Models ........................................... 6 - 18Platform Control Box Wiring Diagram - Perkins Models .......................................... 6 - 19Hydraulic Symbols Legend ..................................................................................... 6 - 21Hydraulic Schematic 2WD ...................................................................................... 6 - 22Hydraulic Schematic 4WD ...................................................................................... 6 - 23

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Section Seven Repair ProceduresIntroduction ............................................................................................................... 7 - 1Platform Controls1-1 Joystick Controllers ......................................................................................... 7 - 21-2 Horsepower Limiter Board .............................................................................. 7 - 91-3 Foot Switch ................................................................................................... 7 - 111-4 Toggle Switches ............................................................................................ 7 - 12Platform Components2-1 Platform ........................................................................................................ 7 - 132-2 Platform Leveling Slave Cylinder .................................................................. 7 - 132-3 Platform Rotator ............................................................................................ 7 - 15Jib Boom Components, S-85 Models3-1 Jib Boom ....................................................................................................... 7 - 183-2 Jib Boom Lift Cylinder ................................................................................... 7 - 19Boom Components4-1 Boom Cable Track ........................................................................................ 7 - 214-2 Boom ............................................................................................................ 7 - 24

4-3 Boom Lift Cylinder ......................................................................................... 7 - 274-4 Extension Cylinders ...................................................................................... 7 - 284-5 Platform Leveling Master Cylinder ................................................................ 7 - 30Turntable Covers5-1 Turntable Covers .......................................................................................... 7 - 31

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TABLE OF CONTENTS

xiii

Section Seven Repair Procedures, continuedDeutz F4L1011F Engine6-1 RPM Adjustment ........................................................................................... 7 - 326-2 Flex Plate ...................................................................................................... 7 - 326-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 33Perkins 704-30 Engine7-1 RPM Adjustment ........................................................................................... 7 - 347-2 Flex Plate ...................................................................................................... 7 - 347-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 35Ford LRG 425 EFI Engine8-1 RPM Adjustment ........................................................................................... 7 - 368-2 Flex Plate ...................................................................................................... 7 - 368-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 37Ground Controls9-1 Control Relays .............................................................................................. 7 - 399-2 Power Relay ................................................................................................. 7 - 409-3 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 129-3 Wago Components ...................................................................................... 7 - 419-5 Engine Fault Codes - Ford Models ................................................................ 7 - 41Hydraulic Pumps10-1 Lift/Steer Pump ............................................................................................. 7 - 4310-2 Drive Pump ................................................................................................... 7 - 44



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Section Seven Repair Procedures, continuedManifolds11-1 Function Manifold Components ..................................................................... 7 - 4611-2 Valve Adjustments - Function Manifold ......................................................... 7 - 5011-3 Turntable Rotation Manifold Components ..................................................... 7 - 5211-4 Chassis Jack Manifold Components ............................................................. 7 - 5311-5 Axle Extend Dump Manifold Components ..................................................... 7 - 5411-6 Steer Manifold Components .......................................................................... 7 - 5511-7 2WD Drive Manifold Components ................................................................. 7 - 5611-8 Valve Adjustments - 2WD Drive Manifold ...................................................... 7 - 5711-9 4WD Drive Manifold Components ................................................................. 7 - 5811-10 Valve Adjustments - 4WD Drive Manifold ...................................................... 7 - 6011-11 Jib Boom/Platform Rotate Manifold Components - S-85 Models .................. 7 - 6111-12 Brake/Two Speed Manifold Components ...................................................... 7 - 62

. Fuel and Hydraulic Tanks12-1 Fuel Tank ...................................................................................................... 7 - 6312-2 Hydraulic Tank .............................................................................................. 7 - 64Turntable Rotation Components13-1 Rotation Hydraulic Motor ............................................................................... 7 - 67



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xv

Section Seven Repair Procedures, continued2WD Steering Axle Components14-1 Yoke and Hub ............................................................................................... 7 - 7014-2 Steering Cylinders ......................................................................................... 7 - 7214-3 Tie Rod Cylinder ........................................................................................... 7 - 734WD Steering Axle Components15-1 Yoke and Hub ............................................................................................... 7 - 7415-2 Steering Cylinders, See 14-2, Steering Cylinders ......................................... 7 - 7515-3 Tie Rod Cylinder, See 14-3, Tie Rod Cylinder ............................................... 7 - 75Extendable Axle Components16-1 Extendable Axles .......................................................................................... 7 - 7616-2 Drive Chassis Lift Jacks ................................................................................ 7 - 8016-3 Hydraulic Limit Switches ............................................................................... 7 - 80Non-steering Axle Components17-1 Drive Motor REV B........................................................................................ 7 - 8217-2 Drive Hub REV B........................................................................................... 7 - 8317-3 Wheel Brake ................................................................................................. 7 - 84



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Part No. 72062 Genie S-80 & Genie S-85 2 - 1

Section 2 SpecificationsThird Edition First Printing

Specifications

Machine SpecificationsStowed dimensions S-80 S-85

Length 36 ft 8 in 40 ft 7 in11.2 m 12.4 m

Width, axles retracted 7 ft 111/2 in 7 ft 111/2 in2.4 m 2.4 m

Width, axles extended 10 ft 10 ft3 m 3 m

Height 9 ft 2 in 9 ft 2 in2.8 m 2.8 m

Weight 33,380 lbs 35,860 lbs15,141 kg 16,266 kg

Ground clearance 11 in 11 in27.9 cm 27.9 cm

Operational dimensions

Maximum platform height 80 ft 85 ft24.4 m 25.9 m

Maximum horizontal reach 71 ft 11 in 76 ft 11 in21.9 m 23.4 m

Maximum turntable tailswing 3 ft 81/2 in 3 ft 81/2 in113 cm 113 cm

Wheelbase 9 ft 9 ft2.7 m 2.7 m

Turning radius, inside 10 ft 71/2 in 10 ft 71/2 in(axles extended) 3.23 m 3.23 mTurning radius, outside 23 ft 1 in 23 ft 1 in(axles extended) 7.03 m 7.03 mTurntable rotation continuous continuous

Platform rotation 160 160

Maximum capacity 600 lbs 500 lbs6 foot platform 272 kg 227 kg

Maximum capacity 500 lbs 500 lbs8 foot platform 227 kg 227 kg

Maximum allowable 150 lbs 150 lbsside force (ANSI and CSA) 68 kg 68 kg

Platform dimensions 6 ft 8 ft(Standard) (Optional)

Length 72 in 96 in182.8 cm 243.8 cm

Width 30 in 36 in76.2 cm 91.4 cm

Tires and wheels

Tire size 15-22.5 SAT

Tire ply rating 16Tire contact area 71 sq in

458 sq cm

Overall tire diameter 113 in729 cm

Tire pressure 100 psi6.89 bar

Wheel diameter 221/2 in57 cm

Wheel width 113/4 in29.8 cm

Wheel lugs 10 @ 3/4 -16Lug nut torque, dry bolts 420 ft-lbs

569.4 Nm

Lug nut torque, lubricated bolts 320 ft-lbs433.9 Nm

Fluid capacities

Fuel tank 33 gallons124.9 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 litersDrive hubs 50 fl oz

1.63 liters

Turntable rotation 44 fl ozdrive hub 1.3 liters

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

2 - 2 Genie S-80 & Genie S-85 Part No. 72062

Section 2 Specifications Third Edition First Printing

SPECIFICATIONS

Boom function speeds, maximumfrom platform controls

Jib boom up, (S-85 models) 60 to 70 seconds

Jib boom down, (S-85 models) 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, 360boom fully retracted 80 to 120 seconds

Turntable rotate, 360boom extended 210 to 240 seconds

Platform rotate, 160 8 to 12 seconds

Platform level up 50 to 60 seconds

Platform level down 40 to 50 seconds

Performance SpecificationsDrive speeds, maximum 2WD 4WD

Drive speed, stowed 3.8 mph 3.1 mphGasoline/LPG models 6.1 km/h 4.9 km/h

40 ft/7.2 sec 40 ft/8.8 sec12.2 m/7.2 sec 12.2 m/8.8 sec

Drive speed, stowed 3.3 mph 3 mphDiesel models 5.3 km/h 4.8 km/h

40 ft/8.3 sec 40 ft/9.1 sec12.2 m/8.3 sec 12.2 m/9.1 sec

Drive speed, 0.6 mph 0.6 mphraised or extended - 1.0 km/h 1.0 km/hall models 40 ft/40 sec 40 ft/40 sec

12.2 m/40 sec 12.2 m/40 sec

Gradeability (boom stowed) 2WD 4WDRough terrain 30% 38%



SPECIFICATIONS

Hydraulic SpecificationsHydraulic fluid Dexron equivalent

Drive pump

Type: bi-directional variable displacement piston pump

Displacement @ 2500 rpm 0 to 30.3 gallons per minute0 to 114.7 liters per minute

Maximum drive pressure 3500 psi241.3 bar

Charge pressureNeutral position 290 psi 20 barDrive position 250 psi 17 bar

Medium pressure filter 3 micron

Medium pressure filter 50 psibypass pressure 3.4 bar

Drive manifold

Brake 250 psirelief pressure 17.2 bar

Steer end drive motors 4WD models

Displacement 1.52 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.16 to 2.8 cu in4WD (2 speed motor) 2.62 to 45.9 ccDisplacement per revolution, variable 1.12 to 2.8 cu in2WD 18.4 to 45.9 cc

Function pump

Type: pressure balanced gear

Displacement - static 1.4 cu in19 cc

Displacement 2500 rpm 0 to 14 gpm0 to 53 l/min

Hydraulic tank circuit 10 micron with 25 psireturn line filter (1.7 bar) bypassFunction manifold

Function relief 2900 psivalve pressure 200 bar

Boom down 2300 psirelief valve pressure 158.6 bar

Boom extend 2500 psi172 bar

Steer/axle extend 5 gallons per minuteflow regulator 18.9 liters per minute

Steer regulator 3.5 gallons per minute13.2 liters per minute

Auxiliary pump

Type: fixed displacement gear pump

Displacement - static 0.152 cu in2.5 cc

Displacement 1.4 gallons per minute5.3 liters per minute

Auxiliary pump 2500 psirelief pressure 172 bar



SPECIFICATIONS

Ford Engine LRG-425 EFIDisplacement 153 cu in

2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 inches96.01 x 86.36 mm

Horsepower 70 @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm

High idle 2500 rpm

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 inchescollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 barOil capacity 5 quarts(including filter) 4.7 litersOil viscosity requirements

below 60F / 15.5C 5W-30

-10F to 90F / -23C to 32C 5W-30

above -10F / -23C 5W-50

above 25F / -4C 10W-30

Use oils meeting API classification SH or SG grade.Units ship with 10W-40 CC/SG.

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, minimum 60-80A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)Brush length, new 0.66 in

16.8 mm

Brush length wear limit 0.25 in6.35 mm

Maximum commutator 0.005 inchesrun-out 0.127 mm

Battery

Type 12V, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Electronic Fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 l/min

Ignition System

Spark plug type Motorcraft AWSF-52-C

Spark plug gap 0.042 to 0.046 inches1.07 to 1.18 mm

Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator

Output 95A, 14.5VDC



SPECIFICATIONS

Injection systemInjection pump make OMAPInjection pump pressure 4351 psi

300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement diesel number 2-D

Alternator output 55A, 14 VDC

Starter motor

Current draw, no load 90A

Brush length, new 0.748 in19 mm

Brush length, minimum 0.5 in12.7 mm

Battery

Type 12 VDC, Group 31

Quantity 1



Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz Engine F4L 1011FDisplacement 166.7 cu in

2.732 liters


Bore and stroke 3.58 x 4.13 inches91 x 105 mm




Compression pressure 362 to 435 psi25 to 30 bar

Low idle 1500 rpm

High idle 2300 rpm

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6 bar

Oil capacity 11 quarts(including filter) 10.5 litersOil viscosity requirements

60F / 15.5C (synthetic) 5W-30-10F to 90F / -23C to 32C 10W-40

above -4F / -20C 15W-40

Engine oil should have properties of API classificationCC/SE or CC/SF grades.Units ship with 10W-40 CC/SG.



SPECIFICATIONS

Perkins Engine 704-30Displacement 183 cu in

2.9 liters


Bore and stroke 3.82 x 3.94 inches97 x 100 mm




Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi) of lowest cylinder must bewithin 50 psi (3.45 bar) of highest cylinderLow idle 1600 rpm

High idle 2200 rpm

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.014 in0.35 mm

Exhaust 0.014 in0.35 mm

Lubrication system

Oil pressure 41 psi(at 2600 rpm) 2.8 barOil capacity 7.3 quarts(including filter) 8.3 litersOil viscosity requirements

below 60F / 15.5C 15W-40

-10F to 90F / -23C to 32C 10W-30

above -4F / -20C 15W-40

Engine oil should have properties of API classificationCF4. Units ship with 10-40 CC/SG.

Injection systemInjection pump make Zexel PFR-KXInjection pump pressure 2755 psi 190 barInjector opening pressure 3626 psi 250 barFuel requirement diesel number 2-D

Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator output 65A, 12V DC

Battery

Type 12VDC, Group 31

Quantity 1



Fan belt deflection 3/8 in10 mm



Hydraulic Hose and Fitting Torque SpecificationsSAE O-ring Boss Port - tube fitting Seal-Lok - hose end

SAE Dash Size

Installing into... ft. lbs. Nm

SAE Dash Size ft. lbs. Nm

-4 Aluminum 11 14.9 -4 18 24.4Steel 16 21.7 -6 27 36.6

-6 Aluminum 23 31.2 -8 40 54.2Steel 35 47.5 -10 63 85.4

-8 Aluminum 40 54.2 -12 90 122Steel 60 81.3 -16 120 162.7

-10 Aluminum 69 93.6 -20 140 190Steel 105 142.4 -24 165 223.7

-12 Aluminum 93 126.1Steel 140 190

-16 Aluminum 139 188.5Steel 210 284.7

-20 Aluminum 172 233.2Steel 260 352.5

-24 Aluminum 208 282Steel 315 427.1

SPECIFICATIONS

Hydraulic Hose and Fitting Torque SpecificationsYour machine is equipped with Parker Seal-Lok O-ring face seal fittings and hose ends. Machines thatutilize Parker Seal-Lok O-ring face seal hoses and fittings require that the fittings and hose ends betorqued to specification when they are removed and installed or when new hoses or fittings are installed.

Torque Procedure1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok fittings and hose endsare a custom-size O-ring. Theyare not a standard SAE sizeO-ring. They are available in theO-ring field service kit(Genie part no. 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the tableabove.

6 Operate all machine functions and inspect thehoses and fittings and related components tobe sure that there are no leaks.



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Section 3 Theory of OperationThird Edition First Printing

Theory Of Operation

Power SourceThe Genie S-80 and Genie S-85 are powered byeither a Gasoline/LPG engine or one of two dieselengines. The Gasoline/LPG option uses a FordLRG-425 EFI rated at 70 horsepower @ 2500rpm. The diesel options include a DeutzF4L1011F rated at 56 horsepower @ 3000 rpm,and a Perkins 704-30 rated at 63 horsepower@ 2600 rpm.

Hydraulic SystemAll machine functions are performed by thehydraulic system. The hydraulic system is dividedinto two groups: Boom/Steer functions and Drivefunctions.

Boom/Steer functions are powered by a single-section gear pump, rated at 14 gpm (53 L/min).When the engine is running, this pump supplieshydraulic fluid under pressure to the functionmanifold, where the directional and flow controlvalves are located. To protect from over-pressurization of the Boom/Steer system, the pumpis provided with a pressure relief valve, set at 2900psi (200 bar).Drive functions are powered by a bi-directional,variable output piston pump rated at 0 to 30.3 gpm(0 to 114.7 L/min) @ 2500 rpm. Two internal 3500psi (241 bar) relief valves are used to preventover-pressurization of the closed loop drive system.

The boom lift cylinder, boom extend cylinder,platform leveling slave cylinder, platform rotatorand jib boom cylinder (S-85 models) incorporatecounterbalance valves to prevent movement in theevent of a hydraulic line failure.

Electrical SystemBoom/Steer functions are accomplished bymoving a toggle switch or a controller, whichsends voltage to the appropriate directionalcontrol valve. These directional valves determinewhich direction the hydraulic fluid will travel. Thevolume of hydraulic fluid is determined by eithera proportional valve or flow regulator valve.A proportional valve receives a variable voltagesignal and delivers more hydraulic fluid as thevoltage increases. A flow regulator valve is amechanical valve and delivers a predeterminedamount of hydraulic fluid.

Drive forward or reverse is accomplished bypressing down the foot switch in the platform andmoving the drive controller (joystick) in theappropriate direction. When activated, the drivecontroller completes a circuit to the ElectronicDisplacement Controller (EDC). The EDCregulates drive pump displacement in directrelation to the drive controller position. Ahorsepower limiter printed circuit board(located in the platform control box) is provided tomaintain engine RPM as drive system loadsbecome greater. This is done by sensing engineRPM (via an AC tap on the alternator) and limitingthe amount of current supplied to the drivecontroller/EDC, which de-strokes the pump,reducing pump output.


Section 3 Theory of Operation Third Edition First Printing

THEORY OF OPERATION

Limit switchesThere are two types of limit switches which arefound in various locations on the machine: drivespeed limit switches and a drive enable limitswitch. The function of a drive speed limit switchis to limit the raised or extended drive speed to 0.6miles per hour (1 km/h) when the primary boom israised more than 2 feet (0.6 m) OR when theprimary boom is extended more than 36 inches(0.9 m). The function of the drive enable limitswitch is to limit the ability of the machine to drivewhen the boom is rotated beyond the non-steerwheels.

Machine ControlsThe Genie S-80 and Genie S-85 machines areequipped with operational controls which are foundin two locations: the ground controls, located onthe tank side of the machine, and the platformcontrols, located in the platform. All lift and drivefunctions are available at the platform controls.Only boom functions are available at the groundcontrols.

Ground controls are activated by holding thefunction enable toggle switch to either side, thenmoving a boom function toggle switch in thedirection indicated on the control panel decal.This will determine which boom function willoperate and its direction of travel.

Platform controls use toggle switches and boomfunction controllers (joysticks) to operate the boomfunctions. The drive controller (joystick) regulatesthe drive pump displacement through the EDC indirect relation to the drive controller position. Athumb rocker switch on the top of the drivecontroller is used for steering.

Washing electronic components isnot suggested. Instead, usecompressed air to remove debris.


Third Edition First Printing Section 4 Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, annually and every 2years as specified on the MaintenanceInspection Report.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration: Machine parked on a flat, level surface Boom in the stowed position Turntable rotated with the boom between

the non-steering wheels Turntable secured with the turntable

rotation lock pin Key switch in the OFF position with the

key removed Wheels chocked

About This SectionThis section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend

Safety alert symbolused to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.Redused to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.Orangeused to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.Yellow with safety alert symbolused to indicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.Yellow without safety alertsymbolused to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.Greenused to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming a series of steps.


Third Edition First PrintingSection 4 Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a scheduledaily, quarterly, six months, annual, and two year.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsectionsA, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six month or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES



Checklist A Y N RA-1 ManualsA-2 Decals and placardsA-3 Damage and loose ormissing partsA-4 Engine oil levelA-5 Engine coolant-Liquid cooled modelsA-6 Fuel leaksA-7 Hydraulic oil levelA-8 Hydraulic leaksA-9 Tire pressureA-10 Extendable axlesA-11 Platform andground controlsA-12 Auxiliary powerA-13 Tilt sensorA-14 Limit switchesA-15 Drain filter/separatorDiesel modelsA-16 Air filterA-17 30 Day ServicePerform every 100 hours:A-18 Radiator-Liquid cooled modelsA-19 BatteryA-20 Replace engine oil andfilter-Ford modelsA-21 Electrical wiringPerform every 125 hours:A-22 Oil cooler and fins-Deutz modelsPerform every 200 hours:A-23 Check engine belt -Ford/Perkins modelsA-24 Fuel filter-Ford models

Instructions Make copies of this report to use for

each inspection. Select the appropriate checklist(s) for

the type of inspection to beperformed.

Daily or 8 hourInspection: AQuarterly or 250 hourInspection: A+BSix Month or 500 hourInspection: A+B+CAnnual or 1000 hourInspection: A+B+C+D2 Year or 2000 hourInspection: A+B+C+D+E

Place a check in the appropriate boxafter each inspection procedure iscompleted.

Use the step-by-step procedures insection 4 to learn how to performthese inspections.

If any inspection receives an N, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the R box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist B Y N RB-1 Exhaust systemB-2 Hydraulic tank returnfilter conditionB-3 Tires and wheelsB-4 Brake configurationB-5 Drive hub oil levelB-6 Engine RPMB-7 Key switchB-8 Emergency StopB-9 Ground control overrideB-10 Platform levelingB-11 HornB-12 Foot switchB-13 Engine idle selectB-14 Fuel select-Ford modelsB-15 Drive enable systemB-16 Drive brakesB-17 Drive speed-stowedB-18 Drive speed-raisedor extrendedB-19 Alarm packageB-20 Hydraulic oil analysisB-21 Replace hydraulictank return filterB-22 Drive loop hydraulic filterB-23 Inspect fuel tank capventing systemPerform every 400 hours:B-24 Replace engine air filterB-25 Replace spark plugs-Ford models

Maintenance Inspection Report



Checklist C Y N RC-1 Engine belt-Deutz modelsC-2 Valves-Deutz modelsC-3 Fuel filter/waterseparator-Perkins modelsC-4 Fuel filter-Perkins modelsC-5 Replace engine oil andfilter-Perkins modelsC-6 Starting aid-Perkins modelsC-7 Check the coolant-Liquid cooled modelsC-8 PCV valve-Ford models

Checklist D Y N RD-1 Boom wear padsD-2 Extendable axlesD-3 Free-wheel configurationD-4 Turntable bearing boltsD-5 Grease rotation bearingD-6 Drive hub oilD-7 Replace engine oil andfilter-Deutz modelsD-8 Fuel strainer-Deutz modelsD-9 Fuel filter/waterseparator-Diesel modelsD-10 Change fuel hoses-Deutz modelsD-11 Valves-Perkins modelsD-12 Clean engine breather-Perkins models

MAINTENANCE INSPECTION REPORT

Instructions Make copies of this report to use for

each inspection. Select the appropriate checklist(s) for

the type of inspection to beperformed.

Daily or 8 hourInspection: AQuarterly or 250 hourInspection: A+BSix Month or 500 hourInspection: A+B+CAnnual or 1000 hourInspection: A+B+C+D2 Year or 2000 hourInspection: A+B+C+D+E

Place a check in the appropriate boxafter each inspection procedure iscompleted.

Use the step-by-step procedures insection 4 to learn how to performthese inspections.

If any inspection receives an N, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the R box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Comments

Checklist E Y N RE-1 Hydraulic oilE-2 Engine coolant-Liquid cooled modelsE-3 Fuel hoses-Ford modelsE-4 Replace enginebreather-Perkins modelsE-5 Wheel bearingsPerform every 3000 hours:E-6 Fuel injectors-Perkins models



A-1Inspect the Operators andSafety ManualsMaintaining the operators and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure that the storage container ispresent and in good condition.

2 Check to make sure that the operator's,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

Table A Procedures

A-2Inspect theDecals and PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the many possiblehazards associated with using this machine. Theyalso provide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Refer to the Decals section in the Genie S-80& Genie S-85 Operator's Manual and use thedecal list and illustrations to determine that alldecals and placards are in place.

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.



TABLE A PROCEDURES

A-3Inspect for Damage and Loose orMissing Parts

Daily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including: Electrical components, wiring and electrical cables

Hydraulic hoses, power units, fittings, cylinders and manifolds

Fuel and hydraulic tanks

Drive and turntable motors and drive hubs

Boom wear pads Tires and wheels

Engine and related components Limit switches, alarms, horn and beacon

Nuts, bolts and other fasteners

Platform entry mid-rail or gate

Check entire machine for: Cracks in welds or structural components Dents or damage to machine Battery and connections

Compartment covers and latchesBe sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened.

After you complete each inspection, be sure that allcompartment covers are in place and secured.



A-4Check the Engine Oil Level

Maintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Check the oil level with theengine off.

1 Check the engine oil dipstick.Ford Models:

Result: The oil level should be within the "safe"marks on the dipstick.

Deutz Models:

Result: The oil level should be within the twomarks on the dipstick.

Perkins Models:

Result: The oil level should be within the twonotches on the dipstick.

Ford LRG-425 EFI Engine 4.5 quartsOil capacity (including filter) 4.3 liters

Oil viscosity requirements

below 60F / 15.5C 5W-30

-10 to 90F / -23 to 32C 5W-30

above -10F / -23C 5W-30

above 25F / -4C 10W-30

Use oils meeting API classification SH or SG grade.Units ship with 10-40 CC/SG.

Deutz F4L 1011F Engine 8.5 quartsOil capacity (including filter) 8 liters


below 60F / 15.5C (synthetic) 5W-30

-10F to 90F / -23C to 32C 10W-40

above -4F / -20C 15W-40

Engine oil should have properties of API classificationCC/SE or CC/SF grades. Units ship with 10-40 CC/SG.

Perkins 704-30 Engine 9.6 quartsOil capacity (including filter) 9 liters


below 60F / 15.5C 15W-40

-10F to 90F / -23C to 32C 10W-30

above -4F / -20C 15W-40

Engine oil should have properties of API classificationCF4 grade. Units ship with 10-40 CC/SG.

TABLE A PROCEDURES



TABLE A PROCEDURES

A-5Check the Engine Coolant Level-

Liquid Cooled Models

Maintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine's cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

Burn hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may cause severe burns.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be at theFULL mark.

Do not remove the radiator cap.

A-6Check for Fuel Leaks

Failure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Explosion and fire hazard. Enginefuels are combustible. Inspect themachine in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

1 Open the shutoff valve on the liquid petroleumgas (LPG) tank by turning it counterclockwise(if equipped).



A-7Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position,then visually inspect the sight gauge located onthe side of the hydraulic oil tank.

Result: The hydraulic oil level should be withinthe top 2 inches (5 cm) of the sight gauge.

2 Add oil as needed.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Tank capacity 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 liters

2 Perform a visual inspection around the followingareas.

Ford models:

LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator and throttle body.

An LPG detector may benecessary to locate LPG leaks.

Gasoline tank, manual shutoff valve, fuelpump, fuel filters, fuel rail and fuel injectors,hoses and fittings and throttle body.

Diesel models:

Fuel tank, shutoff valve, hoses and fittings,fuel pump, fuel filter, fuel injection pumps andfuel injectors (atomizers).

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

TABLE A PROCEDURES



TABLE A PROCEDURES

A-8Check for Hydraulic Leaks

Detecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas: Hydraulic tankfilter, fittings, hoses, auxiliary

power unit, filters, and turntable surface Engine compartmenthydraulic filters,

fittings, hoses, pumps, component tray All hydraulic cylinders All hydraulic manifolds Primary, and jib booms The underside of the turntable The underside of the drive chassis Ground area under the machine

A-9Check the Tire Pressure

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.Tip-over hazard. Do not usetemporary flat tire repair products.This procedure does not needto be performed on machinesequipped with the foam-filledtire option.

To safeguard maximum stability, achieveoptimum machine handling and minimize tirewear, it is essential to maintain proper pressurein all air-filled tires.

1 Check each tire with an air pressure gauge. Addair as needed.

Tire specifications

Tire size 15-19.5 NHS

Pressure 100 psi6.9 bar



TABLE A PROCEDURES

A-10Test the Extendable Axles

Tip over hazard. Do not raise orextend the boom unless both axlesare extended. If the axle extensionsystem is not operating correctly,the stability of the machine iscompromised and it may tip over.Be sure the axles are retractedbefore performing this procedure.

1 Start the engine from the ground controls.2 Hold the function enable switch to either side

and activate the boom up function.Result: The boom should raise to horizontal andthen stop. The boom should not raise above thelimit switch unless both axles are extended.

3 Hold the function enable switch to either sideand activate the boom down function.

Result: The boom should lower and return to thestowed position.

4 Hold the function enable switch to either sideand activate the boom extend function.

Result: The boom should extend no more than36 inches (0.9 m) and then stop. The boomshould not extend beyond the limit switchunless both axles are extended.

5 Hold the function enable switch to either sideand activate the boom retract function.

Result: The boom should retract.

6 At the extendable axle controls located at thenon-steer end of the drive chassis, activate thesteer axle drive chassis lift jack cylinder.Result: The cylinder should extend and the drivechassis should raise smoothly, free ofhesitation.

7 Continue holding the chassis jack in theextended position and activate the steer axleEXTEND control handle to extend the steer axle.

Result: The cylinder should extend and the steeraxle should extend smoothly, free of hesitation.

8 Return the chassis jack control handle to theneutral position.Result: The lift jack cylinder should fully retractwhen the control handle is returned to neutral.

9 Activate the non-steer axle drive chassis liftjack cylinder.Result: The cylinder should extend and the drivechassis should raise smoothly, free ofhesitation.

10 Continue holding the chassis jack in theextended position and activate the non-steeraxle EXTEND control handle to extend the steeraxle.

Result: The cylinder should extend and thenon-steer axle should extend smoothly, free ofhesitation.

11 Return the chassis jack control handle to theneutral position.Result: The lift jack cylinder should fully retractwhen the control handle is returned to neutral.



TABLE A PROCEDURES

A-11Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions and shut off the engine. Eachfunction should activate, operate smoothly and befree of hesitation, jerking and unusual noise.1 Pull out the Emergency Stop button at the

ground controls to the ON position.2 Start the engine from the ground controls.3 Do not hold the function enable switch to either

side. Attempt to activate each boom andplatform function toggle switch.Result: All boom and platform functions shouldnot operate.

4 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.Result: All boom and platform functions shouldoperate through a full cycle. Descent alarm (ifequipped) should sound while the boom islowering.

5 Push in the Emergency Stop button to the OFFposition.Result: No function should operate, the engineshould stop.

Machines equipped with PlatformLevel Control Disable Function:The platform level toggle switchwill not operate when the boom israised or extended past the drivespeed limit switches.Diesel models: All functionsshould stop immediately. Theengine will shut off after 2 to 3seconds.

6 Start the engine from the platform controls andmove the lift/drive selector switch to the liftposition (if equipped).

7 Do not press down on the foot switch.8 Attempt to operate all machine functions.

Result: All machine functions should notoperate.

9 Press down the foot switch and activate eachmachine function.

Result: All machine functions should operatethrough a full cycle.

10 Push in the Emergency Stop button to the OFFposition at the platform controls.Result: No function should operate, the engineshould stop.

As a safety feature, selectingand operating the groundcontrols will override theplatform controls, includingthe Emergency Stop switch.Diesel models:All functions should stopimmediately. The engine willshut off after 2 to 3 seconds.



A-12Test the Auxiliary PowerOperationDetection of auxiliary power system malfunctions isessential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. When operating the machine onengine power, selecting auxiliary power will stopthe engine immediately. Auxiliary power isdesigned for short term use only, and excessiveuse will result in battery drain and componentdamage.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ONposition.

2 Lift the red auxiliary powertoggle switch cover(if equipped).

3 Simultaneously hold theauxiliary power toggle switchON and activate each boomfunction toggle switch.Result: All boom functions should operate.

To conserve battery power, testeach function through a partialcycle.

4 Turn the key switch to platform control.5 Pull out the Emergency Stop button to the ON

position at the platform controls, then pressdown the foot switch.

6 Lift the red auxiliary power toggle switch cover(if equipped).

7 Simultaneouslyhold theauxiliary powertoggle switchON and activateeach functioncontroller ortoggle switch.Result: All boom and steer functions shouldoperate. Drive functions should not operate withauxiliary power.

To conserve battery power, testeach function through a partialcycle.

10 Start the engine from the platform controls.11 Press down the foot switch, then lift the red

auxiliary power toggle switch cover(if equipped).

12 Hold the auxiliary power toggle switch in the ONposition.Result: The engine should stop.

13 Start the engine from the ground controls.14 Lift the red auxiliary power toggle switch cover

(if equipped).15 Hold the auxiliary power toggle switch in the ON

position.Result: The engine should stop.

TABLE A PROCEDURES



TABLE A PROCEDURES

a b

c

A-13Test the Tilt SensorThe tilt sensor sounds an alarm located in theplatform when the incline of the turntable exceedsthe rating on the serial plate.

Select a level test area. The tiltalarm should not be sounding priorto the test.

1 Start the engine from the platform controls.2 Open the tank side turntable cover and press

down on one side of the tilt sensor.

Result: The alarm in the platform should sound.Tip-over hazard. The alarm shouldbe audible at the ground controls.If the alarm is not audible at theground controls, replace the alarmin the platform.

a fuel tankb tilt sensorc ground control box

cba

A-14Test the Limit Switches

Drive Limit Switches

Detecting limit switch malfunctions is essential tosafe machine operation. The drive limit switchesare used to restrict drive speed when the boom israised or extended. An improperly functioning drivelimit switch will allow the machine to operate in anunsafe position.

1 Remove the cover from the rear of the turntableto access the drive limit switch.

2 Visually inspect the boom up drive limit switch(LS2) mounted to the turntable riser at the pivotend of the boom. Inspect for the following: Broken or missing roller or arm Loose or missing fasteners Loose wiring

a turntable riserb boomc boom up drive limit switch (LS2)



3 Manually activate the boom up drive limitswitch.

Result: The boom up drive limit switch armshould move freely and spring return to center.A distinct click should be felt and heard.

4 Visually inspect the boom extend drive limitswitch located at the end of the cable track onthe boom. Inspect for the following: Broken or missing roller or arm Missing fasteners Loose wiring

a boom extend drive limit switch (LS1)b cable track

5 Start the engine from the ground controls.6 Extend the boom approximately 3 feet (0.9 m).7 Manually activate the boom extend drive limit

switch (LS1).Result: The boom extend drive limit switch armshould move freely and spring return to center.A distinct click should be felt and heard.

8 Turn the key switch to platform controls andfully retract the boom.

9 Move the lift/drive selector switch to the driveposition (if equipped).

10 Press down the foot switch and slowly move thedrive controller off center.

Result: The machine should move at normaldrive speeds.

11 Move the lift/drive selector switch to the liftposition (if equipped).

12 Raise the boom to just above horizontal.13 Move the lift/drive selector switch to the drive

position (if equipped).14 Slowly move the drive controller off center.

Result: The machine should move at a reduceddrive speed.

15 Move the lift/drive selector switch to the liftposition (if equipped).

16 Lower the boom to the stowed position, thenextend the boom 3 feet (0.9 m).

17 Move the lift/drive selector switch to the driveposition (if equipped).

18 Slowly move the drive controller off center.Result: The machine should move at a reduceddrive speed.

Drive speed, maximum,raised or extended position

All models 1 foot per second (0.6 mph) 0.3 meters per second (0.97 km/h)

ba

TABLE A PROCEDURES



TABLE A PROCEDURES

Drive Enable Limit Switch

A properly functioning drive enable limit switch isessential for safe machine operation andworkplace safety. The drive enable limit switchstops the drive function when the boom is rotatedpast a non-steer wheel and alerts the operator thatthe machine may drive in the opposite directionthat the drive and steer controller is moved.

1 Start the engine from the platform controls androtate the turntable to the left until the boom ispast the left non-steer wheel. Turn the engineoff.

2 Visually inspect the drive enable limit switch forthe following: Broken or missing roller or arm Missing fasteners Loose wiring

a turntableb drive enable limit switch (LS3)c turntable rotation bearing

3 Manually activate the drive enable limit switch.

Result: The drive enable limit switch arm shouldmove freely and spring return to center. Adistinct click should be felt and heard.

4 Start the engine from the platform controls, andpress down the foot switch.

Result: The drive enable indicator light shouldbe on.

5 Rotate the turntable so the boom is between thenon-steer wheels.

Result: The drive enable indicator light shouldbe off and drive function should operate.

6 Rotate the turntable to the left until the boom ispast the left non-steer wheel.

Result: The drive enable indicator light shouldbe on. Drive function should not operate untilthe drive enable override toggle switch isactivated.

7 Rotate the turntable to the right until the boom ispast the right non-steer wheel.

Result: The drive enable indicator light shouldbe on. Drive function should not operate untilthe drive enable override toggle switch isactivated.

a

bc



A-15Drain the Fuel Filter/ WaterSeparator - Diesel Models

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Perform this procedure with theengine off.

Perkins Models:

1 Open the engine side turntable cover and locatethe fuel filter/water separator.

TABLE A PROCEDURES

2 Loosen the vent plug located on the fuel filter/water separator head.

Fuel filter/water separatora head boltb vent plugc drain plugd filter bowle separator head

3 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

4 Tighten the vent plug.If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/waterseparator before starting theengine. Refer to C-4 in thissection, Replace The Fuel FilterElement - Perkins Models, forinstructions on how to prime thefuel filter/water separator.

d

c

e

b

a



TABLE A PROCEDURES

5 Clean up any fuel that may have spilled.6 Start the engine from the ground controls and

check the fuel filter/water separator and ventplug for leaks.


Deutz Models:

1 Open the engine side cover and locate the fuelfilter/water separator.

2 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

a fuel filterb drain plug

3 Clean up any fuel that may have spilled.If the fuel filter is completelydrained, you must prime the fuelfilter/water separator beforestarting the engine. Refer to D-9in this section, Replace The FuelFilter/Water Separator - DeutzDiesel Models, for instructions onhow to prime the fuel filter/waterseparator.

4 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.


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A-16Inspect the Engine Air Filter

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.

Perform this procedure with theengine off.

Ford and Deutz Models:

1 Open the engine side cover and remove theretaining ring from the end cap of the air filtercanister.

2 Remove the end cap from the air cleanercanister.

3 Remove the air filter retaining fastener. Removethe filter element.

4 Clean the inside of the canister and the gasketwith a damp cloth.

5 Inspect the filter element. If needed, blow outfrom inside out using low pressure drycompressed air, or tap dust out taking care notto damage the element.

6 Install the air filter element and install themounting fastener.

7 Install the end cap onto the canister. Install andtighten the retaining ring.

Perkins models:

1 Open the engine side cover and disconnect theretaining fasteners from the end cap of the airfilter canister. Remove the end cap.

2 Remove the filter element.

3 Empty dust discharge valve by pressingtogether the sides of the discharge slot. Cleandischarge slot as needed.

Perkins diesel modelsa air filterb dust discharge valve

4 Clean the inside of the canister and the canisterend cap with a damp cloth.

5 Inspect the filter element. If needed, blow outfrom inside out using low pressure drycompressed air, or tap out dust taking care notto damage the element.

6 Install the filter element

7 Install the end cap onto the canister. Secure theretaining fasteners.

Air filters - Genie part numbersFord LRG-425 EFI Engine 27916Deutz F4L 1011F Engine 27916Perkins 704-30 Engine 62420

TABLE A PROCEDURES

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A-17Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures: A-20 Replace the Engine Oil and Filter -

Ford Models (if applicable) OR C-5 Replace the Engine Oil and Filter -

Perkins Models (if applicable) OR D-9 Replace the Engine Oil Filter -

Deutz Models (if applicable) B-3 Inspect the Tires and Wheels

(including lug nut torque) B-21 Replace the Hydraulic Tank Return

Filter D-4 Check the Turnable Rotation Bearing

Bolts

TABLE A PROCEDURES

A-18Inspect the Radiator -Liquid Cooled Models

Engine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditionsexist.

Maintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.Bodily injury hazard. Beware ofhot engine parts and coolant.Contact with hot engine partsand/or coolant may cause severeburns.



TABLE A PROCEDURES

1 Remove the 2 engine pivot plate retaining bolts.Swing the engine pivot plate away from themachine to access the radiator.

a engine pivot plateb pivot plate retaining boltsc air baffle

2 Inspect the radiator for leaks and physicaldamage.

3 Clean the radiator fins of debris and foreignmaterials.

4 Inspect all radiator hoses and connections.5 Swing the engine pivot plate back to its original

position and install the two engine pivot plateretaining bolts.

A-19Check the Battery

Genie specifications require thatthis procedure be performed every100 hours.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.2 Be sure that the battery cable connections are

free of corrosion.

3 Be sure that the battery hold downs and cableconnections are tight.

a b cb



4 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer.

Result: If any battery cell displays a specificgravity of less than 1.026, the battery must bereplaced.

5 Check the battery acid level of each cell. Ifneeded, replenish with distilled water to thebottom of each battery fill tube. Do not overfill.

6 Install the battery vent caps.Applying a corrosion preventativesealant will help eliminatecorrosion on the battery terminalsand cables.

A-20Replace the Engine Oil andFilter - Ford Models

Ford engine specifications requirethat this procedure be performedevery 100 hours. Perform thisprocedure more often if dustyconditions exist or the machine issubjected to extended low idleoperation.

Periodic replacement of the engine oil and filteris essential to good engine performance. Operatingthe machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily check ofmachine hours against the hours noted on the oilfilter will allow the inspector to anticipate andperform oil and filter changes at the 100 hourinterval.

Bodily injury hazard. Beware of hotengine parts and oil. Contact withhot engine oil and/or engine partsmay cause severe burns.Perform this procedure afterwarming the engine to normaloperating temperature.

1 Open the engine side turntable cover andremove the oil filler cap located on the valvecover.

TABLE A PROCEDURES



2 Pull the oil drain hose out from underneath theengine.

3 Open the engine oil drain valve on the engine oilpan and allow all of the oil from the engine todrain into a suitable container. Seespecifications.

a engine pivot plateb pivot plate retaining boltsc oil drain hosed air baffle

4 Close the engine oil drain valve.5 Remove the 2 engine pivot plate retaining bolts.

Pull the engine pivot plate away from themachine to access the oil filter.

6 Place a container under the oil filter.

7 Use an oil filter wrench and remove the filter.

8 Apply a thin layer of fresh oil on the gasket ofthe new oil filter. Install the filter and tighten itsecurely by hand.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

10 Fill the engine with new oil per specificationsand install the filler cap. See capacityspecifications.

11 Start the engine from the ground controls.Allow the engine to run for 30 seconds, thenturn the engine off.

12 Check the oil filter, oil pan drain hose and drainvalve for leaks.

13 Swing the engine pivot plate back to its originalposition and install the two engine pivot plateretaining bolts.

14 Check the engine oil level dipstick. Add oilif needed.

15 Clean up any oil that may have spilled. Properlydispose of the oil and filter.

Ford LRG-425 EFI Engine 4.5 quartsOil capacity (including filter) 4.3 liters


below 60F / 15.5C 5W-30

-10 to 90F / -23 to 32C 5W-30

above -10F / -23C 5W-30

above 25F / -4C 10W-30

Use oils meeting API classification SH or SG grade.

Oil filter - Genie part number 28656

a bcb d

TABLE A PROCEDURES



A-21Inspect the Electrical Wiring

Genie specifications require thatthis procedure be performed every100 hours.

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance.

Documents

Genie S85 Service Manual