Introduction Service Manual - First Edition

Important Genie North America

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

This service manual covers the Genie S-80 and

Genie S-85 2WD and 4WD models introduced in Genie Europe
1994.
Telephone (44) 01636-813943
This manual provides detailed scheduled Fax (44) 01636-815270
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.

Copyright © 1994 by Genie Industries
Genie Industries has endeavored to deliver the First Edition: First Printing, October 1994
highest degree of accuracy possible. However,
Genie® is a registered trademark of
continuous improvement of our products is a Genie Industries. Registered 2009987
Genie policy. Therefore product specifications are
subject to change without notice. These machines comply with
ANSI/SIA 92.5-1992.
Readers are encouraged to notify Genie of errors Printed on recycled paper
and send in suggestions for improvement. All
Patents Pending
communications will be carefully considered for
future printings of this and other manuals. Please Printed in U.S.A.
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 U.S.A.

If you have any questions, call Genie Industries.

ii Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 1 - Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 & Genie S-85
Operator's Manual will result in death or serious
injury.

Many of the hazards identified in the operator's

manual are also safety hazards when
maintenance and repair procedures are
performed.

Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Part No. 34032 Genie S-80 & Genie S-85 iii

Section 1 - Safety Rules Service Manual - First Edition

SAFETY RULES

Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.

Read each procedure thoroughly. This

manual and the decals, on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for
use. Keep work surfaces clean and free
Indicates the presence of
of debris that could get into machine components
a hazard that will cause
and cause damage.
death or serious injury.
Indicates the presence of
a hazard that may cause Be sure that your workshop or work area
death or serious injury. is properly ventilated and well lit.
Indicates the presence of
a hazard that will or may
cause serious injury or Be sure any forklift, overhead crane or
damage to the machine. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates special weight to be lifted. Use only chains or straps that
operation or maintenance are in good condition and of ample capacity.
information.

Be sure that fasteners intended for one

Be sure to wear protective eye wear and time use (i.e., cotter pins and self-locking
other protective clothing if the situation nuts) are not reused. These components
warrants it. may fail if they are used a second time.

Be aware of potential crushing hazards Be sure to properly dispose of old oil or

such as moving parts, free swinging or other fluids. Use an approved container.
unsecured components, and lifting or Please be environmentally safe.
placing loads. Always wear approved steel-toed
shoes.

iv Genie S-80 & Genie S-85 Part No. 34032

Service Manual -- First
FirstEdition
Edition(February 2009)

Table of Contents

Introduction
Important Information ...................................................................................................... ii

Section One Safety Rules

General Safety Rules ..................................................................................................... iii

Section Two Specifications

Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications (REV B) .............................................................................. 2 - 3
Bolt Torque Specifications ........................................................................................ 2 - 4
Ford LSG 423 Engine Specifications ......................................................................... 2 - 5
Deutz F4L Engine Specifications .............................................................................. 2 - 7

Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 5
Table D ..................................................................................................................... 3 - 6
Maintenance Inspection Report ................................................................................. 3 - 7

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1
A-1 Inspect the Manuals ........................................................................................ 4 - 2
A-2 Inspect the Decals and Placards ..................................................................... 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts ................................................... 4 - 2
A-4 Check the Engine Oil Level ............................................................................. 4 - 3
A-5 Check the Engine Coolant Level - Gasoline/LPG Models ................................. 4 - 3
A-6 Check for Fuel Leaks ...................................................................................... 4 - 3
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 4
A-8 Check for Hydraulic Leaks ............................................................................... 4 - 4

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- First Edition - First Edition
(February 2009)

TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

A-9 Check the Tire Pressure .................................................................................. 4 - 5
A-10 Test the Extendable Axles .............................................................................. 4 - 5
A-11 Test the Platform and Ground Controls ............................................................ 4 - 6
A-12 Test the Auxiliary Power Operation ................................................................. 4 - 6
A-13 Test the Tilt Sensor ......................................................................................... 4 - 7
A-14 Test the Limit Switches ................................................................................... 4 - 8
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................. 4 - 10
A-16 Replace the Engine Air Filter ......................................................................... 4 - 11
B-1 Check the Engine Belt(s) ............................................................................... 4 - 12
B-2 Check the Radiator - Gasoline/LPG Models ................................................... 4 - 12
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ....................... 4 - 12
B-4 Check the Exhaust System ........................................................................... 4 - 13
B-5 Check the Battery ......................................................................................... 4 - 14
B-6 Check the Hydraulic Tank Filter Condition Indicator ....................................... 4 - 14
B-7 Inspect the Electrical Wiring .......................................................................... 4 - 15
B-8 Inspect the Tires and Wheels ........................................................................ 4 - 15
B-9 Confirm the Proper Brake Configuration ......................................................... 4 - 16
B-10 Check the Drive Hub Oil Level and Fastener Torque ..................................... 4 - 16
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models ................ 4 - 17
B-12 Check and Adjust the Engine RPM ............................................................... 4 - 17
B-13 Test the Key Switch ...................................................................................... 4 - 19
B-14 Test the Emergency Stop Buttons ................................................................. 4 - 20
B-15 Test the Ground Control Override .................................................................. 4 - 20
B-16 Test the Platform Self-leveling ...................................................................... 4 - 20
B-17 Test the Service Horn .................................................................................... 4 - 21
B-18 Test the Foot Switch ..................................................................................... 4 - 21
B-19 Test the Engine Idle Select ........................................................................... 4 - 21
B-20 Test the Fuel Select Operation - Gasoline/LPG Models ................................. 4 - 22
B-21 Test the Drive Enable System ....................................................................... 4 - 23
B-22 Test the Drive Brakes .................................................................................... 4 - 23
B-23 Test the Drive Speed - Stowed Position ........................................................ 4 - 24

vi Genie S-80 & Genie S-85 Part No. 34032

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TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued

B-24 Test the Alarm Package - Optional Equipment ............................................. 4 - 24
B-25 Perform Hydraulic Oil Analysis ..................................................................... 4 - 25
B-26 Check the Hydraulic Limit Switch Linkage .................................................... 4 - 25
B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 26
C-1 Check the Boom Wear Pads ......................................................................... 4 - 27
C-2 Check the Extendable Axle Wear Pads ........................................................ 4 - 27
C-3 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 27
C-4 Check the Free-wheel Configuration ............................................................ 4 - 28
C-5 Grease the Turntable Rotation Bearing and Rotate Gear ............................. 4 - 29
C-6 Replace the Torque Hub Oil ......................................................................... 4 - 29
C-7 Replace the Hydraulic Tank Filter ................................................................. 4 - 31
C-8 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 31
C-9 Replace the Diesel Fuel Filter - Deutz Diesel Models ................................... 4 - 32
C-10 Replace the Gasoline Fuel Filter - Gasoline/LPG Models ............................. 4 - 32
C-11 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 34
C-12 Clean or Replace the Distributor Cap and Rotor - Gasoline/LPG Models ..... 4 - 34
C-13 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 35
C-14 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models .................... 4 - 36
C-15 Check and Adjust the Ignition Timing - Gasoline/LPG Models ...................... 4 - 37
C-16 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 37
C-17 Adjust the Turntable Rotation Gear Backlash ............................................... 4 - 37
D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 38
D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models ............ 4 - 39
D-3 Change the Fuel Lines .................................................................................. 4 - 41
D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ........................ 4 - 42
D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ............... 4 - 42
D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models .......................... 4 - 43
D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models .......... 4 - 44
D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 44
D-9 Replace the Timing Belt - Gasoline/LPG Models .......................................... 4 - 44

Part No. 34032 Genie S-80 & Genie S-85 vii

 Service Manual - First Edition

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1
1 Engine Will Not Crank Over ............................................................................ 5 - 3
2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5
3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12
4 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models ................................................................................. 5 - 15
5 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models ................................................................................. 5 - 17
6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19
7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 21
8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 22
9 Engine Low Idle Inoperative - Deutz Diesel Models ...................................... 5 - 24
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 25
11 All Lift and Steer Functions Inoperative, Drive Functions Operational .......... 5 - 26
12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 29
13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 30
14 Boom Up Function Inoperative ..................................................................... 5 - 31
15 Boom Down Function Inoperative ................................................................. 5 - 33
16 Boom Extend Function Inoperative ............................................................... 5 - 35
17 Boom Retract Function Inoperative .............................................................. 5 - 37
18 Turntable Rotate Function Inoperative .......................................................... 5 - 38
19 Turntable Rotate Left Function Inoperative ................................................... 5 - 40
20 Turntable Rotate Right Function Inoperative ................................................ 5 - 41
21 All Platform Leveling Functions Inoperative .................................................. 5 - 42
22 Platform Level Up Function Inoperative ........................................................ 5 - 43
23 Platform Level Down Function Inoperative ................................................... 5 - 44

viii Genie S-80 & Genie S-85 Part No. 34032

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TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts, continued

24 Platform Rotate Left Function Inoperative .................................................... 5 - 45
25 Platform Rotate Right Function Inoperative .................................................. 5 - 47
26 Jib Boom Up Inoperative - S-85 Models ....................................................... 5 - 49
27 Jib Boom Down Inoperative - S-85 Models ................................................... 5 - 51
28 Drive Chassis Jack Function Inoperative ...................................................... 5 - 53
29 Axle Extend/Retract Inoperative ................................................................... 5 - 54
30 Steer Left Function Inoperative ..................................................................... 5 - 55
31 Steer Right Function Inoperative .................................................................. 5 - 56
32 All Drive Functions Inoperative, All Other Functions Operate Normally ........ 5 - 57
33 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 60
34 Traction Function Inoperative ....................................................................... 5 - 61
35 Machine Will Not Drive At Full Speed ........................................................... 5 - 62
36 Machine Drives At Full Speed With Platform Raised or Extended ................ 5 - 63
37 Drive Enable System Is Malfunctioning ........................................................ 5 - 64
38 Auxiliary Functions Inoperative ..................................................................... 5 - 65

Section Six Schematics

Introduction ............................................................................................................... 6 - 1
Electrical Symbols Legend ....................................................................................... 6 - 2
Electrical Schematic - Gasoline/LPG Models ........................................................... 6 - 3
Ground Control Box Legend - Gasoline/LPG Models ............................................... 6 - 5
Relay Panel Legend - Gasoline/LPG Models ........................................................... 6 - 6
Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 7
Electrical Schematic - Diesel Models ....................................................................... 6 - 8
Ground Control Box Legend - Diesel Models ......................................................... 6 - 10
Platform Control Box Legend - Diesel Models ........................................................ 6 - 11
Hydraulic Symbols Legend ..................................................................................... 6 - 12
2WD Hydraulic Schematic ...................................................................................... 6 - 13
4WD Hydraulic Schematic ...................................................................................... 6 - 14

Part No. 34032 Genie S-80 & Genie S-85 ix

 Service Manual - First Edition

TABLE OF CONTENTS

Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 6
1-3 Foot Switch ..................................................................................................... 7 - 8
1-4 Resistors ......................................................................................................... 7 - 9
1-5 Toggle Switches ............................................................................................. 7 - 9
1-6 Control Relays .............................................................................................. 7 - 10
Platform Components
2-1 Platform ........................................................................................................ 7 - 11
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 11
2-3 Platform Rotator ............................................................................................ 7 - 12
Jib Boom Components - S-85 Models
3-1 Jib Boom ....................................................................................................... 7 - 14
3-2 Jib Boom Lift Cylinder ................................................................................... 7 - 15
3-3 Jib Boom / Platform Rotate Manifold Components ....................................... 7 - 16
Boom Components
4-1 Plastic Cable Track ....................................................................................... 7 - 17
4-2 Boom ............................................................................................................ 7 - 17
4-3 Boom Lift Cylinder ........................................................................................ 7 - 20
4-4 Extension Cylinders ...................................................................................... 7 - 20
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 21
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 22
Deutz Engine F4L 1011
6-1 RPM Adjustment ........................................................................................... 7 - 23
6-2 Flex Plate ...................................................................................................... 7 - 23
6-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 23
Ford LSG-423 Engine
7-1 Governor Actuator ........................................................................................ 7 - 24
7-2 Choke Adjustments ....................................................................................... 7 - 25

x Genie S-80 & Genie S-85 Part No. 34032

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FirstEdition
Edition(February 2009)

TABLE OF CONTENTS

Section Seven Repair Procedures, Ford LSG-423 Engine, continued

7-3 Timing Adjustment ........................................................................................ 7 - 26
7-4 Carburetor Adjustment ................................................................................... 7 - 26
7-5 RPM Adjustment ........................................................................................... 7 - 26
7-6 Flex Plate ...................................................................................................... 7 - 26
7-7 Water Temperature and Oil Pressure Gauges ................................................ 7 - 27
7-8 Vacuum Switch ............................................................................................. 7 - 27
Ground Controls
8-1 Control Relays ............................................................................................... 7 - 28
8-2 Toggle Switches, See 1-5, Toggle Switches .................................................... 7 - 9
8-3 Wago® Components ...................................................................................... 7 - 29
8-4 Resistor ......................................................................................................... 7 - 29
8-5 Power Relay .................................................................................................. 7 - 30
Hydraulic Pumps
9-1 Lift/Steer Pump ............................................................................................. 7 - 31
9-2 Drive Pump ................................................................................................... 7 - 31
Function Manifolds
10-1 Function Manifolds (REV B) .......................................................................... 7 - 34
10-2 Valve Adjustments - Function Manifold (REV B) ........................................... 7 - 37
Fuel and Hydraulic Tanks
11-1 Hydraulic Tank .............................................................................................. 7 - 40
11-2 Fuel Tank ...................................................................................................... 7 - 41
Turntable Rotation Components
12-1 Rotation Hydraulic Motor ............................................................................... 7 - 42
12-2 Turntable Rotation Manifold Components ...................................................... 7 - 44
2WD Steering Axle Components
13-1 Yoke and Hub ................................................................................................ 7 - 45
13-2 Steering Cylinders ......................................................................................... 7 - 46
13-3 Tie Rod Cylinder ............................................................................................ 7 - 47

Part No. 34032 Genie S-80 & Genie S-85 xi

 Service Manual - First Edition

TABLE OF CONTENTS

Section Seven Repair Procedures, continued

4WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 48
14-2 Steering Cylinders ........................................................................................ 7 - 49
14-3 Tie Rod Cylinder ........................................................................................... 7 - 49
Extendable Axle Components
15-1 Extendable Axle ............................................................................................ 7 - 50
15-2 Drive Chassis Hydraulic Jacks ...................................................................... 7 - 51
15-3 Hydraulic Limit Switches ............................................................................... 7 - 52
15-4 Chassis Jack / Axle Manifolds ...................................................................... 7 - 53
Steer Manifold
16-1 Steer Manifold Components ......................................................................... 7 - 54
Non-steering Axle Components
17-1 Drive Motor ................................................................................................... 7 - 55
17-2 Torque Hub ................................................................................................... 7 - 55
2WD Drive Manifold
18-1 2WD Drive Manifold Components ................................................................. 7 - 56
18-2 Valve Adjustments ........................................................................................ 7 - 57
4WD Drive Manifold
19-1 4WD Drive Manifold Components ................................................................. 7 - 58
19-2 Valve Adjustments ........................................................................................ 7 - 60

xii Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 2 - Specifications

Specifications

Machine Specifications Platform dimensions 6 ft 8 ft

(Standard) (Optional)
Stowed dimensions S-80 S-85
Length 6 ft 8 ft
Length 36 ft 8 in 40 ft 7 in 1.83 m 2.44 m
11.2 m 12.4 m Width 30 in 36 in
Width, axles retracted 7 ft 111/2in 7 ft 111/2in 76.2 cm 91.4 cm
2.43 m 2.43 m Tires and wheels
Width, axles extended 10 ft 10 ft Tire size 15-22.5 SAT
3.0 m 3.0 m
Tire ply rating 16
Height 9 ft 2 in 9 ft 2 in Tire contact area 113 sq in
2.79 m 2.79 m 729 sq cm
Weight 33,380 lbs 35,860 lbs Overall tire diameter 43.3 in
15,141 kg 16,266 kg 110 cm
Ground clearance 11 in 11 in Tire pressure 100 psi
28 cm 28 cm 6.89 bar

Operational dimensions Wheel diameter 22.5 in

57.1 cm
Maximum platform height 80 ft 85 ft
Wheel width 11.75 in
24.4 m 25.9 m
29.8 cm
Maximum horizontal reach 71 ft 11 in 76 ft 11 in Wheel lugs 10 @ 3/4 -16
21.9 m 23.4 m
Lug nut torque, dry bolts 420 ft-lbs
Maximum turntable tailswing 3 ft 81/2 in 3 ft 81/2 in 569.5 Nm
113.0 cm 113.0 cm
Lug nut torque, wet bolts 320 ft-lbs
Wheelbase 9 ft 0 in 9 ft 0 in 433.9 Nm
2.7 m 2.7 m
Fluid capacities
Minimum turning circle, 23 ft 1 in 23 ft 1 in Fuel tank 30 gallons
outside (axles extended) 7.0 m 7.0 m 114 liters
Minimum turning circle, 10 ft 71/2 in 10 ft 71/2 in LPG tank 33.5 pounds
inside (axles extended) 3.2 m 3.2 m 15.2 kg
Turntable rotation continuous continuous Hydraulic tank 45 gallons
170 liters
Platform rotation 160° 160°
Hydraulic system 55 gallons
Maximum capacity 600 lbs 500 lbs (including tank) 208 liters
6 foot platform 272 kg 227 kg
Drive torque hub 50 fl oz
Maximum capacity 500 lbs 500 lbs 1.47 liters
8 foot platform 227 kg 227 kg Steer torque hub (4WD) 44 fl oz
Continuous improvement of our products is a Genie 1.30 liters
policy. Product specifications are subject to change Turntable rotation 44 fl oz
without notice. torque hub 1.30 liters

Part No. 34032 Genie S-80 & Genie S-85 2-1

Section 2 - Specifications Service Manual - First Edition

PERFORMANCE SPECIFICATIONS

Performance Specifications
Drive speeds, maximum 2WD 4WD Boom function speeds, minimum/maximum
from platform controls
Boom stowed 3.8 mph 3.1 mph
Gasoline/LPG models 6.1 km/h 4.9 km/h Jib Boom up 40 to 60 seconds
40 ft/7.2 sec 40 ft/8.8 sec
12.2 m/7.2 sec 12.2 m/8.8 sec Jib Boom down 50 to 80 seconds

Boom stowed 3.3 mph 3 mph Boom up 90 to 120 seconds

Deutz diesel models 5.3 km/h 4.8 km/h
Boom down 90 to 120 seconds
40 ft/8.3 sec 40 ft/9.1 sec
12.2 m/8.3 sec 12.2 m/9.1 sec Boom extend 140 to 170 seconds
Boom raised or extended 0.68 mph 0.68 mph Boom retract 80 to 110 seconds
All models 1.1 km/h 1.1 km/h
40 ft/40 sec 40 ft/40 sec Turntable rotate - 360°
12.2 m/40 sec 12.2 m/40 sec boom fully stowed 80 to 120 seconds

Turntable rotate - 360°

boom extended 210 to 240 seconds
Gradeability (boom stowed) 2WD 4WD
Platform rotate - 160° 10 to 20 seconds
Rough terrain 30% 38%
Platform level up 35 to 65 seconds

Platform level down 25 to 55 seconds

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

Service Manual -- First
FirstEdition
Edition(February 2009) Section 2 - Specifications

HYDRAULIC SPECIFICATIONS

Hydraulic Specifications
Hydraulic fluid Dexron II equivalent Function pump

Drive pump Type: pressure balanced gear

Type: bi-directional variable displacement piston pump Displacement - static 1.14 cu in

19 cc
Displacement - 2500 rpm 0 to 30.3 gallons per minute
0 to 114.7 liters per minute Displacement - 2500 rpm 0 to 12.3 gallons per minute
0 to 46.6 liters per minute
Maximum drive pressure 3500 psi
241.3 bar Hydraulic tank circuit 10 micron with 25 psi
return line filter (1.7 bar) bypass
Charge pressure
neutral position 360 psi 25 bar Function manifold
drive position 250 psi 17 bar
Function relief 2900 psi
Medium pressure filter 3 micron valve pressure 200 bar

Medium pressure filter 50 psi Boom down 2300 psi

bypass pressure 3.4 bar relief valve pressure 159 bar

Drive manifold Boom extend 1950 psi

134 bar
Brake 250 psi
relief pressure 17.2 bar Steer/axle extend 5 gallons per minute
flow regulator 18.9 liters per minute
Steer end drive motors 4WD models
Steer regulator 3.5 gallons per minute
Displacement 1.52 cu in 13.2 liters per minute
per revolution 25 cc
Axle and jack cylinder pressure 2500 psi
Non-steer end drive motors 172 bar
Displacement per revolution, variable 0.16 to 2.8 cu in Auxiliary pump
4WD (2 speed motor) 2.62 to 45.9 cc
Type: fixed displacement gear pump
Displacement per revolution, variable 1.12 to 2.8 cu in
2WD 18.4 to 45.9 cc Displacement - static 0.152 cu in
2.5 cc

Displacement 1.4 gallons per minute

5.3 liters per minute

Auxiliary pump 3000 psi

relief pressure 207 bar

Part No. 34032 Genie S-80 & Genie S-85 2-3

Section 2 - Specifications Service Manual - First Edition

BOLT TORQUE SPECIFICATIONS

Bolt Torque Specifications

Size Threads SAE Grade 5 Bolts 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
7
/8 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 25% less than dry torque specifications for each bolt size.

These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

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

Service Manual - First Edition Section 2 - Specifications

FORD ENGINE LSG-423 SPECIFICATIONS

Ford Engine LSG-423

Displacement 140 cu in Starter motor
2.3 liters
Normal engine cranking speed 110 rpm
Number of cylinders 4
Current draw, normal load 150A
Bore & stroke 3.780 x 3.126 inches
96 x 79.4 mm Current draw, maximum load 460A

Horsepower 63 @ 4000 rpm Current draw, no load 70A

Firing order 1-3-4-2 Maximum circuit voltage drop 0.5V DC

while starting (normal temperature)
Low idle - carburetor 900 rpm
Brush length, new 0.50 in
Low idle - electronic governor 1600 rpm 12.7 mm

High idle 2500 rpm Brush length wear limit 0.25 in

6.35 mm
Governor electronic
Brush spring tension 40 ounces
Compression ratio 9.5:1 11 Newtons
Compression pressure (approx.) 150 to 175 psi Bolt torque 55 to 75 inch-pounds
10 to 12 bar through brush 6 to 8.5 Nm
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder Brush mounting 15 to 20 foot-pounds
bolt torque 20 to 27 Nm
Valve clearances 0.040 to 0.050 inches
1.0 to 1.3 mm Maximum commutator 0.005 inches
run-out 0.127 mm
Lubrication system
Battery
Oil pressure 40 to 60 psi
(operating temp. @ 2500 rpm) 2.75 to 4.1 bar Type 12V, Group 31

Oil capacity 5 quarts Quantity 1

(including filter) 4.7 liters
Cold cranking ampere 1000A
Oil viscosity requirements
Reserve capacity @ 25A rate 200 minutes
Temperature below 60°F / 15.5°C 5W-30
Fuel pump
-10°F to 90°F / -23°C to 32°C 10W-30
Static pressure 5 to 7 psi
Temperature above 10W-40 to 10W-50 0.34 to 0.48 bar
-10°F / -23°C
Minimum volume flow 1 pint
Temperature above 20W-40 or 20W-50 (in 25 seconds) 473 cc
25°F / -4°C

Use oils meeting API classification SG (labeled SG/CC

or SG/CD) as they offer improved wear protection.
(units ship with 10W-40 SG/CC)

Part No. 34032 Genie S-80 & Genie S-85 2-5

Section 2 - Specifications Service Manual - First Edition

FORD ENGINE LSG-423 SPECIFICATIONS

Ignition System Bolt torque specifications

torque torque
Ignition spark advance 10° BTDC Bolt description (size) ft-lbs Nm
Ignition coil primary 1.13 to 1.25W Distributor clamp bolt (M-10) 14 to 21 19 to 28
resistance @ 75°F / 24°C
Distributor vacuum tube 5 to 8 7 to 11
Ignition coil secondary 7700 to 9300W to manifold adaptor
resistance @ 75°F / 24°C
Exhaust manifold to cylinder head bolt or nut (M-10):
Spark plug type Motorcraft AWSF-52 torque in sequence
first step 14 to 19 19 to 26
Spark plug gap 0.042 to 0.046 inches
second step 20 to 30 27 to 41
1.07 to 1.18 mm
Flywheel to crankshaft 56 to 64 76 to 87
Engine coolant
bolt (M-10)
Capacity 11.5 quarts
Fuel pump to cylinder 14 to 21 19 to 28
10.9 liters
block (M-8)
Alternator
Intake manifold to 14 to 21 19 to 28
Output 35A, 14.5V cylinder head bolt or nut (M-8)

Fan belt deflection 3/8to 1/2 inch Oil pressure sending unit to block 8 to 18 11 to 24
9 to 12 mm
Oil pan drain plug to pan (M-14) 15 to 25 20 to 34
Bolt torque specifications
Oil pan to block (M-6) 10 to 13.5 14 to 18
torque torque
Bolt description (size) ft-lbs Nm Oil filter insert to block 20 to 35 27 to 47
Auxiliary shaft gear bolt (M-10) 28 to 40 38 to 54 Rocker arm cover to 5 to 8 7 to 11
cylinder head (M-6)
Auxiliary shaft thrust 6 to 9 8 to 12
plate bolt (M-6) Spark plug to cylinder 5 to 10 7 to 14
head (M-14)
Timing belt tensioner 28 to 40 38 to 54
pivot bolt (M-10) Temperature sending 8 to 18 11 to 24
unit to block (M-14)
Timing belt tensioner 14 to 21 19 to 28
adjusting bolt (M-8) Water jacket drain plug to block 23 to 28 31 to 38
Camshaft gear bolt (M-12) 50 to 71 68 to 96 Water pump to block bolt (M-8) 14 to 21 19 to 28
Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12 Auxiliary shaft cover bolt (M-6) 6 to 9 8 to 12
Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20 Water outlet connection 14 to 21 19 to 28
bolt (M-8)
Carburetor spacer to 10 to 14 14 to 19
manifold bolt (M-8) Cylinder front cover bolt (M-6) 6 to 9 8 to 12
Crankshaft damper 103 to 133 140 to 180 Inner timing belt cover 14 to 21 19 to 28
bolt (M-14) stud (M-8)
Cylinder head bolt (M-12): torque in sequence Outer timing belt cover 6 to 9 8 to 12
first step 50 to 60 68 to 81 bolt (M-6)
second step 80 to 90 108 to 122

2-6 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 2 - Specifications

DEUTZ ENGINE F4L 1011 SPECIFICATIONS

Deutz Engine F4L 1011 Injection pump pressure 4351 psi

300 bar
Displacement 166.7 cu in
2.732 liters Injector opening pressure 3626 psi
250 bar
Number of cylinders 4
Fuel requirement diesel number 2-D
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm Alternator output 55A, 14V

Horsepower 56 @ 3000 rpm Starter motor

Firing order 1-3-4-2 Current draw, no load 90A

Compression ratio 18.5:1 Brush length, new 0.7480 in

19 mm
Compression pressure 362 to 435 psi
25 to 30 bar Brush length, minimum 0.5 in
12.7 mm
Low idle 1300 rpm
Battery
High idle 2300 rpm
Type 12V, Group 31
Governor centrifugal mechanical
Quantity 1
Valve clearance, cold
Cold cranking ampere 1000A
Intake 0.012 in
0.3 mm Reserve capacity @ 25A rate 200 minutes

Fan belt deflection 3/8to 1/2 inch

Exhaust 0.020 in
0.5 mm 9 to 12 mm

Lubrication system Bolt tightening specifications

torque torque
Oil pressure 26 to 87 psi Bolt description (size, grade) ft-lbs Nm
1.8 to 6.0 bar
Camshaft/thrust bearing bolt 15 to 18 20 to 24
Oil capacity 11 quarts (M-8 x 35, 8.8)
(including filter) 10.5 liters
Rocker arm bolts 15 to 18 20 to 24
Oil viscosity requirements (M-8 x 45, 8.8)

Temperature below 60°F / 15.5°C (synthetic) 5W-30 Rocker arm set screw nut 15 to 18 20 to 24

-10°F to 90°F / -23°C to 32°C 10W-40 Cylinder head cover 6 to 7 8 to 10

Temperature above -4°F / -34°C 15W-40 Blower rotor nut 33 to 41 45 to 55

(M-17 Valeo or M-18 Bosch)
Engine oil should have properties of API classification
CC/SG or CD/SG grades. Blower carrier bolts 15 to 18 20 to 24
(units ship with 10W-40 SG/CC) (M-8 x 50 Torx, 8.8)

Injection system V-belt pulley bolts 28 to 34 38 to 46

(M-10 x 16, 8.8)
Injection pump make OMAP

Part No. 34032 Genie S-80 & Genie S-85 2-7

Section 2 - Specifications Service Manual - First Edition

DEUTZ ENGINE F4L 1011 SPECIFICATIONS

torque torque
Bolt tightening specifications, continued
ft-lbs Nm
torque torque
Bolt description (size, grade) ft-lbs Nm Oil thermostat housing screw 37 to 44 50 to 60
plug (M-38 x 1.5)
Idler pulley/V-belt pulley bolt 27 to 32 36 to 44
(M-10 x 25, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 35 Torx, 8.8)
Idler pulley for toothed belt 30 to 36 41 to 49
(M-10 x 50, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 80 Torx, 8.8)
Oil pump bolts 15 to 18 20 to 24
(M-8 x 35 Torx) Oil thermostat housing bolts 14 to 16 19 to 22
(M-6 x 105 Torx, 8.8)
Oil filter bracket bolts 7 to 8 9 to 11
(M-8 x 20 Torx, 8.8) Valve plunger housing bolts 14 to 16 19 to 22
(M-8 x 30 Torx, 8.8)
Oil intake housing bolts 15 to 18 20 to 24
(M-8 x 75 Torx) Alternator nuts (M-5) 3 4
Fuel pump bolts 15 to 18 20 to 24 Fuel bracket bolts (M-8 x 20, 8.8) 15 20
Injection pump bolts 15 to 18 20 to 24 Adapter housing bolts 70 to 77 95 to 105
(M-12 x 35, 10.9 or M-12 x 75, 10.9)
Injector cap nut 30 to 37 40 to 50
first step second step
Injector fastening bolt 15 to 18 20 to 24
tightening tightening
Injection line 10 to 12 13.5 to 16.5 torque angles
ft-lbs Nm 1st 2nd
Air intake manifold bolts 15 to 18 20 to 24
(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

2-8 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections

Scheduled Maintenance Inspections

About This Section

Warm Cold Dealer
Tools are New parts engine engine service
required required required required suggested
The Schedule

There are 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
Observe and Obey: the Maintenance Inspection Report have been
divided into four subsections—A, B, C, D. Use the
Maintenance inspections shall be completed by following chart to determine which group(s) of
a person trained and qualified on the procedures are required to perform a scheduled
maintenance of this machine. inspection.
Scheduled maintenance inspections shall be
completed daily, quarterly, annually and every Inspection Table or Checklist
2 years as specified on the Maintenance
Daily A
Inspection Report.
Failure to properly complete each Quarterly A+B
inspection when required may
Annual A+B+C
cause death, serious injury or
substantial damage.
Two year A+B+C+D
Immediately tag and remove from service a
damaged or malfunctioning machine.
Maintenance Tables
Repair any machine damage or malfunction
before operating machine. The maintenance tables contained in this section
provide summary information on the specific
Keep records on all inspections for three years. physical requirements for each inspection.
Machines that have been out of service for a Complete step-by-step instructions for each
period longer than 3 months must complete the scheduled maintenance procedure are provided in
quarterly inspection. 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. 34032 Genie S-80 & Genie S-85 3-1

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Maintenance Tables

Table A Tools are New parts

Warm
engine
Cold
engine
Dealer
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 the 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 & Genie S-85 Part No. 34032

Service Manual - First Edition (Februay 2009) Section 3 - Scheduled Maintenance Inspections

MAINTENANCE TABLES

Table A, continued Tools are New parts

Warm
engine
Cold
engine
Dealer
service
required required required required suggested

Every 100 hours, perform the following two engine

maintenance procedures.

A-15 Replace the Engine Oil and Filter -

Gasoline/LPG Models

A-16 Replace the Engine Air Filter

Table B

B-1 Check the Engine Belt(s)

B-2 Check the Radiator -

Gasoline/LPG Models

B-3 Check the Oil Cooler and Cooling Fins -

Deutz Diesel Models

B-4 Check the Exhaust System

B-5 Check the Battery

B-6 Check the Hydraulic Tank

Filter Condition Indicator

B-7 Inspect the Electrical Wiring

B-8 Inspect the Tires and Wheels

(including lug nut torque)

B-9 Confirm the Proper Brake Configuration

B-10 Check the Drive Hub Oil Level

and Fastener Torque

B-11 Check and Adjust the Engine Idle Mixture -

Gasoline/LPG Models

B-12 Check and Adjust the Engine RPM

Part No. 34032 Genie S-80 & Genie S-85 3-3

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

MAINTENANCE TABLES

Table B, continued Tools are New parts

Warm
engine
Cold
engine
Dealer
service
required required required required suggested

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 Service Horn

B-18 Test the Foot Switch

B-19 Test the Engine Idle Select

B-20 Test the Fuel Select Operation -

Gasoline/LPG Models

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 -

Optional Equipment

B-25 Perform Hydraulic Oil Anaysis

See D-1 Test or Replace the Hydraulic Oil

B-26 Check the Hydraulic Limit Switch Linkage

Every 500 hours, perform the following engine

maintenance procedure.

B-27 Replace the Engine Oil and Filter -

Deutz Diesel Models

3-4 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 3 - Scheduled Maintenance Inspections

MAINTENANCE TABLES

Table C Tools are New parts

Warm
engine
Cold
engine
Dealer
service
required required required required suggested

C-1 Check the Boom Wear Pads

C-2 Check the Extnedable Axle Wear Pads

C-3 Check the Turntable Rotation Bearing Bolts

C-4 Check the Free-wheel Configuration

C-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 -

Deutz Diesel Models

C-10 Replace the Gasoline Fuel Filter -

Gasoline/LPG Models

C-11 Replace the PCV Valve -

Gasoline/LPG Models

C-12 Clean or Replace the Distributor Cap

and Rotor - Gasoline/LPG Models

C-13 Replace the Spark Plugs -

Gasoline/LPG Models

C-14 Check and Adjust the Air/LPG Mixture -

Gasoline/LPG Models

C-15 Check and Adjust the Ignition Timing -

Gasoline/LPG Models

C-16 Check the Engine Valve Clearances -

Deutz Diesel Models

C-17 Adjust the Turntable Backlash

Part No. 34032 Genie S-80 & Genie S-85 3-5

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

MAINTENANCE TABLES

Table D Tools are New parts

Warm
engine
Cold
engine
Dealer
service
required required required required suggested

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

D-4 Check the Engine Valve Clearance -

Gasoline/LPG Models

D-5 Check the Engine Cylinder Compression -

Gasoline/LPG Models

D-6 Clean the PCV Hoses and Fittings -

Gasoline/LPG Models

D-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

3-6 Genie S-80 & Genie S-85 Part No. 34032

Service Manual -- First
FirstEdition
Edition(February 2009) Section 3 - Scheduled Maintenance Inspections

Maintenance Inspection Report

Model Checklist A Y N R B-19 Engine
Warm idle select
Cold Dealer
Tools are New parts engineselect-gasoline
engine service
Refer to Table A B-20 Fuel
Serial number required required required required suggested
A-1 Manuals B-21 Drive enable system
Date A-2 Decals and placards B-22 Drive brakes
A-3 Damage, loose or B-23 Drive speed-stowed
Hour meter missing parts B-24 Alarm package
Machine owner A-4 Engine oil level B-25 Hydraulic oil analysis
A-5 Engine coolant-gasoline B-26 Hydraulic limit switch
Inspected by (print) A-6 Fuel leaks Perform every 500 hours:
A-7 Hydraulic oil level B-27 Replace engine oil
Inspector signature
A-8 Hydraulic leaks and filter-Deutz
Inspector title A-9 Tire pressure
A-10 Extendable axles Checklist C Y N R
Inspector company
A-11 Platform and Refer to Table C
Instructions ground controls C-1 Boom wear pads
· Make copies of this page to use for A-12 Auxiliary power C-2 Axle Wear Pads
each inspection. A-13 Tilt sensor C-3 Turntable bearing bolts
· Select the appropriate checklist(s) for A-14 Limit switches
the type of inspection to be C-4 Free-wheel configuration
performed. Perform every 100 hours: C-5 Grease rotation bearing
A-15 Replace engine oil
C-6 Torque hub oil
Daily Inspection: A and filter-gasoline
C-7 Hydraulic tank filter
Quarterly Inspection: A+B A-16 Replace air filter
C-8 Drive loop hydraulic filter
Annual Inspection: A+B+C
C-9 Fuel filter-diesel
2 Year Inspection: A+B+C+D Checklist B Y N R
C-10 Fuel filter-gasoline
Refer to Table B
· Place a check in the appropriate box C-11 PCV valve-gasoline
after each inspection procedure is B-1 Engine belt(s)
completed. C-12 Distibutor cap-gasoline
B-2 Engine radiator
· Use the maintenance tables in this C-13 Spark plugs-gasoline
B-3 Oil cooler and fins-Deutz
section and the step-by-step C-14 Air/LPG mixture
procedures in section 4 to learn how B-4 Exhaust system
C-15 Ignition timing-gasoline
to perform these inspections. B-5 Battery C-16 Valves-Deutz
· If any inspection receives an “N”, tag B-6 Hydraulic tank filter C-17 Turntable backlash
and remove the machine from
B-7 Electrical wiring
service, repair and re-inspect it. After
repair, place a check in the “R” box. B-8 Tires and wheels Checklist D Y N R
Legend B-9 Brake configuration Refer to Table D
Y = yes, acceptable B-10 Drive hub maintenance D-1 Hydraulic oil
N = no, remove from service B-11 Idle mixture-gasoline D-2 Engine coolant-gasoline
R = repaired B-12 Engine RPM D-3 Change fuel lines
Comments B-13 Key Switch D-4 Valves-gasoline
B-14 Emergency Stop D-5 Compression-gasoline
B-15 Ground control override D-6 PCV hoses-gasoline
B-16 Platform leveling D-7 Fuel injection-Deutz
B-17 Service horn D-8 Toothed belt-Deutz
B-18 Foot switch D-9 Timing belt-Ford

Part No. 34032 Genie S-80 & Genie S-85 3-7

Section 3 - Scheduled Maintenance Inspections Service Manual - First Edition

Warm Cold Dealer

Tools are New parts engine engine service
required required required required suggested

This page intentionally left blank.

3-8 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

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.

Observe and Obey: Symbols Legend

Maintenance inspections shall be completed by Indicates the presence of a

a person trained and qualified on the hazard that will cause death or
maintenance of this machine. serious injury.

Scheduled maintenance inspections shall be Indicates the presence of a

hazard that may cause death or
completed daily, quarterly, annually and every
serious injury.
2 years as specified on the Maintenance
Inspection Report. Indicates the presence of a
hazard that will or may cause
Failure to perform each procedure
serious injury or damage to the
as presented and scheduled may
machine.
cause death, serious injury or
substantial damage. Indicates special operation or
maintenance information.
Immediately tag and remove from service a
damaged or malfunctioning machine. Indicates that a specific result is expected after
performing a step.
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
· turntable secured with the turntable
rotation lock pin
· key switch in the OFF position with the
key removed
· wheels chocked

Part No. 34032 Genie S-80 & Genie S-85 4-1

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table A Procedures

A-1 2 Inspect all decals for legibility and damage.

Replace any damaged or illegible decal
Inspect the Manuals immediately.
Maintaining the operator’s and safety manuals in Contact your authorized Genie
good condition is essential to safe machine distributor or Genie Industries if
operation. Manuals are included with each replacement decals are needed.
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational A-3
information necessary for a safe operating
condition.
Inspect for Damage, Loose or
Missing Parts
1 Check to be sure that the storage container is
present and in good condition. Daily machine condition inspections are essential
to safe machine operation and good machine
2 Check to make sure that the operator's,
performance. Failure to locate and repair damage,
responsibilities and safety manual are present
and discover loose or missing parts may result in
and complete in the storage container in the
an unsafe operating condition.
platform.
1 Inspect the entire machine for damage and
3 Examine the pages of each manual to be sure
improperly installed or missing parts including:
that they are legible and in good condition.
· electrical components, wiring and electrical
4 Always return the manuals to the storage
cables
container after use.
· hydraulic hoses, fittings, cylinders and
Contact your authorized Genie
manifolds
distributor or Genie Industries if
replacement manuals are needed. · fuel and hydraulic tanks
· drive and turntable rotation motors and
A-2 torque hubs
Inspect the · axle components and wear pads
Decals and Placards · boom components and wear pads
Maintaining all of the safety and instructional · dents or damage to machine
decals and placards in good condition is
mandatory for safe machine operation. Decals · tires and wheels
alert operators and personnel to the many · engine and related components
possible hazards associated with using this
machine. They also provide users with operation · limit switches, alarms, horn and beacon
and maintenance information. An illegible decal · nuts, bolts and other fasteners
will fail to alert personnel of a procedure or hazard
and could result in unsafe operating conditions. · platform entry mid-rail or gate

1 Refer to the Decals section in the · cracks in welds or structural components

Genie S-80 & Genie S-85 Operator's Manual · compartment covers and latches
and use the decal list and illustrations to
determine that all decals and placards are in
place.

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

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-4 A-5
Check the Engine Oil Level Check the Engine Coolant Level
Maintaining the proper engine oil level is essential - Gasoline/LPG Models
to good engine performance and service life. Maintaining the engine coolant at the proper level
Operating the machine with an improper oil level is essential to engine service life. Improper coolant
can damage engine components. level will affect the engine's cooling capability and
Check the oil level with the damage engine components. Daily checks will
engine off. allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
1 Check the oil level dipstick. Add oil as needed.
1 Check the fluid level in the coolant recovery
Result: The oil level should be in the "safe" tank. Add fluid as needed.
zone.
Result: The fluid level should be in the
NORMAL range.
Ford Engine LSG-423 5 quarts
Oil capacity (including filter) 4.7 liters Fluids in the radiator are under
pressure and extremely hot. Use
Ford Engine LSG-423 Oil viscosity requirements
caution when adding fluids.
below 60F / 15.5C 5W-30

-10 to 90F / -23 to 32C 10W-30 A-6

above -10F / -23C 10W-40 or 10W-50
Check for Fuel Leaks
Failure to detect and correct fuel leaks will result in
above 25F / -4C 20W-40 or 20W-50
an unsafe condition. An explosion or fuel fire may
cause death or serious injury.
Use oils meeting API classification SG (labeled SG/CC
or SG/CD) as they offer improved wear protection. Engine fuels are combustible.
Inspect the machine in an open,
Deutz Engine F4L 1011 11 quarts well-ventilated area away from
Oil capacity (including filter) 10.5 liters
heaters, sparks, flames and
lighted tobacco. Always have an
Deutz Engine F4L 1011 Oil viscosity requirements
approved fire extinguisher within
below 60°F / 15.5°C (synthetic) 5W-30
easy reach.
1 Open the shutoff valve on the liquid petroleum
-10°F to 90°F / -23°C to 32°C 10W-40 gas (LPG) tank by turning it counterclockwise.

above -4°F / -34°C 15W-40

Engine oil should have properties of API classification

CC/SG or CD/SG grades.

Part No. 34032 Genie S-80 & Genie S-85 4-3

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE A PROCEDURES

2 Perform a visual inspection around the A-8

following areas. (An LPG detector may be
necessary to locate LPG leaks.) Check for Hydraulic Leaks
Gasoline/LPG models: Detecting hydraulic fluid leaks is essential to
operational safety and good machine
· LPG tank, hoses and fittings, solenoid shutoff performance. Undiscovered leaks can develop into
valve, LPG regulator and carburetor hazardous situations, impair machine functions
· gasoline tank, manual shutoff valve, solenoid and damage machine components.
shutoff valve, hoses and fittings, fuel pump
1 Inspect for hydraulic oil puddles, dripping or
and carburetor
residue on or around the following areas:
Deutz Diesel models:
· hydraulic tank—filter, fittings, hoses, auxiliary
· fuel tank, shutoff valve, hoses and fittings, power unit and turntable surface
fuel pump, fuel filter, fuel injection pumps and
· engine compartment—fittings, hoses, main
fuel injectors
pump, filter and turntable surface
If a fuel leak is discovered, keep
· all hydraulic cylinders
any additional personnel from
entering the area and do not · all hydraulic manifolds
operate the machine. Repair the
leak immediately. · boom(s)
· the underside of the turntable
A-7 · the underside of the drive chassis
Check the Hydraulic Oil Level
· ground area under the machine
Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in
oil level that might indicate the presence of
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 II equivalent

Tank capacity 45 gallons

170 liters

Hydraulic system 55 gallons

(including tank) 208 liters

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

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-9 A-10
Check the Tire Pressure Test the Extendable Axles
This procedure does not need Proper axle extention is essential to safe machine
to be performed on machines operation. If the axle extention system is not
equipped with the foam-filled operating correctly, the stability of the machine is
tire option. compromised and it may tip over.

An over-inflated tire can explode 1 Start the engine from the ground controls.
and may cause death or serious
2 Activate the steer axle drive chassis lift jack
injury.
cylinder.
To safeguard maximum stability, achieve
Result: The cylinder should extend and the
optimum machine handling and minimize tire
drive chassis should raise smoothly, free of
wear, it is essential to maintain proper pressure
hesitation.
in all air-filled tires.
3 Continue holding the chassis jack in the
1 Check each tire with an air pressure gauge and
extended position and extend the steer axle.
add air as needed.
Result: The cylinder should extend and the
Tire specifications steer axle should extend smoothly, free of
hesitation.
Tire size 15-22.5 SAT
4 Return the chassis jack control handle to the
neutral position.
Pressure 100 psi
6.89 bar Result: The lift jack cylinder should fully retract
when the control handle is returned to neutral.
5 Activate the non-steer axle drive chassis lift
jack cylinder.
Result: The drive chassis should raise
smoothly, free of hesitation.
6 Continue holding the chassis jack in the
extended position and extend the non-steer
axle.
Result: The non-steer axle should extend
smoothly, free of hesitation.
7 Return the chassis jack control handle to the
neutral position.
Result: The lift jack cylinder should fully retract
when the control handle is returned to neutral.

Part No. 34032 Genie S-80 & Genie S-85 4-5

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE A PROCEDURES

A-11 A-12
Test the Platform and Test the Auxiliary Power
Ground Controls Operation
Testing the machine functions and the Emergency Detection of auxiliary power system malfunctions
Stop buttons for malfunctions is essential for safe is essential for safe machine operation. An unsafe
machine operation. An unsafe working condition working condition exists if the auxiliary powered
exists if any function fails to operate properly or functions do not operate in the event of a main
either Emergency Stop button fails to stop all the power loss. When operating the machine on
machine functions and shut off the engine. Each engine power, selecting auxiliary power will stop
function should activate, operate smoothly and be the engine immediately. Auxiliary power is
free of hesitation, jerking and unusual noise. designed for short term emergency use only,
and excessive use will result in battery drain
1 Start the engine from the ground controls, and and component damage.
then extend the axles.
1 Turn the key switch to ground control and pull
2 Operate each machine function through a full
out the Emergency Stop button to the ON
cycle.
position.
Result: All machine functions should operate
2 Simultaneously hold the auxiliary power switch
smoothly.
ON while activating the following functions
3 Push in the Emergency Stop button to the OFF through a partial cycle:
position.
· jib boom up/down (S-85 models)
Result: No function should operate, the engine
· boom up/down
should stop.
· extend and retract
Deutz Diesel models:
All functions should stop · turntable rotate right/left
immediately. The engine will
shut off after 2 to 3 seconds.
4 Start the engine from the platform controls, and
then operate each machine function through a
full cycle.
Result: All machine functions should operate
smoothly.
5 Push in the Emergency Stop button to the OFF
position.
Result: No function should operate, the engine
should stop. Result: Each function should operate smoothly.

As a safety feature, selecting

and operating the ground
controls will override the
platform controls, including
the Emergency Stop button.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

3 Turn the key switch to platform control. A-13

4 At the platform controls, pull out the Emergency Test the Tilt Sensor
Stop button to the ON position, then press down
the foot switch. The tilt sensor sounds an alarm in the platform
when the incline of the turntable exceeds
5 Simultaneously hold the auxiliary power switch 4.5 degrees.
on while activating the following functions
through a partial cycle: Select a level test area. The tilt
alarm should not be sounding
· jib boom up/down (S-85 models)
prior to test.
· boom up/down
1 Start the engine from the platform controls.
· extend and retract
2 Open the tank side cover and press down on
· turntable rotate right/left one side of the tilt sensor.
· steer right/left Result: After a 1.5 second delay, the alarm in
the platform should sound.
Result: Each function should operate smoothly.

Auxiliary power will not lift the

boom past the drive limit switch
unless the axles are fully
extended.
a b c

a fuel tank
b tilt sensor
c ground control box

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TABLE A PROCEDURES

A-14 3 Visually inspect the drive limit switch located on

the end of the cable track on the boom. Inspect
Test the Limit Switches for the following:
Drive Limit Switches · broken or missing roller or arm
Detecting limit switch malfunctions is essential to · missing fasteners
safe machine operation. The drive limit switches
are used to restrict drive speed when the boom is · loose wiring
raised or extended. An improperly functioning
drive limit switch will allow the machine to operate
in an unsafe position.
1 Remove the cover from the base of the boom
to access the limit switch.
2 Visually inspect the drive limit switch located
inside the pivot end of the boom. Inspect for
the following:
· broken or missing actuator arm
· missing fasteners
· loose wiring
4 Start the engine from the platform controls and
a extend the axles.
5 Slowly move the drive control handle
off center.
Result: The machine should move at normal
drive speeds.
6 Raise the boom above the drive limit switch.
7 Slowly move the drive control handle off center.
Result: The machine should move at a reduced
drive speed.
8 Lower the boom to the stowed position, then
extend the boom 1 foot (30 cm).
9 Slowly move the drive control handle off center.
d c b Result: The machine should move at a reduced
drive speed.
a drive limit switch
b boom Drive speed, maximum, raised or extended
c extension cylinder
d master cylinder
All models 1 foot per second
0.3 meter per second

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TABLE A PROCEDURES

Drive Enable Limit Switch 2 Manually activate the drive enable limit switch.
1 With the engine off and the boom in the stowed Result: The drive enable limit switch roller
position, visually inspect the drive enable limit should move freely and spring return to center.
switch for the following: A distinct click should be felt and heard.

· broken or missing roller or arm 3 Start the engine from the platform controls.
· missing fasteners 4 Rotate the turntable to the left until the boom is
· loose wiring past the left non-steer wheel.
Result: The drive enable indicator light should
a be on. Drive function should not operate until
the drive enable switch is activated.
5 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 switch is activated.
Axle Extention Hydraulic Limit Switch
1 Start the engine from the ground controls.
Lower the boom to the stowed position.
2 Extend the steer axle.
c b 3 Raise the boom.
Result: The boom should stop raising when the
a turntable drive limit switch is activated.
b drive enable limit switch
c turntable rotation bearing 4 Lower the boom to the stowed position.
5 Retract the steer axle and extend the non-steer
axle.
6 Raise the boom.
Result: The boom should stop raising when the
drive limit switch is activated.
7 Lower the boom to the stowed position.
8 Extend the steer axle.
9 Raise the boom.
Result: The boom should continue to raise to
full height after the drive limit switch is
activated.

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TABLE A PROCEDURES

A-15 2 Pull the end of the oil drain hose out from
under the engine.
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
a b c b
on the oil filter will allow the inspector to anticipate
and perform oil and filter changes at the 100 hour a engine pivot plate
interval. b pivot plate retaining bolts
c oil drain hose
Perform this procedure after
warming the engine to normal 3 Remove the plug from the end of the drain
operating temperature. hose and allow all of the oil from the engine
to drain into a suitable container.
Beware of hot engine parts and
oil. Contact with hot engine oil 4 Install the plug into the drain hose.
and/or engine parts may cause
5 Remove the 2 bolts from under the engine pivot
severe burns.
plate. Swing the engine pivot plate away from
1 Remove the oil filler cap located on the the machine to access the oil filter.
valve cover.
6 Use an oil filter wrench and remove the filter.
7 Apply a thin layer of oil to the new oil filter
gasket (filter part no. 28656). Then install the
filter and tighten it securely by hand.

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TABLE A PROCEDURES

8 Use a permanent ink marker to write the date A-16

and number of hours from the hour meter on
the oil filter. Replace the Engine Air Filter
9 Fill the engine with new oil per specifications Engine specifications require that
and install the filler cap. this procedure be performed every
100 hours. Perform this procedure
10 Start the engine from the ground controls. more often if dusty conditions
Allow the engine to run for 30 seconds, then exist.
turn the engine off.
Maintaining the engine air filter in good condition is
11 Check the oil filter and the oil drain hose essential to good engine performance and service
for leaks. life. Failure to perform this procedure can lead to
12 Swing the engine pivot plate back to its original poor engine performance and component
position and replace the two retaining bolts. damage.

13 Check the engine oil level dipstick. Add oil Perform this procedure with the
if needed. engine off.
1 Remove the end cap from the air cleaner
Ford Engine LSG-423 5 quarts canister.
Oil capacity (including filter) 4.7 liters
2 Remove the mounting fastener from the air
Ford Engine LSG-423 Oil viscosity requirements filter, then remove the filter.
3 Clean the inside of the canister and the gasket
below 60F / 15.5C 5W-30
with a dry cloth.
-10 to 90F / -23 to 32C 10W-30 4 Insert the new filter and replace the mounting
fastener.
above -10F / -23C 10W-40 or 10W-50
5 Replace the end cap on the canister.
above 25F / -4C 20W-40 or 20W-50
Air filters - Genie part numbers
Use oils meeting API classification SG (labeled SG/CC Ford LSG-423 Engine 27916
or SG/CD) as they offer improved wear protection. Deutz F4L 1011 27916

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table B Procedures

B-1 B-2
Check the Engine Belt(s) Check the Radiator
Maintaining the engine belt(s) is essential to good - Gasoline/LPG Models
engine performance and service life. The machine Maintaining the radiator in good condition is
will not operate properly with a loose or defective essential for good engine performance. Operating
belt and continued use may cause component a machine with a damaged or leaking radiator may
damage. result in engine damage. Also, restricting air flow
Do not inspect while the engine through the radiator (i.e., dirt or debris) will affect
is running. Remove the key to the performance of the cooling system. A frequent
secure from operation. check allows the inspector to identify changes in
the condition of the radiator that might indicate
Beware of hot engine cooling system problems.
components. Contact with hot
engine components may cause Do not inspect while the engine
severe burns. is running. Remove the key to
secure from operation.
1 Deutz Diesel models: Remove front engine
cover to access belt. Beware of hot engine
components. Contact with hot
2 All models: Inspect the engine belt(s) for: engine components may cause
· cracking severe burns.

· glazing 1 Inspect the radiator for leaks and physical

damage.
· separation
2 Clean the radiator fins of debris and foreign
· breaks materials.
3 Check the engine belt(s) for proper tension.

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.

Ford engine Deutz Diesel engine Do not inspect while the engine
is running. Remove the key to
secure from operation.
Belt deflection - all models 3 /8inch to 1/2 inch
9 mm to 12 mm Beware of hot engine
components. Contact with hot
engine components may cause
severe burns.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

Oil Cooler B-4

1 Remove the cover from the side of the engine, Check the Exhaust System
then remove the oil cooler top cover.
Maintaining the exhaust system is essential to
2 Inspect the oil cooler for leaks and physical good engine performance and service life.
damage. Running the engine with a damaged or leaking
exhaust system can cause component damage
and unsafe operating conditions.

Do not inspect while the engine

is running. Remove the key to
secure from operation.
a b c
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
a oil cooler access the exhaust system.
b cylinder head cooling fins
c blower fins

3 Clean the oil cooler of debris and foreign

material.
Cooling and Blower Fins
4 Inspect the blower fins for physical damage.
5 Clean the 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.

a b b

a engine pivot plate

b pivot plate retaining bolts

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

2 Be sure that all nuts and bolts are tight.

B-6
Check the Hydraulic Tank Filter
3 Inspect all welds for cracks.
Condition Indicator
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints. Maintaining the hydraulic tank filter in good
condition is essential to good system performance
and safe machine operation. The filter condition
B-5 indicator will show when the hydraulic flow is
bypassing a clogged filter. If the filter is not
Check the Battery frequently checked and replaced, impurities
Proper battery condition is essential to good will remain in the hydraulic system and cause
engine performance and operational safety. component damage.
Improper fluid levels or damaged cables and 1 Start the engine from the platform controls.
connections can result in engine component
damage and hazardous conditions. 2 Move the engine speed control switch to high
idle (rabbit symbol).
Engine fuels are combustible.
Replace the fuel filter in an open, 3 Inspect the filter condition indicator.
well-ventilated area away from
heaters, sparks, flames and a
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Batteries contain acid. Avoid
b
spilling or contacting battery acid.
Neutralize battery acid spills with c
baking soda and 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 cable a filter condition indicator
connections are tight. b filter
c hydraulic tank
4 Remove the battery vent caps and check the
specific gravity with a hydrometer.
Result: The filter should be operating with the
5 Check the battery acid level. If needed, plunger in the green area. If the display shows
replenish with distilled water to the bottom of the plunger in the red area, this indicates that
the battery fill tube. Do not overfill. the hydraulic filter is being bypassed and the
filter should be replaced. See C-7, Replace the
6 Install the vent caps. Hydraulic Tank Filter.

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TABLE B PROCEDURES

B-7 B-8
Inspect the Electrical Wiring Inspect the Tires and Wheels
Maintaining electrical wiring in good condition is (including lug nut torque)
essential to safe operation and good machine Maintaining the tires and wheels in good
performance. Failure to find and replace burnt, condition is essential to safe operation and good
chafed, corroded or pinched wires could result in performance. Tire and/or wheel failure could result
unsafe operating conditions and may cause in a machine tip-over. Component damage may
component damage. also result if problems are not discovered and
Electrocution hazard. Contact with repaired in a timely fashion.
hot or live circuits may result in An over-inflated tire can
death or serious injury. Remove explode and may cause death
all rings, watches and other or serious injury.
jewelry.
1 Check all tire treads and sidewalls for cuts,
1 Inspect the following areas for burnt, chafed, cracks, punctures and unusual wear.
corroded and loose wires:
2 Check each wheel for damage, bends and
· engine compartment electrical panel cracked welds.
· engine wiring harness 3 Check each lug nut for proper torque.
· inside of the ground control box 4 Check the pressure in each air-filled tire.
· turntable manifold wiring
Tires and wheels
2 Start the engine from the ground controls, then
extend the axles and raise the boom above the Tire size 15-22.5 SAT
turntable covers. Tire ply rating 16
3 Inspect the turntable area for burnt, chafed and Tire contact area 113 sq in
pinched cables. 729 sq cm

4 Lower the boom into the stowed position and Overall tire diameter 44.1 in
turn the engine off. 112 cm

5 Inspect the following areas for burnt, chafed, Tire pressure 100 psi
6.89 bar
corroded, pinched and loose wires:
Wheel diameter 22.5 in
· cable track on the boom
57.1 cm
· boom to platform cable harness Wheel width 11.75 in
· inside of the platform control box 29.8 cm
Wheel lugs 10 @ 3/4 -16
· jib boom cable track (S-85 models)
Lug nut torque, dry 420 ft-lbs
569.5 Nm
Lug nut torque, wet 320 ft-lbs
433.9 Nm

Part No. 34032 Genie S-80 & Genie S-85 4 - 15

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TABLE B PROCEDURES

B-9 B-10
Confirm the Proper Check the Drive Hub Oil Level
Brake Configuration and Fastener Torque
Proper brake configuration is essential to safe Failure to maintain proper torque hub oil levels may
operation and good machine performance. cause the machine to perform poorly and continued
Hydrostatic brakes and hydraulically-released, use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not Drive Torque Hubs
fully operational. 1 Drive the machine to rotate the hub until the
1 Check each torque hub disconnect cap to be plugs are located one on top and the other at 90
sure it is in the engaged position. degrees.

brake disengage position

brake engage position

2 Be sure the free-wheel valve on the drive pump

is closed (clockwise). 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 Check the torque of the drive hub mounting
fasteners. Torque the bolts to 160 ft-lbs / 217
a b c d
Nm (lubed) or 210 ft-lbs / 284 Nm (dry).
a drive pump 6 Repeat this procedure for each drive torque hub.
b free-wheel valve
c screwdriver
d lift pump
Torque hub oil Drive Steer

The free-wheel valve should Capacity 50 fl oz 44 fl oz

always remain closed. 1.47 liters 1.30 liters

Type: SAE 90 multipurpose hypoid gear oil - API

service classification GL5

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TABLE B PROCEDURES

Turntable Rotate Torque Hub B-11

1 Remove the plug located on the side of the hub Check and Adjust the Engine Idle
and check the oil level. Mixture - Gasoline/LPG Models
Result: The oil level should be even with the
Complete information to perform this procedure is
bottom of the plug hole.
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.

B-12
Check and Adjust the
Engine RPM
a
Maintaining the engine rpm at the proper setting
b
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.

a torque hub
Gasoline/LPG Models
b plug
Perform this procedure in gasoline
mode with the engine at normal
2 If necessary, add oil until the oil level is even operating temperature.
with the bottom of the side plug hole.
1 Disconnect the blue/black wire from the
3 Apply pipe thread sealant to the plug, and then governor actuator.
install it in the torque hub.
4 Check the torque of the turntable rotate drive
hub mounting fasteners. Torque the bolts to
200 ft-lbs / 271 Nm (dry) or 270 ft-lbs / 366 Nm
(lubed).

Turntable rotate torque hub oil

Capacity 44 fluid ounces

1.30 liters

Type SAE 90 multipurpose hypoid gear oil - API

service classification GL5

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

2 Connect an rpm gauge to the engine, then start If low and high idle rpm’s are correct,
the engine from the ground controls. disregard adjustment steps 8 and 9.
Result: Carburetor low idle should be 900 rpm. 8 Remove the mounting fasteners from the
electronic governor located on the engine
Skip to step 4 if the low idle rpm is correct.
side bulkhead, then remove the back panel
3 Turn the idle adjustment screw on the from the governor.
carburetor clockwise to increase rpm or
9 Restart the engine, turn the low or high speed
counterclockwise to decrease rpm.
set screw clockwise to increase the rpm or
counterclockwise to decrease the rpm.
Do not adjust any trimpot other
than specified in this procedure.

a
b

Gasoline/LPG low idle adjustment b

a carburetor
b adjustment screw
Gasoline/LPG idle adjustment
4 Turn the engine off and reconnect the a low idle adjustment
b high idle adjustment
blue/black wire to the governor actuator.
5 Start the engine from the ground controls. 10 Re-assemble the governor and recheck low
and high idle.
Result: Electronic governor low idle should
be 1600 rpm. Gasoline/LPG models
6 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls. Low idle - carburetor 900 rpm

Result: High idle should be 2500 rpm. Low idle - electronic governor 1600 rpm
7 Turn the engine off. High idle 2500 rpm

Deutz Diesel models

1 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.
Result: Low idle should be 1300 rpm.
Skip to step 3 if the low idle rpm is correct.

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TABLE B PROCEDURES

2 Loosen the lock nut, then turn the adjustment B-13

screw clockwise to increase the rpm or
counterclockwise to decrease the rpm. Tighten Test the Key Switch
the lock nut and recheck the rpm. 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
f
a hazardous operating situation.
e
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
a b c d platform control.
a solenoid boot 3 Check any machine function from the ground
b high idle adjustment nut controls.
c lock nut
d yoke Result: The machine functions should not
e low idle adjustment screw operate.
f lock nut
4 Turn the key switch to ground control.
3 Move the engine idle control switch to high idle
(rabbit symbol) from the ground controls. 5 Check any machine function from the platform
controls.
Result: High idle should be 2300 rpm.
Result: The machine functions should not
If high idle rpm is correct, disregard operate.
adjustment step 4.
6 Turn the key switch to the OFF position.
4 Loosen the yoke lock nut, then turn the
adjustment nut and solenoid boot Result: The engine should stop and no
counterclockwise to increase the rpm or functions should operate.
clockwise to decrease the rpm. Tighten the Deutz Diesel models: All functions
yoke lock nut and recheck the rpm. Be sure should stop immediately. The
solenoid fully retracts, when activating high engine will shut off after 2 to 3
idle. seconds.

Deutz Diesel models

Low idle 1300 rpm

High idle 2300 rpm

Part No. 34032 Genie S-80 & Genie S-85 4 - 19

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

B-14 B-15
Test the Emergency Stop Buttons Test the Ground Control Override
Properly functioning Emergency Stop buttons A properly functioning ground control override is
are essential for safe machine operation. An essential to safe machine operation. The ground
improperly operating Emergency Stop button control override function is intended to allow
will fail to shut off power and stop all machine ground personnel to operate the machine from the
functions, resulting in a hazardous situation for ground controls whether or not the Emergency
ground and platform personnel. Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
As a safety feature, selecting the operator at the platform controls cannot return
and operating the ground controls the boom to the stowed position.
will override the platform controls,
including the Emergency Stop 1 Push in the platform Emergency Stop button
button. to the OFF position.
1 Start the engine from the ground controls. 2 Start the engine from the ground controls.
2 Push down the Emergency Stop button to the 3 Operate each boom function through a
OFF position. partial cycle.
Result: The engine should shut off and no Result: All boom functions should operate.
machine functions should operate.
Deutz Diesel models: All functions
should stop immediately. The
engine will shut off after 2 to 3
seconds.
B-16
Test the Platform Self-leveling
3 Start the engine from the platform controls.
Automatic platform self-leveling throughout
4 Push down the Emergency Stop button to the
the full cycle of boom raising and lowering is
OFF position.
essential for safe machine operation. The
Result: The engine should shut off and no platform is maintained at level by the platform
machine functions should operate. leveling slave cylinder which is controlled by the
master cylinder located at the base of the boom.
The ground Emergency Stop A platform self-leveling failure creates an unsafe
button will stop all machine working condition for platform and
operation, even if the key switch ground personnel.
is switched to platform control.
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 leveling switch.
3 Raise and lower the boom through
a full cycle.
Result: The platform should remain level at
all times to within ±5 degrees.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

B-17 B-18
Test the Service Horn Test the Foot Switch
A functional service horn is essential to safe A properly functioning foot switch is essential to
machine operation. The service horn is activated safe machine operation. Machine functions should
at the platform controls and sounds at the ground activate and operate smoothly as long as the foot
as a warning to ground personnel. An improperly switch is pressed down, and promptly stop when
functioning horn will prevent the operator from the foot switch is released. The foot switch will
alerting ground personnel of hazards or unsafe also shift the engine into high idle if the idle select
conditions. is switched to the rabbit and foot switch symbol.
An improperly functioning foot switch can cause
1 Turn the key switch to platform control and an unsafe working condition and endanger
pull out the Emergency Stop button to the platform and ground personnel.
ON position at both the ground and
platform controls. The engine should not start if the
foot switch is pressed down.
2 Push down the service horn button at the
platform controls. 1 Start the engine from the platform controls.
Result: The service horn should sound. 2 Without pressing down the foot switch, check
the machine functions.
Result: The machine functions should not
operate.
3 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.

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TABLE B PROCEDURES

Foot switch activated high idle (rabbit and foot B-20

switch symbols) should be used for normal
machine operation. This selection activates high Test the Fuel Select Operation
idle only when the foot switch is pressed down. - Gasoline/LPG Models
1 Pull out the Emergency Stop button to the The ability to select and switch between
ON position at both the ground and platform gasoline and LPG fuels as needed is essential to
controls. safe machine operation. A fuel selection can be
made when the engine is running or not.
2 Start the engine from the ground controls. Then
Switching malfunctions and/or the failure of the
move the engine idle control switch to high idle
engine to start and run properly in both fuel
(rabbit symbol) and hold in the ON position.
modes and through all idle speeds can indicate
Result: The engine should change to high idle. fuel system problems that could develop into a
hazardous situation.
3 Release the engine idle control switch.
Perform this test after checking
Result: The engine should return to low idle.
the gasoline and LPG fuel levels,
4 Turn the key switch to platform controls. and warming the engine to normal
operating temperature.
5 At the platform controls, move the engine idle
control switch to high idle (rabbit symbol). 1 Move the fuel select switch to gasoline and
then move the engine idle control switch to foot
Result: The engine should change to high idle. switch activated high idle (rabbit and foot
6 Move the engine idle control switch to low idle switch symbol).
(turtle symbol). 2 Start the engine from the platform controls and
Result: The engine should change to low idle. allow it to run at low idle.

7 Move the engine idle control switch to foot 3 Press down the foot switch to allow the engine
switch activated high idle (rabbit and foot to run at high idle.
switch symbol). Result: The engine should start promptly and
Result: The engine should not change to operate smoothly in low and high idle.
high idle. 4 Release the foot switch and stop the engine.
8 Press down the foot switch. 5 Move the fuel select switch to LPG.
Result: The engine should change to high idle. 6 Restart the engine and allow it to run at
low idle.
Gasoline/LPG models 7 Press down the foot switch to allow the engine
to run at high idle.
Low idle 1600 rpm
Result: The engine should start promptly and
High idle 2500 rpm operate smoothly in low and high idle.
The engine may hesitate
Deutz Diesel models
momentarily and then continue
Low idle 1300 rpm to run on the selected fuel if the
fuel source is switched while
High idle 2300 rpm the engine is running.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

B-21 B-22
Test the Drive Enable System Test the Drive Brakes
Proper drive enable system operation is Proper brake action is essential to safe machine
essential to safe machine operation. When the operation. The drive brake function should operate
boom is past the non-steering wheels, drive smoothly, free of hesitation, jerking and unusual
movement is stopped and the indicator light turns noise. Hydrostatic brakes and hydraulically-
on. The drive enable switch must be used released individual wheel brakes can appear to
to reactivate the drive function and should inform operate normally when they are actually not fully
the operator that the machine will move in the operational.
opposite direction that the drive and steer controls
are moved. An improperly functioning drive enable Be sure that the machine is not in
system may allow the machine to be moved into free-wheel or partial free-wheel
an unsafe position. configuration. Refer to B-9 in this
section, Confirm the Proper Brake
1 Start the engine from the platform controls. Configuration.
2 Rotate the turntable to the right until the boom Select a test area that is firm,
is past the right non-steering wheel. level and free of obstructions.
Result: The drive enable indicator light should 1 Mark a test line on the ground for reference.
turn on.
2 Start the engine from the platform controls.
3 Slowly move the drive control handle off center.
3 Move the engine idle control switch to
Result: The drive function should not operate.
foot switch activated high idle (rabbit and
4 Hold the drive enable toggle switch to either foot switch), then lower the boom into the
side and slowly move the drive control handle stowed position.
off center.
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.
`Always use the color-coded
direction arrows on the 6 Measure the distance between the test line and
platform control panel and the your machine reference point.
drive chassis to identify which
direction the machine will travel. Braking:
paved surface 2WD 4WD
Result: The drive function should operate.
5 Rotate the turntable to the left until the boom is Stopping distance 3 to 5 ft 4 to 6 ft
past the left non-steering wheel. 0.91 to 1.5 m 1.22 to 1.83 m

Result: The drive enable indicator light should

come on.
The brakes must be able to hold
6 Repeat steps 3 and 4. the machine on any slope it is
able to climb.

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TABLE B PROCEDURES

B-23 B-24
Test the Drive Speed Test the Alarm Package
- Stowed Position - Optional Equipment
Proper drive function movement is essential to The alarm package includes:
safe machine operation. The drive function should
· travel alarm
respond quickly and smoothly to operator control.
Drive performance should also be free of · descent alarm
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range. · flashing beacon
Alarms and a beacon are installed to alert
Select a test area that is firm,
operators and ground personnel of machine
level and free of obstructions.
proximity and motion. The alarm package is
1 Create start and finish lines by marking two installed on the turntable covers.
lines on the ground 40 feet (12.2 m) apart.
The alarms and beacon will
2 Start the engine from the platform controls. operate with the engine
running or not running.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and foot 1 At the ground controls, pull out the Emergency
switch), then lower the boom into the stowed Stop button to the ON position and turn the key
position. switch to ground control.
4 Choose a point on the machine; i.e., contact Result: The flashing beacon should be on and
patch of a tire, as a visual reference for use flashing.
when crossing the start and finish lines.
2 Move the boom switch to the DOWN position,
5 Bring the machine to top drive speed before hold for a moment and then release it.
reaching the start line. Begin timing when your
reference point on the machine crosses the Result: The descent alarm should sound when
start line. the switch is held down.

6 Continue at full speed and note the time when 3 Turn the key switch to platform control.
the machine reference point crosses the finish 4 At the platform controls pull out the Emergency
line. Stop button to the ON position.
Result: The flashing beacon should be on
Drive speed:
stowed position 2WD 4WD and flashing.
5 Press down the foot switch. Move the boom
Gasoline/LPG models 40 ft/7.2 sec 40 ft/8.8 sec control handle to the DOWN position, hold for a
12.2 m/7.2 sec 12.2 m/8.8 sec moment and then release it.
Deutz Diesel models 40 ft/8.3 sec 40 ft/9.1 sec
12.2 m/8.3 sec 12.2 m/9.1 sec

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TABLE B PROCEDURES

Result: The descent alarm should sound when B-26

the control handle is held down.
Check the Hydraulic Limit Switch
6 Press down the foot switch. Move the drive
control handle off center, hold for a moment
Linkage
and then release it. Move the drive control 1 Remove the drive chassis steer-end cover.
handle off center in the opposite direction, hold
for a moment and then release it. 2 Extend and retract the axle through 2 cycles
and visually inspect the linkage for damage. Be
Result: The travel alarm should sound when sure the valve actuator is functioning properly.
the drive control handle is moved off center in
either direction. 3 Be sure the lock nut is properly tightened.
4 Repeat procedure for the non-steer end axle.

B-25
Perform Hydraulic Oil Analysis a b c d e

See D-1, Test or Replace the Hydraulic Oil.

a lock nut
b linkage rod
c spring
d valve actuator
e limit switch valve

If the linkage functioning

incorrectly, See 15-3, How to Set
Up the Hydraulic Limit Switch
Linkage.

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE B PROCEDURES

B-27
Replace the Engine Oil and a

Filter - Deutz Diesel Models

Engine specifications require
that this procedure be performed
b
every 500 hours. Perform this c
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
a engine oil level dipstick
or neglecting periodic oil and filter changes can
b oil filter
damage engine components. A frequent check c fuel filter
of elapsed machine hours against the hours
noted on the oil filter will allow the inspector to 6 Apply a thin layer of oil to the new filter gasket
anticipate and perform oil and filter changes at (filter part no. 29561). Then install the filter and
the 500 hour interval. tighten it securely by hand.

Perform this procedure after 7 Use a permanent ink marker to write the date
warming the engine to normal and number of hours from the hour meter on
operating temperature. the oil filter.

Beware of hot engine parts and 8 Fill the engine with new oil per specifications
oil. Contact with hot engine oil and replace the oil filler cap.
and/or engine parts may cause 9 Start the engine from the ground controls.
severe burns. Allow the engine to run for 30 seconds then
1 Remove the oil filler cap located on the turn the engine off.
valve cover. 10 Check the oil filter and oil pan for leaks.
2 Pull the end of the drain hose out from under 11 Check the engine oil level dipstick. Add oil if
the engine. needed.
3 Remove the plug from the end of the drain
hose and allow all of the oil from the engine to Deutz Engine F4L 1011 11 quarts
drain into a suitable container. Oil capacity (including filter) 10.5 liters

4 Install the plug into the drain hose. Deutz Engine F4L 1011 Oil viscosity requirements
5 Use an oil wrench and remove the oil filter.
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.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

Table C Procedures

C-1 1 Start the engine from the ground controls and

extend the axles.
Check the Boom
2 Measure each wear pad. Replace the wear pad
Wear Pads if it is less than 7/16 inch (11 mm) thick. If the
Maintaining the boom wear pads in good condition wear pad is more than 7/16 inch (11 mm) thick,
is essential to safe machine operation. Wear pads shim as necessary to obtain zero clearance
are placed on boom tube surfaces to provide a low and zero drag.
friction, replaceable wear pad between moving 4 Extend and retract the axles through the entire
parts. Improperly shimmed wear pads or range of motion to check for tight spots that
continued use of worn out wear pads may result in could cause binding or scraping.
component damage and unsafe operating
conditions. Always maintain squareness
between the axle outer and inner
1 Start the engine from the ground controls. tubes.
2 Raise the end of the boom to a comfortable
working height (chest high), then extend the
boom 1 foot (30 cm).
C-3
3 Measure each wear pad. Replace the wear pad
if it is less than 7/16 inch (11 mm) thick. If the
Check the Turntable Rotation
wear pad is more than 7/16 inch (11 mm) thick, Bearing Bolts
shim as necessary to obtain zero clearance
Maintaining proper torque on the turntable bearing
and zero drag.
bolts is essential to safe machine operation.
4 Extend and retract the boom through the entire Improper bolt torque could result in an unsafe
range of motion to check for tight spots that operating condition and component damage.
could cause binding or scraping.
1 Raise the boom and place a safety chock on
Always maintain squareness the cylinder. Carefully lower the boom onto the
between the boom outer and inner lift cylinder safety chock.
tubes.
Crushing hazard. Keep hands
away from cylinder and all moving
parts when lowering the boom.
C-2
Check the Extendable Axle Wear The lift cylinder safety chock is
available through Genie,
Pads (part no. 33484).
Maintaining the axle wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on axle tube surfaces to provide 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.

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE C PROCEDURES

2 Be sure that each turntable mounting bolt is Non-steering wheels: All models
torqued in sequence to 210 foot-pounds
(285 Newton meters). 1 Chock the steer wheels to prevent the machine
from rolling.
28 1
24 5
16
20 9
13
2 Center a lifting jack of ample capacity
12 17 (20,000 lbs/9072 Kg) under the drive chassis
8 21
between the non-steer tires.
4 25
30 29 3 Lift the wheels of the ground and then place
3
26 jack stands under the drive chassis for support.
22 7
18 11 4 Disengage the torque hubs by turning over the
14 15
10 19 torque hub disconnect caps on each
6 2 27 23
non-steering wheel hub.
Bolt torque sequence
disengage position

3 Lower the boom to the stowed position.

4 Check to ensure that each bearing mounting
bolt under the drive chassis is torqued in engage position
sequence to 210 foot-pounds
(285 Newton meters). 5 Manually rotate each non-steering wheel.
1
10 15 Result: Each non-steering wheel should rotate
13 7 with minimum effort.
6 12
6 Re-engage the torque hubs by turning over
18 4 the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
3 17
remove the jack stands.
11 5
Collision hazard. Failure to
8 14 re-engage the torque hubs may
16 9
2 cause death or serious injury and
Bolt torque sequence property damage.
Steer wheels: 4WD models
C-4
7 Chock the non-steering wheels to prevent the
Check the Free-wheel machine from rolling.
Configuration
8 Center a lifting jack of ample capacity
Proper use of the free-wheel configuration is (20,000 lbs/9072 Kg) under the drive chassis
essential to safe machine operation. The between the non-steer tires.
free-wheel configuration is used primarily for
9 Lift the wheels of the ground and then place
towing. A machine configured to free-wheel
jack stands under the drive chassis for support.
without operator knowledge may cause death or
serious injury and property damage.

Collision hazard. Select a work

site that is firm and level.

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TABLE C PROCEDURES

10 Disengage the torque hubs by turning over the C-5

torque hub disconnect caps on each
steer wheel hub. Grease the Turntable Rotation
disengage position
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
engage position
result in component damage.
11 Manually rotate each steer wheel.
1 Locate the grease fitting on the platform end of
Result: Each steer wheel should rotate with the tank side bulkhead.
minimum effort.
2 Pump grease into the turntable rotation
12 Re-engage the torque hubs by turning over bearing. Rotate the turntable in increments
the hub disconnect caps. Rotate each wheel to of 4 to 5 inches (10 to 13 cm) at a time and
check for engagement. Lift the machine and repeat this step until the entire bearing has
remove the jack stands. been greased.
Collision hazard. Failure to 3 Apply grease to each tooth of the drive gear,
re-engage the torque hubs may located under the turntable.
cause death or serious injury and
property damage. Oil type Multipurpose grease
All models:

13 Be sure the free-wheel valve on the drive pump

is closed (clockwise).
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

a b c d
drive the machine until one of the two plugs is
a drive pump
at the lowest point.
b free-wheel valve 2 Remove both plugs and drain the oil.
c screwdriver
d lift pump

The free-wheel valve should

always remain closed.

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Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE C PROCEDURES

3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub
and the other is at 90 degrees.
1 Secure the turntable from rotating with the
turntable rotation lock pin.

4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole. unlocked locked
Apply pipe thread sealant to the plugs, and 2 Remove the motor/brake mounting bolts, and
then install the plugs. then remove the motor and brake from the
5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side.
torque hubs.
a b
Non-steer end:
6 Remove the torque hub. See 17-2, How to
Remove a Drive Torque Hub. After removing
the torque hub, drain and replace the oil from
the inside torque hub.

f
Oil capacity per hub
c

non-steer (outside) 50 fl oz 1.47 liters d

non-steer (inside) 4 fl oz 0.11 liters e
steer 44 fl oz 1.30 liters

Type: SAE 90 multipurpose hypoid gear oil - API

service classification GL5

a motor/brake mounting bolt

b motor
c torque hub
d torque hub mounting bolt
e plug
f brake

3 Remove the torque hub mounting bolts, and

then use a lifting device to remove the torque
hub from the machine.
4 Remove the plug from the side of the torque
hub. Then drain the oil from the hub.

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Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

5 Install the torque hub. Torque the hub mounting C-8

bolts to 180 foot-pounds (244 Newton meters).
Replace the Drive Loop
6 Install the brake and motor onto the torque hub.
Hydraulic Filter
7 Fill the hub with oil from the side hole until the
oil level is even with the bottom of the hole. Replacing the drive loop hydraulic filter is essential
Apply pipe thread sealant to the plugs, and to good machine performance and service life. A
then install the plugs. dirty or clogged filter may cause the machine to
perform poorly and continued use may cause
Capacity 44 fluid ounces
component damage. Extremely dirty conditions
1.30 liters may require that the filter be replaced more often.

Beware of hot oil. Contact with

Type: SAE 90 multipurpose hypoid gear oil - API
hot oil may cause severe burns.
service classification GL5
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.
C-7
2 Rotate the filter housing counterclockwise and
Replace the Hydraulic Tank Filter remove the housing.
Replacement of the hydraulic tank filter is 3 Remove the filter element from the housing.
essential for good machine performance and
service life. A dirty or clogged filter may cause the 4 Inspect the housing seal and replace it if
machine to perform poorly and continued use may necessary.
cause component damage. Extremely dirty 5 Install the new filter (part no. 20880) and hand
conditions may require that the filter be replaced tighten the housing onto the filter head. Clean
more often. up any oil that may have spilled during the
installation procedure.
Beware of hot oil. Contact with
hot oil may cause severe burns. 6 Start the engine from the ground controls.
Perform this procedure with the 7 Inspect the filter assembly to be sure that there
engine off. are no leaks.
1 Remove the filter with an oil filter wrench.
2 Apply a thin layer of oil to the new oil filter
gasket.
3 Install the new filter (part no. 20293) and
tighten it securely by hand. Clean up any oil
that may have spilled during the installation
procedure.
4 Start the engine from the ground controls.
5 Inspect the filter and related components to
be sure that there are no leaks.

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TABLE C PROCEDURES

C-9 3 Apply a thin layer of oil or diesel fuel to the new

fuel filter gasket.
Replace the Diesel Fuel
4 Install the new filter (part no. 29560) and
Filter - Deutz Diesel Models tighten it securely by hand. Clean up any
Replacing the diesel fuel filter is essential to good diesel fuel that might have spilled during the
engine performance and service life. A dirty or procedure.
clogged filter may cause the engine to perform 5 Turn the manual fuel shutoff valve, located at
poorly and continued use may cause component the fuel tank, to the OPEN position.
damage. Extremely dirty conditions may require
that the filter be replaced more often. 6 Start the engine from the ground controls, then
inspect the fuel filter for leaks.
Engine fuels are combustible.
Replace the fuel filter in an open, If a fuel leak is discovered, keep
well-ventilated area away from any additional personnel from
heaters, sparks, flames and entering the area and do not
lighted tobacco. Always have an operate the machine. Repair
approved fire extinguisher within the leak immediately.
easy reach.
Perform this procedure with the
engine off. C-10
1 Turn the manual fuel shutoff valve, located at Replace the Gasoline Fuel
the fuel tank, to the CLOSED position.
Filter - Gasoline/LPG Models
2 Remove the fuel filter with a filter wrench.
Replacing the gasoline 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 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,
a well-ventilated area away from
b
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.

a fuel filter Perform this procedure with the

b oil filter engine off.

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TABLE C PROCEDURES

1 Remove the 2 bolts from under the engine pivot a b

plate. Swing the engine pivot plate away from
the machine to access the fuel filter, located
near the carburetor.

a b a
Gasoline/LPG models
a fuel filter
b hose from the fuel filter to
a pivot plate retaining bolts the carburetor
b engine pivot plate c hose from the fuel pump to
the fuel filter
2 Loosen the filter bracket mounting bolt. d hose from the fuel shutoff
Disconnect the fuel hoses from the filter, then valve to the fuel pump
slide the filter out of the bracket.
3 Install the new fuel filter in the bracket with
the flow direction arrow on the filter, pointing
toward the carburetor. Tighten the bracket
mounting bolt, then connect the fuel hoses
to the filter.
4 Clean up any fuel that may have spilled during
the installation procedure.
5 Start the machine from the ground controls,
then inspect the fuel filter and hoses 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.
6 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.

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TABLE C PROCEDURES

C-11 2 Remove the hoses from the PCV valve, then

remove the valve.
Replace the PCV Valve
- Gasoline/LPG Models a b

Yearly replacement of the PCV valve is essential

to good engine performance. A malfunctioning
valve can impair crankcase ventilation and may
cause engine damage. c

Perform this procedure with the

engine off.
1 Remove the 2 bolts from under the engine pivot
plate. Swing the engine pivot plate away from
the machine to access the PCV valve.

Shown with distributor cap removed

a PCV valve
b hose, PCV valve to carburetor
c hose, PCV valve to crankcase

3 Install the new PCV valve. Connect the hoses.

4 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.

C-12
Clean or Replace the
a b a
Distributor Cap and Rotor
- Gasoline/LPG Models
a pivot plate retaining bolts A distributor cap and rotor that are clean and free
b engine pivot plate of damage, wear and corrosion are essential to
good engine performance and service life. A dirty
or worn cap and rotor may cause the engine to
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may require that the cap and rotor be replaced
more often.

Perform this procedure with the

engine off.

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TABLE C PROCEDURES

1 Remove the 2 bolts from under the engine pivot C-13

plate. Swing the engine pivot plate away from
the machine to access the distributor. 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
result in component damage.

Perform this procedure with the

engine off.
1 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.
a b a
5 Install the new spark plugs, then connect the
a pivot plate retaining bolts wires. Be sure that each spark plug wire is
b engine pivot plate attached to the correct spark plug.

2 Label and disconnect the coil and spark plug

Spark plug specifications
wires from the distributor cap.
3 Remove the cap and rotor from the distributor. Spark plug type Motorcraft AWSF-42

4 Clean the cap and rotor using electrical contact Spark plug gap 0.042 to 0.046 inches
cleaner or a damp cloth. 1.07 to 1.18 mm
5 Completely dry the cap and rotor.
Spark plug torque 5 to 10 foot-pounds
Moisture in the distributor cap will 7 to 14 Nm
cause the engine to run poorly.
6 Inspect the cap and rotor for corrosion, cracks
and abrasion. Replace the cap and rotor if they
are damaged.
7 Install the rotor and cap, then connect the coil
and spark plug wires.
8 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.
9 Start the engine from the ground controls and
check the engine for proper operation.

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TABLE C PROCEDURES

C-14 3 Load the system by pressing the boom retract

switch, then move the engine idle control
Check and Adjust the Air/LPG switch to high idle (rabbit symbol).
Mixture - Gasoline/LPG Models 4 Adjust the high idle adjustment screw to obtain
Maintaining the proper air-to-fuel mixture during an air-to-fuel mixture ratio of 13.0:1 to 13.2:1,
LPG operation is essential to good engine using an exhaust gas analyzer.
performance. Preliminary setting is 1/4 inch of
Engine fuels are combustible. threads showing. Measure from
Perform this procedure in an top of lock nut to top of
open, well-ventilated area away adjustment screw.
from heaters, sparks, flames and If an exhaust gas analyzer is not
lighted tobacco. Always have an available, adjust to obtain peak or
approved fire extinguisher within optimum rpm.
easy reach.
5 Hold the adjustment screw and tighten the
The engine rpm needs to be lock nut.
preset for gasoline fuel operation
before adjusting the LPG idle 6 Move the engine idle control switch to low idle
mixture. Refer to B-12, Check and (turtle symbol) and adjust the low idle screw to
Adjust the Engine RPM. obtain an air-to-fuel mixture ratio
of 13.0:1 to 13.2:1.
The engine should be warmed to
normal operating temperature
before performing this procedure.
1 Move the fuel select switch to LPG fuel and
start the engine from the ground controls.
2 Loosen the high idle mixture adjustment
lock nut.

a
a
a low idle mixture adjustment screw

Preliminary setting: turn low idle

adjustment screw clockwise all
the way in. Turn low idle
adjustment screw
a high idle mixture
adjustment screw
counterclockwise 2 3/4 turns.

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TABLE C PROCEDURES

C-15 C-17
Check and Adjust the Ignition Adjust the Turntable Rotation
Timing - Gasoline/LPG Models Gear Backlash
Complete information to perform this procedure is The turntable rotation torque hub is mounted on
available in the Ford LSG-423 2.3 Liter Industrial an adjustable plate that controls the gap between
Engine Service Manual (Ford number: 194-216). the rotation motor gear and the turntable bearing.
Genie part number 29586. Maintaining proper backlash of the turntable
bearing is essential to safe machine operation.
Improper backlash could result in an unsafe
operating condition and component damage.
C-16
Check the Engine Valve See 12-1, How to Adjust the
Turntable Rotation Gear
Clearances - Deutz Diesel Models Backlash.
Complete information to perform this procedure
is available in the Deutz FL 1011 Workshop
Manual (Deutz Number 02611642). Genie part
number 29789.

Part No. 34032 Genie S-80 & Genie S-85 4 - 37

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

Table D Procedures

D-1 2 Remove the drain plug from the hydraulic tank.

Test or Replace the Hydraulic Oil 3 Completely drain the tank into a suitable
container. See capacity specifications listed
Replacement or testing of the hydraulic oil is below.
essential for good machine performance and
service life. Dirty oil and suction strainers may 4 Disconnect and cap the two suction hoses
cause the machine to perform poorly and that are attached to the hydraulic tank
continued use may cause component damage. shutoff valves.
Extremely dirty conditions may require oil changes 5 Remove the strainer assemblies from the tank.
to be performed more often.
6 Carefully clean any foreign material from
The machine uses Dexron II the strainers. Clean the strainers from the
equivalent hydraulic oil. Before inside out.
replacing the hydraulic oil, the oil
may be tested by an oil distributor 7 Apply pipe thread sealant to the strainer
for specific levels of contamination mounting threads, and then install them.
to verify that changing the oil is 8 Apply pipe thread sealant to the drain plug,
necessary. If the hydraulic oil and then install it in the tank.
is not replaced at the two year
inspection, quarterly testing 9 Install the two suction hoses.
(B-25) thereafter should be 10 Fill the tank with hydraulic oil until the level is
completed. within the top 2 inches (5 cm) of the sight
Perform this procedure with the gauge. Do not overfill.
boom in the stowed position. 11 Clean up any oil that may have spilled and
1 Close the two hydraulic shutoff valves located open the hydraulic tank valves.
at the hydraulic tank. 12 Prime the pump by doing the following:
Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
Gasoline/LPG models:
Remove the high tension lead from the center
of the ignition coil.
open closed
Electrocution hazard. Contact with
Component damage hazard. The electrically charged circuits may
engine must not be started with cause death or serious injury.
the hydraulic tank shutoff valves Remove all rings, watches and
in the CLOSED position or other jewelry.
component damage will occur.
If the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the condition.

4 - 38 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

Deutz Diesel models: D-2

Hold the manual fuel shutoff valve Change or Recondition the
counterclockwise to the CLOSED position.
Engine Coolant
a - 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

coolant. Contact with hot engine
parts and/or coolant will cause
severe burns.
Perform this procedure with the
a manual fuel shutoff valve
engine off and cooled.
All models:
1 Put on protective clothing and eye wear.
Crank the engine with the starter motor for
2 Disconnect the coolant return hose at the
15 seconds, wait 15 seconds, then crank the
radiator and drain the coolant return tank.
engine an additional 15 seconds or until the
pressure reaches 320 psi (22 bar). 3 Remove the radiator cap from the radiator.
13 Connect the wiring and start the engine from
the ground controls. Check the hydraulic tank
for leaks.

Hydraulic system

Hydraulic tank capacity 45 gallons

170 liters

Hydraulic system 55 gallons

capacity (including tank) 208 liters

Hydraulic fluid Dexron ll equivalent

Part No. 34032 Genie S-80 & Genie S-85 4 - 39

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE D PROCEDURES

4 Remove the 2 bolts from under the engine pivot 10 Disconnect hose A from hard line B and hold
plate. Swing the engine pivot plate away from until coolant starts to pour out of the open
the machine to access the radiator drain valve. hose. Then immediately reconnect the hose.

a b

a hose A
b hard line B

a b a 11 Fill the radiator and then fill the coolant

recovery tank to the NORMAL range.
12 Clean up any coolant spilled during this
a pivot plate retaining bolts procedure.
b engine pivot plate
13 Start the engine from the ground controls,
5 Open the drain valve on the radiator and allow run it for 30 seconds, and then turn it off.
all the coolant to drain into a container.
14 Inspect for leaks and then check the fluid
6 After all the coolant has drained, close the drain level in the coolant recovery tank. Add
valve. Connect the coolant return hose to water if needed.
the radiator.
15 Start the engine from the ground controls
7 Open the drain valve on the engine block and and run it until reaching normal operating
allow the coolant to drain into a container. temperature.
After the fluid is drained, close the drain valve.
16 Allow engine to cool and check the fluid level in
8 Replace all coolant hoses and clamps. the coolant recovery tank. Add water if needed.
9 Pour the proper coolant mixture (anti-freeze
and water) for your climate into the radiator Ford Engine LSG-423 11.5 quarts
until it is full. Coolant capacity 10.9 liters

4 - 40 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-3 a b b b b b b b

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 f e d c
pressure. Wrap a cloth around
fuel hoses to absorb leaking fuel Deutz Diesel models
a hose from the injector to
before disconnecting them.
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

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

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE D PROCEDURES

a b D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.

D-5
c Check the Engine Cylinder
Compression
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
d Engine Service Manual (Ford number: 194-216).
Genie part number 29586.

Gasoline/LPG models
a fuel filter
b hose from the fuel filter to
the carburetor
c hose from the fuel pump
to the fuel filter
d hose from the fuel shutoff
valve to the fuel pump

3 Clean up any fuel that may have spilled during

this procedure.
4 Start the engine from the ground controls, then
inspect the fuel filter and hoses 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.

4 - 42 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-6 2 Disconnect the hoses from the PCV valve, then

disconnect the hoses from the engine.
Clean the PCV Hoses and
Fittings - Gasoline/LPG Models a b

Maintaining PCV hoses is essential to good engine

performance. Improperly functioning PCV hoses
will fail to ventilate the crankcase and continued
use of neglected hoses could result in component
damage.

Perform this procedure with the c

engine off.
1 Remove the 2 bolts from under the engine pivot
plate. Swing the engine pivot plate away from
the machine to access the PCV hoses.

Shown with distributor cap removed

a PCV valve
b hose, PCV valve to carburetor
c hose, PCV valve to crankcase

3 Clean the hoses with a mild cleaning solvent.

4 Dry both hoses and inspect them for cracks
and damage. Replace the hoses if they are
damaged.

a b a

a pivot plate retaining bolts

b engine pivot plate

Part No. 34032 Genie S-80 & Genie S-85 4 - 43

Section 4 - Scheduled Maintenance Procedures Service Manual - First Edition

TABLE D PROCEDURES

D-7
Check the Fuel Injection Pumps
and Injectors
- Deutz Diesel Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Workshop Manual
(Deutz number: 0291 1942). Genie part number
29789.

D-8
Check the Toothed Belt
- Deutz Diesel Models
Complete information to perform this procedure is
available in the Deutz FL 1011 Operation Manual
(Deutz number: 0297 4706 EN). Genie part
number 29790.

D-9
Replace the Timing Belt
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: 194-216).
Genie part number 29586.

4 - 44 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 4 - Scheduled Maintenance Procedures

Part No. 34032 Genie S-80 & Genie S-85 4 - 45

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-80 & Genie S-85 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
with electrically charged circuits
· machine parked on a flat level surface
may result in death or serious
· boom in stowed position injury. Remove all rings, watches
· turntable rotated with the boom between and other jewelry.
the non-steering wheels
Bodily injury hazard. Spraying
· turntable secured with the turntable hydraulic oil can penetrate and
rotation lock pin burn skin. Loosen hydraulic
· key switch in the OFF position with the connections very slowly to allow
key removed the oil pressure to dissipate
gradually. Do not allow oil to
· wheels chocked
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Part No. 34032 Genie S-80 & Genie S-85 5-1

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

TROUBLESHOOTING FLOW CHARTS

About This Section General Repair Process

When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved

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.

5-2 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 1

Engine Will Not )NKIQHGZZKX_\URZGMK RKYYZNGT )NKIQHGZZKX_IUTJOZOUT

< 58INKIQGRZKXTGZUX
Crank Over 58INKIQHGZZKX_
<UXSUXK IGHRKY58XKVRGIKZNK
Be sure the key switch HGZZKX_
is in the appropriate
position. )NKIQ\URZGMKGZIKTZKX < :XGIKIOXI[OZHGIQ
ZKXSOTGRUTYZGXZY]OZIN ZNXU[MNZNKQK_Y]OZIN
Be sure the emergency KSKXMKTI_YZUVH[ZZUT
GTJ)(XKVGOXUVKT
stop buttons are pulled <
up into the on position.
.URJYZGXZY]OZINGTJ < 8KVRGIKYZGXZZUMMRK
Be sure the circuit INKIQ\URZGMKGZKOZNKX Y]OZIN
YOJKZKXSOTGRUTYZGXZ
breaker(s) are not Y]OZIN
tripped.
<

.URJYZGXZY]OZINGTJ < 8KVGOXHRQ]OXKIOXI[OZ

INKIQ\URZGMKGZ LXUSYZGXZY]OZINZU
ZKXSOTGR:( :(

<

.URJYZGXZY]OZINGTJ < 8KVGOXHRQ]OXKIOXI[OZ

INKIQ\URZGMKGZ LXUS:(ZUYZGXZ
ZKXSOTGR UTYZGXZ RUIQU[ZSUJ[RKZKXSOTGR
RUIQU[ZSUJ[RK 

<

.URJYZGXZY]OZINGTJ )NKIQXKVGOXUVKTOT
INKIQ\URZGMKGZ < VU]KXY[VVR_]OXKZU
ZKXSOTGR GTJGZ ZKXSOTGR GTJUT
YZGXZRUIQU[ZSUJ[RK YZGXZRUIQU[ZSUJ[RK

<

.URJYZGXZY]OZINGTJ )NKIQMXU[TJ]OXKZU HGJ

INKIQ\URZGMKGZ < ZKXSOTGR UTYZGXZ 8KVGOXUVKTOTMXU[TJ
ZKXSOTGR UTYZGXZ RUIQU[ZSUJ[RK ]OXK
RUIQU[ZSUJ[RK
MUUJ

< )UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5-3

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 1

.URJYZGXZY]OZINGTJ < 8KVGOXUVKTOTHRQ]OXK

)UTZOT[KJLXUSZNK INKIQ\URZGMKGZ LXUSZKXSOTGR UTYZGXZ
VXK\OU[YVGMK ZKXSOTGR UT)8 RUIQU[ZSUJ[RKZU)8

<

)NKIQ\URZGMKGZ < 8KVGOXXKJ]OXKIOXI[OZ

ZKXSOTGR UT)8 LXUSHGZZKX_ZU)(ZU
)8ZKXSOTGR 
<

.URJYZGXZY]OZINGTJ )NKIQMXU[TJZU HGJ 8KVGOXUVKTOTMXU[TJ

<
INKIQ\URZGMKGZ ZKXSOTGR UT)8 ZU)8
ZKXSOTGR UT)8
MUUJ

< 8KVRGIK)8XKRG_

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTHRQ]OXK

OTOZOGZKZKXSOTGRYZGXZKX IOXI[OZLXUS)8ZU
YURKTUOJ YZGXZKXYURKTUOJ

<

)NKIQXKVGOXUX
XKVRGIKYZGXZKXUXYZGXZKX
YURKTUOJ

5-4 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 2

Engine Cranks .URJYZGXZY]OZINGTJ RKYY )NKIQHGZZKX_IUTJOZOUT

INKIQHGZZKX_\URZGMK ZNGT 58INKIQGRZKXTGZUX58
Over But Will ]NORKKTMOTKOY < INKIQLUXYNUXZIOXI[OZY
IXGTQOTM 58INKIQHGZZKX_
Not Start - IGHRKY58XKVRGIKZNK
Gasoline/LPG SUXKZNGT< HGZZKX_

Models )NKIQOLKTMOTKIUURGTZ IUTZOT[OZ_ )NKIQOLXGJOGZUXGTJUX NUZ )NKIQKTMOTKIUURGTZ

U\KXZKSVKXGZ[XK KTMOTKHRUIQLKKRY RK\KR58INKIQXGJOGZUX
Be sure to check the YKTJOTMYOMTGRVUYZNGY K^IKYYO\KR_NUZ LOTYLUXIRUMMOTM58
engine oil level and fill IUTZOT[OZ_ZUMXU[TJ INKIQKTMOTKLGTHKRZY
as needed. 58YKK,UXJYKX\OIK
SGT[GRLUX
TUZNUZ ZXU[HRKYNUUZOTMGT
Be sure to check fuel
U\KXNKGZOTMKTMOTK
levels and engine
coolant level. 8KSU\K]NZ]OXKLXUS
ZKSVKXGZ[XKYKTJOTM 8KVRGIKZKSVKXGZ[XK
Be sure the gasoline [TOZINKIQIUTZOT[OZ_ZU IUTZOT[OZ_ Y]OZINYKTJKX
shut-off valve is in the MXU[TJ
on position.
TUIUTZOT[OZ_
Be sure that automatic
choke is not sticking TUIUTZOT[OZ_ 8KSU\K]NZ]OXKLXUS 8KVGOXYNUXZOT]NZ]OXK
closed. :( IUTZOT[OZ_ IOXI[OZLXUS:(ZU
ZKSVKXGZ[XKYKTJKX
Perform following tests TUIUTZOT[OZ_
in gasoline mode only.
8KVGOXYNUXZOT]NZ]OXK
IOXI[OZLXUSZKXSOTGR 
YZGXZRUIQU[ZSUJ[RKZU
:(58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

MUUJ
8KSU\K YVGXQVR[M YVGXQ -UZU)NGXZ'
GTJMXU[TJYVGXQVR[M VGMK
HUJ_)XGTQKTMOTKGTJ
UHYKX\KYVGXQ

]KGQUXTUYVGXQ

*OYGHRKYZGXZKXH_ 9KK,UXJYKX\OIK
XKSU\OTMHRQ]OXKGZZNK < SGT[GRLUX
YZGXZKXYURKTUOJNURJ ZXU[HRKYNUUZOTMOMTOZOUT
YZGXZY]OZINGTJINKIQ Y_YZKS
\URZGMKGZVUYOZO\K
ZKXSOTGRUTOMTOZOUTIUOR

RKYYZNGT<

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5-5

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 2

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOT]NZ 
)UTZOT[KJLXUSZNK INKIQ\URZGMKGZ]NZ < ]OXKZUOMTOZOUTIUOR
VXK\OU[YVGMK UTZKXSOTGR UL
)8

<
<
)NKIQ\URZGMKGZXKJ 8KVGOXUVKTOTXKJ]OXK
]OXKUTZKXSOTGR UL IOXI[OZLXUSHGZZKX_ZU
)8 )(ZU)8ZU)8

<

.URJYZGXZY]OZINGTJ < .URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHRQ]OXK

INKIQ\URZGMKGZ INKIQ\URZGMKGZ < LXUSZKXSOTGR UT
ZKXSOTGR UL)8 ZKXSOTGR UTYZGXZ )8ZUZKXSOTGR UT
RUIQU[ZSUJ[RK YZGXZRUIQU[ZSUJ[RK

<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTVU]KX

ZKXSOTGR GTJUT Y[VVR_]OXKYZUZKXSOTGR
YZGXZRUIQU[ZSUJ[RK GTJUTYZGXZ
RUIQU[ZSUJ[RK
<

< )NKIQMXU[TJ]OXK HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UTYZGXZ IOXI[OZZUYZGXZRUIQU[Z
RUIQU[ZSUJ[RK SUJ[RK

MUUJ

8KVRGIKZNKYZGXZ
RUIQU[ZSUJ[RK58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

)NKIQMXU[TJZU TUMUUJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZU)8

MUUJ

)UTZOT[KJUTZNKTK^Z
VGMK

5-6 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 2

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHXT 8
)UTZOT[KJLXUSZNK INKIQ\URZGMKGZHXT < ]OXKZUOMTOZOUTIUOR
VXK\OU[YVGMK 8]OXKUTZKXSOTGR
UL)8

<

)NKIQ\URZGMKGZ]NZ < 8KVGOXUVKTOT]NZ]OXK

]OXKUTZKXSOTGR UL IOXI[OZLXUSZKXSOTGR 
)8 UT)8ZUZKXSOTGR 
UT)8
<

.URJYZGXZY]OZINGTJ < 8KVGOXUVKTOTHRQ]OXK

INKIQ\URZGMKGZ LXUSZKXSOTGR UT
ZKXSOTGR UL)8 )8ZU UT)8

<

)NKIQMXU[TJZU TUMUUJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZU)8

MUUJ

/L]KGQYVGXQYZORR
K^OYZYIUTZGIZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5-7

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 2A

Engine Cranks )XGTQKTMOTKGTJINKIQ 8KVGOXUVKTOT]NOZK

\URZGMKGZG[ZUSGZOI ]OXKIOXI[OZLXUS
Over But Will INUQK < OMTOZOUTSUJ[RKZU
G[ZUSGZOIINUQK
Not Start -
<
Gasoline/LPG
Models or )NKIQG[ZUSGZOIINUQK 'JP[YZUXXKVRGIK
LUXVXUVKXGJP[YZSKTZUX HGJ
G[ZUSGZOIINUQK58
Engine Runs OTZKXTGRJGSGMK IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
While Cranking MUUJ
Then Dies
=OZNQK_Y]OZINUTGTJ 8KVGOXUVKTOTXKJ]NZ
Continuation of “good HUZNS[YNXUUS ]OXKIOXI[OZLXUS
Y]OZINKYV[RRKJU[Z < :(ZU\GI[[SY]OZIN
spark” fault path. INKIQ\URZGMKGZXKJ]NZ
]OXKUT\GI[[S
Perform these tests in Y]OZIN
gasoline mode only.
<
< HGJ
8KSU\KZNKHRQ]OXK :[XTSGINOTKULL9KK 8KVRGIK\GI[[SY]OZIN
]OZNJOUJKLXUSZKXSOTGR 8KVGOXYKIZOUTLUX
UT)8IXGTQZNK \GI[[SY]OZININKIQ
KTMOTKU\KXLUX
YKIUTJYGTJINKIQ
\URZGMKGZXKJHRQ]OXK UQ
UT\GI[[SY]OZIN HGJ
XKIUTTKIZHRQ]OXKGLZKX 8KVRGIK\GI[[SROTK
)NKIQ\GI[[SROTKLUX
ZKYZ XKYZXOIZOUTY

UQ
<
9KK,UXJYKX\OIK
SGT[GRZUZXU[HRKYNUUZ
RU]SGTOLURJ\GI[[S
=OZNQK_Y]OZINUTGTJ
HUZNS[YNXUUS
Y]OZINKYV[RRKJU[Z
JOYIUTTKIZ]OXKYLXUS < 8KVGOXUVKTOTXKJHRQ
\GI[[SY]OZINGTJ ]OXKIOXI[OZLXUS\GI[[S
IUTTKIZZNK]OXKY Y]OZINZU)8
ZUMKZNKX)NKIQZNK
\URZGMKGZZKXSOTGR 
UT)8

<

)UTZOT[KJUTZNKTK^Z
VGMK

5-8 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 2A

=OZNQK_Y]OZINUTGTJ < 8KVGOXUVKTOTXKJ

)UTZOT[KJLXUSZNK HUZNS[YNXUUS VU]KX]OXKIOXI[OZ]OZN
VXK\OU[YVGMK Y]OZINKYV[RRKJU[Z JOUJK
INKIQ\URZGMKGZIKTZKX
ZKXSOTGRUTL[KRYKRKIZ
Y]OZINOTVRGZLUXS
IUTZXURHU^

<
<
=OZNQK_Y]OZINUTGTJ 8KVRGIKZUMMRKY]OZIN
HUZNS[YNXUUS
Y]OZINKYV[RRKJU[Z
INKIQ\URZGMKUT
MGYUROTKYOJKHR[]NZ
]OXKULL[KRYKRKIZ
Y]OZIN

<

=OZNQK_Y]OZINUTGTJ 8KVGOXUVKTOTHR[]NZ
HUZNS[YNXUUS < ]OXKIOXI[OZLXUSZUMMRK
Y]OZINKYV[RRKJU[Z Y]OZINZU:6ZU:(
INKIQ\URZGMKGZ
ZKXSOTGR:(

<

=OZNQK_Y]OZINUTGTJ < 8KVGOXUVKTOTHR[]NZ

HUZNS[YNXUUS ]OXKIOXI[OZLXUS:(ZU
Y]OZINKYV[RRKJU[Z ZKXSOTGR UT)8
INKIQ\URZGMKGZHR[]NZ
]OXKGZZKXSOTGR UT
)8

<

=OZNQK_Y]OZINUTGTJ < )NKIQMXU[TJ]OXKUT TUMUUJ 8KVGOXUVKTOTMXU[TJ

HUZNS[YNXUUS ZKXSOTGR UL)8 ]OXK
Y]OZINKYV[RRKJU[Z
)XGTQKTMOTKGTJINKIQ
\URZGMKGZZKXSOTGR  MUUJ
UT)8
8KVRGIK)8
<

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5-9

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 2A

.URJYZGXZY]OZINGTJ < 8KVGOXUVKTOTHR[]NZ

)UTZOT[KJLXUSZNK INKIQ\URZGMKGZHR[]NZ ]OXKIOXI[OZ)8ZU
VXK\OU[YVGMK ]OXKUTGTZOJOKYKR\GR\K GTZOJOKYKR\GR\K
UTKTMOTKIGXH[XKZUX

<

.URJYZGXZY]OZINGTJ < 8KVGOXUVKTOTHR[]NZ

INKIQ\URZGMKGZHR[]NZ ]OXKIOXI[OZLXUS
]OXKUTMGYUROTK GTZOJOKYKR\GR\KZU
YURKTUOJGZMGYUROTK MGYUROTKYURKTUOJ
ZGTQ

<

.URJYZGXZY]OZINJUKY TU 8KIUTTKIZZNKZ]U
KTMOTKLOXK% ]OXKYZU\GI[[SY]OZIN
GTJINKIQLUXL[KRROTK
HRUIQGMK58XKVRGIK
_KY GTZOJOKYKR\GR\K58YKK
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-UZUINGXZ( ZXU[HRKYNUUZOTML[KR
VGMK V[SVGTJUXIGXH[XKZUX
58)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

5 - 10 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 2B

Engine Runs )XGTQKTMOTKGTJINKIQ < )XGTQKTMOTKGTJINKIQ < 8KVGOXUXXKVRGIK

\URZGMKGZZKXSOTGR  \URZGMKGZUXMHRQ  GRZKXTGZUX58IUTZGIZ
While Cranking UTYZGXZRUIQU[ZSUJ[RK ]OXKUTGRZKXTGZUX -KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
Then Dies
ZU<

8KVGOXUVKTOTUXMHRQ
ZU< ]OXKIOXI[OZLXUS
GRZKXTGZUXZU:(ZU
ZKXSOTGR UTYZGXZ
RUIQU[ZSUJ[RK

=NORKIXGTQOTMKTMOTK _KY *OYIUTTKIZ]NZ ]OXK )NKIQUORRK\KR58

LUXYKIUTJYINKIQ LXUSUORVXKYY[XKYKTJKX XKVRGIKUORVXKYY[XK
IUTZOT[OZ_ZUMXU[TJUT GTJINKIQIUTZOT[OZ_ZU _KY YKTJOTM[TOZ58XKLKXZU
ZKXSOTGR YZGXZ MXU[TJUTYOMTGRVUYZUL ,UXJYKX\OIKSGT[GRLUX
RUIQU[ZSUJ[RK/Y YKTJKX]NORKIXGTQOTM ZXU[HRKYNUUZOTMRU]UOR
IUTZOT[OZ_SGOTZGOTKJ% ZNKKTMOTK/YIUTZOT[OZ_ VXKYY[XK
SGOTZGOTKJ%

TU

TU 8KVGOXYNUXZZUMXU[TJ
OT]NZ ]OXKLXUS
YKTJKXZU:(ZUYZGXZ
RUIQU[ZSUJ[RKZKXSOTGR


)NKIQ\URZGMKGZ *OYIUTTKIZXKJ]OXK 8KVRGIKYZGXZRUIQU[Z

ZKXSOTGR UTYZGXZ < LXUSZKXSOTGR UTYZGXZ < SUJ[RK58IUTY[RZ
RUIQU[ZSUJ[RK RUIQU[ZSUJ[RKGTJ -KTOK/TJ[YZXOKY
INKIQ\URZGMKGZ 9KX\OIK*KVGXZSKTZ
ZKXSOTGR 

<
<
8KVGOXYNUXZZUVU]KXOT
XKJ]OXKIOXI[OZLXUS
:(

8KVRGIKYZGXZRUIQU[Z
SUJ[RK58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 11

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 3

Engine Cranks .URJYZGXZY]OZINGTJ RKYY )NKIQHGZZKX_IUTJOZOUT

INKIQHGZZKX_\URZGMK ZNGT 58INKIQGRZKXTGZUX58
Over But Will ]NORKKTMOTKOYIXGTQOTM < INKIQLUXYNUXZIOXI[OZY
58INKIQHGZZKX_IGHRKY
Not Start - 58XKVRGIKZNKHGZZKX_
Deutz Diesel SUXKZNGT<
Models )NKIQOLKTMOTKIUURGTZ IUTZOT[OZ_ )NKIQOLUORIUURKX NUZ )NKIQKTMOTKUORRK\KR
U\KXZKSVKXGZ[XK GTJUXKTMOTKHRUIQ 58UORIUURKXLOTYLUX
Be sure to check the YKTJOTMYOMTGRVUYZNGY LKKRYK^IKYYO\KR_NUZ IRUMMOTM58INKIQ
engine oil level and fill IUTZOT[OZ_ZUMXU[TJ KTMOTKLGTHKRZY58YKK
as needed. *K[Z`YKX\OIKSGT[GR
LUXZXU[HRKYNUUZOTMGT
TUZNUZ U\KXNKGZOTMKTMOTK
Be sure to check
fuel level.
Be sure the diesel 8KSU\K]NZ]OXKLXUS
ZKSVKXGZ[XKYKTJOTM 8KVRGIKZKSVKXGZ[XK
shut-off valve is in [TOZINKIQIUTZOT[OZ_ZU IUTZOT[OZ_ Y]OZINYKTJKX
the on position. MXU[TJUT]OXK

TUIUTZOT[OZ_

TUIUTZOT[OZ_ 8KSU\K]NZ]OXKLXUS 8KVGOXYNUXZOT]NZ]OXK

:( IUTZOT[OZ_ IOXI[OZLXUS:(ZU
ZKSVKXGZ[XKYKTJKX
TUIUTZOT[OZ_

8KVGOXYNUXZOT]NZ]OXK
IOXI[OZLXUSYZGXZRUIQU[Z
SUJ[RKZU:(58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

UX
*OYGHRKYZGXZKXH_ < :[XTSGINOTKULLGTJ OTLOTOZK 8KVRGIKZNKL[KR
XKSU\OTMHRQ]OXKGZZNK OYURGZKZNKL[KRYURKTUOJ UNSY YURKTUOJ
YZGXZKXYURKTUOJNURJ )NKIQZNKXKYOYZGTIKUL
YZGXZY]OZINGTJINKIQ ZNKYURKTUOJ
\URZGMKGZVUYOZO\K
ZKXSOTGRUTL[KR
YURKTUOJ UNSY

9KK*K[Z`YKX\OIK
< SGT[GRLUX
ZXU[HRKYNUUZOTML[KR
)UTZOT[KJUTZNKTK^Z Y_YZKS
VGMK

5 - 12 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 3

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOT]NZ 
)UTZOT[KJLXUSZNK INKIQ\URZGMKGZ]NZ < ]OXKLXUS)8ZUL[KR
VXK\OU[YVGMK ]OXKUTZKXSOTGR  YURKTUOJ
UL)8

<
<
)NKIQ\URZGMKGZXKJ 8KVGOXUVKTOTXKJ]OXK
]OXKUTZKXSOTGR UL IOXI[OZLXUSHGZZKX_ZU
)8 )(ZU)8ZU)8

<

.URJYZGXZY]OZINGTJ .URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHRQ]OXK

< INKIQ\URZGMKGZ < LXUSZKXSOTGR UT
INKIQ\URZGMKGZ
ZKXSOTGR UL)8 ZKXSOTGR UTYZGXZ )8ZUZKXSOTGR UT
RUIQU[ZSUJ[RK YZGXZRUIQU[ZSUJ[RK

<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTVU]KX

ZKXSOTGR GTJUT Y[VVR_]OXKYZUZKXSOTGR
YZGXZRUIQU[ZSUJ[RK GTJUTYZGXZRUIQU[Z
SUJ[RK
<

< )NKIQMXU[TJ]OXK HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UTYZGXZ IOXI[OZZUZKXSOTGR UT
RUIQU[ZSUJ[RK YZGXZRUIQU[ZSUJ[RK

MUUJ

8KVRGIKZNKYZGXZ
RUIQU[ZSUJ[RK58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

)NKIQMXU[TJZU TUMUUJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZU)8

MUUJ

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 13

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 3

)XGTQKTMOTKGTJINKIQ < )XGTQKTMOTKGTJINKIQ < 8KVGOXUXXKVRGIK

)UTZOT[KJLXUSZNK \URZGMKGZUXMHRQ  GRZKXTGZUX58IUTZGIZ
VXK\OU[YVGMK \URZGMKGZZKXSOTGR UT
YZGXZRUIQU[ZSUJ[RK ]OXKUTGRZKXTGZUX -KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
ZU<

8KVGOXUVKTOTUXMHRQ
ZU< ]OXKIOXI[OZLXUS
GRZKXTGZUXZU:(ZU
ZKXSOTGR UTYZGXZ
RUIQU[ZSUJ[RK

=NORKIXGTQOTMKTMOTK *OYIUTTKIZ]NZ ]OXK )NKIQUORRK\KR58

LUXYKIUTJYINKIQ _KY LXUSUORVXKYY[XKYKTJKX XKVRGIKUORVXKYY[XK
IUTZOT[OZ_ZUMXU[TJUT GTJINKIQIUTZOT[OZ_ZU _KY YKTJOTM[TOZ58XKLKXZU
ZKXSOTGR UTYZGXZ MXU[TJUTYOMTGRVUYZUL *K[Z`YKX\OIKSGT[GR
RUIQU[ZSUJ[RK/Y YKTJKX]NORKIXGTQOTM LUXZXU[HRKYNUUZOTMRU]
IUTZOT[OZ_SGOTZGOTKJ% ZNKKTMOTK/YIUTZOT[OZ_ UORVXKYY[XK
SGOTZGOTKJ%

TU

TU 8KVGOXYNUXZZUMXU[TJ
]NZ ]OXKLXUS
YKTJKXZU:(ZUYZGXZ
ZKXSOTGR UTRUIQU[Z
SUJ[RK

)NKIQ\URZGMKGZ < *OYIUTTKIZXKJ]OXK 8KVRGIKYZGXZRUIQU[Z

ZKXSOTGR UTYZGXZ LXUSZKXSOTGR UTYZGXZ < SUJ[RK58IUTY[RZ
RUIQU[ZSUJ[RK RUIQU[ZSUJ[RKGTJ -KTOK/TJ[YZXOKY9KX\OIK
INKIQ\URZGMKGZ *KVGXZSKTZ
ZKXSOTGR 

<
<
8KVGOXVUYOZO\KYNUXZOT
XKJ]OXKIOXI[OZLXUS
:(
8KVRGIKYZGXZRUIQU[Z
SUJ[RK58IUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

5 - 14 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 4

Engine Will Not *OYIUTTKIZ26-Y[VVR_

ROTKLXUS26-ZGTQGTJ
Start On LPG, HRKKJVXKYY[XKLXUS
ROTK
But Will Start
On Gasoline -
Gasoline/LPG =OZNQK_Y]OZINUTGTJ < 8KVRGIKL[KRYKRKIZ
Models HUZNS[YNXUUS Y]OZIN
Y]OZINKYV[RRKJU[Z
Be sure fuel select INKIQ\URZGMKGZ26-
YOJKHR[XKJ]OXKUL
switch is switched L[KRYKRKIZY]OZIN
to LPG.
<
Be sure to check
LPG fuel level. =OZNQK_Y]OZINUTGTJ 8KVGOXUVKTOTHR[XKJ
HUZNS[YNXUUS < ]OXKIOXI[OZLXUSL[KR
Y]OZINKYV[RRKJU[Z YKRKIZY]OZINZU:6ZU
INKIQ\URZGMKGZ:( :(

<

=OZNQK_Y]OZINUTGTJ < 8KVGOXUVKTOTHR[XKJ

HUZNS[YNXUUS ]OXKIOXI[OZLXUS:(ZU
Y]OZINKYV[RRKJU[Z ZKXSOTGR UT)8
INKIQ\URZGMKGZ
ZKXSOTGR UT)8

<

)XGTQKTMOTKLUX < 8KVGOXUVKTOTXKJHRQ

YKIUTJYGTJINKIQ ]OXKIOXI[OZLXUS\GI[[S
\URZGMKGZZKXSOTGR  Y]OZINZU)8ZU)8
UT)8

<

)NKIQMXU[TJ]OXKZU HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ZUZKXSOTGR UT)8

MUUJ

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 15

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 4

.URJYZGXZY]OZINGTJ < 8KVRGIK)8XKRG_

)UTZOT[KJLXUSZNK INKIQ\URZGMKGZ
VXK\OU[YVGMK ZKXSOTGR UT)8

<

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHR[XKJ
INKIQ\URZGMKGZHR[XKJ < ]OXKIOXI[OZLXUS)8
]OXKUT26-YURKTUOJ ZKXSOTGR ZU26-
YURKTUOJ
<
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY
26-YURKTUOJ 8KVRGIK26-YURKTUOJ

ZUUNSY

8KIUTTKIZ26-ZGTQ
GTJYZGXZKXZNKTYKK
3GOTZKTGTIKYKIZOUTLUX
26-GJP[YZSKTZY58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 16 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 5

Engine Will =OZNQK_Y]OZINUTGTJ < 8KVRGIKL[KRYKRKIZ

HUZNS[YNXUUS Y]OZIN
Not Start On Y]OZINKYV[RRKJU[Z
Gasoline, INKIQ\URZGMKGZ
MGYUROTKYOJKHR[]NZ
But Will Start ]OXKULL[KRYKRKIZ
Y]OZIN
On LPG -
<
Gasoline/LPG
Models =OZNQK_Y]OZINUTGTJ < 8KVGOXUVKTOTHR[]NZ
HUZNS[YNXUUS ]OXKIOXI[OZLXUSL[KR
Be sure fuel select Y]OZINKYV[RRKJU[Z YKRKIZY]OZINZU
INKIQ\URZGMKGZ:( :6ZU:(
switch is switched
to gasoline.
<
Be sure to check
gasoline fuel level. =OZNQK_Y]OZINUTGTJ < 8KVGOXUVKTOTHR[]NZ
HUZNS[YNXUUS ]OXKIOXI[OZLXUS:(ZU
Y]OZINKYV[RRKJU[Z ZKXSOTGR UT)8
Be sure that engine INKIQ\URZGMKGZ
choke is operating ZKXSOTGR UT)8
properly.
<

)XGTQKTMOTKLUX < 8KVGOXUVKTOTXKJHRQ

YKIUTJYGTJINKIQ ]OXKIOXI[OZLXUS\GI[[S
\URZGMKGZZKXSOTGR  Y]OZINZU)8
UT)8

<

)NKIQMXU[TJ]OXKZU HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZUZKXSOTGR UT
)8
MUUJ

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHR[]NZ
INKIQ\URZGMKGZHR[]NZ < ]OXKIOXI[OZLXUS)8
]OXKUTGTZOJOKYKR\GR\K ZKXSOTGR 
UTIGXH[XKZUX ZUGTZOJOKYKR\GR\K58
XKVRGIK)8
<

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 17

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 5

.URJYZGXZY]OZINGTJ 8KVGOXUVKTOTHR[]NZ
)UTZOT[KJLXUSZNK INKIQ\URZGMKGZHR[]NZ < ]OXKIOXI[OZLXUS)8
VXK\OU[YVGMK ]OXKUTMGYUROTK ZUL[KRYURKTUOJ
YURKTUOJGZL[KRZGTQ

<
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY 8KVRGIKMGYUROTK
MGYUROTKYURKTUOJ YURKTUOJ

ZUUNSY

)NKIQMXU[TJ]OXKZU HGJ
MGYYURKTUOJ 8KVGOXMXU[TJ]OXK

MUUJ
UX
OTLOTOZK
)NKIQXKYOYZGTIKUL UNSY 8KVRGIKGTZOJOKYKR
GTZOJOKYKR\GR\K \GR\K

ZUUNSY

8KIUTTKIZYZGXZKX
INKIQGTZOJOKYKRGTJ
L[KR\GR\KLUXJKLKIZY
58YKK,UXJYKX\OIK
SGT[GRLUXIGXH[XKZUX
ZXU[HRKYNUUZOTM

5 - 18 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 6

Engine 9ZGXZKTMOTKGTJY]OZIN < )NKIQ\URZGMKGZIKTZKX

<
8KVGOXUVKTOTIOXI[OZ
XVSYKRKIZZUNOMNOJRK ZKXSOTGRUTXVSYKRKIZ Y[VVR_OTM<ZUIKTZKX
High Idle XGHHOZY_SHURLUX Y]OZIN ZKXSOTGRULY]OZIN
Inoperative - LURRU]OTMINKIQY)NKIQ
\URZGMKGZHRQXKJ]OXK <
Gasoline/LPG UTXVSY]OZIN

Models 8KVRGIKXVSYKRKIZ
< ZUMMRKY]OZIN
If high idle operates
on LPG but not on < 8KVGOXUVKTOTHRQXKJ
)NKIQ\URZGMKGZ:( ]OXKIOXI[OZLXUSZUMMRK
gasoline, see Ford Y]OZINZU:6ZU:(
service manual for <
carburetor
troubleshooting. )NKIQ\URZGMKGZ 8KVGOXUVKTOTHRQXKJ
<
ZKXSOTGR HRQXKJUL ]OXKIOXI[OZLXUS
If high idle operates )8 :(ZU)8
on gasoline but not
on LPG, see Repair <
section for LPG
regulator adjustments. )NKIQMXU[TJ]OXKZU HGJ 8KVGOXUVKTOTMXU[TJ
ZKXSOTGR UT)8 ]OXKZUZKXSOTGR UT
Be sure throttle )8
linkage from governor MUUJ
to carburetor is not
)NKIQ\URZGMKGZ < 8KVGOXUVKTOTVU]KX
binding, see Repair ZKXSOTGR UT)8 ]OXKLXUSZKXSOTGR'
section. UT)8ZU)8
<
Be sure high idle can
be achieved by <
)NKIQ\URZGMKGZ 8KVRGIK)8XKRG_
grasping the governor ZKXSOTGR'UT)8
actuator arm and
momentarily pulling to <
throttle the carburetor.
)NKIQ\URZGMKGZ < 8KVGOXYNUXZOTHRQXJ
ZKXSOTGRUT 8]OXKZUZKXSOTGR 
KRKIZXUTOIMU\KXTUX UTVXKIOYOUTMU\KXTUX

<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOT]NZ]OXK

ZKXSOTGR UT)8 IOXI[OZLXUS)8
ZKXSOTGR ZU)8

<

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 19

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 6

)NKIQ\URZGMKGZ 8KVGOXUVKTOTXJHRQ
)UTZOT[KJLXUSZNK ZKXSOTGR UT)8 8]OXKIOXI[OZLXUS
VXK\OU[YVGMK <
\GI[[STY]OZINZU)8
ZU)8ZUZKXSOTGR 
< UT)8

)NKIQMXU[TJ]OXKZU HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZUZKXSOTGR UT
)8
MUUJ

)NKIQ\URZGMKZU < 8KVRGIK)8XKRG_

ZKXSOTGR UT)8

<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTXKJ]NZ

ZKXSOTGRXKJ]NZ]OXK ]OXKIOXI[OZLXUSZKXSOTGR
UTKRKIZXUTOIMU\KXTUX UT)8ZUZKXSOTGR
UTKRKIZXUTOI
MU\KXTUX
<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTXKJ]NZ

ZKXSOTGRXKJ]NZ]OXK ]OXKIOXI[OZLXUS
UTMU\KXTUXGIZ[GZUX KRKIZXUTOIMU\KXTUXZU
MU\KXTUXGIZ[GZUX
<

)NKIQIUTZOT[OZ_LXUS TU 8KVGOXUVKTOTHR[HRQ
ZKXSOTGR UTVXKIOYOUT IUTZOT[OZ_ ]OXKIOXI[OZLXUS
MU\KXTUXZUHR[HRQ MU\KXTUXGIZ[GZUXZU
ZKXSOTGR UTMU\KXTUX KRKIZXUTOIMU\KXTUX58
GIZ[GZUX INKIQGTJUXXKVRGIK
MU\KXTUXGIZ[GZUX
L[RRIUTZOT[OZ_

:[XTSGINOTKULL UX
XKSU\KHUZN]OXKY OTLOTOZK
LXUSMU\KXTUXGIZ[GZUX UNSY 8KVRGIKMU\KXTUX
GTJINKIQXKYOYZGTIK GIZ[GZUX
GIXUYYMU\KXTUX
GIZ[GZUXZKXSOTGRY

ZUUNSY

8KIUTTKIZMU\KXTUX 8KVGOXUVKTOTHXU]T
]OXKYGTJXKYZGXZKTMOTK < ]OXKIOXI[OZLXUSOMTOZOUT
GTJINKIQ\URZGMKGZ SUJ[RKZUKRKIZXUTOI
KRKIZXUTOIMU\KXTUX MU\KXTUX
ZKXSOTGRHXU]T]OXK

ZU<

9KK3GOTZKTGTIK
YKIZOUTLUXMU\KXTUX
GJP[YZSKTZY58XKVRGIK
KRKIZXUTOIMU\KXTUX

5 - 20 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 7

Engine Low Idle 9ZGXZKTMOTKGTJY]OZIN /YURGZKZNKMXU[TJGTJ

XVSYKRKIZZURU]OJRK < VRGZLUXSXVSY]OZINKY
Inoperative - Z[XZRKY_SHUR)NKIQ INKIQOTJO\OJ[GRR_GTJ
\URZGMKGZZKXSOTGR  XKVRGIKJKLKIZO\K
Gasoline/LPG HRQXJ]OXKUT)8 Y]OZIN
Models
<
If low idle operates
on LPG but not on )NKIQ\URZGMKGZ < 8KVGOXUVKTOT]NZ]OXK
gasoline, see Ford ZKXSOTGR UT)8 IOXI[OZLXUSZKXSOTGR
'UT)8ZU)8
service manual for ZKXSOTGR 
carburetor <
troubleshooting. <
)NKIQ\URZGMKGZ 8KVRGIK)8XKRG_
ZKXSOTGR 'UT)8
If low idle operates
on gasoline but not
<
on LPG, see Repair
section for LPG )NKIQ\URZGMKGZ 8KVGOXUVKTOTHRQXKJ
<
regulator adjustments. ZKXSOTGR UT ]OXKIOXI[OZLXUS)8
KRKIZXUTOIMU\KXTUX ZKXSOTGR 'ZU
Be sure throttle KRKIZXUTOIMU\KXTUX
linkage from governor < ZKXSOTGR 
to carburetor is not
binding, see Repair )NKIQ\URZGMKGZ < 8KVGOXUVKTOTHXU]T
section. KRKIZXUTOIMU\KXTUX ]OXKIOXI[OZLXUSOMTOZOUT
ZKXSOTGRHXU]T]OXK SUJ[RKZUKRKIZXUTOI
MU\KXTUX
ZU<

:[XTSGINOTKULL 8KINKIQZNXUZZRKROTQGMK
XKSU\KHR[HRQ]OXK KTMOTKMUKYZUNOMNOJRK YKK8KVGOXYKIZOUT58
LXUSZKXSOTGR UT INKIQGTJUXXKVRGIK
KRKIZXUTOIMU\KXTUXGTJ MU\KXTUXGIZ[GZUX58
XKYZGXZKTMOTK YKK,UXJYKX\OIK
SGT[GRLUXIGXH[XKZUX
KTMOTKMUKYZURU]OJRK ZXU[HRKYNUUZOTM

8KINKIQKRKIZXUTOI
MU\KXTUXGJP[YZSKTZY
58XKVRGIKKRKIZXUTOI
MU\KXTUX

Part No. 34032 Genie S-80 & Genie S-85 5 - 21

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 8

Engine 9ZGXZKTMOTKY]OZINXVS )NKIQNOMNOJRK

YURKTUOJ GJP[YZSKTZYKK
YKRKIZY]OZINZUNOMNOJRK
High Idle XGHHOZY_SHURGTJ V[RRYOT 3GOTZKTGTIKYKIZOUTUX
INKIQOLYVKKJ YKK*K[Z`]UXQYNUV
Inoperative - YURKTUOJV[RRYOT SGT[GRZUZXU[HRKYNUUZ
Deutz Diesel L[KROTPKIZOUTY_YZKS
YURKTUOJJUKY
Models TUZV[RROT
)NKIQ\URZGMKGZHRQXKJ < )NKIQ\URZGMKUTXKJ < 8KVGOXUVKTOTIOXI[OZ
Be sure mechanical ]OXKUTXVSYKRKIZ ]OXKGZIKTZKXZKXSOTGR Y[VVR_OTM<ZUIKTZKX
linkage is not binding Y]OZIN ULXVSYKRKIZY]OZIN ZKXSOTGRULY]OZIN
or defective.
<
Be sure 2-speed <
solenoid grounding 8KVRGIKZUMMRKY]OZIN
wires are free of
<
corrosion and have full )NKIQ\URZGMKGZ:( 8KVGOXUVKTOTHRQXKJ
continuity to ground. ]OXKIOXI[OZLXUSZUMMRK
Y]OZINZU:6ZU:(
<

)NKIQ\URZGMKGZ < 8KVGOXUVKTOTHRQXKJ

ZKXSOTGR UT)8 ]OXKIOXI[OZLXUS:(ZU
ZKXSOTGR UT)8
<

)NKIQ\URZGMKZU < 8KVGOXUVKTOT]NZ]OXK

ZKXSOTGR UT)8 IOXI[OZLXUSZKXSOTGR 
UT)8ZUZKXSOTGR 
UT)8
<

)NKIQMXU[TJ]OXKZU HGJ 8KVGOXUVKTOTMXU[TJ

ZKXSOTGR UT)8 ]OXKZUZKXSOTGR UT
)8
MUUJ

)NKIQ\URZGMKZU <
ZKXSOTGR UT)8 8KVRGIK)8XKRG_

<

)NKIQ\URZGMKGZOTOZOGZK < 8KVGOXUVKTOTHRQXKJ

ZKXSOTGR UT)8 ]OXKIOXI[OZLXUS
)8ZU)8
<

)UTZOT[KJUTZNKTK^Z
VGMK

5 - 22 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 8

)NKIQMXU[TJ]OXKZU HGJ 8KVGOXMXU[TJ]OXKZU

)UTZOT[KJLXUSZNK ZKXSOTGR UT)8
VXK\OU[YVGMK ZKXSOTGR UT)8

MUUJ

)NKIQ\URZGMKZU < 8KVGOXUVKTOT]NZ]OXK

ZKXSOTGR UT)8 IOXI[OZLXUS)8ZU)8
ZU)8
<

)NKIQ\URZGMKGZZNK < 8KVRGIK)8XKRG_

HRQXKJ]OXKUTZNK 58XKVGOXUVKTOT
YVKKJYURKTUOJ HRQXKJ]OXKIOXI[OZLXUS
ZKXSOTGR UT)8ZU
< YVKKJYURKTUOJ

YURKTUOJ
)NKIQOLYVKKJ HOTJY )NKIQROTQGMKUX
YURKTUOJSU\KYOTGTJ XKVRGIKYURKTUOJ
U[ZLXKKR_

SU\KYLXKKR_

8KVRGIKYVKKJ
YURKTUOJ4UZK
XKYOYZGTIKGIXUYY
YURKTUOJZKXSOTGRY
YNU[RJHKGVVXU^OSGZKR_
UNSY

Part No. 34032 Genie S-80 & Genie S-85 5 - 23

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 9

Engine 'ZVRGZLUXSIUTZXURY /YURGZKZNKVRGZLUXSGTJ

YZGXZKTMOTKGTJY]OZIN < MXU[TJXVSY]OZINKY
Low Idle XVSYKRKIZY]OZINZU INKIQOTJO\OJ[GRR_GTJ
SGOTZGOTKJRU]OJRK XKVRGIKJKLKIZO\K
Inoperative - Z[XZRKY_SHUR)NKIQ Y]OZIN
Deutz Diesel \URZYGZHRQXKJ]OXKUT
XVSYKRKIZY]OZIN
Models
<
Check if
<
mechanical linkage )NKIQ\URZGMKGZZNK 8KVRGIK)8XKRG_
from 2-speed XKJ]OXKUTZNK
YVKKJYURKTUOJ
solenoid to fuel
injection system is
<
binding or defective.
YURKTUOJ
)NKIQOLYVKKJ HOTJY )NKIQROTQGMKUX
YURKTUOJSU\KYOTGTJ XKVRGIKYURKTUOJ
U[ZLXKKR_

SU\KYLXKKR_

)NKIQGJP[YZSKTZUL
ROTQGMKGTJL[KR
OTPKIZOUTY_YZKSRU]
OJRK9KK3GOTZKTGTIK
YKIZOUT

UQ

9KK*K[Z`]UXQYNUV
SGT[GRZUZXU[HRKYNUUZ
L[KROTPKIZOUTY_YZKS58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 24 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 10

All Functions )NKIQN_JXG[ROI RU] ,ORR]OZN*K^XUT//

LR[OJRK\KR KW[O\GRKTZN_JXG[ROI
Inoperative, LR[OJ
Engine Starts UQ
and Runs )NKIQV[SVY[IZOUT 5VKT\GR\KY/LKTMOTK
ROTKYN[ZULL\GR\KY IRUYKJ NGYHKKTX[T]OZN
<GR\KNGTJRKYYNU[RJ \GR\KYIRUYKJOZSG_
HKVGXGRRKR]OZNNUYK NG\KJGSGMKJUTK
UXHUZNV[SVY
UVKT

*OYIUTTKIZIKTZKXIUOR YVROTK :XU[HRKYNUUZ

]OXKLXUSJOYZXOH[ZUXIGV Z[XTY OTUVKXGZO\KHUUS
GTJOYURGZKLXUS L[TIZOUTYGTJ
MXU[TJOTM*K[Z` OTUVKXGZO\KJXO\K
SUJKRYNURJSGT[GR L[TIZOUTYYKVGXGZKR_
L[KRYN[ZULLRK\KX
IU[TZKXIRUIQ]OYK
8KSU\KL[TIZOUTV[SV
LXUSSGOTV[SVH[Z
RKG\KGRRNUYKY
IUTTKIZKJ.URJYZGXZ
Y]OZINGTJIXGTQKTMOTK
U\KX]NORKUHYKX\OTM
YVROTKJXO\KGZXKGXUL
SGOTV[SV

YVROTKJUKYTUZZ[XT

+TMOTKZUV[SVLRK^
VRGZKIU[VROTMOY
JKLKIZO\K9KK
8KVGOXYKIZOUT

Part No. 34032 Genie S-80 & Genie S-85 5 - 25

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 11

All Lift and /TYZGRRGZU69/  :XU[HRKYNUUZKGIN

VXKYY[XKMG[MKUT VYO L[TIZOUTOTJO\OJ[GRR_UX
Steer Functions ZNKL[TIZOUTSGTOLURJ IUTY[RZ-KTOK/TJ[YZXOKY
9ZGXZKTMOTKNURJZNK 9KX\OIK*KVGXZSKTZ
Inoperative, HUUSXKZXGIZL[TIZOUT
Drive Functions GTJINKIQZNKN_JXG[ROI
VXKYY[XK
Operational
RKYYZNGTVYO
Be sure the hydraulic

suction line shutoff 'JP[YZZNKL[TIZOUT VYOUX .URJZNKHUUSXKZXGIZ
valve for the lift/steer SGTOLURJXKROKL\GR\K SUXK Y]OZINGTJXKGJP[YZ
OZKS'(GRRZNK]G_OT ZNKXKROKLVXKYY[XKZU
pump is in the open IRUIQ]OYKIU[TZOTM VYO
position. ZNKT[SHKXULZ[XTY
.URJZNKHUUSXKZXGIZ
Be sure all grounding Y]OZINGTJXKINKIQ
wires for the hydraulic ZNKVXKYY[XK
manifold valves are free
RKYYZNGTVYO
of corrosion and have
full continuity to ground. YZKKXOTMUVKXGZKY
)NKIQYZKKXL[TIZOUTY -UZUINGXZ'VGMK

Be sure axles are fully
extended. YZKKXOTMOTUVKXGZO\K

)NKIQZNKL[TIZOUT UQ 8KVRGIKZNKXKROKL\GR\K
V[SVYKK8KVGOX 58SGTOLURJNGY
YKIZOUT OTZKXTGRJKLKIZYIUTY[RZ
-KTOK/TJ[YZXOKY
HGJ 9KX\OIK*KVGXZSKTZ

8KVRGIKZNKV[SV

5 - 26 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 11A

All Lift Functions )GT_U[L[RR_XKZXGIZGTJ 5VKXGZKHUUSJU]T < 8KVGOX58XKVRGIKZNK

RU]KXZNKHUUS%OL GTJINKIQ\URZGMKGZ KRKIZXOIGRJ[SV\GR\K
Inoperative, Steer HUUSOYGRXKGJ_OT TU KRKIZXOIGRJ[SV\GR\K
YZU]KJVUYOZOUTLURRU] TK^ZZUL[TIZOUT
and Drive _KYVGZN SGTOLURJ
Functions
<
Operational
_KY 8KVGOXUVKTOTXKJHRQ
LXUS:(ZU:(

=OZNHUUSOTYZU]KJ 8KVGOXUVKTOTXKJ 
VUYOZOUTGTJKTMOTK < < ]OXKLXUS:(ZU
X[TTOTMINKIQ\URZGMK )NKIQ\URZGMKGZ:( KRKIZXOIGRJ[SV\GR\K
GZKRKIZXOIGRJ[SV\GR\K
TK^ZZUL[TIZOUT <
SGTOLURJ 8KVGOXUVKTOT29
< IOXI[OZHKZ]KKT:(
)NKIQ\URZGMKGZ:(
GTJ:(58XKVRGIK
29
<
<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOT29
IOXI[OZHKZ]KKT:(
< GTJ:(58XKVRGIK
< 29
8KVGOXUVKTOT]NOZK
]OXK]OZNJOUJKLXUS
:(ZU:(

5VKXGZKHUUS[V HUUSOTUVKXGZO\K 8KVGOXUXXKVRGIKZNK

L[TIZOUT KRKIZXOIGRJ[SV\GR\K

HUUSUVKXGZKY

=ORRHUUSXGOYKGHU\K
JXO\KROSOZY]OZIN

TU
SUXK
/TYZGRRGVYO ZNGT 8KVGOX58XKVRGIKZNK
VXKYY[XKMG[MK VYO VORUZUVKXGZKJJ[SV
HKZ]KKTZNKN_JXG[ROI \GR\K
NUYKZUVORUZVUXZULZNK
VORUZUVKXGZKJJ[SV
\GR\K

RKYYZNGTVYO

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 27

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 11A

)NKIQG^RKK^ZKTYOUT 'JP[YZZNKG^RK
)UTZOT[KJLXUSZNK N_JXG[ROIROSOZY]OZINKY K^ZKTYOUTN_JXG[ROIROSOZ
VXK\OU[YVGMK LUXVXUVKXGJP[YZSKTZ HGJ Y]OZINKY
XKLKXZUXKVGOXVXUIKJ[XK
%%%

MUUJ

/TYZGRRGVYO SUXK
VXKYY[XKMG[MKOTZNK ZNGT
N_JXG[ROINUYKHKZ]KKT VYO 8KVGOX58XKVRGIK
ZNKN_JXG[ROIROSOZY]OZIN LGORKJN_JXG[ROIROSOZ
GTJYZKKXKTJINGYYOY Y]OZINUXY]OZINKY
ROLZPGIQ\GR\K

RKYYZNGTVYO

'JP[YZZNKN_JXG[ROIROSOZ SUXK
Y]OZINXKROKL\GR\K ZNGT
25)':/54GRRZNK]G_ VYO 8KVGOX58XKVRGIK
OTIRUIQ]OYKIU[TZOTM N_JXG[ROIROSOZY]OZIN
ZNKT[SHKXULZ[XTYGTJ XKROKL\GR\K
XKINKIQZNKVXKYY[XK

RKYYZNGTVYO

'JP[YZZNKINGYYOYROLZ SUXK
PGIQXKROKL\GR\K ZNGT
25)':/54GRRZNK]G_ VYO 8KVGOX58XKVRGIK
OTIRUIQ]OYKIU[TZOTM INGYYOYROLZPGIQXKROKL
ZNKT[SHKXULZ[XTYGTJ \GR\K
XKINKIQZNKVXKYY[XK

RKYYZNGTVYO

8KVGOX58XKVRGIK
N_JXG[ROIROSOZY]OZIN
XKROKL\GR\K58XKVGOX
58XKVRGIKINGYYOYROLZ
PGIQXKROKL\GR\K58
XKVGOX58XKVRGIKLRU]
XKM[RGZUX\GR\KOZKS'
GZZNKYZKKXSGTOLURJ58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 28 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 12

Ground *UKYZNKKTMOTKYZGXZ _KY 9ZGXZZNKKTMOTKLXUS

<
8KVGOXUVKTOTXKJ]OXK
LXUSZNKMXU[TJ ZNKMXU[TJIUTZXURYGTJ IOXI[OZLXUSQK_Y]OZIN
Controls IUTZXURY% INKIQZNK\URZGMKUT ZUL[TIZOUTY]OZINKY
ZNKIKTZKXVURKXKJ
Inoperative, ]OXKULZNKVRGZLUXS
Platform RK\KRY]OZIN

Controls TU <
Operate
:XU[HRKYNUUZZNK
Normally L[TIZOUTYOTJO\OJ[GRR_

Be sure all other )NKIQ\URZGMKGZXKJ

functions operate ]OXKUTMXU[TJIUTZXURY 8KVGOXUVKTOTXKJ]OXK
normally, including IUTZGIZULZNKQK_ < IOXI[OZLXUSKSKXMKTI_
Y]OZINZNKXKJ]OXK YZUVH[ZZUTZUZNK
platform controls. INKIQKJYNU[RJ QK_Y]OZIN
UXOMOTGZKGZZNK
KSKXMKTI_YZUVH[ZZUT

<

)NKIQ\URZGMKGZXKJ < )NKIQOLQK_Y]OZIN _KY 8KVRGIKQK_Y]OZIN

]OXKGZMXU[TJIUTZXURY OTZKXTGRIGSOY IUTZGIZLUXMXU[TJ
IUTZGIZUTZNKQK_ GIZO\GZOTMMXU[TJ IUTZXURY
Y]OZIN IUTZGIZ

TU
<
8KVRGIKQK_Y]OZIN

8KVGOXUVKTOTXKJ]OXK
IOXI[OZLXUSQK_Y]OZIN
ZUL[TIZOUTY]OZINKY

Part No. 34032 Genie S-80 & Genie S-85 5 - 29

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 13

Platform *UKYKTMOTKYZGXZLXUS _KY 9ZGXZKTMOTKLXUSZNK < :KYZGTJXKVRGIKLUUZ

ZNKVRGZLUXSIUTZXURY% VRGZLUXSZNKTVXKYY Y]OZIN58XKVGOXUVKT
Controls JU]TZNKLUUZY]OZIN OT]NZ]OXKIOXI[OZLXUS
GTJINKIQ\URZGMKGZ LUUZY]OZINZU:6
Inoperative, :6
Ground
<
Controls TU
Operate 8KVGOXUVKTOT]NZ]OXK
IOXI[OZLXUS:6ZU
Normally L[TIZOUTIUTZXURRKXY

Be sure all <

)NKIQ\URZGMKGZ:( )NKIQLUXUVKTOTXKJ
cables are in good ]OXKIOXI[OZLXUSQK_
condition with no Y]OZINZU:(58
< 8KVRGIKZNKQK_Y]OZIN
kinks or abrasions. VRGZLUXSIUTZGIZY
<
)NKIQ\URZGMKGZ:6 8KVGOXUVKTOTHRQ
]OXKIOXI[OZLXUS:(
:6
<

)NKIQ\URZGMKGZHRQ < 8KVRGIKIUTZGIZUT

]OXKUTVRGZLUXS KSKXMKTI_YZUVH[ZZUT
KSKXMKTI_YZUVH[ZZUT

<
<
)NKIQ\URZGMKGZ:6 8KVGOXUVKTOTHRQ]OXK
IOXI[OZLXUSKSKXMKTI_
YZUVH[ZZUTZU:6
<

8KVGOXUVKTOTHRQ]OXK
IOXI[OZLXUS:6ZULUUZ
Y]OZIN58XKVRGIKLUUZ
Y]OZIN

5 - 30 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 14

Boom Up .URJMXU[TJIUTZXUR 8KVGOXUVKTOTXKJ]NZ

L[TIZOUTY]OZIN[VGTJ < ]OXKIOXI[OZ]OZNJOUJK
Function INKIQ\URZYGZXKJ]NZ LXUS:(ZUVXUVUXZOUTGR
]OXKUTHUUSL[TIZOUT \GR\K
Inoperative VXUVUXZOUTGR\GR\K
Be sure all other
ZU<
functions operate
normally. UXOTLOTOZKUNSY
8KSU\KHUZN]OXKYLXUS 8KVRGIKIUOR
\GR\KIUORGTJINKIQ
If boom up function XKYOYZGTIKGIXUYYZNK
operates normally from IUORZKXSOTGRY
the ground controls but
not from the platform ZUUNSY
controls, troubleshoot
the platform controller. .URJZUMMRKY]OZIN[V L[TIZOUTUVKXGZKY 8KVRGIKJKLKIZO\K
GTJSGT[GRR_U\KXXOJK VXUVUXZOUTGR\GR\K
See Repair section. VXUVUXZOUTGR\GR\KV[YN
OTH[ZZUTUTKTJUL
If boom up function \GR\KYVUUR4UZK
operates normally from 5\KXXOJOTMZNK\GR\K]ORR
XKW[OXKZ]UVKUVRK/LG
the platform controls but NKRVKXOYTUZG\GORGHRK
not from the ground OTZKXINGTMKZNK\GR\K
controls, troubleshoot OZKS'']OZNGROQK
\GR\KOZKS@
the ground control
toggle switch or replace
L[TIZOUTOTUVKXGZO\K
resistor. See Repair
section. .URJMXU[TJIUTZXUR 8KVGOXUVKTIOXI[OZOT
L[TIZOUTY]OZIN[V < XKJ]OXKLXUS:(ZU
)NKIQ\URZYGZXKJ]OXK HUUSL[TIZOUT
UTHUUSL[TIZOUT JOXKIZOUTGR\GR\K
JOXKIZOUTGR\GR\K

<

8KSU\KHUZN]OXKYLXUS
\GR\KIUOR)NKIQ
XKYOYZGTIKGIXUYYIUOR UXOTLOTOZKUNSY
8KVRGIKIUOR
ZKXSOTGRY

ZUUNSY

/TZKXINGTMKLRU]
XKM[RGZUX\GR\KOZKS? L[TIZOUTUVKXGZKY 8KVRGIKJKLKIZO\KLRU]
]OZNGROQK\GR\K XKM[RGZUX\GR\K
OZKS>

L[TIZOUTOTUVKXGZO\K

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 31

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 14

.URJZUMMRKY]OZIN[V L[TIZOUT )NKIQZNKXKYOYZGTIK UX

)UTZOT[KJLXUSZNK UVKXGZKY ULZNKJOXKIZOUTGR OTLOTOZK
VXK\OU[YVGMK GTJSGT[GRR_U\KXXOJK 8KVRGIKZNKJKLKIZO\K
JOXKIZOUTGR\GR\KV[YN \GR\KIUORY UNSY \GR\KIUORY
OTH[ZZUTUTKTJUL
\GR\KYVUUR4UZK
5\KXXOJOTMZNK\GR\K]ORR ZUUNSY
XKW[OXKZ]UVKUVRK/LG
NKRVKXOYTUZG\GORGHRK 8KVRGIKZNK\GR\K
OTZKXINGTMKZNK\GR\K
OZKS8]OZNGROQK
\GR\KOZKS9

L[TIZOUTOTUVKXGZO\K

/TZKXINGTMKINKIQ\GR\K L[TIZOUTUVKXGZKY 8KVRGIKJKLKIZO\K

OZKS3]OZNGROQK YN[ZZRK\GR\K
\GR\KOZKS1

L[TIZOUTOTUVKXGZO\K

/TYZGRRGZU69/ )NKIQLUXSKINGTOIGR
VXKYY[XKMG[MKGZZNK  XKYZXOIZOUTYQKKVOTM
W[OIQJOYIUTTKIZ VYO HUUSLXUSSU\OTM
IU[VROTMUTZNKL[TIZOUT 58XKVGOXI_ROTJKX
SGTOLURJGTJNURJZNK 58I_ROTJKX
L[TIZOUTY]OZIN IU[TZKXHGRGTIK\GR\K

RKYYZNGTVYO

8KVGOXI_ROTJKX
58XKVRGIKI_ROTJKX
IU[TZKXHGRGTIK\GR\K
58SGTOLURJNGY
OTZKXTGRJKLKIZIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 32 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 15

Boom Down .URJMXU[TJIUTZXUR < 8KVGOXUVKTOTXKJHRQ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(ZU
Function INKIQ\URZYGZXKJHRQ JOXKIZOUTGR\GR\K
Inoperative ]OXKUTHUUSL[TIZOUT
JOXKIZOUTGR\GR\K
Be sure all other
<
functions operate
UX
normally including .URJZUMMRKY]OZINJU]T OTLOTOZK
L[TIZOUT )NKIQZNKXKYOYZGTIK
boom up function. GTJSGT[GRR_U\KXXOJK UVKXGZKY ULZNKJU]TJOXKIZOUTGR UNSY 8KVRGIKZNKIUOR
ZNKJU]TJOXKIZOUTGR \GR\KIUOR
If boom down function \GR\KV[YNOTH[ZZUTUT
KTJUL\GR\KYVUUR
operates normally from
4UZK U\KXXOJOTMZNK ZUUNSY
the ground controls but \GR\K]ORRXKW[OXKZ]U
not from the platform VKUVRK/LGNKRVKXOYTUZ 8KVRGIKZNK\GR\K
controls, troubleshoot G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS8]OZNG
the platform controller. ROQK\GR\KOZKS9
See Repair section.
L[TIZOUTOTUVKXGZO\K
If boom down function
operates normally from /TYZGRRGZU69/ )U[TZOTMZNKZ[XTY =OZNHUUSL[RR_RU]KXKJ
the platform controls but VXKYY[XKMG[MKGZZNK  GJP[YZZNKHUUSJU]T Ud]RcX^] NURJZNKL[TIZOUTJU]T
not from the ground W[OIQJOYIUTTKIZ VYO XKROKL\GR\KOZKS,OTGRR ^_TaPcTb Y]OZIN'JP[YZZNKXKROKL
IU[VROTMUTZNKL[TIZOUT ZNK]G_:NKTUVKXGZK \GR\KZUXKGJ69/
controls, troubleshoot SGTOLURJGTJNURJZNK ZNKL[TIZOUTJU]T GTJXKVRGIKZNKI_ROTJKX
the ground control L[TIZOUTY]OZIN IU[TZKXHGRGTIK\GR\K
toggle switch or replace
resistor. See Repair L[TIZOUTOTUVKXGZO\K
section.
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYGTJUXG
RKYYZNGTVYO IUTJOZOUTK^OYZYOT]NOIN
ZNKI_ROTJKX
IU[TZKXHGRGTIK\GR\KOY
TUZGRRU]OTMZNKI_ROTJKX
ZUXKZXGIZUXZNKI_ROTJKX
NGYOTZKXTGRJKLKIZY
*OYIUTTKIZOTMN_JXG[ROI
ROTKYUXGJP[YZOTMZNK
)UTZOT[KJUTZNKTK^Z I_ROTJKXIU[TZKXHGRGTIK
VGMK \GR\KOTZNOYYOZ[GZOUT
IGTHK\KX_JGTMKXU[Y
6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 33

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 15

 =OZNHUUSL[RR_RU]KX
)UTZOT[KJLXUSZNK 'JP[YZZNKHUUSJU]T VYOUX
XKROKL\GR\KOZKS, NURJZNKL[TIZOUTJU]T
VXK\OU[YVGMK SUXK Y]OZIN'JP[YZZNKXKROKL
OTUTKZ[XTIRUIQ]OYK
:NKT]OZNVXKYY[XK \GR\KZUXKGJVYO
MG[MKYZORRGZZGINKJ
UVKXGZKZNKL[TIZOUT
JU]T

RKYYZNGTVYO

8KSU\KZNKHUUSJU]T 8KVGOXZNKHUUSROLZ
NOMNVXKYY[XKROTKLXUS VYO I_ROTJKX
ZNKSGTOLURJGTJIGVZNK
VUXZ.URJJU]TL[TIZOUT
GTJXKINKIQVXKYY[XK

RKYYZNGTVYO

/TZKXTGRJKLKIZOT
SGTOLURJ58UTKULZNK
VXK\OU[YZKYZYOT\UR\OTM
ZNKV[SVUXSGTOLURJ
IUSVUTKTZY]GY
VUYYOHR_U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

5 - 34 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 16

Boom Extend .URJMXU[TJIUTZXUR < 8KVGOXUVKTOT]NZXKJ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(ZU
Function INKIQ\URZYGZ]NZXKJ VXUVUXZOUTGR\GR\K
Inoperative ]OXKUTVXUVUXZOUTGR
\GR\K
Be sure all other
ZU<
functions operate
UX
normally. 8KSU\KHUZN]OXKYLXUS OTLOTOZK
\GR\KIUORGTJINKIQ UNSY
If boom extend function XKYOYZGTIKGIXUYYZNK 8KVRGIKIUOR
operates normally from IUORZKXSOTGRY
the ground controls but
not from the platform ZUUNSY
controls, troubleshoot
the platform controller. .URJZUMMRKY]OZINOT L[TIZOUT 8KVRGIKZNKJKLKIZO\K
K^ZKTJVUYOZOUTGTJ UVKXGZKY VXUVUXZOUTGR\GR\K
See Repair section. SGT[GRR_U\KXXOJK
VXUVUXZOUTGR\GR\KV[YN
If boom extend function OTH[ZZUTUTKTJUL
operates normally from \GR\KYVUUR4UZK
U\KXXOJOTMZNK\GR\K]ORR
the platform controls but XKW[OXKZ]UVKUVRK/LG
not from the ground NKRVKXOYTUZG\GORGHRK
controls, troubleshoot OTZKXINGTMKZNK\GR\K
OZKS@]OZNGROQK\GR\K
the ground control OZKS''
toggle switch or CR16
relay. See Repair L[TIZOUTOTUVKXGZO\K
section.
/TZKXINGTMKLRU] L[TIZOUT 8KVRGIKJKLKIZO\KLRU]
XKM[RGZUX\GR\KOZKS> UVKXGZKY XKM[RGZUX\GR\K
]OZNGROQK\GR\K
OZKS?

L[TIZOUTOTUVKXGZO\K
UX
.URJZUMMRKY]OZINGTJ )NKIQZNKXKYOYZGTIKUL OTLOTOZK 8KVRGIKZNKJKLKIZO\K
SGT[GRR_U\KXXOJK L[TIZOUT ZNKJOXKIZOUTGR\GR\K
UVKXGZKY IUOR UNSY \GR\KIUOR
K^ZKTJJOXKIZOUTGR\GR\K
V[YNOTH[ZZUTUTKTJ
UL\GR\KYVUUR4UZK ZUUNSY
U\KXXOJOTMZNK\GR\K]ORR
XKW[OXKZ]UVKUVRK/LG
NKRVKXOYTUZG\GORGHRK 8KVRGIKZNK\GR\K
OTZKXINGTMKZNK\GR\K
OZKS9]OZNGROQK\GR\K
OZKS6

L[TIZOUTOTUVKXGZO\K

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 35

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 16

/TYZGRRGZU69/  )U[TZOTMZNKZ[XTY =OZNHUUSL[RR_

)UTZOT[KJLXUSZNK GJP[YZZNKHUUSK^ZKTJ
Ud]RcX^]
K^ZKTJKJNURJZNK
VXK\OU[YVGMK VXKYY[XKMG[MKGZZNK VYO ^_TaPcTb
W[OIQJOYIUTTKIZ XKROKL\GR\KOZKS*OT K^ZKTJL[TIZOUTY]OZIN
IU[VROTMUTZNKL[TIZOUT GRRZNK]G_:NKT 'JP[YZZNKXKROKL\GR\K
SGTOLURJGTJNURJZNK UVKXGZKZNKK^ZKTJ ZUXKGJ69/GTJ
L[TIZOUTY]OZIN L[TIZOUT XKVRGIKZNKI_ROTJKX
IU[TZKXHGRGTIK\GR\K
L[TIZOUTOTUVKXGZO\K

)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYGTJUXZNK
RKYYZNGTVYO I_ROTJKXNGYOTZKXTGR
JKLKIZY6RKGYKIUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

'JP[YZZNKHUUSK^ZKTJ
XKROKL\GR\KOZKS*OT  =OZNHUUSL[RR_
UTKZ[XTIRUIQ]OYK VYO K^ZKTJKJNURJZNK
:NKT]OZNVXKYY[XK K^ZKTJL[TIZOUTY]OZIN
MG[MKYZORRGZZGINKJ 'JP[YZZNKXKROKL\GR\KZU
UVKXGZKZNKL[TIZOUT XKGJVYO

RKYYZNGTVYO

8KSU\KZNKK^ZKTJ VYO 8KVGOXZNKI_ROTJKX
L[TIZOUTVXKYY[XKROTK GTJUXXKVRGIKI_ROTJKX
LXUSZNKSGTOLURJGTJ IU[TZKXHGRGTIK\GR\KY
IGVZNKVUXZ:NKT]OZN
VXKYY[XKMG[MKYZORR
GZZGINKJUVKXGZKZNK
L[TIZOUT

RKYYZNGTVYO

/TZKXTGRJKLKIZOT
SGTOLURJ58UTKULZNK
VXK\OU[YZKYZYOT\UR\OTM
ZNKV[SVUXSGTOLURJ
IUSVUTKTZY]GY
VUYYOHR_U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

5 - 36 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 17

Boom Retract .URJMXU[TJIUTZXUR < 8KVGOXUVKTOTHRQ]NZ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(ZU
Function INKIQ\URZYGZHRQ]NZ JOXKIZOUTGR\GR\K
Inoperative ]OXKUTK^ZKTJXKZXGIZ
L[TIZOUT\GR\K
Be sure all other
<
functions operate
L[TIZOUT UX
normally including .URJZUMMRKY]OZINJU]T OTLOTOZK
boom extend function. UVKXGZKY )NKIQZNKXKYOYZGTIK UNSY
GTJSGT[GRR_U\KXXOJK ULZNKXKZXGIZJOXKIZOUTGR 8KVRGIKZNKIUOR
ZNKXKZXGIZJOXKIZOUTGR \GR\KIUOR
If boom retract function \GR\KV[YNOTH[ZZUTUT
operates normally from KTJUL\GR\KYVUUR ZUUNSY
4UZK U\KXXOJOTMZNK
the ground controls but \GR\K]ORRXKW[OXKZ]U
not from the platform VKUVRK/LGNKRVKXOYTUZ 8KVRGIKZNK\GR\K
controls, troubleshoot G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS9]OZNG
the platform controller. ROQK\GR\KOZKS6
See Repair section.
L[TIZOUTOTUVKXGZO\K
If boom retract function
operates normally from /TYZGRRGZUVYO  )NKIQLUXSKINGTOIGR
the platform controls but VXKYY[XKMG[MKGZZNK VYO XKYZXOIZOUTYQKKVOTM
not from the ground W[OIQJOYIUTTKIZ HUUSLXUSXKZXGIZOTM
IU[VROTMUTZNKL[TIZOUT 58XKVGOXI_ROTJKX
controls, troubleshoot SGTOLURJGTJNURJZNK 58XKVRGIKI_ROTJKX
the ground control L[TIZOUTY]OZIN IU[TZKXHGRGTIK\GR\K
toggle switch or CR16
relay. See Repair RKYYZNGTVYO
section.
8KVGOXI_ROTJKX
58XKVRGIKI_ROTJKX
IU[TZKXHGRGTIK\GR\K
58SGTOLURJNGY
OTZKXTGRJKLKIZIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 37

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 18

Turntable .URJMXU[TJIUTZXUR < 8KVGOXUVKTOT]NZXKJ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(ZU
Rotate Function INKIQ\URZYGZ]NZXKJ VXUVUXZOUTGR\GR\K58
]OXKUTZ[XTZGHRKXUZGZK XKVRGIKUNSXKYOYZUX
Inoperative L[TIZOUTVXUVUXZOUTGR GZMXU[TJIUTZXURHU^
\GR\K
Be sure all other
functions operate ZU<
normally. UX
8KSU\KHUZN]OXKY OTLOTOZK
If turntable rotate LXUS\GR\KIUORGTJ UNSY
8KVRGIKZNKIUOR
function operates INKIQXKYOYZGTIKGIXUYY
normally from the ZNKIUORZKXSOTGRY
ground controls but
ZUUNSY
not from the platform
controls, troubleshoot L[TIZOUT 8KVRGIKJKLKIZO\K
.URJZUMMRKY]OZINGTJ
the platform controller. SGT[GRR_U\KXXOJK UVKXGZKY VXUVUXZOUTGR\GR\K
See Repair section. VXUVUXZOUTGR\GR\KV[YN
OTH[ZZUTUTKTJUL
If turntable rotate \GR\KYVUUR4UZK
U\KXXOJOTMZNK\GR\K]ORR
function operates XKW[OXKZ]UVKUVRK/LG
normally from the NKRVKXOYTUZG\GORGHRK
platform controls but OTZKXINGTMKZNK\GR\K
OZKS@]OZNGROQK\GR\K
not from the ground OZKS''
controls, troubleshoot
the ground control L[TIZOUTOTUVKXGZO\K
toggle switch or CR16
relay. See Repair /TZKXINGTMKXUZGZOUT L[TIZOUT
section. L[TIZOUTLRU]XKM[RGZUX UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
\GR\KOZKS>]OZNG XKM[RGZUX\GR\K
ROQK\GR\KOZKS?

L[TIZOUTOTUVKXGZO\K
UX
.URJZUMMRKY]OZINZU L[TIZOUT )NKIQZNKXKYOYZGTIK OTLOTOZK 8KVRGIKZNKJKLKIZO\K
RKLZGTJSGT[GRR_ UVKXGZKY ULZNKJOXKIZOUTGR UNSY \GR\KIUORY
U\KXXOJKXUZGZKRKLZ \GR\KIUORY
JOXKIZOUTGR\GR\KV[YN
OTH[ZZUTUTKTJUL ZUUNSY
\GR\KYVUUR4UZK
U\KXXOJOTMZNK\GR\K]ORR
XKW[OXKZ]UVKUVRK/LG 8KVRGIKZNK\GR\K
NKRVKXOYTUZG\GORGHRK
OTZKXINGTMKZNK\GR\K
OZKS6]OZNGROQK\GR\K
OZKS9

L[TIZOUTOTUVKXGZO\K

)UTZOT[KJUTZNKTK^Z
VGMK

5 - 38 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 18

/TZKXINGTMKINKIQ\GR\K L[TIZOUT 8KVRGIKJKLKIZO\K

)UTZOT[KJLXUSZNK UVKXGZKY INKIQ\GR\K
VXK\OU[YVGMK OZKS1]OZNGROQK\GR\K
OZKS3

L[TIZOUTOTUVKXGZO\K

/TYZGRRGZUVYO )NKIQLUXSKINGTOIGR
VXKYY[XKMG[MKGZZNK  XKYZXOIZOUTYQKKVOTM
W[OIQJOYIUTTKIZ VYO Z[XTZGHRKLXUSXUZGZOTM
IU[VROTMUTZNKL[TIZOUT 58INKIQXUZGZOUTSUZUX
SGTOLURJGTJNURJZNK 58INKIQXUZGZOUTHXGQK
L[TIZOUTY]OZIN 58INKIQXUZGZOUT
ZUXW[KN[H
RKYYZNGTVYO

8KVGOXXUZGZOUTSUZUX
58SGTOLURJNGY
OTZKXTGRJKLKIZIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 39

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 19

Turntable .URJMXU[TJIUTZXUR < 8KVGOXUVKTOT]NZHRQ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(ZU
Rotate Left INKIQ\URZYGZ]NZHRQ JOXKIZOUTGR\GR\K
Function ]OXKUTXUZGZKL[TIZOUT
JOXKIZOUTGR\GR\K
Inoperative
<
Be sure all other
UX
functions operate 8KSU\KHUZN]OXKYLXUS OTLOTOZK
normally including XUZGZKRKLZ\GR\KIUORGTJ UNSY
INKIQXKYOYZGTIKGIXUYY 8KVRGIKZNK\GR\KIUOR
turntable rotate right ZNKIUORZKXSOTGRY
function.
ZUUNSY
If turntable rotate left
function operates L[TIZOUT
.URJZUMMRKY]OZINRKLZ UVKXGZKY 8KVRGIKZNKXUZGZK
normally from the GTJSGT[GRR_U\KXXOJK JOXKIZOUTGR\GR\K
ground controls but not XUZGZKRKLZJOXKIZOUTGR
\GR\KV[YNOTH[ZZUTUT
from the platform KTJUL\GR\KYVUUR
controls, troubleshoot 4UZK U\KXXOJOTMZNK
the platform controller. \GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
See Repair section. G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS6]OZNG
If turntable rotate left ROQK\GR\KOZKS9
function operates
normally from the L[TIZOUTOTUVKXGZO\K
platform controls but
 Ve^SdY_^
not from the ground /TYZGRRGVXKYY[XKMG[MK VYO /TZKXINGTMKZNK _`UbQdUc
8KVRGIKJKLKIZO\K
controls, troubleshoot GZZNKW[OIQJOYIUTTKIZ XUZGZKRKLZGTJXOMNZ IU[TZKXHGRGTIK\GR\K
IU[VROTMUTZNKL[TIZOUT IU[TZKXHGRGTIK\GR\KY
the ground control SGTOLURJGTJNURJZNK OZKS'GTJOZKS(UT
toggle switch. See L[TIZOUTY]OZIN Z[XTZGHRKXUZGZOUT
Repair section. SUZUX

L[TIZOUTOTUVKXGZO\K
RKYYZNGTVYO
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKLXUSXUZGZOTM
8KSU\KZNKXUZGZKRKLZ RKLZ58XKVRGIK
JOXKIZOUTGR\GR\K58
L[TIZOUTVXKYY[XKROTK XKVGOXXUZGZOUTSUZUX
LXUSZNKSGTOLURJGTJ
IGVZNKVUXZ9
:NKT]OZNVXKYY[XK 
MG[MKYZORRGZZGINKJ VYO
UVKXGZKZNKL[TIZOUT 8KVGOXXUZGZOUTSUZUX

RKYYZNGTVYO

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
)UTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

5 - 40 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 20

Turntable .URJMXU[TJIUTZXUR < 8KVGOXUVKTOT]NZ]OXK

L[TIZOUTY]OZINGTJ IOXI[OZLXUS:(ZU
Rotate Right INKIQ\URZYGZ]NZ]OXK JOXKIZOUTGR\GR\K
Function UTXUZGZKL[TIZOUT
JOXKIZOUTGR\GR\K
Inoperative
<
Be sure all other
UX
functions operate 8KSU\KHUZN]OXKYLXUS OTLOTOZK
normally including XUZGZKXOMNZ\GR\KIUOR UNSY
GTJINKIQXKYOYZGTIK 8KVRGIKZNK\GR\KIUOR
turntable rotate left GIXUYYZNKIUOR
function. ZKXSOTGRY

If turntable rotate right ZUUNSY

function operates
L[TIZOUT
normally from the .URJZUMMRKY]OZINXOMNZ UVKXGZKY 8KVRGIKZNKXUZGZK
ground controls but GTJSGT[GRR_U\KXXOJK JOXKIZOUTGR\GR\K
XUZGZKXOMNZJOXKIZOUTGR
not from the platform \GR\KV[YNOTH[ZZUTUT
controls, troubleshoot KTJUL\GR\KYVUUR
the platform controller. 4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
See Repair section. VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
If turntable rotate right ZNK\GR\KOZKS6]OZNG
function operates ROQK\GR\KOZKS9
normally from the
platform controls but L[TIZOUTOTUVKXGZO\K
not from the ground  L[TIZOUT 8KVRGIKJKLKIZO\K
controls, troubleshoot /TYZGRRGVXKYY[XKMG[MK VYO /TZKXINGTMKZNK UVKXGZKY IU[TZKXHGRGTIK\GR\K
GZZNKW[OIQJOYIUTTKIZ XUZGZKXOMNZGTJRKLZ
the ground control IU[VROTMUTZNKL[TIZOUT IU[TZKXHGRGTIK\GR\KY
toggle switch. See SGTOLURJGTJNURJZNK OZKS'GTJOZKS(UT
Repair section. L[TIZOUTY]OZIN Z[XTZGHRKXUZGZOUT
SUZUX

L[TIZOUTOTUVKXGZO\K
RKYYZNGTVYO
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTM
Z[XTZGHRKLXUSXUZGZOTM
XOMNZ58XKVRGIK
8KSU\KZNKXUZGZKXOMNZ JOXKIZOUTGR\GR\K58
L[TIZOUTVXKYY[XKROTK XKVGOXXUZGZOUTSUZUX
LXUSZNKSGTOLURJGTJ
IGVZNKVUXZ9 
:NKT]OZNVXKYY[XK VYO
8KVGOXXUZGZOUTSUZUX
MG[MKYZORRGZZGINKJ
UVKXGZKZNKL[TIZOUT

RKYYZNGTVYO

8KVRGIKZNKJOXKIZOUTGR 58 )UTY[RZ-KTOK
\GR\K58ZNKSGTOLURJ /TJ[YZXOKY9KX\OIK
NGYOTZKXTGRJKLKIZY *KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 41

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 21

All Platform .URJMXU[TJIUTZXUR < 8KVGOXUXMXKJ]OXK

L[TIZOUTY]OZINGTJ IOXI[OZLXUS:(ZULRU]
Leveling INKIQ\URZGMKGZUXMXKJ IUTZXUR\GR\K
Functions ]OXKUTVRGZLUXSRK\KR
LRU]IUTZXUR\GR\K
Inoperative OZKS0

Be sure all other <

functions operate UX
OTLOTOZK
normally. 8KSU\KHUZN]OXKYLXUS UNSY
\GR\KIUORGTJINKIQ 8KVRGIKZNKIUOR
Be sure both automatic XKYOYZGTIKGIXUYYIUOR
ZKXSOTGRY
and manual platform
leveling do not operate. ZUUNSY
If automatic leveling
8KSU\KHUZNN_JXG[ROI 8KVRGIKZNK
operates but manual NUYKYLXUSZNKSGTOLURJ _KY
IU[TZKXHGRGTIK\GR\KY
leveling does not, VUXZY62 626R[M OZKSY( )UX\GR\K
troubleshoot Platform ZNKNUYKYGTJIGVZNK HRUIQ'
SGTOLURJLOZZOTMY
Leveling Up Function 5VKXGZKHUUS[V
Inoperative. L[TIZOUTGTJINKIQOL
VRGZLUXSRK\KRY

TU

6R[SHGVXKYY[XKMG[MK  )NKIQLUXSKINGTOIGR

OTZUZNKSGYZKXI_ROTJKX VYO XKYZXOIZOUTY58XKVRGIK
HGXXKRKTJN_JXG[ROI ZNKYRG\KI_ROTJKX
NUYK[YOTMGZKKLOZZOTM IU[TZKXHGRGTIK\GR\KY
5VKXGZKHUUS[V
L[TIZOUTGTJXKGJ
ZNKVXKYY[XK

RKYYZNGTVYO

*KGJNKGJZNKVXKYY[XK
MG[MKOTZUZNKHGXXKR
KTJN_JXG[ROINUYKLXUS RKYY
ZNKSGYZKXI_ROTJKXGTJ ZNGT
XGOYKZNKHUUSUTKOTIN VYO 8KVGOXUXXKVRGIKZNK
GZGZOSK)UTZOT[GRR_
SUTOZUXZNKVXKYY[XK SGYZKXI_ROTJKX
MG[MKJ[XOTMHUUS[V
*UTUZGRRU]ZNK
VXKYY[XKZUK^IKKJ
VYO

VYOUXSUXK

8KVGOXUXXKVRGIKZNK
YRG\KI_ROTJKX

5 - 42 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 22

Platform Level .URJMXU[TJIUTZXUR < 8KVGOXUVKTOTUXM]OXK

L[TIZOUTY]OZINGTJ IOXI[OZLXUS:(ZU
Up Function INKIQ\URZGMKGZUXM JOXKIZOUTGR\GR\K
]OXKUTVRGZLUXSRK\KR[V
Inoperative L[TIZOUTJOXKIZOUTGR
\GR\K
Be sure all other
functions operate <
normally. UX
8KSU\KHUZN]OXKYLXUS OTLOTOZK
If platform level up \GR\KIUORGTJINKIQ UNSY
8KVRGIKZNKIUOR
function operates XKYOYZGTIKGIXUYYZNK
normally from the IUORZKXSOTGRY
ground controls but
ZUUNSY
not from the platform
controls, troubleshoot L[TIZOUT
.URJZUMMRKY]OZINGTJ UVKXGZKY 8KVRGIKZNKVRGZLUXS
the platform control SGT[GRR_U\KXXOJKZNK RK\KROTMJOXKIZOUTGR
toggle switch. See RK\KR[VJOXKIZOUTGR \GR\K
Repair section. \GR\KV[YNOTH[ZZUT
UTKTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
If platform level up \GR\K]ORRXKW[OXKZ]U
function operates VKUVRK/LGNKRVKXOYTUZ
normally from the G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS5]OZN
platform controls but GROQK\GR\KOZKS4
not from the ground
controls, troubleshoot L[TIZOUTOTUVKXGZO\K
the ground control
L[TIZOUT
toggle switch. See /TZKXINGTMKINKIQ\GR\K UVKXGZKY 8KVRGIKJKLKIZO\K
Repair section. OZKS2]OZNROQK\GR\K INKIQ\GR\K
OZKS1

L[TIZOUTOTUVKXGZO\K
 
/TYZGRRGVXKYY[XKMG[MK VYOUX /TZKXINGTMKZNK *OYIUTTKIZOTMN_JXG[ROI
GZZNKW[OIQJOYIUTTKIZ RK\KR[VGTJJU]T VYOUX ROTKYUXGJP[YZOTMZNK
SUXK SUXK
IU[VROTMUTZNKL[TIZOUT IU[TZKXHGRGTIK\GR\KY I_ROTJKXIU[TZKXHGRGTIK
SGTOLURJGTJNURJZNK OZKSY( ) \GR\KYOTZNOYYOZ[GZOUT
L[TIZOUTY]OZIN IGTHK\KX_JGTMKXU[Y
L[TIZOUTUVKXGZKY 6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
RKYYZNGTVYO 8KVRGIKJKLKIZO\K
IU[TZKXHGRGTIK\GR\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 43

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 23

Platform Level .URJMXU[TJIUTZXUR < 8KVGOXUVKTOTUXMHRQ

L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:(
Down Function INKIQ\URZGMKGZUXMHRQ ZUJOXKIZOUTGR\GR\K
]OXKUTVRGZLUXSRK\KR
Inoperative JU]TL[TIZOUT
JOXKIZOUTGR\GR\K
Be sure all other
functions operate <
normally. UX
8KSU\KHUZN]OXKYLXUS OTLOTOZK
If platform level down \GR\KIUORGTJINKIQ UNSY
8KVRGIKZNKIUOR
function operates XKYOYZGTIKGIXUYYZNK
normally from the IUORZKXSOTGRY
ground controls but
ZUUNSY
not from the platform
controls, troubleshoot L[TIZOUT
.URJZUMMRKY]OZINGTJ UVKXGZKY 8KVRGIKZNKVRGZLUXS
the platform control SGT[GRR_U\KXXOJKZNK RK\KROTMJOXKIZOUTGR
toggle switch. See RK\KRJU]TJOXKIZOUTGR \GR\K
Repair section. \GR\KV[YNOTH[ZZUT
UTKTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
If platform level down \GR\K]ORRXKW[OXKZ]U
function operates VKUVRK/LGNKRVKXOYTUZ
normally from the G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS5]OZN
platform controls but GROQK\GR\KOZKS4
not from the ground
controls, troubleshoot L[TIZOUTOTUVKXGZO\K
the ground control
L[TIZOUT
toggle switch. See /TZKXINGTMKINKIQ\GR\K UVKXGZKY 8KVRGIKJKLKIZO\K
Repair section. OZKS2]OZNROQK\GR\K INKIQ\GR\K
OZKS1

L[TIZOUTOTUVKXGZO\K
 
/TYZGRRGVXKYY[XKMG[MK VYOUX /TZKXINGTMKZNKRK\KR[V *OYIUTTKIZOTMN_JXG[ROI
GZZNKW[OIQJOYIUTTKIZ GTJJU]T VYOUX ROTKYUXGJP[YZOTMZNK
SUXK SUXK
IU[VROTMUTZNKL[TIZOUT IU[TZKXHGRGTIK\GR\KY I_ROTJKXIU[TZKXHGRGTIK
SGTOLURJGTJNURJZNK OZKSY( ) \GR\KYOTZNOYYOZ[GZOUT
L[TIZOUTY]OZIN IGTHK\KX_JGTMKXU[Y
L[TIZOUTUVKXGZKY 6RKGYKIUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
RKYYZNGTVYO 8KVRGIKJKLKIZO\K
IU[TZKXHGRGTIK\GR\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 44 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 24

Platform Rotate )NKIQOLPOH POHHUUS .URJVRGZLUXSXUZGZKRKLZ 8KVGOXUVKTOTMXT]NZ

[V <
HUUS[V L[TIZOUTY]OZINGTJ ]OXKIOXI[OZLXUS:6ZU
Left Function OYUVKXGZOUTGR UVKXGZKY INKIQ\URZGMKGZMXT]NZ POHHUUSSGTOLURJ
]OXKUTHUZN\GR\KYUT \GR\KY
Inoperative POHHUUSSGTOLURJ
Be sure all other
<
functions operate
normally. 8KSU\KHUZN]OXKYLXUS UX
\GR\KIUORGTJINKIQ OTLOTOZK
If platform rotate left XKYOYZGTIKGIXUYYZNK UNSY
8KVRGIKZNKIUOR
function operates IUORZKXSOTGRY
normally from the
ground controls but ZUUNSY
not from the platform VRGZLUXS
POHHUUS[V /TJO\OJ[GRR_OTZKXINGTMK
controls, troubleshoot OTUVKXGZO\K KGINPUHSGTOLURJ\GR\K XUZGZK
the platform control ]OZNROQK\GR\KLXUS UVKXGZKY 8KVRGIKZNK
JKLKIZO\K\GR\K
toggle switch. See JXO\KSGTOLURJOZKS8
Repair section.
VRGZLUXSXUZGZK
OTUVKXGZO\K
If platform rotate left
function operates )NKIQLUXSKINGTOIGR
normally from the XKYZXOIZOUTYQKKVOTM
VRGZLUXSLXUSXUZGZOTM
platform controls but 58XKVGOXN_JXG[ROI
not from the ground XUZGZUX
controls, troubleshoot
the ground control
toggle switch. See .URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
Repair section. INKIQ\URZGMKGZMXTHRQ < 8KVGOXUVKTOTMXTHRQ
]OXKUTVRGZLUXSXUZGZK ]OXKIOXI[OZLXUS:(ZU
RKLZL[TIZOUTJOXKIZOUTGR JOXKIZOUTGR\GR\K
\GR\K

<
UX
8KSU\KHUZN]OXKYLXUS OTLOTOZK
\GR\KIUORGTJINKIQ UNSY
XKYOYZGTIKGIXUYYZNK 8KVRGIKZNKIUOR
IUORZKXSOTGRY

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 45

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 24

.URJZUMMRKY]OZINRKLZ L[TIZOUT
)UTZOT[KJLXUSZNK GTJSGT[GRR_U\KXXOJK UVKXGZKY 8KVRGIKZNKVRGZLUXS
VXK\OU[YVGMK ZNKXUZGZKRKLZJOXKIZOUTGR XUZGZKJOXKIZOUTGR\GR\K
\GR\KV[YNOTH[ZZUT
UTKTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS4]OZNG
ROQK\GR\KOZKS5

L[TIZOUTOTUVKXGZO\K

/TYZGRRGVXKYY[XKMG[MK L[TIZOUT
VYO /TZKXINGTMKVXKYY[XK UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
GZZNKW[OIQJOYIUTTKIZ UXSUXK IUSVKTYGZOTMLRU]
IU[VROTMUTZNKXUZGZK IUTZXUR\GR\KOZKS; IUTZXUR\GR\K
L[TIZOUTSGTOLURJGTJ ]OZNROQK\GR\KOZKS<
NURJZNKL[TIZOUTY]OZIN
L[TIZOUTOTUVKXGZO\K

L[TIZOUTVYO 8KVRGIKPOHHUUS
JOXKIZOUTGR\GR\K

/TZKXINGTMKINKIQ L[TIZOUT
OZKS.]OZNROQK\GR\K UVKXGZKY 8KVRGIKJKLKIZO\K
OZKS2 INKIQ\GR\K

L[TIZOUTOTUVKXGZO\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 46 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 25

Platform Rotate POHHUUS POHHUUS

)NKIQOLPOH JU]T /TJO\OJ[GRR_OTZKXINGTMK JU]T
HUUSJU]TOY UVKXGZKY KGINPOHSGTOLURJ\GR\K UVKXGZKY 8KVRGIKJKLKIZO\K
Right Function UVKXGZOUTGR ]OZNROQK\GR\KLXUS
JXO\KSGTOLURJOZKS8 \GR\KY
Inoperative
XUZGZKXOMNZ
Be sure all other OTUVKXGZO\K
functions operate
normally. POHHUUSJU]T )NKIQLUXSKINGTOIGR
OTUVKXGZO\K XKYZXOIZOUTYQKKVOTM
VRGZLUXSLXUSXUZGZOTM
If platform rotate right 58XKVGOXN_JXG[ROI
function operates XUZGZUX
normally from the
ground controls but .URJMXU[TJIUTZXUR
not from the platform L[TIZOUTY]OZINGTJ 8KVGOXUVKTOTMXT]OXK
controls, troubleshoot INKIQ\URZGMKGZMXT <
]OXKUTVRGZLUXSXUZGZK IOXI[OZLXUS:(
the platform control XOMNZL[TIZOUTJOXKIZOUTGR ZUJOXKIZOUTGR\GR\K
toggle switch. See \GR\K
Repair section.
<
If platform rotate right
function operates 8KSU\KHUZN]OXKYLXUS UX
normally from the \GR\KIUORGTJINKIQ OTLOTOZK
platform controls but XKYOYZGTIKGIXUYYZNK UNSY
IUORZKXSOTGRY 8KVRGIKZNKIUOR
not from the ground
controls, troubleshoot ZUUNSY
the ground control
toggle switch. See .URJZUMMRKY]OZINXOMNZ
Repair section. GTJSGT[GRR_U\KXXOJK
ZNKXUZGZKXOMNZ
JOXKIZOUTGR\GR\KV[YN
OTH[ZZUTUTKTJUL L[TIZOUT
\GR\KYVUUR4UZK UVKXGZKY 8KVRGIKZNKVRGZLUXS
U\KXXOJOTMZNK\GR\K]ORR XUZGZKJOXKIZOUTGR\GR\K
XKW[OXKZ]UVKUVRK/LG
NKRVKXOYTUZG\GORGHRK
OTZKXINGTMKZNK\GR\K
OZKS4]OZNGROQK
\GR\KOZKS5

L[TIZOUTOTUVKXGZO\K

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 47

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 25

/TYZGRRGVXKYY[XKMG[MK 
)UTZOT[KJLXUSZNK GZZNKW[OIQJOYIUTTKIZ VYOUX
VXK\OU[YVGMK SUXK 8KVRGIKZNKVRGZLUXS
IU[VROTMUTZNKXUZGZK XUZGZKJOXKIZOUTGR\GR\K
L[TIZOUTSGTOLURJGTJ
NURJZNKL[TIZOUTY]OZIN

RKYYZNGTVYO
L[TIZOUT
/TZKXINGTMKINKIQ\GR\K UVKXGZKY 8KVRGIKJKLKIZO\K
OZKS/]OZNROQK\GR\K INKIQ\GR\K
OZKS2

L[TIZOUTOTUVKXGZO\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 48 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 26

Jib Boom Up 9ZKVUTLUUZY]OZIN < )NKIQ\URZGMKGZ]NZ < 8KVGOXUVKTOT]NZ

GTJINKIQ\URZGMKGZ ]OXKUT)8XKRG_ ]OXKIOXI[OZLXUS:6
Function IKTZKXZKXSOTGRULPOH ZU)8XKRG_
HUUSZUMMRKY]OZIN
Inoperative <

Be sure all other )NKIQ\URZGMKGZMXT <

8KVRGIK)8XKRG_
functions operate ]NZ]OXKUT)8XKRG_
normally.
<
If jib boom up function <
operates normally /YURGZKMXU[TJGTJ
from the ground VRGZLUXSXUZGZKZUMMRK
Y]OZINKYGTJZKYZKGIN
controls but not Y]OZIN8KVRGIK
from the platform JKLKIZO\KY]OZIN
controls, troubleshoot XUZGZKRKLZ
the platform control )NKIQOLVRGZLUXSXUZGZK UVKXGZKY /TJO\OJ[GRR_OTZKXINGTMK POHHUUS
toggle switch or CR13. RKLZOYUVKXGZOUTGR KGINPOHSGTOLURJ\GR\K [V
See Repair section. ]OZNROQK\GR\KLXUS UVKXGZKY 8KVRGIKJKLKIZO\K
JXO\KSGTOLURJOZKS8 \GR\KY
If jib boom up function POHHUUS[V
operates normally OTUVKXGZO\K
from the platform
XUZGZKRKLZ )NKIQPOHHUUSLUX
controls but not from OTUVKXGZO\K SKINGTOIGRXKYZXOIZOUTY
the ground controls, 58XKVGOXPOHHUUS
troubleshoot the I_ROTJKX58XKVRGIK
POHHUUSI_ROTJKX
ground control toggle IU[TZKXHGRGTIK\GR\KY
switch. See Repair
section.
.URJMXU[TJIUTZXUR
L[TIZOUTY]OZINGTJ
INKIQ\URZGMKGZMXTHRQ < 8KVGOXUVKTOTMXTHRQ
]OXKIOXI[OZLXUS:(ZU
]OXKUTPOHHUUS[V JOXKIZOUTGR\GR\K
L[TIZOUTJOXKIZOUTGR
\GR\K

<

8KSU\KHUZN]OXKYLXUS UX
\GR\KIUORGTJINKIQ OTLOTOZK
XKYOYZGTIKGIXUYYZNK UNSY
IUORZKXSOTGRY 8KVRGIKZNKIUOR

ZUUNSY

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 49

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 26

.URJZUMMRKY]OZINGTJ L[TIZOUT 8KVRGIKZNKPOHHUUS[V

)UTZOT[KJLXUSZNK SGT[GRR_U\KXXOJKZNK UVKXGZKY JOXKIZOUTGR\GR\K
VXK\OU[YVGMK POHHUUS[VJOXKIZOUTGR
\GR\KV[YNOTH[ZZUTUT
KTJUL\GR\KYVUUR
4UZK U\KXXOJOTMZNK
\GR\K]ORRXKW[OXKZ]U
VKUVRK/LGNKRVKXOYTUZ
G\GORGHRKOTZKXINGTMK
ZNK\GR\KOZKS4]OZNG
ROQK\GR\KOZKS5

L[TIZOUTOTUVKXGZO\K

 L[TIZOUT
/TYZGRRGVXKYY[XKMG[MK /TZKXINGTMKVXKYY[XK UVKXGZKY 8KVRGIKJKLKIZO\KLRU]
GZZNKW[OIQJOYIUTTKIZ VYOUX IUSVKTYGZOTMLRU] IUTZXUR\GR\K
IU[VROTMUTZNKL[TIZOUT SUXK IUTZXUR\GR\KOZKS;
SGTOLURJGTJNURJZNK ]OZNROQK\GR\KOZKS<
L[TIZOUTY]OZIN
L[TIZOUTOTUVKXGZO\K
RKYYZNGT 8KVRGIKPOHHUUS
VYO JOXKIZOUTGR\GR\K

L[TIZOUT
/TZKXINGTMKINKIQ UVKXGZKY 8KVRGIKJKLKIZO\K
OZKS.]OZNROQK\GR\K INKIQ\GR\K
OZKS2

L[TIZOUTOTUVKXGZO\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 50 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 27

Jib Boom Down )NKIQOLVRGZLUXS XUZGZK /TJO\OJ[GRR_OTZKXINGTMK POHHUUS

XUZGZKXOMNZOY XOMNZ KGINPOHSGTOLURJ\GR\K JU]T
Function UVKXGZOUTGR UVKXGZKY ]OZNROQK\GR\KLXUS UVKXGZKY 8KVRGIKJKLKIZO\K
JXO\KSGTOLURJOZKS8 \GR\KY
Inoperative
POHHUUS[V
Be sure all other OTUVKXGZO\K
functions operate
)NKIQPOHHUUSLUX
normally. XUZGZKXOMNZ SKINGTOIGRXKYZXOIZOUTY
OTUVKXGZO\K 58XKVGOXPOHHUUS
If jib boom down I_ROTJKX58XKVRGIK
function operates POHHUUSI_ROTJKX
normally from the IU[TZKXHGRGTIK\GR\KY
ground controls but
not from the platform .URJMXU[TJIUTZXUR
controls, troubleshoot L[TIZOUTY]OZINGTJ 8KVGOXUVKTOTMXT]OXK
INKIQ\URZGMKGZMXT <
the platform control IOXI[OZLXUS:(
]OXKUTPOHHUUSJU]T ZUJOXKIZOUTGR\GR\K
toggle switch or CR13. L[TIZOUTJOXKIZOUTGR
See Repair section. \GR\K

If jib boom down <

function operates UX
normally from the 8KSU\KHUZN]OXKYLXUS OTLOTOZK
\GR\KIUORGTJINKIQ UNSY
platform controls but 8KVRGIKZNKIUOR
XKYOYZGTIKGIXUYYZNK
not from the ground IUORZKXSOTGRY
controls, troubleshoot
the ground control ZUUNSY
toggle switch. See
Repair section. .URJZUMMRKY]OZINXOMNZ
GTJSGT[GRR_U\KXXOJK L[TIZOUT
ZNKPOHHUUSJU]T UVKXGZKY 8KVRGIKZNKPOHHUUS
JOXKIZOUTGR\GR\KV[YN JOXKIZOUTGR\GR\K
OTH[ZZUTUTKTJUL
\GR\KYVUUR4UZK
U\KXXOJOTMZNK\GR\K]ORR
XKW[OXKZ]UVKUVRK/LG
NKRVKXOYTUZG\GORGHRK
OTZKXINGTMKZNK\GR\K
OZKS4]OZNGROQK
\GR\KOZKS5

L[TIZOUTOTUVKXGZO\K

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 51

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 27

/TYZGRRGVXKYY[XKMG[MK
)UTZOT[KJLXUSZNK GZZNKW[OIQJOYIUTTKIZ VYO
VXK\OU[YVGMK IU[VROTMUTZNKXUZGZK UXSUXK 8KVRGIKZNKPOHHUUS
JOXKIZOUTGR\GR\K
L[TIZOUTSGTOLURJGTJ
NURJZNKL[TIZOUTY]OZIN

RKYYZNGTVYO
L[TIZOUT
/TZKXINGTMKINKIQ UVKXGZKY 8KVRGIKJKLKIZO\K
OZKS/]OZNROQK\GR\K INKIQ\GR\K
OZKS2

L[TIZOUTOTUVKXGZO\K

8KVRGIKZNKJOXKIZOUTGR
\GR\K58ZNKSGTOLURJ
NGYOTZKXTGRJKLKIZY58
UTKULZNKVXK\OU[Y
ZKYZY]GYVUYYOHR_
U\KXRUUQKJUX
JOGMTUYKJOTIUXXKIZR_
8KINKIQGTJUXIUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 52 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 28

Drive Chassis /TYZGRRGVXKYY[XKMG[MK )NKIQLUXSKINGTOIGR

GZZNKZKYZVUXZUT XKYZXOIZOUT58INGYYOY
Jack Function L[TIZOUTSGTOLURJ VYO PGIQG^RKSGTOLURJUX
5VKXGZKTUTYZKKXKTJ INGYYOYROLZPGIQI_ROTJKX
Inoperative ROLZPGIQ GTJIU[TZKXHGRGTIK
\GR\KYNGYOTZKXTGR
Be sure all other JKLKIZ)UTY[RZ-KTOK
function operate RKYYZNGTVYO /TJ[YZXOKY9KX\OIK
normally. *KVGXZSKTZ

Be sure unit is in )NKIQ\URZGMKGZJXO\K 8KSU\KHUZN]OXKYLXUS

stowed position. INGYYOYROLZPGIQJ[SV < \GR\KIUORGTJINKIQ UNSY
\GR\KYRUIGZKJ[TJKX XKYOYZGTIKGIXUYYIUOR 8KVRGIKZNK\GR\KIUOR
Procedure is written for L[TIZOUTSGTOLURJ ZKXSOTGRY
non-steer end lift jack, if
steer end lift jack is ZUUNSY
inoperative repeat
*OYIUTTKIZGTJVR[MZNK
procedure and N_JXG[ROINUYKYLXUS  8KVRGIKZNK
substitute steer for non- ZNKTUTYZKKXKTJPGIQ VYO IU[TZKXHGRGTIK\GR\KUT
steer. )GVZNKLOZZOTM YUTZNK ZNKI_ROTJKX58XKVGOXUX
I_ROTJKX5VKXGZKTUT XKVRGIKZNKI_ROTJKX
YZKKXKTJPGIQ

< RKYYZNGTVYO

8KVRGIKOZKS'UTYZKKX
SGTOLURJ58XKVRGIKUX
XKVGOXOZKS'UTROLZPGIQ
J[SV\GR\KSGTOLURJ
58XKVGOXUXXKVRGIKZNK
INGYYOYPGIQG^RK
SGTOLURJ58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTHKZ]KKT
:(GTJJXO\KINGYYOY
< ROLZPGIQJ[SV\GR\K

<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOT29
]OXOTM58XKVRGIK29
<
<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOT29
]OXOTM58XKVRGIK29
<

8KVGOXUVKTOTVU]KX
Y[VVR_]OXKY]OZNJOUJKY
LXUS:(ZU:(58
LXUS:(ZU:(58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 53

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 29

Axle Extend/ /TYZGRRGVXKYY[XKMG[MK )NKIQLUXSKINGTOIGR

GZZNKZKYZVUXZUT XKYZXOIZOUT58INGYYOY
Retract L[TIZOUTSGTOLURJ VYO PGIQG^RKSGTOLURJUX
5VKXGZKTUTYZKKXKTJ INGYYOYG^RKI_ROTJKX
Function G^RKL[TIZOUT GTJIU[TZKXHGRGTIK
Inoperative \GR\KYNGYOTZKXTGR
JKLKIZ)UTY[RZ-KTOK
RKYYZNGTVYO /TJ[YZXOKY9KX\OIK
Be sure all other *KVGXZSKTZ
function operate
normally.
)NKIQ\URZGMKGZJXO\K 8KSU\KHUZN]OXKYLXUS
INGYYOYROLZPGIQJ[SV < \GR\KIUORGTJINKIQ UNSY
Be sure unit is in \GR\KYRUIGZKJ[TJKX XKYOYZGTIKGIXUYYIUOR 8KVRGIKZNK\GR\KIUOR
stowed position. L[TIZOUTSGTOLURJ ZKXSOTGRY

Procedure is written for ZUUNSY

non-steer end axle, if
steer end axle is *OYIUTTKIZGTJVR[MZNK
inoperative repeat N_JXG[ROINUYKYLXUS  8KVRGIKZNK
ZNKTUTYZKKXKTJG^RK VYO IU[TZKXHGRGTIK\GR\KUT
procedure and
I_ROTJKX)GVZNK ZNKI_ROTJKX58XKVGOXUX
substitute steer for non- LOZZOTM YUTZNKI_ROTJKX XKVRGIKZNKI_ROTJKX
steer. 5VKXGZKTUTYZKKXKTJ
G^RKL[TIZOUT

RKYYZNGTVYO
<
8KVRGIKOZKS'UTYZKKX
SGTOLURJ58XKVRGIKUX
XKVGOXOZKS'UTROLZPGIQ
J[SV\GR\KSGTOLURJ
58XKVGOXUXXKVRGIKZNK
INGYYOYPGIQG^RK
SGTOLURJ58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTHKZ]KKT
:(GTJJXO\KINGYYOY
ROLZPGIQJ[SV\GR\K
<
<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOT29
]OXOTM58XKVRGIK29
<
<
)NKIQ\URZGMKGZ:( 8KVGOXUVKTOT29
]OXOTM58XKVRGIK29
<

8KVGOXUVKTOTVU]KX
Y[VVR_]OXKY]OZNJOUJKY
LXUS:(ZU:(58
LXUS:(ZU:(58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 54 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 30

Steer Left 9ZGXZZNKKTMOTKLXUS < 8KVGOXUXXKVRGIKZNK

ZNKVRGZLUXSVXKYY YZKKXSOIXUY]OZINOT
Function JU]TLUUZY]OZINNURJ IUTZXURRKXNGTJRK
Inoperative ZNKYZKKXY]OZINRKLZGTJ
INKIQ\URZGMKGZ
ZKXSOTGRUTZNKJXO\K
Be sure all other IUTZXURRKXHR[]OXK
functions operate
normally. <

.URJZNKYZKKXY]OZIN < 8KVGOXUVKTOTHR[]OXK

RKLZGTJINKIQ\URZGMK IOXI[OZLXUSYZKKXY]OZIN
GZ:( ZU:6ZU:(

<

.URJZNKYZKKXY]OZIN < 8KVGOXUVKTOTHR[]OXK

RKLZGTJINKIQ\URZGMKGZ IOXI[OZLXUS:(ZU
HR[]OXKUTYZKKX\GR\K YZKKX\GR\K

<
UX
8KSU\KHUZN]OXKYLXUS OTLOTOZK
YZKKXRKLZIUORGTJINKIQ UNSY 8KVRGIKYZKKXRKLZ
XKYOYZGTIKGIXUYYIUOR \GR\KIUOR
ZKXSOTGRY

ZUUNSY

8KVRGIKYZKKX\GR\K58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 55

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 31

Steer Right 9ZGXZZNKKTMOTKLXUS < 8KVGOXUXXKVRGIKZNK

ZNKVRGZLUXSVXKYY YZKKXSOIXUY]OZINOT
Function JU]TLUUZY]OZINNURJ IUTZXURRKXNGTJRK
Inoperative ZNKYZKKXY]OZINXOMNZ
GTJINKIQ\URZGMKGZ
ZKXSOTGRUTZNKJXO\K
Be sure all other IUTZXURRKXHR[HRQ]OXK
functions operate
normally. <

.URJZNKYZKKXY]OZIN < 8KVGOXUVKTOTHR[HRQ

XOMNZGTJINKIQ\URZGMK ]OXKIOXI[OZLXUSYZKKX
GZ:( Y]OZINZU:6ZU:(

<

.URJZNKYZKKXY]OZIN 8KVGOXUVKTOTHR[HRQ
XOMNZGTJINKIQ\URZGMK <
]OXKIOXI[OZLXUS:(
GZHR[HRQ]OXKUT ZUYZKKX\GR\K
YZKKX\GR\K

<
UX
8KSU\KHUZN]OXKYLXUS OTLOTOZK
YZKKXXOMNZIUORGTJ UNSY 8KVRGIKYZKKXXOMNZ
INKIQXKYOYZGTIKGIXUYY \GR\KIUOR
IUORZKXSOTGRY

ZUUNSY

8KVRGIKYZKKX\GR\K58
IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 56 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 32

All Drive 9ZGXZKTMOTKLXUS SGINOTKJUKYTUZSU\K 8KVGOXUXXKVRGIKZNK

MXU[TJIUTZXURYGTJ JXO\KV[SV
Functions YZGTJOTMIRKGXULZNK
Inoperative, ZOXKYSUSKTZGXOR_SU\K
V[SVIUTZXURU\KXXOJK
All Other RK\KXOTKGINJOXKIZOUT

Functions SGINOTKSU\KY
Operate
3U\KZUVRGZLUXS SGINOTK 6RGIKGP[SVKX]OXK
Normally VXKYYJU]TLUUZY]OZIN JXO\KY HKZ]KKT:(GTJ TUJXO\K 8KVGOXUVKTOT
NURJJXO\KKTGHRK :(GTJZKYZJXO\K ]NZ]OXKIOXI[OZLXUS
Be sure the hydraulic Y]OZINZUKOZNKXYOJK ]OZNU[ZNURJOTMJXO\K :6ZU:(
GTJZX_ZUJXO\K KTGHRKY]OZIN
suction line valve is in
the open position.
SGINOTKJXO\KY
Be sure machine is
not in the free wheel 8KVRGIKJXO\KKTGHRK
ROSOZY]OZIN58XKVGOX
configuration. TUJXO\K UVKTOT]OXKIOXI[OZY
LXUSZKXSOTGR:(ZU
ROSOZY]OZINGTJLXUS
ROSOZY]OZINZU:(

*OYIUTTKIZJXO\KV[SV UX
KRKIZXUTOIJOYVRGIKSKTZ OTLOTOZK
IUTZXURRKX+*)]OXKY UNSY
)NKIQXKYOYZGTIK 8KVRGIK+*)
GIXUYYHUZN]OXKYUT
+*)YOJKULW[OIQ
JOYIUTTKIZ

ZUUNSY

6XKYYJU]TLUUZY]OZIN )UXXKIZOTY[LLOIOKTZ
GTJINKIQ\URZGMKGZ RKYYZNGT< \URZGMKY[VVR_
NUXYKVU]KXROSOZKX GRZKXTGZUXUXHGZZKX_
HUGXJZKXSOTGR 58XKVGOXUVKTOT]NZ
]OXKIOXI[OZY[VVR_OTM
<UXSUXK <ZUZKXSOTGR

)UTZOT[KJUTZNKTK^Z
VGMK

Part No. 34032 Genie S-80 & Genie S-85 5 - 57

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

CHART 32

9]OZINXVSYKRKIZ < )NKIQ\URZGMKGZ:( ZU< 8KVGOXUVKTOTUXMHRQ

)UTZOT[KJLXUSZNK Y]OZINZUXGHHOZ]OZNLUUZ ]OXKIOXI[OZLXUS:(ZU
VXK\OU[YVGMK Y]OZINVXKYYJU]TLUUZ NUXYKVU]KXROSOZKX
Y]OZINGTJINKIQ < ZKXSOTGR
\URZGMKGZZKXSOTGRUT
NUXYKVU]KXROSOZKX )NKIQ\URZGMKGZ 8KVGOXUVKTOTUXMHRQ
ZU<
UXMHRQ]OXKUTKTMOTK ]OXKIOXI[OZLXUS
GRZKXTGZUX GRZKXTGZUXZU:(

<
ZU<
8KVGOXUXXKVRGIK
GRZKXTGZUX

6XKYYJU]TLUUZY]OZIN
GTJINKIQ\URZGMKGZ < 8KVRGIKNUXYKVU]KX
ZKXSOTGRUT ROSOZKXHUGXJ
NUXYKVU]KXROSOZKX

ZU<

6XKYYJU]TLUUZY]OZIN 8KVGOXUVKTOTXKJ]OXK
GTJINKIQ\URZGMKGZ < IOXI[OZLXUSNUXYKVU]KX
ZKXSOTGRUTJXO\K ROSOZKXHUGXJZUJXO\K
IUTZXURRKX IUTZXURZKXSOTGR

ZU<

)UTZOT[KJUTZNKTK^Z
VGMK

5 - 58 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

CHART 32

*OYIUTTKIZJXO\KV[SV < 8KVGOXUXXKVRGIKJXO\K

)UTZOT[KJLXUSZNK IUTZXURRKX
VXK\OU[YVGMK +*)]OXKYVXKYYJU]T
LUUZY]OZINNURJJXO\K
IUTZXURRKXOTL[RRLUX]GXJ
VUYOZOUTGTJINKIQ
\URZGMKGIXUYY
ZKXSOTGRYGTJ
UTJXO\KIUTZXURRKX

ZU<

6XKYYJU]TLUUZY]OZIN 8KVGOXUVKTOTKOZNKX
NURJJXO\KIUTZXURRKXOT < ]NZUX]NZHRQ]OXK
L[RRLUX]GXJVUYOZOUT IOXI[OZLXUSJXO\K
GTJINKIQ\URZGMK IUTZXURRKXZU:6GTJ
GIXUYYZKXSOTGRY :6XKYVKIZO\KR_
:6GTJ:6

ZU<

6XKYYJU]TLUUZY]OZIN
NURJJXO\KIUTZXURRKXOT 8KVGOXUVKTOTKOZNKX
L[RRLUX]GXJVUYOZOUT <
]NZUX]NZHRQ]OXK
GTJINKIQ\URZGMK IOXI[OZLXUS:(GTJ
GIXUYYZKXSOTGRY :(XKYVKIZO\KR_
:(GTJ:(

ZU<

6XKYYJU]TLUUZY]OZIN 8KVGOXUVKTOT]NZHRQ
NURJJXO\KIUTZXURRKXOT ]OXKIOXI[OZLXUS:(ZU
L[RRLUX]GXJVUYOZOUTGTJ < +*)W[OIQJOYIUTTKIZ
INKIQ\URZGMKGIXUYY 58XKVGOXUVKTOT]NZ
ZNKZ]U]OXKYGZ+*) ]OXKIOXI[OZLXUS:(ZU
W[OIQJOYIUTTKIZ +*)W[OIQJOYIUTTKIZ

ZU<

8KVRGIKJXO\KV[SV
+*)58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ

Part No. 34032 Genie S-80 & Genie S-85 5 - 59

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 33

Drive Forward *OYIUTTKIZZNK+*) \URZGMKXKGJOTMYJOLLKXKTZ 8KVGOXUXXKVRGIKZNK

]OXKIUTTKIZUXLXUSZNK JXO\KIUTZXURRKX
Or Reverse JXO\KV[SVYZGXZ
Function KTMOTKSU\KZNKJXO\K
IUTZXURRKXZUL[RRLUX]GXJ
Inoperative VUYOZOUTGTJTUZKZNK
\URZGMKGIXUYYZKXSOTGRY
:(GTJ:(
Be sure all other 8K\KXYKZNK\URZSKZKX
functions operate RKGJYGTJSU\KZNK
normally including JXO\KIUTZXURRKXZUL[RR
XK\KXYKVUYOZOUTGTJ
drive in opposite TUZKZNK\URZGMK
direction of
malfunction. \URZGMKXKGJOTMYZNKYGSK

'JP[YZZNKJXO\KV[SV *KLKIZO\K9[TJYZXGTJ
T[RRTK[ZXGR9KK TUOSVXU\KSKTZ JXO\KV[SVIUTZGIZ
9[TJYZXGTJ9KXOKY 9[TJYZXGTJG[ZNUXO`KJ
9KX\OIK3GT[GR XKVGOXLGIOROZ_

Y_SVZUSYOSVXU\K

)NKIQGRRJXO\KYVKKJY
GTJSUTOZUXLUXXKI[XXOTM
Y_SVZUSY6UYYOHRK
IUTZGSOTGZOUTOT
N_JXG[ROIY_YZKS

5 - 60 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 34

Traction 'T_Z_VKULZXGIZOUT

VXUHRKSIUTY[RZ-KTOK
Function /TJ[YZXOKY9KX\OIK

Inoperative *KVGXZSKTZ

Be sure all other

functions operate
normally.

Part No. 34032 Genie S-80 & Genie S-85 5 - 61

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 35

Machine Will =OZNHUUSL[RR_YZU]KJ L[RR 8KVGOXUXXKVRGIKHUUS

INKIQ:(LUX IUTZOT[OZ_ ROLZJXO\KROSOZY]OZINUX
Not Drive At IUTZOT[OZ_ZUMXU[TJ HUUSK^ZKTJROSOZ
Y]OZIN
Full Speed
TUIUTZOT[OZ_
Be sure all other
=OZNHUUSL[RR_YZU]KJ L[RR 5XGTMK]OXKYNUXZKJ
functions operate
INKIQNUXYKVU]KX IUTZOT[OZ_ ZUMXU[TJXKVGOX
normally. ROSOZKXHUGXJZKXSOTGR UXGTMK]OXKIOXI[OZLXUS
LUXIUTZOT[OZ_ZUMXU[TJ :(ZUNUXYKVU]KX
Be sure the free-wheel ROSOZKXHUGXJ
valve is closed on the TUIUTZOT[OZ_
drive pump.
8KGJP[YZUXXKVRGIK
NUXYKVU]KXROSOZKX
HUGXJ9KK8KVGOX
YKIZOUT58IUTY[RZ
-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ

5 - 62 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 36

Machine Drives 8GOYKHUUSULLJXO\K L[RR *OYIUTTKIZKRKIZXUTOI *KLKIZO\K9[TJYZXGTJ

ROSOZY]OZINZ[XT IUTZOT[OZ_ JOYVRGIKSKTZIUTZXURRKX ZU< JXO\KV[SV8KVRGIKUX
At Full Speed SGINOTKULLGTJINKIQ +*)]OXKYUTJXO\K XKVGOXGZG[ZNUXO`KJ
IUTZOT[OZ_HKZ]KKT V[SVSU\KJXO\K 9[TJYZXGTJXKVGOX
With Platform MXU[TJGTJZKXSOTGR IUTZXURRKXZUL[RRLUX]GXJ LGIOROZ_
Raised or UTNUXYKVU]KXROSOZKX VUYOZOUTGTJINKIQ
HUGXJ \URZGMKHKZ]KKT
Extended ZKXSOTGRYGTJ
UTJXO\KIUTZXURRKX
Remove machine from
service immediately. ZU<
TUIUTZOT[OZ_
Be sure boom lift drive 8KVRGIKNUXYKVU]KX
limit switch or boom ROSOZKXHUGXJ
extend drive limit switch
L[RR
is not being held down )NKIQIUTZOT[OZ_ IUTZOT[OZ_ 8KVGOXUVKTOTUXM]OXK
or up. HKZ]KKTMXU[TJ IOXI[OZLXUS:(ZU
GTJ:( NUXYKVU]KXROSOZKX
HUGXJZKXSOTGR
Be sure wiring to limit
switches is intact and TUIUTZOT[OZ_
shows no sign of
8KVGOXROSOZY]OZIN
tampering. ]OXOTM58XKVRGIKHUUS
ROLZJXO\KROSOZY]OZIN58
Be sure orange wire XKVRGIKHUUSK^ZKTJ
(cable 1) is properly JXO\KROSOZY]OZIN
attached to horsepower
limiter.

Part No. 34032 Genie S-80 & Genie S-85 5 - 63

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

Chart 37

Drive Enable *UTUZNURJZNKJXO\K =ORRNURJOTMZNKJXO\K :XU[HRKYNUUZ

KTGHRKY]OZINGTJ TU KTGHRKY]OZINGRRU] TU NUXYKVU]KXROSOZHUGXJ
System Is INKIQOLSGINOTK]ORR HUUSZUJXO\KOT JXO\KIUTZXURRKXUX
JXO\KOTZNKYZU]KJ YZU]KJVUYOZOUTU\KX JXO\KV[SV9KKINGXZ
Malfunctioning VUYOZOUT]OZNHUUSU\KX TUTYZKKX]NKKRY% 
TUTYZKKX]NKKRY%
_KY

_KY 8KVGOXUXXKVRGIKJXO\K
KTGHRKROSOZY]OZIN

*UTUZNURJZNKJXO\K
KTGHRKY]OZINGTJ
INKIQOLSGINOTK]ORR _KY 8KVGOXUXXKVRGIKJXO\K
JXO\KOTZNKYZU]KJ KTGHRKROSOZY]OZIN
VUYOZOUT]OZNHUUSU\KX
ZNKYZKKX]NKKRY%

TU

=ORRNURJOTMZNKJXO\K
KTGHRKY]OZINGRRU]
HUUSZUJXO\KOT
YZU]KJVUYOZOUTU\KX
YZKKX]NKKRY%

TU

8KVGOXUXXKVRGIKJXO\K
KTGHRKZUMMRKY]OZIN

5 - 64 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 5 - Troubleshooting Flow Charts

Chart 38

Auxiliary =OZNKTMOTKTUZX[TTOTM V[SV *KGJNKGJGVXKYY[XK RKYYZNGT .URJG[^OROGX_Y]OZIN

ROLZY]OZINIU\KXNURJ X[TY MG[MKOTZUZNKVXKYY[XK VYO GTJGJP[YZV[SVXKROKL
Functions G[^OROGX_Y]OZINGTJ ROTKULZNKG[^OROGX_ \GR\KUXXKVRGIKV[SV
ROYZKTLUXYU[TJUL V[SVGTJNURJZNK
Inoperative G[^OROGX_V[SVX[TTOTM G[^OROGX_VU]KXY]OZIN
Be sure all other
VYO
functions operate
normally. 8KIUTTKIZVXKYY[XK
ROTKGTJINKIQHGZZKX_
Be sure key switch IUTJOZOUT:NKXKOY
V[SVJUKYTUZX[T
is in the appropriate VUYYOHR_TUZKTU[MN
position and the HGZZKX_IGVGIOZ_ZU
UVKXGZKHUZNG[^V[SV
emergency stop GTJL[TIZOUT\GR\KY
buttons are pulled
up into the on
.URJZNKG[^OROGX_VU]KX 8KVRGIKJKLKIZO\K
position. Y]OZINGTJINKIQZNK <
G[^OROGX_VU]KX
\URZGMKGZZKXSOTGR ZUMMRKY]OZIN
Be sure engine is :(
not running when
using auxiliary <
power.
.URJZNKG[^OROGX_VU]KX
Note: Operating Y]OZINGTJINKIQZNK 8KVGOXUVKTOTXKJ]OXK
\URZGMKGZOTOZOGZK <
auxiliary power with
ZKXSOTGRXKJ]OXKUT IOXI[OZLXUS
the engine running 68SUZUXYZGXZ :(ZU68
should immediately YURKTUOJ
kill the engine.
<

.URJZNKG[^OROGX_VU]KX
Y]OZINGTJINKIQZNK <
\URZGMKGZVUYOZO\K 8KVRGIK68XKRG_
VU]KXIGHRKUTG[^OROGX_
VU]KX[TOZ

<

)NKIQG[^OROGX_VU]KX
[TOZMXU[TJOTMIGHRK
58XKVGOXUXXKVRGIK
KRKIZXOISUZUX

Part No. 34032 Genie S-80 & Genie S-85 5 - 65

Section 5 - Troubleshooting Flow Charts Service Manual - First Edition

This page intentionally left blank.

5 - 66 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 6 - Schematics

Schematics

About This Section

There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

Observe and Obey: Electrocution hazard. Contact with

electrically charged circuits may
Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Bodily injury hazard. Spraying
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to squirt
Read, understand and obey the safety rules
or spray.
and operating instructions printed in the
Genie S-80 & Genie S-85 Operator's Manual. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use. Malfunction Identify Troubleshoot
discovered symptoms

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 34032 Genie S-80 & Genie S-85 6-1

Section 6 - Schematics Service Manual - First Edition

Electrical Symbols Legend

TB17
15AMP. DP1

WTS1 N.O.
BLK
1
2
Circuit breaker 3

GRN/BLK
ORG/BLK-1

4
5
Water temperature 6
7
switch 8

normally open
Wire color
with cable Single axis
number FS1
RED drive controller
BLK
Solenoid or Ground

WHT #51
relay coil supression Foot switch
TB20 circuit TR2 2
1 T
6
PLAT
3
KS1

RED-5

WHT-5
TILT
Terminal ALARM

TB=Terminal base GRND Time delay relay

TP=Terminal platform
Horn Key switch
NC NO
TS3

TP29 LS3

START
ENGINE
BLK-5

GRN-5

Quick disconnect L4 OP HORN P4 Toggle switch SPDT

terminal
Limit switch
Light
BLK #21 TB21
Horn button
normally open TS6
LS2
T-circuits connect NC

LEFT
RIGHT
at terminal
10

P1
Limit switch
normally closed Toggle switch DPDT
Resistor held open Emergency Stop
button BP2

T-circuits normally closed PWM

A
connect +
-
VAC X
R

Vacuum switch Single axis

CR4

Tilt sensor proportional

Connection
no terminal controller
Relay contact
OPS1 N.C.

normally open
1 START RELAY
2 TACHOMETER
3 START INPUT
Spark plug 4 AUX. ON
5 GROUND
PR4 BATTERY
6

Circuits crossing Oil pressure 7 KEY PWR.

no connection switch 8
9
KEY BYPASS
IGN./FUEL ON
normally closed 10 ENG. FAULT
Relay panel
contactor Ignition start
module
Glow plug BP1
Diode AUX.
1
PUMP D2 D1
2 A R
3
4 - +
5 + -
LS1 6 R A
NO 7 D1 D2
+
Auxiliary pump 8
9
10

Limit switch
normally open Horsepower Dual axis
-
held closed limiter board Ramp up and down
proportional controller
Battery

6-2 Genie S-80 & Genie S-85 Part No. 34032

Section 6 - Schematics Service Manual

Electrical Schematic -
Gasoline/LPG Models
A B C D E F G H I J K L M N O

6-3 Genie S-80 & Genie S-85 Part No. 34032

 Service Manual Section 6 - Schematics

Electrical Schematic -
Gasoline/LPG Models
O N M L K J I H G F E D C B A

Part No. 34032 Genie S-80 & Genie S-85 6-4

Service Manual Section 6 - Schematics

Ground Control Box Legend -

Gasoline/LPG Models

Part No. 34032 Genie S-80 & Genie S-85 6-5

Section 6 - Schematics Service Manual

Relay Panel Legend -

Gasoline/LPG Models

6-6 Genie S-80 & Genie S-85 Part No. 34032

Service Manual Section 6 - Schematics

Platform Control Box Legend -

Gasoline/LPG Models

Part No. 34032 Genie S-80 & Genie S-85 6-7

Section 6 - Schematics Service Manual

Electrical Schematic -
Diesel Models
A B C D E F G H I J K L M N O

6-8 Genie S-80 & Genie S-85 Part No. 34032

 Service Manual Section 6 - Schematics

Electrical Schematic -
Diesel Models
O N M L K J I H G F E D C B A

Part No. 34032 Genie S-80 & Genie S-85 6-9

Service Manual Section 6 - Schematics

Ground Control Box Legend -

Diesel Models

Part No. 34032 Genie S-80 & Genie S-85 6 - 10

Section 6 - Schematics Service Manual

Platform Control Box Legend -

Diesel Models

6 - 11 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 6 - Schematics

Hydraulic Symbols Legend

Double acting 2 pos., 3 way, shuttle valve

Pressure gauge cylinder

0.035 Solenoid operated

proportional valve
Orifice with size

Filter

3 pos., 3 way, directional valve

Variable orifice 150 psi

or shut-off valve

Flow regulator valve

Fixed displacement
pump

Check valve
Pilot operated bypass
valve with psi

Solenoid operated 2 pos.,

Bi-directional, 3 way, directional valve
variable
displacement pump
Adjustable
relief valve
Flow divider/combiner

Solenoid operated 3 pos.,

4 way, directional valve
Bi-directional motor Priority
flow divider

Manually operated
2 pos., 2 way valve Manually operated 3 pos.,
2-speed, 4 way valve with pilot port
bi-directional motor

Solenoid operated
dump valve
M

Pump prime mover

(motor)

Pump prime mover

(engine) Differential
sensing valve

Counterbalance valve

Part No. 34032 Genie S-80 & Genie S-85 6 - 12

 Service Manual Section 6 - Schematics

2WD Hydraulic Schematic

O N M L K J I H G F E D C B A

Part No. 34032 Genie S-80 & Genie S-85 6 - 13

 Service Manual Section 6 - Schematics

4WD Hydraulic Schematic

O N M L K J I H G F E D C B A

Part No. 34032 Genie S-80 & Genie S-85 6 - 14

Service Manual - First Edition Section 7 - Repair Procedures

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.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. Then to
Repair procedures shall be completed by a
re-assemble, perform the disassembly steps in
person trained and qualified on the repair of
reverse order.
this machine.
General Repair Process
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction Malfunction Identify Troubleshoot
discovered symptoms
before operating the machine.

Before Repairs Start: problem

still exists
Read, understand and obey the safety rules
and operating instructions in the
Return to Inspect Perform
Genie S-80 & Genie S-85 Operator’s Manual. service and test repair
problem
Be sure that all necessary tools and parts are solved
available and ready for use.
Symbols Legend
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may Indicates the presence of a
produce hazardous conditions. hazard that will cause death
or serious injury.
Unless otherwise specified, perform each
repair procedure with the machine in the Indicates the presence of a
following configuration: hazard that may cause death
or serious injury.
· machine parked on a flat, level surface
· boom in stowed position Indicates the presence of a
hazard that will or may cause
· turntable rotated with the boom between
serious personal injury or
the non-steering wheels
damage to the machine.
· turntable secured with the turntable
rotation lock pin Indicates special operation or
maintenance information.
· key switch in the OFF position with the
key removed Indicates that a specific result is expected
· wheels chocked after performing a series of steps.
· axles retracted

Part No. 34032 Genie S-80 & Genie S-85 7-1

Section 7 - Repair Procedures Service Manual - First Edition

Platform Controls

1-1 1 Check the battery condition with a volt meter.

The reading should be 12V DC or more to
Joystick Controllers accurately adjust the controller.

Maintaining joystick controllers at the proper 2 Turn the key switch to platform control and
settings is essential to safe machine operation. pull out the Emergency Stop button to the
Every joystick controller should operate smoothly ON position at both the ground and platform

and provide proportional speed control over its controls. Do not start the engine.
entire range of motion. 3 Open the platform control box lid and locate
the boom up/down controller.
a b
a b c d e f g h i j

a terminal "D2" directional output

f e d c b terminal "A" proportional output
c terminal "-" ground
Platform control box d terminal "+" positive
a horsepower limiter board e terminal "R" activates max-out range
b terminals f terminal "D1" directional output
c drive proportional controller g ramp rate adjustable trimpot
d extend/retract proportional controller h lo range adjustable trimpot
e boom proportional controller i threshold adjustable trimpot
f turntable rotate proportional controller j hi range adjustable trimpot

4 Set the preliminary ramp rate: Turn the trimpot

adjustment screw clockwise 15 turns or until
Boom Up/Down Controller you hear a repeated click.
Adjustments 5 Connect the red(+) lead from a volt meter to
Do not adjust the joystick the “A” terminal on the controller printed circuit
controllers unless the static board. Connect the black(-) lead to ground.
battery voltage is above 6 Set the threshold: Press down the foot switch,
12V DC and the alternator then slowly move the control handle off center
is operating properly with until the moment a voltage reading appears.
13.6 to 14.5V DC output. Adjust the voltage to 3.5V DC. Turn the
Electrocution hazard. Contact threshold trimpot adjustment screw clockwise
with electrically charged circuits to increase the voltage or counterclockwise to
may result in death or serious decrease the voltage.
injury. Remove all rings, watches
and other jewelry.

7-2 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

7 Set the hi range: Press down the foot switch, 16 Start a timer and simultaneously move the
then move the control handle all the way to control handle all the way to the UP position.
the UP position. Adjust the voltage to 9.1V DC. Note how long it takes to reach the maximum
Turn the max-out trimpot adjustment screw voltage recorded in step 14. This is the
clockwise to increase the voltage or ramp speed.
counterclockwise to decrease the voltage.
17 Set the ramp rate: turn the trimpot to obtain
8 Set the lo range: Press down the foot switch, a 3 to 4 second ramp speed. Turn the
then move the control handle all the way to the trimpot clockwise to increase the time or
DOWN position. Adjust the voltage counterclockwise to decrease the time.
to 8.3V DC. Turn the dual range trimpot
adjustment screw clockwise to increase the Boom up/down specifications
voltage or counterclockwise to decrease
Threshold 3.5V DC
the voltage.
Boom up - hi range 9.1V DC
9 Start the engine and move the engine idle
Cycle time 90 to 120 seconds
control switch to foot switch activated high
idle (rabbit and foot switch symbol). Lower Boom down - lo range 8.3V DC
the boom to the stowed position. Cycle time 90 to 120 seconds

Engine should be at normal Ramp rate 3 to 4 seconds

operating temperature.
10 Start a timer and record how long it takes for
the boom to fully raise. Adjust the Turntable Rotation Controller
max-out trimpot to achieve a 90 to 120 second Adjustments
cycle time.
Do not adjust the joystick
11 Start a timer and record how long it takes for
controllers unless the static
the boom to fully lower. Adjust the dual range
battery voltage is above
trimpot to achieve a 90 to 120 second cycle
12V DC and the alternator is
time.
operating properly with
If the function cycle time is not 13.6 to 14.5V DC output.
achievable, check the relief valve
Electrocution hazard. Contact
pressure. See 10-2, Valve
with electrically charged circuits
Adjustments - Function Manifold.
may result in death or serious
12 Turn the engine off and re-connect the injury. Remove all rings, watches
volt meter. and other jewelry.
13 Pull out the Emergency Stop button to 1 Check the battery condition with a volt meter.
the ON position. The reading should be 12V DC or more to
accurately adjust the controller.
14 Press down the foot switch and then move the
control handle all the way to the UP position. 2 Turn the key switch to platform control and
Record the maximum voltage reading. pull out the Emergency Stop button to
the ON position at both the ground and
15 Start the engine. platform controls. Do not start the engine.

Part No. 34032 Genie S-80 & Genie S-85 7-3

Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

3 Open the platform control box lid and locate 7 Set the hi range: Press down the foot switch,
the turntable rotation controller. Refer to the fully retract the boom, then move the control
platform control box illustration, page 7-2. 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
a b c d e f g h i j voltage or counterclockwise to decrease the
voltage.
8 Set the 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 Start the engine and move the engine idle
control switch to foot switch activated high idle
(rabbit and foot switch symbol).
a terminal "D2" directional output
b terminal "A" proportional output Engine should be at normal
c terminal "-" ground
d terminal "+" positive
operating temperature.
e terminal "R" activates max-out range
10 Fully retract the boom, then start a timer and
f terminal "D1" directional output
g ramp rate adjustable trimpot record how long it takes the turntable to rotate
h lo range adjustable trimpot through a complete circle. Adjust the max-out
i threshold adjustable trimpot trimpot to achieve an 80 to 120 second cycle
j hi range adjustable trimpot
time.
4 Set the preliminary ramp rate: Turn the trimpot 11 Extend the boom, then start a timer and record
adjustment screw clockwise 15 turns or until how long it takes the turntable to rotate through
you hear a repeated click. a complete circle. Adjust the lo range trimpot to
5 Connect the red(+) lead from a volt meter to the achieve a 210 to 240 second cycle time.
“A” terminal on the controller printed circuit 12 Turn the engine off and re-connect the
board. Connect the black(-) lead to ground. volt meter.
6 Set the threshold: Press down the foot switch, 13 Pull out the Emergency Stop button to
then slowly move the control handle off center the ON position.
until the moment a voltage reading appears.
Adjust the voltage to 3.5V DC. Turn the 14 Press down the foot switch and then move the
threshold trimpot adjustment screw clockwise control handle all the way to the left or right.
to increase the voltage or counterclockwise Record the maximum voltage reading.
to decrease the voltage. 15 Start the engine.

7-4 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

16 Start a timer and simultaneously move the 3 Open the platform control box lid and locate
control handle all the way to the left or right. the boom extend/retract controller. Refer to the
Note how long it takes to reach the maximum platform control box illustration, page 7-2.
voltage recorded in step 14. This is the
ramp rate. a b c d e f g h i j

17 Set the ramp rate: Turn the trimpot to obtain

a 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 80 to 120 seconds a ramp rate adjustable trimpot
lo range (boom extended) 4.5V DC b dual (lo) range adjustable trimpot
Cycle time 210 to 240 seconds c terminal "R", activates max-out range
d terminal unused
Ramp rate 5 seconds e terminal "X", auxiliary
f terminal "-", ground
g terminal "+", battery, positive
h terminal "A", proportional output
i threshold adjustable trimpot
j max-out adjustable trimpot

Boom Extend/Retract Controller 4 Set the preliminary ramp rate: Turn the trimpot
Adjustments adjustment screw clockwise 15 turns or until
you hear a repeated click.
Do not adjust the joystick
controllers unless the static 5 Connect the red(+) lead from a volt meter to
battery voltage is above the “A” terminal on the controller printed circuit
12V DC and the alternator board. Connect the black(-) lead to ground.
is operating properly with 6 Set the threshold: Press down the foot switch,
13.6 to 14.5V DC output. then slowly move the control handle off center
Electrocution hazard. Contact until the moment a voltage reading appears.
with electrically charged circuits Adjust the voltage to 3.5V DC. Turn the
may result in death or serious threshold trimpot adjustment screw clockwise
injury. Remove all rings, watches to increase the voltage or counterclockwise to
and other jewelry. decrease the voltage.

1 Check the battery condition with a volt meter. 7 Set the max-out: Press down the foot switch,
The reading should be 12V DC or more to then move the control handle all the way to
accurately adjust the controller. the EXTEND position. Adjust the voltage to
9.75V DC. Turn the max-out trimpot adjustment
2 Turn the key switch to platform control and screw clockwise to increase the voltage or
pull out the Emergency Stop button to the counterclockwise to decrease the voltage.
ON position at both the ground and platform
controls. Do not start the engine.

Part No. 34032 Genie S-80 & Genie S-85 7-5

Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

8 Set the dual (lo) range: Press down the foot Boom up/down specifications
switch, then move the control handle all the
way to the RETRACT position. Adjust the voltage Threshold 3.5V DC
to 8.9V DC. Turn the dual range trimpot
Boom extend - Max-out 9.75V DC
adjustment screw clockwise to increase the
Cycle time 140 to 170 seconds
voltage or counterclockwise to decrease
the voltage. Boom retract - Dual (lo) range 8.9V DC
Cycle time 80 to 110 seconds
9 Start the engine and move the engine idle
control switch to foot switch activated high Ramp rate 3 seconds
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 1-2
the boom to fully extend. Adjust the
max-out trimpot to achieve an 140 to 170 Horsepower Limiter Board
second cycle time.
The horsepower limiter board is responsible for
11 Start a timer and record how long it takes for governing drive pump output. It senses engine
the boom to fully retract. Adjust the dual range rpm from the alternator. The horsepower limiter
trimpot to achieve an 80 to 110 second cycle board senses drops in rpm normally due to
time. increased drive resistance (rough terrain or
If the function cycle time is not incline), and decreases voltage to the drive
achievable, check the relief valve controller which in turn decreases voltage to the
pressure. See 10-2, Valve drive pump, thereby reducing pump output to
Adjustments - Function Manifold. maintain optimum engine rpm and horsepower.
Three adjustments are required for optimum
12 Turn the engine off and re-connect the performance.
volt meter.
13 Pull out the Emergency Stop button to How to Adjust the Horsepower
the ON position. Limiter Board
14 Press down the foot switch and then move the The engine rpm must be
control handle all the way to the EXTEND correct before performing this
position. Record the maximum voltage reading. procedure. See Maintenance
15 Start the engine. Procedure B-12, Check and
Adjust the Engine RPM.
16 Start a timer and simultaneously move the
control handle all the way to the EXTEND Do not adjust the horsepower
position. Note how long it takes to reach the limiter board unless the static
maximum voltage recorded in step 14. This is battery voltage is above 12V DC
the ramp speed. and the alternator is operating
properly with 12.5 to 14.5V DC
17 Set the ramp rate: turn the trimpot to obtain output.
a 3 second ramp speed. Turn the
trimpot clockwise to increase the time or Gasoline/LPG models: Perform
counterclockwise to decrease the time. this procedure in gasoline mode.

7-6 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

1 Remove the fasteners from the platform 4 Start the engine from the platform controls.
control box lid.
5 Move the engine idle control switch to foot
2 Open the control box lid and locate the switch activated high idle (rabbit and foot
horsepower limiter board. switch symbol).
Electrocution hazard. Contact 6 Press down the foot switch and adjust the
with electrically charged circuits "A" potentiometer counterclockwise to increase
may result in death or serious voltage or clockwise to decrease voltage.
injury. Remove all rings, watches
and other jewelry. "A" potentiometer specifications - all models

Voltage setting 10.5 to 11.5V DC

a

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).
Platform control box 10 Press down the foot switch and re-adjust the
a horsepower limiter board "A" potentiometer to the previous voltage
setting in step 6.
3 Connect the black(-) lead from a DC volt meter
to the no. 2 terminal, and the red(+) lead to the 11 Be sure that the boom is in the stowed position,
no. 10 terminal. then drive the machine and observe how the
engine rpm reacts to drive control handle
a movement. If the engine surges or hunts,
12V DC or greater
ground
adjust the "C" potentiometer counterclockwise
b
engine rpm sensor until surging is minimized.
not used
not used Under an extreme load, an
low drive speed limit switch
not used excessive counterclockwise
not used adjustment to the "C"
not used
output to drive controller
c
potentiometer will cause
the engine to stall. The "C"
potentiometer adjustment is a
Horsepower limiter board compromise between engine
a "A" potentiometer-maximum voltage
output to the controller in the stowed stability (surging) and engine
position rpm droop.
b "B" potentiometer-maximum voltage
output to the drive controller in the
boom raised position
c "C" potentiometer-reaction rate or
how fast the voltage output reacts to
the change in engine rpm

Part No. 34032 Genie S-80 & Genie S-85 7-7

Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

12 Disconnect the volt meter. 1-3

13 Raise the boom above the drive limit switch. Foot Switch
How to Test the Foot Switch
a 1 Turn the key switch to the OFF position and
separate the wiring quick disconnect plug from
the platform toe board.
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.

Test Desired result

green to black continuity

(zero W)
b green to white no continuity
(infinite W)
a drive limit switch
b boom extension cylinder black to white no continuity
14 Drive the machine for 40 feet (12 m) and
record the elapsed time. Repeat this step in
Do not use the color of the
the opposite drive direction.
connector as a guide for these
15 Adjust the "B" potentiometer to obtain the tests. Use the actual wire color
correct raised drive speed of 1 foot per second to identify which connector to
(30.5 cm per second). Turn the "B" use for testing.
potentiometer counterclockwise to increase
3 Press down the foot switch. Connect the leads
voltage or clockwise to decrease voltage.
from an ohmmeter or continuity tester to each
16 Close the platform control box lid and install wire combination listed below and check for
the fasteners. continuity.

Drive speed specifications Test Desired result

Stowed position distance: 40 ft / 12 m green to black no continuity

2WD 4WD (infinite W)
Gasoline/LPG models 40 ft/7.2 sec 40 ft/8.8 sec
green to white no continuity
12.2 m/7.2 sec 12.2 m/8.8 sec
Deutz Diesel models 40 ft/8.3 sec 40 ft/9.1 sec black to white continuity
12.2 m/8.3 sec 12.2 m/9.1 sec (zero W)

Boom raised or distance: 40 ft / 12 m

extended 1 foot per second
All models 30.5 cm per second

7-8 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

Left Center Right

1-4
Resistors
The resistors is used on 4WD machines to
maintian low range drive speed. The resistors are
located in the platform control box.

Refer to the schematic legends

1 3 1 3 1 3
for resistor locations and values. 2 2 2
Single pole
How to Test the Resistors double throw
(SPDT) 1 2 3 1 2 3 1 2 3
1 Turn the key switch to the OFF position. 6 6 6
4 5 4 5 4 5

2 Disconnect either end of one of the wires Double pole

double throw
connected to the resistor to be tested. (DPDT)
3 Connect the leads from an ohmmeter to each 1 2 3 1 2 3 1 2 3

end or wiring of the resistor being tested.

4 Compare the ohmmeter reading with the Test Desired result
resistance rating printed on the resistor.
Left position
terminal 1 to 2, 3, 4, 5 & 6 no continuity
(infinite W)
1-5 terminal 2 to 3 continuity
Toggle Switches (zero W)
terminal 2 to 4, 5 & 6 no continuity
Toggle switches used for single function switching terminal 3 to 4, 5 & 6 no continuity
are single pole double throw (SPDT) switches.
Dual function switching requires a double pole terminal 4 to 5 & 6 no continuity
double throw (DPDT) switch. terminal 5 to 6 continuity
Center position There are no terminal combinations
How to Test a Toggle Switch that will produce continuity
Continuity is the equivalent of 0 to (infinite W)
3 ohms. A simple continuity tester Right position
may not accurately test the switch. terminal 1 to 2 continuity
This procedure covers fundamental switch testing (zero W)
and does not specifically apply to all varieties of terminal 1 to 3, 4, 5 & 6 no continuity
toggle switches. (infinite W)
1 Turn the key switch to the OFF position. Tag terminal 2 to 3, 4, 5 & 6 no continuity
and disconnect all wiring from the toggle switch
to be tested. terminal 3 to 4, 5 & 6 no continuity

2 Connect the leads of an ohmmeter to the terminal 4 to 5 continuity

switch terminals in the following combinations
terminal 4 to 6 no continuity
listed below to check for continuity.
terminal 5 to 6 no continuity

Part No. 34032 Genie S-80 & Genie S-85 7-9

Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM CONTROLS

1-6
Control Relays e a

d b
Relays used for single function switching are
single pole double throw (SPDT) relays. c

How to Test a Single Pole Double

Throw Relay
a terminal no. 87a - N.C.
Electrocution hazard. b terminal no. 85 - coil
c terminal no. 30 - common
Contact with electrically charged d terminal no. 86 - ground
circuits may cause death or e terminal no. 87 - N.O.
serious injury. Remove all rings,
watches and other jewelry.
Control Relay Schematic - without resistor
Direct Connection Relay
85 87 87A
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 86
any other combination.
30
Test Desired result
terminal 85 to 86 without resistor 85 to 95W
terminal 87 to 87a & 30 no continuity
(infinite W)
terminal 87a to 30 continuity
(zero W)

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 & 30 no continuity
(infinite W)
terminal 87 to 30 continuity
(zero W)

7 - 10 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

Platform Components

2-1 3 Remove the pin retainer fastener from

the rod-end pin.
Platform
4 Remove the external retaining ring from the
barrel-end pin.
How to Remove the Platform
5 Drive the rod-end pin out using a soft
1 Remove the cable harness from the cable metal drift.
clamp located on the platform mounting
bracket and separate the foot switch quick 6 Use a soft metal drift and drive the barrel-end
disconnect plug. pin out.
2 Remove the platform control box mounting 7 Carefully pull the cylinder out of the boom.
bolts, then lower the control box and
8 Disconnect the hydraulic hoses from the
set it aside.
slave cylinder and connect them together
3 Remove the platform mounting bolts and lift the with a connector. Cap the fittings on the
platform off the mount. cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
2-2 connections very slowly to allow
Platform Leveling Slave Cylinder the oil pressure to dissipate
gradually. Do not allow oil to
The slave cylinder and the rotator pivot are the squirt or spray.
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.

How to Remove the Slave

Cylinder
Before cylinder removal is
considered, bleed the slave
cylinder to be sure there is no
air in the closed loop.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks under
the platform. Then lower the boom until the
platform is resting on the blocks.

Part No. 34032 Genie S-80 & Genie S-85 7 - 11

Section 7 - Repair Procedures Service Manual - First Edition

PLATFORM COMPONENTS

How to Bleed the Slave Cylinder 2-3

Do not start the engine. Use Platform Rotator
auxiliary power for all machine
functions in this procedure. The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
1 Raise the boom to a horizontal position. 160 degrees.
2 Move the platform level switch up and down
through two platform leveling cycles to remove How to Remove the
any air that might be in the system. Platform Rotator
Component damage hazard. Mark
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.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Disconnect and plug the hydraulic hoses from
the platform rotator manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 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.

7 - 12 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

PLATFORM COMPONENTS

5 Support the platform rotator. Do not apply 3 Open the top bleed valve on the rotator, but do
any lifting pressure. not remove it.
S-80 Models: a

6 Support the platform leveling slave cylinder.

7 Remove the pin retainer from the slave cylinder
rod-end pivot pin and the rotator pivot pin.
8 Use a soft metal drift to drive both pins out,
then remove the platform rotator from the
machine.
S-85 Models:

6 Remove the pin retainers from the jib boom and

leveling links to platform rotator pivot pins. Do
not remove the pins. d c b

7 Support the jib boom and leveling links.

a top bleed valve
8 Use a soft metal drift to drive both pins out, b bottom bleed valve
then remove the platform rotator from the c clear hose
d container
machine.
4 Hold the platform rotate switch to the LEFT
position until the platform is fully rotated.
How to Bleed the Platform Rotator Continue holding the switch until air stops
coming out of the bleed valve. Then close
Do not start the engine. Use the bleed valve.
auxiliary power for all machine
functions in this procedure. Crushing hazard. Keep clear of
the platform during rotation.
1 Move the platform rotate switch to the right
then the left through two platform rotation 5 Connect the clear hose to the bottom bleed
cycles, then hold the switch to the RIGHT valve and open the valve. Do not remove the
position until the platform is fully rotated to the bleed valve.
right. 6 Hold the platform rotate switch to the RIGHT
2 Connect a clear hose to the top bleed valve. position until the platform is fully rotated.
Place the other end of the hose in a container Continue holding the switch until air stops
to collect any drainage. Secure the container to coming out of the bleed valve. Then close
the boom. the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have
spilled.
8 Rotate the platform full right then left and
inspect the bleed valves for leaks.

Part No. 34032 Genie S-80 & Genie S-85 7 - 13

Section 7 - Repair Procedures Service Manual - First Edition

Jib Boom Components - S-85 Models

3-1 6 Tag, disconnect and plug all the hydraulic

hoses from the jib boom manifold.
Jib Boom - S-85 Models
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the Jib Boom burn skin. Loosen hydraulic
Perform this procedure with the connections very slowly to allow
boom in the stowed position. the oil pressure to dissipate
gradually. Do not allow oil to
1 Remove the platform. See 2-1, squirt or spray.
How to Remove the Platform.
7 Remove the cable tray from the side of the
2 Remove the platform mounting weldment jib boom.
and the platform rotator. See 2-3, How to
Remove the Platform Rotator. 8 Support the jib boom with an overhead crane.

3 Support the platform pivot weldment with a 9 Remove the pin retainer from the jib boom
lifting device. pivot pin. Use a soft metal drift to remove the
pin, then remove the jib boom from the
4 Disconnect and plug the jib boom lift cylinder primary boom.
hydraulic hoses.
Crushing hazard. The jib boom
Bodily injury hazard. Spraying will fall when the pin is removed
hydraulic oil can penetrate and if it is not properly supported.
burn skin. Loosen hydraulic
connections very slowly to allow 10 Remove the pin retainers from the jib boom
the oil pressure to dissipate lift cylinder rod-end pivot pin. Do not remove
gradually. Do not allow oil to the pin.
squirt or spray. 11 Remove both of the jib boom leveling links from
5 Remove the pin retainer from the jib boom lift the primary boom.
cylinder barrel-end pivot pin. Use a soft metal 12 Support the jib boom lift cylinder with an
drift to remove the pin. overhead crane.
13 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 primary boom.
Crushing hazard. The jib boom
lift cylinder will fall when the pin
is removed if it is not properly
supported.

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Service Manual - First Edition Section 7 - Repair Procedures

JIB BOOM COMPONENTS - S-85 MODELS

3-2 3 Remove the pin retainers from the jib boom

lift cylinder rod-end pivot pin. Do not remove
Jib Boom Lift Cylinder the pin.
- S-85 Models 4 Use a soft metal drift to tap the rod-end pivot
pin half way out. Then lower the leveling link
How to Remove the Jib Boom to the ground. Tap the pin the other direction
Lift Cylinder and remove the opposite leveling link. Do not
remove the pin.
Perform this procedure with the
5 Support the jib boom lift cylinder with an
boom in the stowed position.
overhead crane.
1 Raise the jib boom slightly and place blocks
6 Remove the pin retainer from the jib boom lift
under the platform mounting weldment. Then
cylinder barrel-end pivot pin. Use a soft metal
lower the jib boom until the platform is resting
drift to remove the barrel-end pin.
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 cylinder will fall when it is
removed if it is not properly
supported.

2 Disconnect and plug the jib boom lift cylinder

hydraulic hoses.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Part No. 34032 Genie S-80 & Genie S-85 7 - 15

Section 7 - Repair Procedures Service Manual - First Edition

JIB BOOM COMPONENTS - S-85 MODELS

3-3
Jib Boom / Platform Rotate Manifold Components S-85 Models
1 2 position 3 way valve ....................... A ........... Platform rotate select ....................... 8-10 ft-lbs / 11-14 Nm
2 2 position 3 way valve ....................... B ........... Platform rotate 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

SAE No. 6 1/ 4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/ 8 75 ft-lbs / 102 Nm

How to Check the Resistance

of a Valve Coil
2
1 Turn the key switch to the OFF position and
1 disconnect the wires from the valve coil to
be tested.
2 Connect the leads from an ohmmeter to the
valve coil terminals.

Valve coil specification

2 position 3 way valve 6.3W

7 - 16 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

Boom Components

4-1 4-2
Plastic Cable Track Boom
The boom cable track guides cables and hoses How to Shim the Boom
running up the boom. It can be repaired link by link
without removing the cables and hoses that run Measure each wear pad. Replace
through it. Removing the entire boom cable track the pad if it is less than 7/16 inch
is only necessary when performing major repairs (11 mm) thick. If the pad is more
that involve removing the boom. than 7/16 inch (11 mm) thick,
perform the following procedure.
How to Repair the Plastic 1 Extend the boom until the wear pads are
Cable Track accessible.
Component damage hazard. 2 Loosen the wear pad mounting fasteners.
The boom cable track can be
3 Install the new shims under the wear pad to
damaged if it is twisted.
obtain zero clearance and zero drag.
4 Tighten the mounting fasteners.
5 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
scraping or binding.
a Always maintain squareness
between the outer and inner boom
b tubes.

How to Remove
a link separation point the Boom
b lower clip
This procedure requires specific
1 Use a screwdriver to pry out and down on the repair skills, lifting equipment and
lower clip. a suitable workshop. Attempting
this procedure without these skills
2 Repeat step 1 for each link.
and tools may cause death or
3 To remove a single link, open the lower clip serious injury and significant
and then use a screwdriver to pry the link component damage. Dealer
to the side. service is strongly recommended.
Perform this procedure with the
boom in the stowed position.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Remove the platform rotator and leveling slave
cylinder. See 2-3, How to Remove the Platform
Rotator.

Part No. 34032 Genie S-80 & Genie S-85 7 - 17

Section 7 - Repair Procedures Service Manual - First Edition

BOOM COMPONENTS

S-85 Models: Remove the jib boom. See 3-1,

14 Attach an overhead 5 ton (4536 kg) crane to
How to Remove the Jib Boom.
the center point of the boom.
3 Remove the mounting fasteners from the
15 Attach a similar lifting device to the lift cylinder.
counterbalance valve manifold on the end of
the boom. Then remove the manifold and set it 16 Use the crane to lift the boom to a horizontal
aside. position.
4 Remove the drive speed limit switch 17 Place support blocks under the cylinder, across
mounted on the side of the cable track. Do not the turntable.
disconnect the wiring.
18 Remove the pin retaining fastener from the
5 Support the cable track with an overhead boom lift cylinder rod-end pin. Use a soft metal
crane. drift to remove the pin.
6 Remove the hose/cable cover from the pivot Crushing hazard. The boom lift
end of the boom. cylinder will fall unless it is
properly supported.
7 Remove the cable track mounting bolts at the
platform end of the boom. 19 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
8 Remove the side panel from the cable track to
damage.
access the cable track mounting bolts.
20 Remove the pin retaining fastener from the
9 Remove the cable track mounting fasteners,
boom pivot pin.
then remove the cable track from the
boom and lay it off to the side. 21 Remove the boom pivot pin with a soft metal
drift, then carefully remove the boom from the
Component damage hazard.
machine.
The boom cable track
can be damaged if it is twisted. Crushing hazard. If the overhead
crane is not properly attached,
10 Remove the turntable end cover.
the boom may become
11 Remove the retaining bolt from the master unbalanced and fall when it is
cylinder rod-end pivot pin. Use a soft metal drift removed from the machine.
to remove the pin. Pull the cylinder back and
secure it from moving. How to Disassemble
12 Remove the drive speed limit switch the Boom
mounted on the inside of the pivot end of Complete disassembly of the
the boom. Do not disconnect the wiring. boom is only necessary
13 Tag, disconnect and plug the extension cylinder if the outer or inner boom tubes
hydraulic hoses. Cap the fittings on the must be replaced. The extension
cylinder. cylinder can be removed without
completely disassembling of the
Bodily injury hazard. Spraying boom. See 4-4, How to Remove
hydraulic oil can penetrate and the Extension Cylinder.
burn skin. Loosen hydraulic
connections very slowly to allow 1 Remove the boom. See 4-2,
the oil pressure to dissipate How to Remove the Boom.
gradually. Do not allow oil to
squirt or spray.

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Service Manual - First Edition Section 7 - Repair Procedures

BOOM COMPONENTS

12 Support the number 3 boom tube with an

2 Place blocks under the extension cylinder for
overhead crane at the platform end of the
support.
boom.
3 Remove the retaining rings from the extension
Crushing hazard. The boom tubes
cylinder barrel-end pivot pin at the base of the
will fall when they are removed
number 1 boom tube. Use a soft metal drift to
from the boom if they are not
remove the pin.
properly supported.
4 Remove and label the wear pads from the top
13 Support and slide the number 3 boom tube out
side of the number 1 boom tube at the platform
of the number 2 tube. Place the number 3 tube
end of the boom.
on blocks for support.
Pay careful attention to the
During removal, the overhead
location and amount of shims used
crane strap will need to be
with each wear pad.
carefully adjusted for proper
5 Remove the two wear pad stop bolts from each balancing.
side of the number 1 boom tube (located on the
14 Remove the retaining rings from the extension
outside).
cylinder rod-end pivot pin at the platform end of
6 Support the number 2 and 3 boom tubes with the number 3 boom tube. Use a soft metal drift
an overhead crane at the platform end of the to remove the pin.
boom.
15 Remove the two wear pad stop bolts from each
Crushing hazard. The boom tubes side of the number 3 boom tube (located on the
will fall when they are removed outside).
from the boom if they are not
16 Support and slide the extension cylinder out of
properly supported.
the base end of the number 3 tube. Place the
7 Support and slide the number 2 and 3 boom extension cylinder on blocks for support.
tubes out of the number 1 tube. Place the
During removal, the overhead
number 2 and 3 tubes on blocks for support.
crane strap will need to be
During removal, the overhead carefully adjusted for proper
crane strap will need to be balancing.
carefully adjusted for proper
17 Remove and label the wear pads from the
balancing.
extension cylinder.
8 Remove and label the wear pads from the top
Pay careful attention to the
side of the number 2 boom tube at the platform
location of each wear pad.
end of the boom.
9 Remove the trunnion cap mounting fasteners at
the base of the number 2 boom tube. Then use
a slide hammer to remove the trunnion caps.
10 Remove the sliding wear pad assembly from the
extension cylinder at the base of the number 2
boom tube.
11 Carefully rotate the base end of the extension
cylinder until the pin mounting bore is in a
vertical position.

Part No. 34032 Genie S-80 & Genie S-85 7 - 19

Section 7 - Repair Procedures Service Manual - First Edition

BOOM COMPONENTS

4-3 cylinder rod-end pivot pin. Use a soft metal drift

to remove the pin, then allow the lift cylinder to
Boom Lift Cylinder rest on the blocks. Protect the cylinder rod
from damage.
How to Remove the Boom Crushing hazard. The lift
Lift Cylinder cylinder will fall unless it is
properly supported.
This procedure requires specific
repair skills, lifting equipment and 8 With the lift cylinder being supported by the
a suitable workshop. Attempting overhead crane, pull the cylinder toward the
this procedure without these skills platform until it is out.
and tools may result in death or
Component damage hazard. The
serious injury and significant
cables and hydraulic hoses can
component damage. Dealer
be damaged if the lift cylinder is
service is strongly recommended.
pulled across them.
1 Raise the boom until the boom is horizontal.
4-4
2 Place support blocks under the cylinder across
the turntable. Extension Cylinders
3 Support the boom with an overhead crane. The extension cylinder consists of two cylinders
Do not lift the boom. that are fastened together. The first cylinder
4 Support the balance point of the boom lift extends and retracts the number 2 boom tube.
cylinder with an overhead crane or similar lifting The second cylinder extends and retracts the
device. number 3 boom tube. The extension cylinders are
equipped with counterbalance valves to prevent
Crushing hazard. If the overhead movement in the event of a hydraulic line failure.
crane is not properly attached,
the lift cylinder may become How to Remove the
unbalanced and fall when it is
disconnected from the machine.
Extension Cylinders
5 Tag, disconnect and plug the boom lift cylinder This procedure requires specific
hydraulic hoses. Cap the fittings on the repair skills, lifting equipment and
cylinder. a suitable workshop. Attempting
this procedure without these skills
Bodily injury hazard. Spraying and tools may cause death or
hydraulic oil can penetrate and serious injury and significant
burn skin. Loosen hydraulic component damage. Dealer
connections very slowly to allow service is strongly recommended.
the oil pressure to dissipate
gradually. Do not allow oil to 1 Extend the boom all the way to full extension.
squirt or spray. 2 Remove the mounting fasteners from the guide
pads, located on the outside of the number 3
6 Remove the mounting fasteners from the lift
boom tube.
cylinder mounting bracket.
3 Retract the boom until the cylinder rod-end pin
7 Remove the pin retaining fastener from the lift
is accessible in the number 3 boom tube.

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Service Manual - First Edition Section 7 - Repair Procedures

BOOM COMPONENTS

4 Remove the platform. See 2-1, How to Remove 4-5

the Platform.
Platform Leveling
5 Remove the platform leveling slave cylinder.
See 2-2, How to Remove the Slave Cylinder.
Master Cylinder
S-85 Models: Remove the jib boom. See 3-1, The master cylinder acts as a pump for the slave
How to Remove the Jib Boom. cylinder. It’s part of the closed circuit hydraulic
loop that keeps the platform level through the
6 Raise the boom to a horizontal position.
entire range of boom motion. The master cylinder
7 Remove the snap rings from the extension is located at the base of the boom.
cylinder rod-end pin (at the platform end). Use
a soft metal drift to remove the pin. How to Remove the Platform
8 Remove the turntable end cover. Leveling Master Cylinder
9 Tag, disconnect and plug the extension cylinder 1 Raise the boom until the rod-end pivot pin is
hydraulic hoses. Cap the fittings on the accessible.
cylinder.
2 Remove the turntable end cover to access the
Bodily injury hazard. Spraying master cylinder.
hydraulic oil can penetrate and
3 Tag, disconnect and plug the master cylinder
burn skin. Loosen hydraulic
hydraulic hoses. Cap the fittings on the
connections very slowly to allow
cylinder.
the oil pressure to dissipate
gradually. Do not allow oil to Bodily injury hazard. Spraying
squirt or spray. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
10 Remove the pin retaining fasteners from both
connections very slowly to allow
sides of the extension cylinder at the base end
the oil pressure to dissipate
of the boom.
gradually. Do not allow oil to
11 Use a slide hammer to remove the pins. squirt or spray.
12 Support and slide the extension cylinder out of 4 Remove the pin retaining fasteners from both
the boom. master cylinder pins.
Crushing hazard. The extension 5 Use a soft metal drift to remove the pins.
cylinder will fall when it is removed
from the extension boom if it is
not properly supported.
Note the length of the cylinder
after removal. The cylinder must
be at the same length for
installation.

Part No. 34032 Genie S-80 & Genie S-85 7 - 21

Section 7 - Repair Procedures Service Manual - First Edition

Turntable Covers

5-1
Turntable Covers

How to Remove a
Turntable Cover
1 Raise the turntable cover. Support the open
cover with an overhead crane or forklift.
Do not lift it.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
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.
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.
If a turntable cover must be
replaced, be sure that all
appropriate safety and
instructional decals are
applied to the new cover.
Alignment adjustments may be
necessary when a new cover
is installed.

7 - 22 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

Deutz Engine F4L 1011

6-1 3 Apply Loctite® removable thread sealant to the

coupler set screw. Torque the set screw to
RPM Adjustment 45 ft-lbs (61 Nm).
Refer to Maintenance Procedures, B-12, Component damage hazard. Do
Check and Adjust the Engine RPM. not force the drive pump during
installation or the flex plate teeth
may become damaged.
6-2 4 Assemble the engine and torque the pump
Flex Plate mountint plate to 34 ft-lbs (46 Nm).

The flex plate acts as a coupler between the

engine and the pump. It is bolted to the engine 6-3
flywheel and has a splined center to drive Oil Temperature and Pressure
the pump.
Gauges
How to Remove the Flex Plate
The oil temperature gauge is an electrical gauge.
1 Disconnect the wiring plug at the electronic The sending unit has limit contacts that are factory
displacement controller (EDC), located on set. The contacts will close at 300o F (147o C).
the drive pump. When the contacts close, the engine will shut off
2 Support the drive pump with an appropriate to prevent damage and will not start until the
lifting device. Then remove all of the pump temperature drops below the contact point.
mounting plate to engine bell housing bolts. Temperature will be indicated when the key is on
and the Emergency Stop Button is pulled out to
3 Carefully pull the pump away from the engine the ON position.
and secure it from moving.
Component damage hazard.
4 Remove the flex plate mounting fasteners, Do not crank the engine with
then remove the flex plate from the engine. the over-temperature light on.
How to Install the Flex Plate The oil pressure gauge is an electrical gauge. The
sending unit has limit contacts that are factory set.
1 Install the flex plate onto the flywheel with the The contacts will close at 7 psi (0.48 bar). When
flat side of the spline against the flywheel. the contacts close, the engine will shut off to
Torque the flex plate mounting bolts to prevent damage. Oil pressure will be indicated
34 ft-lbs (46 Nm). when the engine is running.
2 Install the coupler onto the pump shaft with the
Component damage hazard.
set screw toward the pump. Leave a 1/2 inch
Do not crank the engine with the
(12.7 mm) gap between the coupler and pump
low oil pressure light on.
end plate.

Part No. 34032 Genie S-80 & Genie S-85 7 - 23

Section 7 - Repair Procedures Service Manual - First Edition

Ford LSG-423 Engine

a b c d

g
110°

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
f actuator shaft
Actuator and Linkage g actuator arm

Adjustment of the governor

actuator is only necessary when
the governor actuator or the
4 Position the linkage rod so that the throttle is in
linkage has been replaced.
the idle position. Then adjust the clevis yoke on
1 Connect the linkage rod to the throttle plate the linkage rod to obtain the proper length.
shaft, then tighten the lock nut. Install the yoke onto the actuator arm.
2 Fasten the lock nut and clevis yoke to the 5 With the throttle in the idle position and the
linkage rod. Do not tighten the lock nut actuator arm at a 110 degree angle to the
against the clevis yoke. linkage, rotate the clevis yoke on the linkage
rod two turns counterclockwise to pre-load the
3 Loosen the fastener on the actuator arm. spring. Tighten the lock nut on the linkage rod.
Rotate the actuator arm until it is at a
110 degree angle to the linkage rod. Then
tighten the actuator arm fastener.

7 - 24 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

FORD LSG-423 ENGINE

6 Manually pull the actuator arm through a full 7-2

cycle to be sure that the linkage moves freely.
Be sure that the linkage activates the throttle Choke Adjustments
shaft to approximately half throttle.
This engine is equipped with an electrically heated
The linkage must be free of automatic choke. The choke has a poppet valve to
friction and obstruction. Do not enhance cold starting ability on LPG fuel.
let it rub against the engine,
brackets or hoses. Choke adjustments are affected
by climate. Richer adjustment
Component damage hazard. will be necessary in colder
If the throttle linkage is improperly climates, leaner adjustment
adjusted and allowed to reach full in warmer climates.
throttle, the engine will over-rev
and cause component damage. Automatic Choke with
Poppet Valve
The choke functions in both gasoline and LPG
mode. The choke butterfly may be adjusted to a
fully closed (rich) position for colder climates and
the poppet valve will provide a flow path during
LPG fueled operation.

rich lean

Part No. 34032 Genie S-80 & Genie S-85 7 - 25

Section 7 - Repair Procedures Service Manual - First Edition

FORD LSG-423 ENGINE

7-3 Flex Plate Removal

Timing Adjustment 1 Disconnect and remove the hose between
the carburetor venturi and the air cleaner.
Complete information to perform this procedure is
available in the Ford LSG-423 2.3 Liter Industrial 2 Disconnect the linkage from the governor,
Engine Service Manual (Ford number: 194-216). then remove the governor linkage from
Genie part number 29586. the carburetor. Do not alter the length of
the linkage.
3 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
7-4 the drive pump.
Carburetor Adjustment 4 Remove the mounting fasteners from the
regulator mounting bracket, then pull the
Complete information to perform this procedure is bracket up past the bell housing. Secure
available in the Ford LSG-423 2.3 Liter Industrial the bracket before continuing.
Engine Service Manual (Ford number: 194-216).
Genie part number 29586. 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
7-5 engine and secure it from moving.
RPM Adjustment 7 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine.
Refer to Maintenance Procedures, B-12, Check
and Adjust the Engine RPM. How to Install the Flex Plate
1 Install the flex plate onto the flywheel with the
raised spline against the flywheel. Torque the
flex plate mounting bolts to 34 ft-lbs (46 Nm).
7-6
2 Install the coupler onto the pump shaft with the
Flex Plate set screw towards the pump. Leave a 1/4 inch
(6.35 mm) gap between the coupler and pump
The flex plate acts as a coupler between the end plate.
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive 3 Apply Loctite® removable thread sealant to the
the pump. coupler set screw. Torque the set screw to
45 ft-lbs (61 Nm).
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 Assemble the engine and torque the pump
mounting plate to 34 ft-lbs (46 Nm).

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Service Manual - First Edition Section 7 - Repair Procedures

FORD LSG-423 ENGINE

7-7 7-8
Water Temperature and Oil Vacuum Switch
Pressure Gauges
How to Test the Vacuum Switch
The water temperature gauge is an electrical
gauge. The sending unit has limit contacts that are a b
factory set. The contacts will close at 230o F
(109o 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.

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 d c
the contacts close, the engine will shut off to
prevent damage. Oil pressure will be indicated a ohmmeter
b common terminal (SOL.)
when the engine is running. c vacuum switch
d normally open terminal (ING.)
Component damage hazard.
Do not crank the engine with the 1 Connect the leads from an ohmmeter or
low oil pressure light on. continuity tester to the common and normally
open terminals.
Result: There should be no continuity
(infinite W).
2 Apply mild suction to the vacuum port.
Result: The switch should close and show full
continuity (zero W).
Component damage hazard.
Do not short the vacuum switch
terminals to ground.

Part No. 34032 Genie S-80 & Genie S-85 7 - 27

Section 7 - Repair Procedures Service Manual - First Edition

Ground Controls

8-1
Control Relays e a

d b
Relays used for single function switching are
single pole double throw (SPDT) relays. c

How to Test a Single Pole Double

Throw Relay
a terminal no. 87a - N.C.
Electrocution hazard. b terminal no. 85 - coil
c terminal no. 30 - common
Contact with electrically charged d terminal no. 86 - ground
circuits may cause death or e terminal no. 87 - N.O.
serious injury. Remove all rings,
watches and other jewelry. Control Relay Schematic - with resistor
Direct Connection Relay
85 87 87A
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.
86 30
Test Desired result
terminal 85 to 86 with resistor 75 to 85W Control Relay Schematic - without resistor
terminal 85 to 86 without resistor 85 to 95W
85 87 87A
terminal 87 to 87a & 30 no continuity
(infinite W)
terminal 87a to 30 continuity
(zero W)

86
3 Connect 12V DC to terminal 85 and a ground
wire to terminal 86, then test the following
30
terminal combinations.

Test Desired result

terminal 87 to 87a & 30 no continuity
(infinite W)
terminal 87 to 30 continuity
(zero W)

7 - 28 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

GROUND CONTROLS

8-2 8-4
Toggle Switches Resistors
See 1-5, Toggle Switches. How to Test the Resistor
The resistor is used to maintain proper control of
8-3 boom function speeds. A 10 ohm resistor reduces
Wago® Components voltage to all the boom function switches.

Refer to the schematic legends for

How to Remove a Wago® resistor locations and values.
Component 1 Turn the key switch to the OFF position.
Electrocution hazard. 2 Disconnect either end of one of the wires
Contact with electrically charged connected to the resistor to be tested.
circuits may cause death or
3 Connect the leads from an ohmmeter to each
serious injury. Remove all rings,
end or wiring of the resistor being tested.
watches and other jewelry.
4 Compare the ohmmeter reading with the
A small screwdriver is provided
resistance rating printed on the resistor.
and should be used when
removing a Wago® 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 Use the provided screwdriver to push in and
release the wire from the component.
3 Locate the removal tab on the bottom or top
side of the component.
4 Use the provided screwdriver to gently pry up
on the tab of the component and remove it.

Part No. 34032 Genie S-80 & Genie S-85 7 - 29

Section 7 - Repair Procedures Service Manual - First Edition

GROUND CONTROLS

8-5
Power Relay a b b a

Electrocution hazard. Contact with

electrically charged circuits may
result in death or serious injury.
Remove all rings, watches and
other jewelry.

How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
a high amp power contact terminal
1 Connect the leads from an ohmmeter to each (large post)
terminal combination and check for continuity. b solenoid activate coil terminal
(small post)
Test Desired result

2 small posts 13 to 17W

2 large posts no continuity

(infinite W)

Any small post to no continuity

any large post (infinite W)

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 W)

7 - 30 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

Hydraulic Pumps

9-1 9-2
Lift/Steer Pump Drive Pump

How to Remove the The drive pump is a bi-directional variable

displacement piston pump. The pump output is
Lift/Steer Pump controlled by the electronic displacement controller
1 Close the two hydraulic tank valves located at (EDC), located on the pump. The only adjustment
the hydraulic tank. that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local
authorized service center.

How to Remove the Drive Pump

open closed Component damage hazard. The
work area and surfaces where this
Component damage hazard. The procedure will be performed must
engine must not be started with be clean and free of debris that
the hydraulic tank shutoff valves could get into the hydraulic
in the CLOSED position or system and cause severe
component damage will occur. component damage. Dealer
If the tank valves are closed, service is recommended.
remove the key from the key
switch and tag the machine to 1 Disconnect the electrical connection at the
inform personnel of the condition. electronic displacement controller (EDC)
located on the drive pump.
2 Disconnect and plug the lift/steer pump
hydraulic hoses. Cap the fittings. 2 Close the two hydraulic tank valves located at
the hydraulic tank.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Remove the pump mounting bolts. Carefully open closed
remove the pump. Component damage hazard. The
Component damage hazard. engine must not be started with
Be sure to open the two hydraulic the hydraulic tank shutoff valves
tank valves and prime the pump in the CLOSED position or
after installing the pump. 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.

Part No. 34032 Genie S-80 & Genie S-85 7 - 31

Section 7 - Repair Procedures Service Manual - First Edition

HYDRAULIC PUMPS

3 Tag and disconnect the hydraulic hoses from

the pumps and plug them.
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.
4 Support the pump and remove the two
drive pump mounting bolts. Carefully
remove the pump.
Component damage hazard.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.

How to Prime the Pump

1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
2 Gasoline/LPG models: Remove the high
tension lead from the center of the ignition coil.
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 counterclockwise to the CLOSED
position.
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).

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Part No. 34032 Genie S-80 & Genie S-85 7 - 33

Section 7 - Repair Procedures Service Manual - First Edition (February 2009)

Function Manifolds

10-1
Function Manifolds
Index Schematic
No. Description Item Function Torque

1 3 position 4 way D03 valve ............... N ........... Platform rotate .................................. 30-35 in-lbs / 3-4 Nm
2 Counterbalance valve ....................... B ........... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
3 Sandwich valve manifold .................. A ........... Platform level
4 3 position 4 way D03 valve ............... O ........... Platform level .................................... 30-35 in-lbs / 3-4 Nm
5 3 position 4 way D03 valve ............... P ........... Turntable rotate ................................ 30-35 in-lbs / 3-4 Nm
6 Cover plate ........................................ Q ....................................................................... 30-35 in-lbs / 3-4 Nm
7 3 position 4 way D03 valve ............... R ........... Boom up/down ................................. 30-35 in-lbs / 3-4 Nm
8 3 position 4 way D03 valve ............... S ........... Boom extend/retract ......................... 30-35 in-lbs / 3-4 Nm
9 Counterbalance valve ....................... C ........... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
10 Check valve ....................................... K ........... Turntable rotate
differential sensing .......................... 11-13 ft-lbs / 15-18 Nm
11 Check valve ....................................... M .......... Boom up/down
differential sensing ........................... 11-13 ft-lbs / 15-18 Nm
12 Flow regulator valve .......................... Y ........... Boom up/down ................................. 10-12 ft-lbs / 14-16 Nm
13 Relief valve, 1950 psi (134 bar) ........ D ........... Boom extend .................................... 25-30 ft-lbs / 34-41 Nm
14 Relief valve, 2300 psi (159 bar) ........ F ........... Boom down ....................................... 25-30 ft-lbs / 34-41 Nm
15 Proportional solenoid valve .............. AA ......... Boom ................................................ 10-12 ft-lbs / 14-16 Nm
16 Flow regulator valve .......................... X ........... Turntable rotate/boom
extend/retract .................................... 10-12 ft-lbs / 14-16 Nm
17 Normally closed poppet valve .......... J ............ Platform level .................................... 25-30 ft-lbs / 34-41 Nm
18 Proportional solenoid valve .............. Z ........... Turntable rotate/boom
extend/retract .................................... 10-12 ft-lbs / 14-16 Nm
19 Flow regulator valve .......................... V ........... Platform level .................................... 10-12 ft-lbs / 14-16 Nm
20 Differential sensing valve .................. AC ........ All functions ...................................... 10-12 ft-lbs / 14-16 Nm
21 Flow regulator valve .......................... U ........... Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm
22 Flow regulator valve .......................... W .......... Differential sensing circuit ................ 10-12 ft-lbs / 14-16 Nm
23 Diagnostic fitting ............................................... Testing
24 Relief valve, 2900 psi (200 bar) ........ AB ......... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
25 Priority flow regulator valve ............... T ........... Steering ............................................ 10-12 ft-lbs / 14-16 Nm
26 Check valve ....................................... I ............ Platform rotate right -
differential sensing ........................... 11-13 ft-lbs / 15-18 Nm
27 Check valve ....................................... H ........... Platform rotate left -
differential sensing ........................... 11-13 ft-lbs / 15-18 Nm
28 Check valve ....................................... L ........... Platform level -
differential sensing ........................... 11-13 ft-lbs / 15-18 Nm

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Service Manual - First Edition Section 7 - Repair Procedures

FUNCTION MANIFOLDS

1 2 3 4 5 6 7 8

10

11

28 12

27

26

25 13

14

24

15

16

23 22 21 20 19 18 17

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Section 7 - Repair Procedures Service Manual - First Edition

FUNCTION MANIFOLDS

Index Schematic
No. Description Item Function Torque
1 Normally open pilot
operated 2 position 2 way
directional valve ................................. A ........... Directs flow from
pressure port to tank port ................. 25-30 ft-lbs / 34-41 Nm
2 Normally open electrically
operated 2 position 2 way
directional valve ................................. B ........... Directs flow from
pressure port to tank port ................. 10-12 ft-lbs / 14-16 Nm
3 Normally open pilot
operated 2 position 2 way
directional valve ................................. A ........... Directs flow from index 2 on
steer manifold to index 4 on
lift jack dump valves ......................... 10-12 ft-lbs / 14-16 Nm
4 Relief valve, 200 psi (13.7 bar) ......... B ........... Chassis lift jacks ............................... 25-30 ft-lbs / 34-41 Nm

Boom Function Dump Valves Drive Chassis Lift Jack Dump Valves

1 2 3 4

7 - 36 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition (February 2009) Section 7 - Repair Procedures

FUNCTION MANIFOLDS

10-2 How to Adjust the Boom Down

Valve Adjustments - Relief Valve
Function Manifold Perform this procedure with the boom in the
stowed position.
How to Adjust the Main 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure
Relief Valve gauge to the test port (item 23) on the function
manifold.
Perform this procedure with the boom in the stowed
position. 2 Start the engine from the ground controls.
1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 3 Hold the boom down switch with the boom fully
gauge to the test port (item 23) on the function lowered, and observe the pressure reading on
manifold. the pressure gauge.
2 Start the engine from the ground controls. 4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item 14,
3 Hold the retract switch with the boom fully function manifold).
retracted, and observe the pressure reading on
the pressure gauge. 5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
4 Turn the engine off. Use a wrench to hold the decrease the pressure. Then install the relief
relief valve and remove the cap (item 24, valve cap.
function manifold).
Tip-over hazard. Do not adjust
5 Adjust the internal hex socket. Turn it clockwise the relief valves higher than
to increase the pressure or counterclockwise to recommended.
decrease the pressure. Then install the relief
valve cap. 6 Restart the engine. Hold the boom down switch
with the boom fully lowered and recheck the
Tip-over hazard. Do not adjust valve pressure.
the relief valves higher than
recommended. Boom down relief valve specifications
6 Restart the engine. Hold the retract switch with Pressure 2300 psi
the boom fully retracted, and recheck the valve 159 bar
pressure.

Main relief valve specifications

Pressure 2900 psi

200 bar

Part No. 34032 Genie S-80 & Genie S-85 7 - 37

Section 7 - Repair Procedures Service Manual - First Edition

FUNCTION MANIFOLDS

How to Adjust the Boom Extend How to Override a Valve

Relief Valve A hydraulic valve may need to be manually
Perform this procedure with the boom in the overridden to troubleshoot a malfunction. The
stowed position. proportional boom functions (boom up/down and
turntable rotate) use a variable position
1 Connect a 0 to 3000 psi (0 to 206 bar) pressure proportional valve and a three position directional
gauge to the test port (item 23) on the function valve. Example: one position for boom up, one
manifold. position for neutral and one position for boom
down. The platform rotate function uses a three
2 Start the engine from the ground controls.
position valve. The platform level uses a three
3 Hold the extend switch with the boom fully position and a two position valve. The three
extended, and observe the pressure reading on position valves and the proportional valves can be
the pressure gauge. manually overridden. To identify the manifold
valves see 10-1, Function Manifold, in this section.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item 13, 1 Push the button on the end of the valve in
function manifold). ¼ inch (6 mm).
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
the relief valves higher than
recommended.
6 Restart the engine. Hold the extend switch with
the boom fully extended, and recheck the valve
pressure.

Boom extend relief valve specifications 2 Move the ground control function switch for the
function being overridden to operate function.
Pressure 1950 psi
134 bar Collision hazard. Impact with moving boom
components may cause death or
serious injury. Use extreme
caution when overriding a
machine function. Identify the
direction of machine movement
before overriding a valve.

7 - 38 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

FUNCTION MANIFOLDS

How to Check the Resistance

of a Valve Coil
1 Turn the key switch to the OFF 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 5W

3 position 4 way directional valve 4.5W

Normally closed poppet valve 7W

Part No. 34032 Genie S-80 & Genie S-85 7 - 39

Section 7 - Repair Procedures Service Manual - First Edition

Fuel and Hydraulic Tanks

11-1 4 Disconnect the hydraulic hoses from the tank.

Hydraulic Tank 5 Remove the mounting fasteners from the
bottom of the tank.
The primary functions of the hydraulic tank are to 6 Use an appropriate lifting device to remove the
cool, clean and deaerate the hydraulic fluid during tank from the machine.
operation. This tank has a 45 gallon (170 liter)
capacity and an oil level gauge with a temperature Always use pipe thread sealant
indicator. It utilizes internal suction strainers for when installing the drain plug.
the pump supply lines and has an external return Use only Dexron II equivalent
line filter with a condition indicator. hydraulic fluid.
How to Remove the Component damage hazard.
Hydraulic Tank Be sure to open the two hydraulic
tank valves and prime the pump
Component damage hazard. after installing the hydraulic tank.
The work area and surfaces
where this procedure will be How to Prime the Pump
performed must be clean and 1 Connect a 0 to 600 psi (0 to 41 bar) pressure
free of debris that could get gauge to the test port on the drive pump.
into the hydraulic system.
2 Gasoline/LPG models: Remove the high
1 Remove the fuel tank. See 11-2, How to tension lead from the center of the ignition coil.
Remove the Fuel Tank.
Electrocution hazard.
2 Close the two hydraulic tank valves located at Contact with electrically charged
the hydraulic tank. circuits may cause death or
serious injury. Remove all rings,
watches and other jewelry.
Deutz Diesel models: Hold the manual fuel
shutoff valve counterclockwise to the CLOSED
position.
3 Crank the engine with the starter motor for
open closed 15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
3 Completely drain the oil from the tank by pressure reaches 320 psi (22 bar).
removing the drain plug located in the
bottom of the tank.
Burn hazard. Contact with hot oil
may cause severe burns.

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Service Manual - First Edition Section 7 - Repair Procedures

FUEL AND HYDRAULIC TANKS

11-2
Fuel Tank

How to Remove the Fuel Tank

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.
1 Turn the manual fuel shutoff valve to the
CLOSED position.

2 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.
3 Remove the mounting fasteners from the
bottom of the tank.
4 Use an appropriate lifting device to remove the
tank from the machine.
Clean the fuel tank and inspect
for rust and corrosion before
installing.

Part No. 34032 Genie S-80 & Genie S-85 7 - 41

Section 7 - Repair Procedures Service Manual - First Edition

Turntable Rotation Components

12-1 2 Tag and disconnect the hydraulic hoses from

the motor and manifold, and plug them.
Rotation Hydraulic Motor
Bodily injury hazard.
Spraying hydraulic oil can
How to Remove the Rotation penetrate and burn skin. Loosen
Hydraulic Motor hydraulic connections very slowly
to allow the oil pressure to
1 Secure the turntable from rotating with the
dissipate gradually. Do not
turntable rotation lock pin.
allow oil to squirt or spray.
3 Remove the motor mounting bolts, then
remove the motor from the brake.

a b

d
Unlocked position
f

a motor/brake mounting bolts

b motor
c brake
d torque hub mounting bolts
e torque hub
f plug

How to Remove the Turntable

Rotation Brake or Torque Hub
Locked position
Refer to Maintenance Procedures, C-6, How to
Replace the Torque Hub Oil.

7 - 42 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

How to Adjust the 5 Turn the adjustment

bolt 3/8 of a turn
Turntable Rotation Gear Backlash counterclockwise. Then
The turntable rotation torque hub is mounted on a tighten the lock nut on the
adjustable plate that controls the gap between the adjustment bolt.
rotation motor gear and the turntable bearing. 6 Rotate the torque hub
pivot plate away from the
Be sure to check the backlash
turntable until it contacts the adjustment bolt.
with the machine on a flat level
Then tighten the mounting fasteners on the
surface.
torque hub pivot plate.
1 Loosen the mounting fasteners on the torque
7 Rotate the turntable through an entire rotation.
hub pivot plate.
Check for tight spots that could cause binding.
Readjust if necessary.

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.

Part No. 34032 Genie S-80 & Genie S-85 7 - 43

Section 7 - Repair Procedures Service Manual - First Edition

TURNTABLE ROTATION COMPONENTS

12-2
Turntable Rotation Manifold Components
Index Schematic
No. Description Item Function Torque

1 Shuttle valve 2 position 3 way ........... C ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ A ........... Turntable rotate - right ...................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ........................ B ........... Turntable rotate - left ........................ 35-40 ft-lbs / 47-54 Nm

1 2 3

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

SAE No. 6 1/ 4 18 ft-lbs / 24 Nm

SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/ 8 75 ft-lbs / 102 Nm

7 - 44 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

2WD Steering Axle Components

13-1 5 Remove the lug nuts, then the tire and

wheel assembly.
Yoke and Hub
6 Remove the retaining bolt from the king pin.
How to Remove the Yoke 7 Attach a strap from a lifting device to the
and Hub yoke/hub assembly for support.
8 Use a slide hammer to remove the upper king
1 Remove the retaining bolt, then the pivot pin
pin, then use a soft metal drift to drive the
from both the steering cylinder and the tie rod.
lower king pin down and out.
Crushing hazard. The yoke/hub
a b c d assembly will fall when the king
pins are removed if it is not
properly supported.

Torque specifications dry lubricated

Lug nut 420 ft-lbs 320 ft-lbs

569.5 Nm 433.9 Nm

g f f e

a tie rod
b axle
c king pin/retaining bolt
d yoke
e hub
f pivot pin/retaining bolt
g steering cylinder

2 Loosen the wheel lug nuts. Do not

remove them.
3 Block the non-steering wheels, and then
center a lifting jack under the steering axle.
4 Raise the machine 6 inches (15 cm) and place
blocks under the chassis for support.

Part No. 34032 Genie S-80 & Genie S-85 7 - 45

Section 7 - Repair Procedures Service Manual - First Edition

2WD STEERING AXLE COMPONENTS

How to Remove the 6 Install the washer and slotted nut.

Hub and Bearings 7 Tighten the slotted nut to 35 foot-pounds
(47 Nm).
1 Loosen the wheel lug nuts. Do not remove
them. 8 Loosen the slotted nut, then re-tighten to
8 foot-pounds (11 Nm).
2 Block the non-steering wheels and place a
lifting jack under the steering axle. 9 Install a new cotter pin. Bend the cotter pin
to lock it in.
3 Raise the machine and place blocks under
the chassis for support. 10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
4 Remove the lug nuts. Then remove the tire 420 foot-pounds (569.5 Nm).
and wheel assembly.
5 Remove the dust cap, cotter pin and
slotted nut.
13-2
6 Pull the hub off the spindle. The washer and Steering Cylinders
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry How to Remove a
the bearing seal out of the hub. Remove the
rear bearing.
Steering Cylinder
There are two identical steering cylinders that
How to Install the work in parallel. They are part of the same
Hub and Bearings hydraulic circuit, but move in opposite directions.
The tie rod maintains equal movement of the tires.
When replacing a wheel bearing, Bushings are used at both ends of each steering
both the inner and outer bearings cylinder clevis.
including the pressed-in races
must be replaced. 1 Disconnect and plug the hydraulic hoses from
the steering cylinder. Cap the fittings.
1 Be sure that both bearings are packed
with grease. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
2 Place the large inner bearing into the rear
burn skin. Loosen hydraulic
of the hub.
connections very slowly to allow
3 Press the bearing seal evenly into the hub the oil pressure to dissipate
until it is flush. gradually. Do not allow oil to
squirt or spray.
4 Slide the hub onto the yoke spindle.
2 Remove the pin retaining fasteners. Then
Component damage. Do not remove the pivot pin from each end of the
apply excessive force or damage steering cylinder.
to the lip of the seal may occur.
3 Remove the steering cylinder.
5 Place the outer bearing into the hub.

7 - 46 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

2WD STEERING AXLE COMPONENTS

13-3 3 Loosen the jam nut on the adjustable end

of the tie rod cylinder.
Tie Rod Cylinder
4 Remove the pin retaining fasteners, then
remove the pivot pin from the adjustable end of
How to Remove the the tie rod cylinder.
Tie Rod Cylinder
5 Slide the tie rod cylinder off the yoke and adjust
1 Disconnect and plug the hydraulic hoses from it by turning the end.
the tie rod cylinder. Cap the fittings.
One turn on the adjustable end
Bodily injury hazard. Spraying equals approximately 1/8 inch
hydraulic oil can penetrate and (3.2 mm) change in the front
burn skin. Loosen hydraulic and rear measurements.
connections very slowly to allow
6 Slide the tie rod onto the yoke. Install the
the oil pressure to dissipate
pivot pin, then install the retaining bolt.
gradually. Do not allow oil to
squirt or spray. 7 Tighten the jam nut against the tie rod.
2 Remove the pin retaining fasteners, then 8 Recheck the front and back measurements
remove the pivot pin from each end of the tie (step 2). If further adjustment is needed, repeat
rod cylinder. steps 3 through 7.
3 Remove the tie rod cylinder. Toe-in specification 0 ± 1/8 inch (6.35 mm)
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.
2 Measure the steer tires, front to front and back
to back, using a measuring fixture.

Part No. 34032 Genie S-80 & Genie S-85 7 - 47

Section 7 - Repair Procedures Service Manual - First Edition

4WD Steering Axle Components

14-1 3 Tag, disconnect and plug the hydraulic hoses

from the wheel motor. Cap the wheel motor
Yoke and Hub hydraulic fittings.
Bodily injury hazard. Spraying
How to Remove the Yoke hydraulic oil can penetrate and
and Hub burn skin. Loosen hydraulic
connections very slowly to allow
The yoke installation utilizes bushings and a thrust
the oil pressure to dissipate
washer that may require periodic replacement.
gradually. Do not allow oil to
The yoke must be removed before the torque hub
squirt or spray.
can be removed.
4 Loosen the wheel lug nuts. Do not
1 Start the engine from the ground controls. remove them.
Rotate the turntable until the platform is
between the steer tires. 5 Block the non-steering wheels, and then center
a lifting jack under the steering axle.
2 Remove the pin retaining fasteners, then
remove the pivot pin from both the steering 6 Raise the machine 15 inches (38 cm) and place
cylinder and the tie rod cylinder. blocks under the chassis for support.
7 Remove the lug nuts, then remove the tire and
wheel assembly.
8 Remove the roll pin from the upper king pin.
9 Remove the retaining bolts from the upper and
lower king pins.

a 10 Attach a strap from a lifting device to the

yoke/torque hub assembly for support.

f e d c
a king pin
b torque hub
c yoke
d pivot pin
e tie rod cylinder
f steer cylinder

7 - 48 Genie S-80 & Genie S-85 Part No. 34032

Service Manual - First Edition Section 7 - Repair Procedures

4WD STEERING AXLE COMPONENTS

11 Use a slide hammer to remove the upper king 14-3

pin, then use a soft metal drift to drive the
lower king pin down and out. Tie Rod Cylinder
Crushing hazard. The yoke/torque
hub assembly will fall when the
How to Remove the
lower king pin is removed if it is Tie Rod Cylinder
not properly supported.
This procedure is the same as the 2WD
12 Place the yoke/torque hub assembly on a flat procedure. See Repair Procedure 13-3,
surface with the torque hub down. Remove the How to Remove the Tie Rod Cylinder.
bolts that secure the yoke to the torque hub.
How to Perform the Toe-in
Torque specifications dry lubricated
Adjustment
Lug nut 420 ft-lbs 320 ft-lbs
569.5 Nm 433.9 Nm This procedure is the same as the 2WD
procedure. See Repair Procedure 13-3,
Torque hub mounting bolts 180 ft-lbs How to Perform the Toe-in Adjustment.
244 Nm

Drive motor mounting bolts 75 ft-lbs

102 Nm

14-2
Steering Cylinders

How to Remove a
Steering Cylinder
This procedure is the same as the 2WD
procedure. See repair procedure 13-2,
How to Remove a Steering Cylinder.

Part No. 34032 Genie S-80 & Genie S-85 7 - 49

Section 7 - Repair Procedures Service Manual - First Edition

Extendable Axle Components

15-1 4 Raise the machine 15 inches (38 cm) and place

blocks under the chassis for support.
Extendable Axles
5 Remove the lug nuts, then remove the tire and
The extendable axles are used to widen the foot wheel assembly.
print of the drive chassis for stability. Non-steer end: proceed to step 9.
How to Shim the Extendable Axle Steer End:
Measure each wear pad. Replace 6 Remove the pin retaining fasteners. Then
the pad if it is less than 7/16 inch remove the pivot pins from the steer cylinder
(11 mm) thick. If the pad is more and tie rod cylinder. Pull the cylinders off of the
than 7/16 inch (11 mm) thick, yoke/hub assembly.
perform the following procedure.
7 Remove the steer cylinder mounting lug from
1 Extend the axle. the inner axle.
2 Remove the wear pad mounting fasteners. 8 Disconnect the axle extension cylinder
hydraulic hoses at the tee next to the lift jack.
3 Install the new shims under the wear pad to
Do not disconnect them from the cylinder.
obtain zero clearance and zero drag.
4WD Models:
4 Use a round punch to align the shim to the
wear pad. Install the mounting fasteners. Disconnect and plug the hydraulic hoses
from the wheel motor. Cap the wheel motor
5 Extend and retract the axle through an entire
hydraulic fittings.
cycle. Check for tight spots that could cause
scraping or binding. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Always maintain squareness
burn skin. Loosen hydraulic
between the outer and inner axle
connections very slowly to allow
tubes.
the oil pressure to dissipate
How to Remove the Inner Axle gradually. Do not allow oil to
squirt or spray.
This procedure requires specific
9 Remove the drive chassis cover.
repair skills and a suitable
workshop. Attempting this 10 Remove the retaining ring from the axle
procedure without these skills extension cylinder pivot pin. Then remove the
and tools may result in death or pin.
serious injury and significant
component damage. Dealer 11 Disconnect and plug the hydraulic hoses
service is strongly recommended. from the wheel motor. Cap the wheel motor
hydraulic fittings.
1 Extend the axle to be removed.
Bodily injury hazard. Spraying
2 Loosen the wheel lug nuts. Do not hydraulic oil can penetrate and
remove them. burn skin. Loosen hydraulic
connections very slowly to allow
3 Block the wheels on the opposite end of the
the oil pressure to dissipate
machine, and then center a lifting jack under
gradually. Do not allow oil to
the axle to be removed.
squirt or spray.

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Service Manual - First Edition Section 7 - Repair Procedures

EXTENDABLE AXLE COMPONENTS

12 Attach a strap from a lifting device to the 15-2

inner axle for support.
Drive Chassis Lift Jacks
13 Use a soft metal drift to remove the cylinder
pivot pin. The drive chassis lift jacks are used to lift the drive
14 Remove the lock plate from the top side of the chassis for axle extension. The lift jacks should
inner axle. Then remove the lower wear pads. not be used to support the machine during
maintenance or repair procedures.
15 Carefully pull the inner axle out of the axle.
How to Remove a Chassis
How to Remove the Axle
Lift Jack
Extension Cylinder
1 Remove the drive chassis cover.
1 Remove the yoke/hub assembly. See 13-1 or
14-1, How to Remove the Yoke and Hub. 2 Disconnect and plug the hydraulic hoses
from the cylinder. Cap the cylinder hydraulic
2 Disconnect and plug the hydraulic hoses fittings.
from the cylinder. Cap the cylinder hydraulic
fittings. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Bodily injury hazard. Spraying burn skin. Loosen hydraulic
hydraulic oil can penetrate and connections very slowly to allow
burn skin. Loosen hydraulic the oil pressure to dissipate
connections very slowly to allow gradually. Do not allow oil to
the oil pressure to dissipate squirt or spray.
gradually. Do not allow oil to
squirt or spray. 3 Attach a strap from a lifting device to the
cylinder for support.
3 Remove the retaining bolt, then the pivot pins
from each end of the cylinder. Remove the 4 Remove the lift jack mounting fasteners. Then
cylinder from the axle. remove the jack from the machine.

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Section 7 - Repair Procedures Service Manual - First Edition

EXTENDABLE AXLE COMPONENTS

15-3 3 Use the lift jack to raise the machine.

Hydraulic Limit Switches 4 Extend the axles completely.
5 Lower the machine and turn the linkage rod
The hydraulic limit switches are 2 position 2 way clockwise until it completely compresses the
valves. The switches sense full axle extension and valve actuator. Then turn the linkage rod
allow the boom functions to operate. counterclockwise 1/8 inch. Tighten the lock nut.
How to Set Up the Hydraulic Limit 6 Raise the machine.
Switch Linkage 7 Extend and retract both axles through 2 cycles
and check boom functions. If the boom will not
Adjustment of the hydraulic limit raise past the drive limit switch, readjust as
switch linkage is only necessary 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.

a b c d e

a lock nut
b linkage rod
c spring
d valve actuator
e limit switch valve

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Service Manual - First Edition Section 7 - Repair Procedures

EXTENDABLE AXLE COMPONENTS

15-4
Chassis Jack/Axle Manifold Components
Index Schematic
No. Description Item Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ....................................................... Directional control
3 Priority flow regulator valve ............... A ........... Chassis lift jacks ............................... 10-12 ft-lbs / 14-16 Nm
4 Inline check valve .............................. B ........... Chassis lift jacks
5 Pilot to open check valve ................................. Directs flow from cylinder
barrel end to tank .............................. 25-30 ft-lbs / 34-41 Nm
6 Relief valve, 200 psi (13.7 bar) ......... A ........... Hydraulic limit switch ........................ 25-30 ft-lbs / 34-41 Nm

Chassis Jack/Axle Manifold Priority Flow Regulator Valve

Hydraulic Jack Check Valve

Hydraulic Limit Switch Relief Valve

5

Part No. 34032 Genie S-80 & Genie S-85 7 - 53

Section 7 - Repair Procedures Service Manual - First Edition

Steer Manifolds

16-1
Steer Manifold Components
Index Schematic
No. Description Item Function Torque
1 3 position 4 way D03 valve .............................. Steering ............................................. 30-35 in-lbs / 3-4 Nm
2 Priority flow regulator valve ............... A ........... Chassis lift jacks &
extendable axles ............................... 10-12 ft-lbs / 14-16 Nm

Plug Torque Specifications

Description Hex size Torque Description Hex size Torque

1/ 8 SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 2 50 in-lbs / 6 Nm
3/16 SAE No. 10 9/16 55 ft-lbs / 75 Nm
SAE No. 4 13 ft-lbs / 18 Nm
1/ 4 SAE No. 12 5/ 8 75 ft-lbs / 102 Nm
SAE No. 6 18 ft-lbs / 24 Nm

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Service Manual - First Edition Section 7 - Repair Procedures

Non-steering Axle Components

17-1 17-2
Drive Motor Torque Hub
Component damage hazard. How to Remove a Drive
Repairs to the motor should only
be performed by an authorized Torque Hub
Sundstrand-Sauer dealer. 1 Remove the drive motor. See 17-1, How to
Remove a Drive Motor.
How to Remove a Drive Motor
2 Disconnect the hydraulic hose from the brake
A drive motor can only be removed from the inside and plug it. Then remove the hydraulic fitting
of the chassis. and the bleed valve.
Component damage hazard. The 3 Loosen the wheel lug nuts. Do not
work area and surfaces where this remove them.
procedure will be performed must
be clean and free of debris that 4 Center a lifting jack under the non-steering
could get into the hydraulic axle. Raise the machine and place blocks
system and cause severe under the drive chassis to support it.
component damage. Dealer 5 Remove the wheel lug nuts, then the tire and
service is recommended. wheel assembly.
1 Disconnect the hydraulic hoses from the drive 6 Place a second lifting jack under the torque hub
motor and plug them. for support.
Bodily injury hazard. Spraying 7 Remove the bolts that attach the torque hub to
hydraulic oil can penetrate and the chassis, then remove the torque hub.
burn skin. Loosen hydraulic
connections very slowly to allow Crushing hazard. The torque
the oil pressure to dissipate hub will fall if it is not properly
gradually. Do not allow oil to squirt supported when the mounting
or spray. bolts are removed.
2 Remove the drive motor mounting bolts. Torque specifications
3 Slide the drive motor shaft out of the brake and Lug nut (dry) 420 ft-lbs
then remove it. 569.5 Nm
Lug nut (lubricated) 320 ft-lbs
Torque specifications 433.9 Nm
Drive motor mounting bolts 75 ft-lbs Drive torque hub mounting bolts 120 ft-lbs
102 Nm 163 Nm

Drive motor mounting bolts 75 ft-lbs

102 Nm

Part No. 34032 Genie S-80 & Genie S-85 7 - 55

Section 7 - Repair Procedures Service Manual - First Edition

2WD Drive Manifold

18-1
2WD Drive Manifold Components
Index Schematic
No. Description Item Function Torque
1 Relief valve, 250 psi (17 bar) ............ B ........... Charge pressure circuit .................... 15-18 ft-lbs / 20-24 Nm
2 Shuttle valve 3 position 3 way ........... A ........... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path or brake
release and 2-speed motor shift ....... 15-18 ft-lbs / 20-24 Nm
3 Orifice 0.070 in (1.78 mm) ................ D ........... Drive circuit
4 Flow divider/combiner valve .............. C ........... Controls flow to drive motors
in forward and reverse ...................... 25-30 ft-lbs / 34-41 Nm
5 Diagnostic fitting ............................................... Testing

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Service Manual - First Edition Section 7 - Repair Procedures

2WD DRIVE MANIFOLD

Plug Torque Specifications 18-2

Valve Adjustments
Description Hex size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm How to Adjust the Charge

SAE No. 4 3/16 13 ft-lbs / 18 Nm Pressure Relief Valve
SAE No. 6 1/4 18 ft-lbs / 24 Nm 1 Connect a 0 to 600 psi (0 to 41 bar) pressure
5/16
gauge to the test port located on the drive
SAE No. 8 50 ft-lbs / 68 Nm
manifold.
SAE No. 10 9/16 55 ft-lbs / 75 Nm Bodily injury hazard. Spraying
SAE No. 12 5/8 75 ft-lbs / 102 Nm 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 Start the engine from the platform controls.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the relief valve and
remove the cap (index 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 Turn the engine off, then remove the
pressure gauge.

Relief valve specifications

Pressure 250 psi

17 bar

Part No. 34032 Genie S-80 & Genie S-85 7 - 57

Section 7 - Repair Procedures Service Manual - First Edition

4WD Drive Manifold

19-1
4WD Drive Manifold Components
Index Schematic
No. Description Item Function Torque
1 Shuttle valve 3 position 3 way ........... A ........... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path or brake
release and 2-speed motor shift ....... 15-18 ft-lbs / 20-24 Nm
2 Relief valve, 250 psi (17 bar) ............ E ........... Charge pressure circuit .................... 15-18 ft-lbs / 20-24 Nm
3 Orifice 0.052 in (1.32 mm) ................ H ........... Drive circuit, non-steer end
4 Flow divider/combiner valve .............. C ........... Controls flow to steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
5 Flow divider/combiner valve .............. A ........... Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
6 Orifice 0.070 in (1.78 mm) ................ F ........... Drive circuit, steer end
7 Orifice 0.070 in (1.78 mm) ................ G ........... Drive circuit, non-steer end
8 Flow divider/combiner valve .............. B ........... Controls flow to flow
divider/combiner valves 4 and 5 ... 25-30 ft-lbs / 34-41 Nm
9 Diagnostic fitting ............................................... Testing

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Service Manual - First Edition Section 7 - Repair Procedures

4WD DRIVE MANIFOLD

1 2 3 4 5

Part No. 34032 Genie S-80 & Genie S-85 7 - 59

Section 7 - Repair Procedures Service Manual - First Edition

4WD DRIVE MANIFOLD

Plug Torque Specifications 6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
Description Hex size Torque 7 Turn the engine off, then remove the
SAE No. 2 1/ 8 50 in-lbs / 6 Nm pressure gauge.

SAE No. 4 3/16 13 ft-lbs / 18 Nm Relief valve specifications

SAE No. 6 1/ 4 18 ft-lbs / 24 Nm Pressure 250 psi

17 bar
SAE No. 8 5/16 50 ft-lbs / 68 Nm

SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 12 5/ 8 75 ft-lbs / 102 Nm

19-2
Valve Adjustments

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.
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.
2 Start the engine from the platform controls.
3 Drive the machine slowly in either direction
and observe the pressure reading on the
pressure gauge.
4 Turn the engine off. Hold the relief valve and
remove the cap (index 2).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.

7 - 60 Genie S-80 & Genie S-85 Part No. 34032

 Genie North America
18340 NE 76th Street
P.O. Box 97030
Redmond, Washington
98073-9730

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