Genie Industries S-80

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(815) 933-2122

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aerialliftequipment.com

Alexander Equipment Sales and Rental

1511 Commerce Drive, Bourbonnais, IL 60914

Genie S-85

SERVICE MANUAL

| RECOURCE LIBRARY

Main Page

Default Chapter6
- Table of Contents6
Specifications15
- Machine Specifications15
- Performance Specifications16
- Hydraulic Specifications17
- Ford LRG 423 Engine Specifications18
- Deutz F4L 1011F Engine Specifications20
- Hydraulic Hose and Fitting Torque Specifications22
- Bolt Torque Specifications23
Scheduled Maintenance Inspections25
- Maintenance Inspection Report31
Scheduled Maintenance Procedures33
- Inspect the Manuals34
- Inspect the Decals and Placards34
- Inspect for Damage, Loose or Missing Parts34
- Check the Engine Oil Level35
- Check the Engine Coolant Level - Gasoline/Lpg Models35
- Check for Fuel Leaks35
- Check the Hydraulic Oil Level36
- Check for Hydraulic Leaks36
- Check the Tire Pressure37
- Test the Extendable Axles37
- Test the Platform and Ground Controls38
- Test the Auxiliary Power Operation39
- Test the Tilt Sensor39
- Test the Limit Switches40
- Replace the Engine Oil and Filter - Gasoline/Lpg Models43
- Drain the Fuel Filter/Water Separator - Deutz Diesel Models44
- Replace the Engine Air Filter45
- Check the Engine Belt46
- Check the Radiator - Gasoline/Lpg Models47
- Check the Oil Cooler and Cooling Fins - Deutz Diesel Models47
- Check the Exhaust System48
- Check the Battery49
- Check the Hydraulic Tank Filter Condition Indicator49
- Inspect the Electrical Wiring50
- Inspect the Tires and Wheels (Including Lug Nut Torque)50
- Confirm the Proper Brake Configuration51
- Check the Oil Level in the Torque Hubs51
- Check and Adjust the Engine Idle Mixture - Gasoline/Lpg Models52
- Check and Adjust the Engine RPM52
- Test the Key Switch54
- Test the Ground Control Override55
- Test the Platform Self-Leveling55
- Test the Horn55
- Test the Foot Switch55
- Test the Engine Idle Select56
- Test the Fuel Select Operation - Gasoline/Lpg Models56
- Test the Drive Enable System57
- Test the Drive Brakes58
- Test the Drive Speed - Stowed Position58
- Test the Alarm Package - Optional Equipment59
- Check the Hydraulic Limit Switch Linkage59
- Perform Hydraulic Oil Analysis59
- Replace the Engine Oil and Filter - Deutz Diesel Models60
- Check the Boom Wear Pads61
- Check the Extendable Axle Wear Pads61
- Check the Turntable Rotation Bearing Bolts62
- Check the Free-Wheel Configuration62
- Grease the Turntable Rotation Bearing and Rotate Gear64
- Replace the Torque Hub Oil64
- Replace the Hydraulic Tank Filter66
- Replace the Drive Loop Hydraulic Filter66
- Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models67
- Replace the Gasoline Fuel Filter - Gasoline/Lpg Models68
- Replace the PCV Valve - Gasoline/Lpg Models69
- Replace the Spark Plugs - Gasoline/Lpg Models69
- Check and Adjust the Air/Lpg Mixture - Gasoline/Lpg Models70
- Check and Adjust the Ignition Timing - Gasoline/Lpg Models71
- Check the Engine Valve Clearances - Deutz Diesel Models71
- Check the Turntable Rotation Gear Backlash71
- Test or Replace the Hydraulic Oil72
- Change or Recondition the Engine Coolant - Gasoline/Lpg Models72
- Change the Fuel Lines74
- Check the Engine Valve Clearance - Gasoline/Lpg Models75
- Check the Engine Cylinder Compression - Gasoline/Lpg Models75
- Clean the PCV Hoses and Fittings - Gasoline/Lpg Models76
- Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models76
- Check the Toothed Belt - Deutz Diesel Models77
- Replace the Timing Belt - Gasoline/Lpg Models77
- Grease the Steer Axle Wheel Bearings, 2WD Models77
- Engine will Not Crank over81
- Engine Cranks over but will Not Start - Gasoline/Lpg Models86
- Engine Runs While Cranking then dies86
- Engine Cranks over but will Not Start - Deutz Diesel Models90
- Engine will Not Start on LPG, but will Start on Gasoline - Gasoline/Lpg Models93
- Engine will Not Start on Gasoline, but will Start on LPG95
- Engine High Idle Inoperative - Gasoline/Lpg Models97
- Engine Low Idle Inoperative - Gasoline/Lpg Models100
- Engine High Idle Inoperative - Deutz Diesel Models101
- Engine Low Idle Inoperative - Deutz Diesel Models103
- All Functions Inoperative, Engine Starts and Runs104
- All Lift and Steer Functions Inoperative, Drive Functions Operational105
- All Lift Functions Inoperative, Steer and Drive Functions Operational106
- Ground Controls Inoperative, Platform Controls Operate Normally108
- Platform Controls Inoperative, Ground Controls Operate Normally109
- Boom up Function Inoperative110
- Boom down Function Inoperative113
- Boom Extend Function Inoperative116
- Boom Retract Function Inoperative119
- Turntable Rotate Left Function Inoperative122
- Turntable Rotate Right Function Inoperative126
- All Platform Leveling Functions Inoperative130
- Platform Level up Function Inoperative131
- Platform Level down Function Inoperative133
- Platform Rotate Left Function Inoperative135
- Platform Rotate Right Function Inoperative138
- Drive Chassis Jack Function Inoperative145
- Axle Extend/Retract Inoperative147
- Steer Left Function Inoperative148
- Steer Right Function Inoperative150
- All Drive Functions Inoperative, All Other Functions Operate Normally152
- Drive Forward or Reverse Function Inoperative155
- Traction Function Inoperative156
- Machine will Not Drive at Full Speed157
- Machine Drives at Full Speed with Platform Raised or Extended158
- Drive Enable System Is Malfunctioning159
- Auxiliary Functions Inoperative160
Schematics163
- Electrical Components164
- Electrical Symblos Legend166
- Abbreviation Legend167
- Electrical Schematic-Gasoline/Lpg Models169
- Ground Control Box Legend - Gasoline/Lpg Models171
- Ground Control Box Wiring Diagram-Gasoline/Lpg Models172
- Platform Control Box Legend - Gasoline/Lpg Models173
- Platform Control Box Wiring Diagram-Gasoline/Lpg Models174
- Hydraulic Symbols Legend182
- 2WD Hydraulic Schematic183
- 4WD Hydraulic Schematic184
Platform Controls186
- Joystick Controllers186
- Horsepower Limiter Board190
- Foot Switch192
- Resistors193
- Toggle Switches193
- Control Relays194
Platform Components195
- Platform195
- Platform Leveling Slave Cylinder195
- Platform Rotator196
Jib Boom Components, S-85 Models199
- Jib Boom, S-85 Models199
- Jib Boom / Platform Rotate Manifold Components, S-85 Models199
Boom Components202
- Boom Cable Track202
- Boom204
- Boom Lift Cylinder206
- Extension Cylinders207
- Platform Leveling Master Cylinder208
Turntable Covers210
Deutz Engine F4L 1011F211
- RPM Adjustment211
- Flex Plate211
Ford LRG-423 Engine212
- Governor Actuator212
- Choke Adjustments213
- Timing Adjustment214
- Carburetor Adjustment214
- RPM Adjustment214
- Flex Plate214
- Water Temperature and Oil Pressure Gauges215
- Vacuum Switch216
Ground Controls217
- Control Relays217
- Wago Components217
- Resistors217
- Power Relay218
Hydraulic Pumps219
- Lift/Steer Pump219
- Drive Pump219
Manifolds222
- Function Manifold Components222
- Valve Adjustments - Function Manifold226
- Turntable Rotation Manifold Components229
- Chassis Jack Manifold Components230
- Axle Extend Dump Manifold Components231
- Steer Manifold Components233
- 2WD Drive Manifold Components236
- Valve Adjustments, 2WD Drive Manifold238
- 4WD Drive Manifold Components240
- Valve Adjustments, 4WD Drive Manifold242
Fuel and Hydraulic Tanks243
- Fuel Tank243
- Hydraulic Tank243
Turntable Rotation Components246
- Rotation Hydraulic Motor246
2WD Steering Axle Components249
- Yoke and Hub249
- Steering Cylinders250
- Tie Rod Cylinder251
4WD Steering Axle Components252
- Yoke and Hub252
- Steering Cylinders253
- Tie Rod Cylinder253
Extendable Axle Components254
- Extendable Axles254
- Drive Chassis Lift Jacks256
- Hydraulic Limit Switches256
Non-Steering Axle Components257
- Drive Motor257
- Torque Hub257

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Genie Industries S-80 Specifications

General

Brand	Genie Industries
Model	S-80
Category	Boom Lifts
Language	English

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