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February 2012

S-80 • S-85 • S-80X Part No.122985

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate operator's

manual on your machine before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled maintenance

information for the machine owner and user. It also

provides troubleshooting fault codes and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However, several

procedures require specialized skills, tools, lifting

equipment and a suitable workshop. In these instances,

we strongly recommend that maintenance and repair be

performed at an authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degree of

accuracy possible. However, continuous improvement of

our products is a Genie policy. Therefore, product

specifications are subject to change without notice.

Readers are encouraged to notify Genie of errors and

send in suggestions for improvement. All

communications will be carefully considered for future

printings of this and all other manuals.

Contact Us:

http://www.genielift.com

e-mail: [email protected]

Serial Number Information

Genie offers the following Service

Manuals for these models:

Title Part No.

Genie S-80 and S-85 Service Manual

(from serial number 101 to 785) ..........34032

Genie S-80 and S-85 Service Manual

(from serial number 786 to 965) ..........52270

Genie S-80 and S-85 Service Manual

(from serial number 966 to 3081) ........ 72062

Genie S-80 and S-85 Service Manual

(from serial number 3082 to 3737) ......77832

Genie S-80 and S-85 Service Manual

(from serial number 3738 to 5380) ... 111165

Genie S-80 and S-85 Service Manual

(from serial number 5381 to 7999) ... 122149

Introduction

Copyright © 2011 Terex Corporation

122985 Rev D February 2012

Seventh Edition, Fourth Printing

"Genie" and "S" are registered trademarks of

Terex South Dakota, Inc. in the USA and many

other countries.

Printed on recycled paper

Printed in U.S.A.

ii

February 2012

Part No.122985 S-80 • S-85 • S-80X

Revision Date Section Procedure / Schematic Page / Description

D 2/2012 2 - Spec. 2-1

3 - Maint. 3-1, 3-51

4 - Repair 4-3 to 4-6, 4-18

6 - Schem.

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.

3-3_Section 3_Maintenance Procedure Page #.

4-48_Section 4_Repair Procedure Page #.

Fault Codes_Section 5.

6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Revision History

February 2012

S-80 • S-85 • S-80X Part No.122985

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.

3-3_Section 3_Maintenance Procedure Page #.

4-48_Section 4_Repair Procedure Page #.

Fault Codes_Section 5.

6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

February 2012

Part No.122985 S-80 • S-85 • S-80X

iii

Serial Number Legend

S80 08 - 12345

Model

Model year

Sequence

number

PN - 77055

Country of manufacture: USA

This machine complies with:

Model: S-80

Serial number: S8008-12345

Electrical schematic number: ES503

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/06

2006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 80 ft/ 24.4 m

Maximum platform reach : 71 ft 6 in/ 21.8 m

Sequence number

(stamped on chassis)

Serial label

(located under cover)

Terex South Dakota

500 Oak Wood road

PO Box 1150

Watertown, SD 57201

USA

February 2012

S-80 • S-85 • S-80X Part No.122985

This page intentionally left blank.

iv

February 2012

Part No.122985 S-80 • S-85 • S-80X

Danger

Failure to obey the instructions and safety rules in

this manual, and the

Genie S-80 and 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.

Safety Rules

Section 1 • Safety Rules

v

February 2012

S-80 • S-85 • S-80X Part No.122985

SAFETY RULES

Section 1 - Safety Rules

vi

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

Note: Used to indicate operation or maintenance

information.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for use.

Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area is

properly ventilated and well lit.

February 2012

Part No.122985 S-80 • S-85 • S-80X

Table of Contents

Introduction

Important Information ...................................................................................................

ii

Serial Number Information ............................................................................................

ii

Serial Number Legend .................................................................................................

iii

Section 1 Safety Rules

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

v

Section 2 Rev Specifications

Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Hydraulic Oil Specifications ................................................................................... 2 - 2

Hydraulic Component Specifications ...................................................................... 2 - 3

Valve Coil Resistance Specifications ..................................................................... 2 - 4

Continental TME27 Engine Specifications ............................................................. 2 - 5

Deutz TD2011L04i Engine Specifications............................................................... 2 - 6

Perkins 804D-33 Engine Specifications ................................................................. 2 - 7

Machine Torque Specifications .............................................................................. 2 - 8

Manifold Component Specifications ....................................................................... 2 - 8

Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 9

SAE and Metric Torque Specifications................................................................. 2 - 10

vii

February 2012

S-80 • S-85 • S-80X Part No.122985

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

A-3 Perform Engine Maintenance ....................................................................... 3 - 8

A-4 Perform Function Tests ................................................................................ 3 - 9

A-5 Test the Oscillate Axle ................................................................................. 3 - 9

A-6 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10

A-7 Perform 30 Day Service ............................................................................. 3 - 10

A-8 Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 11

A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11

A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13

A-11 Perform Engine Maintenance ..................................................................... 3 - 14

A-12 Replace the Drive Hub Oil .......................................................................... 3 - 15

A-13 Perform Engine Maintenance - Perkins Models .......................................... 3 - 17

Checklist B Procedures

B-1 Inspect the Battery(s) ................................................................................. 3 - 18

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19

B-3 Test the Key Switch ................................................................................... 3 - 21

B-4 Check the Exhaust System ....................................................................... 3 - 21

viii