Genie S-80 S-85 Boom Lift Parts Manual 2015 – PDF Parts Catalog SN 3082 to 7999

Description

Genie S-80 & S-85 Parts Manual – Part No. 77810 Rev E29

This is the complete illustrated parts catalog for the Genie S-80 and Genie S-85 telescopic boom lifts built from serial number 3082 through 7999. Published by Genie (A Terex Brand) in June 2015 under part number 77810, Revision E29, it is the reference used to identify, order and verify every replaceable component on these machines – from a single decal or o-ring up to a complete boom tube assembly or turntable rotator. The file is delivered as an instant-download PDF, no shipping required.

File Details

• Manual type: Parts Manual
• Brand: Genie (A Terex Brand)
• Models: S-80, S-85
• Serial number range: from SN 3082 to 7999
• Part number: 77810
• Revision: Rev E29
• Publication date: June 2015
• Language: English
• Page count: 266 pages
• File format: PDF
• Manufacturer: Terex South Dakota, Inc., 18340 NE 76th Street, Redmond, WA 98052, USA

Chapters Covered

• 100 Decals
• 200 Drive Chassis Components
• 300 Turntable Components
• 400 Engine Components
• 500 Boom Components
• 600 Platform Components
• 700 Hydraulic Components
• 800 Accessories
• Indices
• Required Parts, Recommended Parts and Manuals
• How To Order Parts

100 Decals

Two full decal groups are broken out with their own exploded illustrations and itemised tables: Decals with Words (101.1) and Decals with Symbols (102.1). Each entry lists the part number, description and quantity per machine, including warning, danger, instruction and cosmetic decals for the tank side, drive chassis, engine side and platform. Shading conventions in the diagrams indicate decals hidden under covers, so you can locate a faded or missing warning label exactly where it belongs. Decal kits such as 102435, 102443 and 111323 are listed with the specific item numbers they contain.

200 Drive Chassis Components

Covers the complete drive chassis and axle assemblies for both 2WD and 4WD configurations. Subsections include the 2WD Steer Axle Linkage (201.1), Extendable Steer Axle Installation (202.1), 2WD Steer Axle, Wheel and Hubs (203.1), Non-steer Axle – Wheels and Hubs (204.1), Extendable Non-steer Axle Installation (205.1), 4WD Steer Axle Linkage (206.1) and 4WD Steer Axle – Wheel and Hubs (207.1). Tie rod cylinders, steer cylinders, axle extension cylinders, counterbalance valves, seal kits, wear pads, shims, bearings, hubs, wheel drives, brake discs and drive motors are all itemised, with serial-number breakpoints noted where a component changed mid-production.

300 Turntable Components

This chapter splits hydraulic and fuel tank configurations by fuel type and serial number: gasoline/LPG to SN 5380 (301.1), gasoline/LPG from SN 5381 (301.2) and diesel models (302.1). It continues with the Function Manifold and Auxiliary Power Unit Installation (303.1), the Turntable Rotator and Hydraulic Rotary Coupler Installation (304.1), two views of the Ground Controls (305.1 and 306.1), and the tank-side, engine-side and centre turntable covers (307.1, 308.1, 309.1). Sight gauges, strainers, filler caps, return filters, level sensors, LP tanks, fuel pumps and hoses are all listed alongside the swing drive assembly, counterweight castings and the limit switch hardware.

400 Engine Components

The engine chapter is organised by engine family with serial-number cut-offs, so you order the correct part for the correct build. Groups include Perkins 704-30 (to SN 3737) across four views, Perkins 804D-33 (from SN 3738) across three views, Deutz F4L-913 (to SN 3772) across four views, Deutz BF4L-2011/TD2011-L04i (from SN 3773) across two views, GM 3.0L EFI in two views, and Ford LRG-425 EFI and EFO across four views. Continental TME-27 models are covered in three views. The chapter closes with the shared Engine Tray and Battery section (423.1). Each engine group itemises filters, belts, water pumps, thermostats, alternators, starter motors, injection lines, glow plugs, mufflers, exhaust components, mounts, isolators and the specific brackets and heat shields unique to that engine.

500 Boom Components

Covers the full boom assembly with exploded views: Boom Installation (501.1), Extension Boom in two views (502.1, 503.1), the Extension Cylinder Assembly (504.1), Cable Track Installation (505.1), the Slave Cylinder and Platform Rotator (506.1), and the Jib Boom and Platform Rotator (507.1) with a dedicated Jib Detail (508.1) and Platform Installation (509.1). Boom tubes, wear pads, shims, pins, rod ends, bearings, counterbalance valves, sequence valves, cable track components and limit switch hardware are all listed. The jib detail section notes where the older jib has been superseded and identifies the service kit required for first-time replacement.

600 Platform Components

Platform assemblies are listed by size (4 ft, 5 ft, 6 ft, 8 ft) and by region – USA/Canadian, Australian, European, Asia/South American – with separate word-decal and symbol-decal variants. The platform installation section is followed by dedicated Platform Controls views for the S-80 (602.1, 603.1) and the S-85 (602.1, 603.1), and by two joystick sections split at serial number 5519/5520 (604.1 and 604.2). Control box switches, LED indicator lights, E-stop buttons and boots, alarms, joysticks, service harnesses, PCB assemblies, foot switch kits and platform heater components are all itemised.

700 Hydraulic Components

The largest technical chapter covers the traction, function and accessory manifolds plus the complete hose and fitting schedule. Sections include 2WD Traction Manifold split at SN 3834/3835, 4WD Traction Manifold across three sub-sections including the current replacement manifold 139712, the Axle Select Manifold and Two-Speed/Brake Manifold (703.1), the Function Manifold in two views (704.1, 705.1), the Jib Boom and Platform Rotator Manifolds (706.1) and Pumps (707.1). The hose and fitting drawings then break the machine into four circuits – steer and axle extension (708.1), drive system to SN 3834 (709.1) and from SN 3835 (709.2), turntable components (710.1), and the boom (711.1 and 712.1) – with every hose assembly, adapter, union, tee and bulkhead fitting numbered against the schematic. Individual relief valves, flow dividers, check valves, shuttle valves, proportional solenoids, coils and seal kits are listed with their circuit function.

800 Accessories

Twenty-one accessory sections cover the options fitted to these machines: Alarm and Beacon Package and Driving Lights (801.1), Platform Options (802.1), Ground and Platform Control Box Covers (803.1), the full Hostile Environment Package across boom, turntable, engine air cleaner and cylinder bellows sections (804.1 through 807.1), Panel Cradle Option (808.1), Platform Overload Option (809.1), the Belt-driven Generator Option in two views (810.1, 811.1), Air Line to Platform (812.1), the three-part Welder Option (813.1 to 815.1), the Hydraulic Generator Option for Continental TME-27 engines (816.1, 817.1), Cold Start Package and Full Gauge Option (818.1), Hydraulic Oil Cooler Option (819.1), Half-Mesh and Pipe Cradle Option (820.1) and the Operator Protection Structure (821.1).

Reference Sections

Front matter includes a Required Parts list giving the air, fuel, oil and water-separator filter numbers and v-belt part numbers per engine family, a Recommended Parts list for Genie Blue and Genie Gray paint in gallon and aerosol form, and a Manuals table cross-referencing the correct operator’s and service manuals for the same serial ranges. At the back there is a numeric Part Number Index listing every part in the manual with the page it appears on, an alphabetical Part Description Index, and a Fitting Cross References section.

Why This Genie S-80 / S-85 Parts Manual Matters

Ordering the wrong part on a boom lift is expensive and slow. Genie changed components mid-production repeatedly on the S-80 and S-85 – the Perkins 704-30 gave way to the 804D-33 at SN 3738, the Deutz F4L-913 was replaced by the BF4L-2011/TD2011-L04i at SN 3773, the 4WD traction manifold was superseded twice, and the platform joysticks changed design at SN 5520. The 77810 parts manual records each of those breakpoints and tells you exactly which variant applies to your machine. Whether you are rebuilding a steer cylinder, replacing a swing drive friction disc, chasing a leaking hydraulic hose on the boom, sourcing the correct decal kit for a re-certification, or simply matching a filter number before a service, this catalog gives you the part number, quantity and location on the machine.

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Instant PDF Delivery

This Genie S-80 S-85 parts catalog is supplied as a downloadable PDF that opens on any laptop, tablet or smartphone. There is no physical book to wait for and nothing to pay for shipping. Print the specific exploded view or parts table you need for the job and take it into the workshop, or search the file on screen while you are standing at the machine. Because the entire 266-page manual is delivered in one file, you have the complete decal list, chassis, turntable, engine, boom, platform, hydraulic and accessory sections available whenever a part has to be identified or ordered.