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Genie S-80 S-85 S-80X Service Manual 1259369 – PDF DOWNLOAD
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Description
Genie S-80 S-85 S-80X Service Manual 1259369 – PDF DOWNLOAD
Language : English
Pages : 359
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 S-80X Service Manual 1259369 – PDF DOWNLOAD
Front Cover.......................................................................................... 1 Important Information................................................................................ 2 Find a Manual for this Model......................................................................... 2 Revision History..................................................................................... 3 Serial Number Legend................................................................................. 5 General Safety Rules................................................................................. 6 Table of Contents.................................................................................... 8 Specifications....................................................................................... 21 Machine Specifications........................................................................... 21 Performance Specifications....................................................................... 22 Hydraulic Oil Specifications..................................................................... 22 Hydraulic Component Specifications............................................................... 25 Manifold Component Specifications................................................................ 26 Continental TME27 Engine Specifications.......................................................... 27 Deutz TD2011L04i Engine Specifications........................................................... 28 Deutz TD 2.9 Engine Specifications............................................................... 29 Perkins 804D-33 Engine Specifications............................................................ 30 Perkins 404F-22T Engine Specifications........................................................... 31 Machine Torque Specifications.................................................................... 32 Hydraulic Hose and Fitting Torque Specifications................................................. 33 Torque Procedure................................................................................. 34 Scheduled Maintenance Procedures..................................................................... 36 Introduction..................................................................................... 36 Pre-Delivery Preparation Report.................................................................. 39 Maintenance Inspection Report.................................................................... 40 Checklist A Procedures........................................................................... 42 A-1 Inspect the Manuals and Decals........................................................... 42 A-2 Perform Pre-operation Inspection......................................................... 43 A-3 Perform Function Tests................................................................... 43 A-4 Perform Engine Maintenance – Perkins Models.............................................. 44 A-5 Perform Engine Maintenance – Deutz Models................................................ 44 A-6 Perform Engine Maintenance – Continental Models.......................................... 45 A-7 Test the Oscillate Axle.................................................................. 45 A-8 Check the High Pressure Hydraulic Filter Condition Indicator............................. 46 A-9 Perform 30-Day Service.................................................................. 46 A-10 Perform Engine Maintenance – Continental Models......................................... 47 A-11 Perform Engine Maintenance – Continental Models......................................... 47 A-12 Grease the Turntable Rotation Bearing and Rotate Gear................................... 48 A-13 Replace the Drive Hub Oil............................................................... 48 Checklist B Procedures........................................................................... 49 B-1 Inspect the Batteries.................................................................... 49 B-2 Inspect the Electrical Wiring............................................................ 50 B-3 Check the Exhaust System................................................................. 52 B-4 Inspect the Engine Air Filter............................................................ 53 B-5 Perform Engine Maintenance – Continental Models.......................................... 54 B-6 Perform Engine Maintenance – Perkins Models.............................................. 54 B-7 Confirm the Proper Brake Configuration................................................... 55 B-8 Inspect the Tires, Wheels and Lug Nut Torque............................................. 55 B-9 Check the Drive Hub Oil Level and Fastener Torque........................................ 56 B-10 Check the Oscillate Directional Valve Linkage........................................... 57 B-11 Test the Ground Control Override........................................................ 57 B-12 Test the Platform Self-leveling......................................................... 58 B-13 Test the Engine Idle Select............................................................. 58 B-14 Test the Fuel Select Operation - Ford Models............................................ 59 B-15 Test the Drive Brakes................................................................... 60 B-16 Test the Drive Speed - Stowed Position.................................................. 61 B-17 Test the Drive Speed - Raised or Extended Position...................................... 61 B-18 Test the Alarm Package (if equipped) and the Descent Alarm.............................. 62 B-19 Inspect the Fuel and Hydraulic Tank Cap Venting Systems................................. 63 B-20 Perform Hydraulic Oil Analysis.......................................................... 64 B-21 Inspect the Boom Extend/Retract Cables.................................................. 65 B-22 Test the Emergency Power System......................................................... 67 Checklist C Procedures........................................................................... 68 C-1 Perform Engine Maintenance - Continental Models.......................................... 68 C-2 Perform Engine Maintenance - Deutz Models................................................ 68 C-3 Perform Engine Maintenance - Perkins Models.............................................. 69 C-4 Replace the Engine Air Filter Element.................................................... 69 C-5 Check and Adjust the Engine RPM.......................................................... 70 C-6 Grease the Platform Overload Mechanism (if equipped)..................................... 72 C-7 Test the Platform Overload System (If equipped).......................................... 72 C-8 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X......................... 74 Checklist D Procedures........................................................................... 77 D-1 Check the Boom Wear Pads................................................................. 77 D-2 Check the Free-wheel Configuration....................................................... 78 D-3 Check the Turntable Rotation Bearing Bolts............................................... 80 D-4 Inspect for Turntable Bearing Wear....................................................... 81 D-5 Replace the Hydraulic Filters............................................................ 82 D-6 Replace the Drive Hub Oil................................................................ 83 D-7 Perform Engine Maintenance - Continental Models.......................................... 85 D-8 Perform Engine Maintenance - Deutz Models................................................ 85 D-9 Perform Engine Maintenance - Perkins Models.............................................. 86 D-10 Inspect the Boom Extend/Retract Cables.................................................. 86 Checklist E Procedures........................................................................... 88 E-1 Test or Replace the Hydraulic Oil........................................................ 88 E-2 Perform Engine Maintenance - Perkins Models.............................................. 90 E-3 Perform Engine Maintenance - Deutz Models................................................ 90 E-4 Perform Engine Maintenance - Perkins Models.............................................. 91 E-5 Perform Cooling System Maintenance - Perkins 404F Models................................. 91 E-6 Remove and Inspect the Boom Extend/Retract Cables........................................ 92 Cable Replacement Criteria............................................................... 94 Repair Procedures.................................................................................... 95 Introduction..................................................................................... 95 Platform Controls................................................................................ 97 1-1 ALC-500 Circuit Board.................................................................... 97 How to Remove the ALC-500 Circuit Board.................................................. 97 1-2 Joysticks................................................................................ 98 How to Adjust the Joystick Max-out Setting............................................... 99 How to Adjust the Joystick Ramp Rate Setting.............................................100 How to Adjust the Joystick Threshold Setting.............................................101 How to Calibrate the Boom Angle Sensor...................................................102 Platform Components..............................................................................104 2-1 Platform.................................................................................104 2-2 Platform Leveling Slave Cylinder.........................................................105 How to Remove the Platform Leveling Slave Cylinder.......................................105 How to Bleed the Slave Cylinder..........................................................105 2-3 Platform Rotator.........................................................................106 How to Remove the Platform Rotator.......................................................106 How to Bleed the Platform Rotator........................................................107 2-4 Platform Overload System.................................................................108 Jib Boom Components..............................................................................111 3-1 Jib Boom.................................................................................111 3-2 Jib Boom Lift Cylinder...................................................................112 Boom Components..................................................................................113 4-1 Cable Track..............................................................................113 How to Remove the Cable Track, S-80......................................................113 How to Repair the Cable Track............................................................115 4-2 Boom.....................................................................................115 How to Shim the Boom.....................................................................115 How to Remove the Boom...................................................................116 4-3 Boom Lift Cylinder.......................................................................118 4-4 Boom Extension Cylinder..................................................................120 4-5 Boom Extend/Retract Cables...............................................................122 How to Adjust the Extend/Retract Cables..................................................122 How to Replace the Boom Extend/Retract Cables............................................124 4-6 Platform Leveling Master Cylinder........................................................126 Engines..........................................................................................127 5-1 RPM Adjustment...........................................................................127 5-2 Flex Plate...............................................................................127 How to Remove the Flex Plate.............................................................127 How to Install the Flex Plate............................................................130 How to install the Pump and Bell Housing Assembly........................................131 Ground Controls..................................................................................132 6-1 Control Relays...........................................................................132 Hydraulic Pumps..................................................................................133 7-1 Function Pump............................................................................133 7-2 Drive Pump...............................................................................134 How to Prime the Pump....................................................................135 Manifolds........................................................................................136 8-1 Function Manifold........................................................................136 8-2 Valve Adjustments - Function Manifold....................................................138 How to Adjust the System Relief Valve....................................................138 How to Adjust the Boom Down Relief Valve.................................................138 How to Adjust the Boom Extend Relief Valve...............................................139 8-3 Brake/Two-Speed Manifold Components......................................................140 8-4 Turntable Rotation Manifold Components...................................................141 8-5 Platform Rotate Manifold Components......................................................142 8-6 Platform Manifold Components, S-80.......................................................143 8-7 Platform Manifold Components, S-85.......................................................144 8-8 2WD Traction Manifold Components.........................................................145 8-9 4WD Traction Manifold Components.........................................................146 8-10 Drive Oil Diverter Manifold Components (welder option)..................................148 8-11 Valve Adjustments - Traction Manifold...................................................149 8-12 Valve Coils.............................................................................150 Valve Coil Resistance Specifications.....................................................150 Fuel and Hydraulic Tanks.........................................................................152 9-1 Fuel Tank................................................................................152 9-2 Hydraulic Tank...........................................................................153 Turntable Rotation Components....................................................................155 10-1 Turntable Rotation Drive Hub Assembly...................................................155 How to Remove the Turntable Rotation Drive Hub Assembly..................................155 How to Remove the Turntable Rotation Hydraulic Motor.....................................156 How to Adjust the Turntable Rotation Gear Backlash.......................................157 Steer Axle Components............................................................................159 11-1 Yoke and Drive Hub......................................................................159 11-2 Drive Motors............................................................................160 11-3 Drive Hubs..............................................................................160 11-4 Steer Cylinders.........................................................................161 Non-steer Axle Components........................................................................162 12-1 Drive Motor.............................................................................162 12-2 Drive Hub...............................................................................162 Oscillating Axle Components......................................................................163 13-1 Oscillate Axle Cylinders................................................................163 13-2 Oscillate Directional Valve.............................................................164 How to Adjust the Oscillate Relief Valve.................................................164 How to Set Up the Directional Valve Linkage..............................................165 Fault Codes..........................................................................................167 Introduction.....................................................................................167 Control System Fault Codes.......................................................................168 How to Retrieve Control System Fault Codes...................................................168 Control System Fault Codes...................................................................169 Fault Code Display - Deutz and Perkins Models....................................................173 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models..........173 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models....174 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models.....................175 Main Menu Structure - Deutz D 2.9 L4 Models..................................................176 Main Menu Structure - Perkins 404F-22 Models.................................................177 Deutz D 2.9 L4 Engine Fault Codes................................................................178 Perkins 404F-22 Engine Fault Codes...............................................................189 Continental TME27 Engine Fault Codes.............................................................191 How to Retrieve Continental Engine Fault Codes...............................................191 How to Clear Engine Fault Codes from the ECM.................................................191 Continental TME27 Engine Fault Codes.........................................................192 Schematics...........................................................................................198 Introduction.....................................................................................198 Electrical Symbol Legend.........................................................................199 Hydraulic Symbols Legend.........................................................................200 Relay and Fuse Panel Legend - Deutz TD2011L04i...................................................201 Relay and Fuse Panel Legend - Deutz TD2.9 L4.....................................................201 Relay and Fuse Panel Legend - Perkins 404F-22T...................................................201 Relay and Fuse Panel Legend - Perkins 804D-33....................................................202 Relay and Fuse Panel Legend - Continental TME27..................................................202 Connector Pin Legends............................................................................203 Continental TME27 Engine Harness.................................................................208 S-80X Ground Control Box Wiring Diagram..........................................................209 Deutz TD2.9 L4 Engine Harness....................................................................212 Perkins 404F-22T Engine Harness..................................................................213 Electrical Schematics, S-80X – ANSI and CSA Models...............................................215 Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).............................216 Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)...............................220 Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).............................221 Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...........................224 Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA).............................228 Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...........................229 Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)...........................232 Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA).............................236 Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)...........................237 Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)............................240 Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)..............................244 Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)............................245 Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)..........................248 Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)............................252 Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)..........................253 Electrical Schematics, S-80, S-85 – ANSI and CSA Models..........................................255 Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).......................256 Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).........................260 Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).......................261 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).....................264 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).......................268 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).....................269 Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).....................272 Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).......................276 Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).....................277 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)......................280 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)........................284 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)......................285 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)....................288 Ground Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)......................292 Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)....................293 Electrical Schematics, S-80, S-85 – CE Models....................................................295 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE).............................296 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)...............................300 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).............................301 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)..............................304 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)................................308 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)..............................309 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)............................312 Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)..............................316 Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)............................317 Electrical Schematics, S-80, S-85 – AS Models....................................................319 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS).............................320 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)...............................324 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS).............................325 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)..............................328 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)................................332 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)..............................333 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)............................336 Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)..............................340 Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)............................341 Schematics - Options.............................................................................343 Continental Options Schematic................................................................344 Deutz and Perkins Options Schematic..........................................................345 Platform Level Cutout, CTE Option............................................................348 12 kW Hydraulic Generator Wiring Diagram.....................................................349 12 kW Hydraulic Generator Electrical Schematic...............................................352 Belt Driven Generator Option.................................................................353 Hydraulic Schematics.............................................................................355 Hydraulic Schematic, 2WD Models..............................................................356 Hydraulic Schematic, 4WD Models..............................................................357 Back Cover...........................................................................................359
S.S 05/24
