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Genie S-80 S-85 S-80X Service & Repair Manual 1269074 – PDF DOWNLOAD
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Genie S-80 S-85 S-80X Service & Repair Manual 1269074 – PDF DOWNLOAD
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Description
Genie S-80 S-85 S-80X Service & Repair Manual 1269074 – PDF DOWNLOAD
Language : English
Pages : 301
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 S-80X Service & Repair Manual 1269074 – PDF DOWNLOAD
Front Cover.......................................................................................... 1 Important Information................................................................................ 2 Find a Manual for this Model......................................................................... 2 Revision History..................................................................................... 3 Serial Number Legend................................................................................. 4 General Safety Rules................................................................................. 5 Table of Contents.................................................................................... 7 Specifications....................................................................................... 15 Machine Specifications........................................................................... 15 Performance Specifications....................................................................... 16 Hydraulic Oil Specifications..................................................................... 16 Hydraulic Component Specifications............................................................... 19 Manifold Component Specifications................................................................ 20 Continental TME27 Engine Specifications.......................................................... 21 Deutz TD2011L04i Engine Specifications........................................................... 22 Deutz TD 2.9 Engine Specifications............................................................... 23 Perkins 804D-33 Engine Specifications............................................................ 24 Perkins 404F-22T Engine Specifications........................................................... 25 Machine Torque Specifications.................................................................... 26 Hydraulic Hose and Fitting Torque Specifications................................................. 27 Torque Procedure................................................................................. 28 Repair Procedures.................................................................................... 30 Introduction..................................................................................... 30 Platform Controls................................................................................ 32 1-1 ALC-500 Circuit Board.................................................................... 32 How to Remove the ALC-500 Circuit Board.................................................. 32 1-2 Joysticks................................................................................ 33 How to Adjust the Joystick Max-out Setting............................................... 33 How to Adjust the Joystick Ramp Rate Setting............................................. 34 How to Adjust the Joystick Threshold Setting............................................. 36 How to Calibrate the Boom Angle Sensor................................................... 37 Platform Components.............................................................................. 38 2-1 Platform................................................................................. 38 2-2 Platform Leveling Slave Cylinder......................................................... 39 How to Remove the Platform Leveling Slave Cylinder....................................... 39 How to Bleed the Slave Cylinder.......................................................... 39 2-3 Platform Rotator......................................................................... 40 How to Remove the Platform Rotator....................................................... 40 How to Bleed the Platform Rotator........................................................ 41 2-4 Platform Overload System................................................................. 42 Jib Boom Components.............................................................................. 45 3-1 Jib Boom................................................................................. 45 3-2 Jib Boom Lift Cylinder................................................................... 46 Boom Components.................................................................................. 47 4-1 Cable Track.............................................................................. 47 How to Remove the Cable Track, S-80...................................................... 47 How to Repair the Cable Track............................................................ 49 4-2 Boom..................................................................................... 49 How to Shim the Boom..................................................................... 49 How to Remove the Boom................................................................... 50 4-3 Boom Lift Cylinder....................................................................... 52 4-4 Boom Extension Cylinder.................................................................. 54 4-5 Boom Extend/Retract Cables............................................................... 56 How to Adjust the Extend/Retract Cables.................................................. 56 How to Replace the Boom Extend/Retract Cables............................................ 58 4-6 Platform Leveling Master Cylinder........................................................ 60 4-7 Primary Boom Angle Sensor, S-80X......................................................... 61 Engines.......................................................................................... 63 5-1 RPM Adjustment........................................................................... 63 5-2 Flex Plate............................................................................... 63 How to Remove the Flex Plate............................................................. 63 How to Install the Flex Plate............................................................ 66 How to install the Pump and Bell Housing Assembly........................................ 67 Ground Controls.................................................................................. 68 6-1 Control Relays........................................................................... 68 Hydraulic Pumps.................................................................................. 69 7-1 Function Pump............................................................................ 69 7-2 Drive Pump............................................................................... 70 How to Prime the Drive Pump.............................................................. 71 Manifolds........................................................................................ 72 8-1 Function Manifold........................................................................ 72 8-2 Valve Adjustments - Function Manifold.................................................... 74 How to Adjust the System Relief Valve.................................................... 74 How to Adjust the Boom Down Relief Valve................................................. 74 How to Adjust the Boom Extend Relief Valve............................................... 75 8-3 Brake/Two-Speed Manifold Components...................................................... 76 8-4 Turntable Rotation Manifold Components................................................... 77 8-5 Platform Rotate Manifold Components...................................................... 78 8-6 Platform Manifold Components, S-80....................................................... 79 8-7 Platform Manifold Components, S-85....................................................... 80 8-8 2WD Traction Manifold Components......................................................... 81 8-9 4WD Traction Manifold Components......................................................... 82 8-10 Drive Oil Diverter Manifold Components (welder option).................................. 84 8-11 Valve Adjustments - Traction Manifold................................................... 85 8-12 Valve Coils............................................................................. 86 Valve Coil Resistance Specifications..................................................... 86 Fuel and Hydraulic Tanks......................................................................... 88 9-1 Fuel Tank................................................................................ 88 9-2 Hydraulic Tank........................................................................... 89 Turntable Rotation Components.................................................................... 91 10-1 Turntable Rotation Drive Hub Assembly................................................... 91 How to Remove the Turntable Rotation Drive Hub Assembly.................................. 91 How to Remove the Turntable Rotation Hydraulic Motor..................................... 92 How to Adjust the Turntable Rotation Gear Backlash....................................... 93 Steer Axle Components............................................................................ 95 11-1 Yoke and Drive Hub...................................................................... 95 11-2 Drive Motors............................................................................ 96 11-3 Drive Hubs.............................................................................. 96 11-4 Steer Cylinders......................................................................... 97 Non-steer Axle Components........................................................................ 98 12-1 Drive Motor............................................................................. 98 12-2 Drive Hub............................................................................... 98 Oscillating Axle Components...................................................................... 99 13-1 Oscillate Axle Cylinders................................................................ 99 13-2 Oscillate Directional Valve.............................................................100 How to Adjust the Oscillate Relief Valve.................................................100 How to Set Up the Directional Valve Linkage..............................................101 Fault Codes..........................................................................................103 Introduction.....................................................................................103 Control System Fault Codes.......................................................................104 How to Retrieve Control System Fault Codes...................................................104 Control System Fault Codes...................................................................105 Fault Code Display - Deutz and Perkins Models....................................................108 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models..........108 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models....109 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models.....................110 Main Menu Structure - Deutz D 2.9 L4 Models..................................................111 Main Menu Structure - Perkins 404F-22 Models.................................................112 Deutz D 2.9 L4 Engine Fault Codes................................................................113 Perkins 404F-22 Engine Fault Codes...............................................................124 Continental TME27 Engine Fault Codes.............................................................126 How to Retrieve Continental Engine Fault Codes...............................................126 How to Clear Engine Fault Codes from the ECM.................................................126 Continental TME27 Engine Fault Codes.........................................................127 Schematics...........................................................................................132 Introduction.....................................................................................132 Electrical Symbol Legend.........................................................................133 Hydraulic Symbols Legend.........................................................................134 Relay and Fuse Panel Legend - Deutz TD2011L04i...................................................135 Relay and Fuse Panel Legend - Deutz TD2.9 L4.....................................................135 Relay and Fuse Panel Legend - Perkins 404F-22T...................................................135 Relay and Fuse Panel Legend - Perkins 804D-33....................................................136 Relay and Fuse Panel Legend - Continental TME27..................................................136 Connector Pin Legends............................................................................137 Continental TME27 Engine Harness.................................................................142 S-80X Ground Control Box Wiring Diagram..........................................................143 Deutz TD2.9 L4 Engine Harness....................................................................146 Perkins 404F-22T Engine Harness..................................................................147 Electrical Schematics, S-80X – ANSI and CSA Models...............................................149 Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).............................150 Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)...............................154 Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).............................155 Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...........................158 Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA).............................162 Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...........................163 Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)...........................166 Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA).............................170 Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)...........................171 Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)............................174 Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)..............................178 Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)............................179 Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)..........................182 Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)............................186 Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)..........................187 Electrical Schematics, S-80, S-85 – ANSI and CSA Models..........................................189 Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).......................190 Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).........................194 Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).......................195 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).....................198 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).......................202 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).....................203 Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).....................206 Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).......................210 Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA).....................211 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)......................214 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)........................218 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)......................219 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)....................222 Ground Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)......................226 Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)....................227 Electrical Schematics, S-80, S-85 – CE Models....................................................229 Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)...............................230 Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE).................................234 Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)...............................235 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE).............................238 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)...............................242 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).............................243 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)..............................246 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)................................250 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)..............................251 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)............................254 Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)..............................258 Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)............................259 Electrical Schematics, S-80, S-85 – AS Models....................................................261 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS).............................262 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)...............................266 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS).............................267 Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)..............................270 Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)................................274 Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)..............................275 Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)............................278 Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)..............................282 Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)............................283 Schematics - Options.............................................................................285 Continental Options Schematic................................................................286 Deutz and Perkins Options Schematic..........................................................287 Platform Level Cutout, CTE Option............................................................290 12 kW Hydraulic Generator Wiring Diagram.....................................................291 12 kW Hydraulic Generator Electrical Schematic...............................................294 Belt Driven Generator Option.................................................................295 Hydraulic Schematics.............................................................................297 Hydraulic Schematic, 2WD Models..............................................................298 Hydraulic Schematic, 4WD Models..............................................................299 Back Cover...........................................................................................301
S.S 05/24
