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Genie S-80 S-85 S-80X Service & Repair Manual 1287339GT – PDF DOWNLOAD
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Genie S-80 S-85 S-80X Service & Repair Manual 1287339GT – PDF DOWNLOAD
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Description
Genie S-80 S-85 S-80X Service & Repair Manual 1287339GT – PDF DOWNLOAD
Language : English
Pages : 277
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 S-80X Service & Repair Manual 1287339GT – PDF DOWNLOAD
Front Cover ................................................................................. 1 Introduction................................................................................. 2 Revision History............................................................................. 3 Serial Number Legend..................................................................... 4 Table of Contents............................................................................ 7 Section 2 Specifications..................................................................... 15 Machine Specifications................................................................... 15 Performance Specifications............................................................... 16 Hydraulic Oil Specifications............................................................. 16 Hydraulic Fluid Temperature Range........................................................ 17 Hydraulic Component Specifications....................................................... 19 Manifold Component Specifications........................................................ 20 Deutz TD2011L04i Engine.................................................................. 21 Deutz TD 2.9 Engine...................................................................... 22 Perkins 404D-22T Engine.................................................................. 23 GM 3.0L Engine........................................................................... 24 Machine Torque Specifications............................................................ 25 Hydraulic Hose and Fitting Torque Specifications......................................... 26 Seal-Lok™ Fittings....................................................................... 26 Section 3 Repair Procedures.................................................................. 29 Platform Controls........................................................................ 31 1-2Joysticks......................................................................... 32 How to Calibrate a Joystick...................................................... 32 How to Adjust the Joystick Max-out Setting....................................... 32 How to Adjust the Joystick Ramp Rate Setting..................................... 33 How to Adjust the Joystick Threshold Setting..................................... 35 How to Calibrate the Boom Angle Sensor........................................... 36 1-1ALC-500 Circuit Board............................................................. 31 How to Remove the ALC-500 Circuit Board.............................................. 31 2-1Platform.............................................................................. 37 2-4Platform Overload System (if equipped)............................................ 41 How to Calibrate the Platform Overload System (if equipped)...................... 41 2-3Platform Rotator.................................................................. 39 How to Remove the Platform Rotator............................................... 39 How to Bleed the Platform Rotator................................................ 40 How to Remove the Platform........................................................... 37 2-2Platform Leveling Cylinder........................................................ 38 How to Remove the Platform Leveling Cylinder......................................... 38 How to Bleed the Slave Cylinder...................................................... 38 3-1Jib Boom.............................................................................. 44 3-2Jib Boom Lift Cylinder............................................................ 45 How to Remove the Jib Boom Lift Cylinder......................................... 45 How to Remove the Jib Boom........................................................... 44 4-1Cable Track........................................................................... 46 How to Remove the Cable Track........................................................ 46 How to Repair the Cable Track........................................................ 48 4-2Boom.................................................................................. 48 How to Shim the Boom................................................................. 48 How to Remove the Boom............................................................... 49 4-3Boom Lift Cylinder................................................................ 51 How to Remove the Boom Lift Cylinder................................................. 51 4-4Boom Extension Cylinder........................................................... 53 How to Remove the Boom Extension Cylinder............................................ 53 4-5 Boom Extend and Retract Cables................................................... 55 How to Adjust the Boom Extend/Retract Cables......................................... 55 How to Replace the Boom Extend/Retract Cables........................................ 57 4-6Platform Leveling Master Cylinder................................................. 59 How to Remove the Platform Leveling Master Cylinder.................................. 59 4-7Primary Boom Angle Sensor......................................................... 60 How to Replace the Primary Boom Angle Sensor......................................... 60 5-1RPM Adjustment........................................................................ 62 5-2Flex Plate............................................................................ 62 How to Remove the Flex Plate......................................................... 62 How to Install the Flex Plate........................................................ 65 How to Install the Pump and Bell Housing Assembly.................................... 66 6-1Control Relays........................................................................ 67 How to Test a Single Pole Double Throw Relay......................................... 67 7-1Function Pump......................................................................... 68 How to Remove the Function Pump...................................................... 68 7-2Drive Pump............................................................................ 69 How to Remove the Drive Pump......................................................... 69 How to Prime the Drive Pump...................................................... 70 8-1Function Manifold Components.......................................................... 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 8-3Brake / Two Speed Manifold Components............................................. 76 8-4Turntable Rotation Manifold Components............................................ 77 8-5Platform Rotate Manifold Components............................................... 78 8-6Platform Manifold Components, S-80................................................ 79 8-7Platform Manifold Components, S-85................................................ 80 8-8Traction Manifold Components, 2WD................................................. 81 8-9Traction Manifold Components, 4WD................................................. 82 8-10Diverter Manifold Components (welder option)..................................... 84 8-11Valve Adjustments - Traction Manifold............................................ 85 How to Adjust the Hot Oil Relief Valve............................................... 85 8-12Valve Coils...................................................................... 86 How to Test a Coil................................................................... 86 Valve Coil Resistance Specification.................................................. 86 How to Test a Coil Diode............................................................. 87 9-1Fuel Tank............................................................................. 88 How to Remove the Fuel Tank.......................................................... 88 9-2Hydraulic Tank........................................................................ 89 How to Remove the Hydraulic Tank..................................................... 89 10-1Turntable 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 11-1Yoke and Drive Hub........................................................... 95 How to Remove the Yoke and Drive Hub Assembly................................ 95 11-2Drive Motors............................................................. 96 How to Remove a Drive Motor.............................................. 96 11-3Drive Hub............................................................ 96 How to Remove a Drive Hub............................................ 96 11-4Steer Cylinders.................................................. 97 How to Remove a Steer Cylinder................................... 97 12-1Drive Motors................................................. 98 How to Remove a Drive Motor.................................. 98 12-2Drive Hub................................................ 98 How to Remove a Drive Hub................................ 98 13-1Oscillating Axle Cylinders........................... 99 How to Remove an Oscillating Axle Cylinder........... 99 13-2Oscillate Directional Valve..............................................100 How to Adjust the Oscillate Relief Valve.................................100 How to Set Up the Directional Valve Linkage..................................101 Section 4 Fault Codes........................................................................103 How to Retrieve Control System Fault Codes...............................................104 How to Retrieve Active Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models....108 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 Section 5 Schematics.........................................................................126 Electrical Symbol Legend.................................................................126 Hydraulic Symbol Legend .................................................................126 S-80X Ground Control Box Wiring Diagram..................................................138 Deutz TD2.9 L4 Engine Harness............................................................139 Electrical Schematic, S-80X..............................................................143 Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).....................142 Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).......................146 Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).....................147 Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...................150 Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA).....................154 Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...................155 Electrical Schematic, S-80X - Perkins 404TD-22 Models (ANSI / CSA)...................158 Ground Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA).....................162 Platform Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA)...................163 Electrical Schematic, S-80X – GM 3.0L Models (ANSI / CSA)............................166 Ground Control Box, S-80X - GM 3.0L Models (ANSI / CSA)..............................170 Platform Control Box, S-80X - GM 3.0L Models (ANSI / CSA)............................171 Electrical Schematics, S80/85- ANSI/CSA .................................................172 Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)...............174 Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).................178 Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)...............179 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).............182 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA)...............186 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA).............187 Electrical Schematic, S-80 • S-85 - Perkins 404TD-22 Models (ANSI / CSA).............190 Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (ANSI / CSA)...............194 Platform Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA)...................195 Electrical Schematic, S-80 • S-85 - GM 3.0L Models (ANSI / CSA)......................198 Ground Control Box, S-80 • S-85 - GM 3.0L Models (ANSI / CSA)........................202 Platform Control Box, S-80 • S-85 - GM 3.0L Models (ANSI / CSA)......................203 Electrical Schematics, S80/85 - CE.......................................................204 Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE).......................206 Ground Control Box, S-80 • S-85 - Deutz TD2.9 Models (CE)...........................210 Platform Control Box, S-80 • S-85 - Deutz TD2.9 Models (CE).........................211 Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE).....................214 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).......................218 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).....................219 Electrical Schematic, S-80 • S-85 - Perkins 404TD-22 Models (CE).....................222 Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (CE).......................226 Platform Control Box, S-80 • S-85 - Perkins 404TD-22 Models (CE).....................227 Electrical Schematic, S-80 • S-85 - GM 3.0L Models (CE)..............................230 Ground Control Box, S-80 • S-85 - GM 3.0L Models (CE)................................234 Platform Control Box, S-80 • S-85 - GM 3.0L Models (CE)..............................235 Electrical Schematics, S80/85 - AS.......................................................236 Deutz TD2011L04i Models (AS).........................................................238 Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS).......................242 Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS).....................243 Electrical Schematic, S-80 • S-85 - Perkins 404TD-22 Models (AS).....................246 Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (AS).......................250 Platform Control Box, S-80 • S-85 - Perkins 404TD-22 Models (AS).....................251 Electrical Schematic, S-80 • S-85 - GM 3.0L Models (AS)..............................254 Ground Control Box, S-80 • S-85 - GM 3.0L Models (AS)................................258 Platform Control Box, S-80 • S-85 - GM 3.0L Models (AS)..............................259 Schematics- Options .....................................................................260 GM 3.0L Options Schematic............................................................262 Deutz and Perkins Options Schematic..................................................263 Platform Level Cutout, CTE Option....................................................266 12 kW Hydraulic Generator Wiring Diagram.............................................267 12 kW Hydraulic Generator Electrical Schematic.......................................270 Belt Driven Generator Option.........................................................271 Hydraulic Schematics ....................................................................271 Hydraulic Schematic, 2WD Models......................................................274 Hydraulic Schematic, 4WD Models......................................................275 Back Cover...................................................................................277 Return to Front Cover ....................................................................... 1
S.S 05/24
