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Genie S-80 S-85 Service Manual 111165 – PDF DOWNLOAD
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Description
Genie S-80 S-85 Service Manual 111165 – PDF DOWNLOAD
Language : English
Pages : 303
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 Service Manual 111165 – PDF DOWNLOAD
Cover................................................................................................ 1 Introduction......................................................................................... 2 Revision History..................................................................................... 3 Serial Number Legend................................................................................. 5 Safety Rules......................................................................................... 6 Table of Contents.................................................................................... 8 Specifications....................................................................................... 19 Machine Specifications........................................................................... 19 Performance Specifications....................................................................... 19 Hydraulic Specifications......................................................................... 20 Hydraulic Component Specifications............................................................... 20 Valve Coil Resistance Specifications............................................................. 21 GM 3.0L EFI Engine............................................................................... 22 Ford LRG-425 EFI Engine.......................................................................... 23 Deutz F4L 913 Engine............................................................................. 25 Deutz BF4L-2011 Engine........................................................................... 26 Perkins 804C-33.................................................................................. 28 Machine Torque Specifications.................................................................... 29 Manifold Component Specifications................................................................ 29 Hydraulic Hose and Fitting Torque Specifications................................................. 30 SAE and Metric Fastener Torque Chart............................................................. 31 Scheduled Maintenance Procedures..................................................................... 33 Pre-delivery Preparation......................................................................... 35 Maintenance Inspection Report.................................................................... 37 Checklist A Procedures........................................................................... 39 A-1 Inspect the Manuals and Decals........................................................... 39 A-2 Perform Pre-operation Inspection......................................................... 40 A-3 Perform Function Tests................................................................... 40 A-4 Perform Engine Maintenance- All Models................................................... 41 A-5 Check the Hydraulic Filter Condition Indicators.......................................... 42 A-6 Grease the Extendable Axles.............................................................. 43 A-7 Test the Oscillate Axle.................................................................. 43 A-8 Test the Extendable Axles................................................................ 44 A-9 Perform 30 Day Service................................................................... 45 A-10 Perform Engine Maintenance- Deutz Models................................................ 45 A-11 Inspect the Fuel Filter/Water Separator - Deutz and Perkins Models...................... 46 A-12 Grease the Turntable Rotation Bearing and Rotate Gear................................... 47 A-13 Perform Engine Maintenance.............................................................. 47 A-14 Perform Engine Maintenance- Deutz Models................................................ 48 A-15 Replace the Drive Hub Oil............................................................... 49 A-16 Perform Engine Maintenance - GM, Ford and Perkins Models................................ 50 Checklist B Procedures........................................................................... 51 B-1 Inspect the Battery(s)................................................................... 51 B-2 Inspect the Electrical Wiring............................................................ 52 B-3 Test the Key Switch...................................................................... 54 B-4 Check the Exhaust System................................................................. 54 B-5 Inspect the Engine Air Filter............................................................ 55 B-6 Check the Engine Oil Cooler and Cooling Fins - Deutz Models.............................. 56 B-7 Confirm the Proper Brake Configuration................................................... 57 B-8 Inspect the Tires, Wheels and Lug Nut Torque............................................. 58 B-9 Check the Drive Hub Oil Level and Fastener Torque........................................ 59 B-10 Check and Adjust the Engine RPM......................................................... 60 B-11 Perform Engine Maintenance- All Models.................................................. 62 B-12 Check the Oscillate Directional Valve Linkage........................................... 63 B-13 Test the Ground Control Override........................................................ 63 B-14 Test the Platform Self-leveling......................................................... 64 B-15 Test the Engine Idle Select Operation................................................... 64 B-16 Test the Fuel Select Operation - GM Models.............................................. 65 B-17 Test the Drive Enable System............................................................ 66 B-18 Test the Drive Brakes................................................................... 67 B-19 Test the Drive Speed - Stowed Position.................................................. 68 B-20 Test the Drive Speed - Raised or Extended Position...................................... 68 B-21 Test the Alarm Package (if equipped).................................................... 69 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System.................................. 70 B-23 Perform Hydraulic Oil Analysis.......................................................... 71 B-24 Perform Engine Maintenance - GM and Ford Models......................................... 72 Checklist C Procedures........................................................................... 73 C-1 Perform Engine Maintenance - Deutz and Perkins Models.................................... 73 C-2 Grease the Platform Overload Mechanism (if equipped)..................................... 74 C-3 Test the Platform Overload System (if equipped).......................................... 74 C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models......................... 77 C-5 Replace the Fuel Filter/Water Separator - Diesel Models.................................. 77 C-6 Perform Engine Maintenance - GM and Ford Models.......................................... 79 Checklist D Procedures........................................................................... 80 D-1 Check the Boom Wear Pads................................................................. 80 D-2 Check the Extendable Axle Wear Pads...................................................... 81 D-3 Check the Free-wheel Configuration....................................................... 82 D-4 Check the Turntable Rotation Bearing Bolts............................................... 83 D-5 Inspect for Turntable Bearing Wear....................................................... 84 D-6 Perform Engine Maintenance - Deutz and Perkins Models.................................... 86 D-7 Replace the Hydaulic Filter Elements..................................................... 87 D-8 Replace the Drive Hub Oil................................................................ 88 D-9 Perform Engine Maintenance - Deutz Models................................................ 90 Checklist E Procedures........................................................................... 91 E-1 Test or Replace the Hydraulic Oil........................................................ 91 E-2 Perform Engine Maintenance - Perkins Models.............................................. 93 E-3 Grease the Steer Axle Wheel Bearings - 2WD Models........................................ 93 E-4 Perform Engine Maintenance - Deutz and Perkins Models.................................... 95 Repair Procedures.................................................................................... 97 Platform Controls................................................................................ 98 1-1 ALC-500 Circuit Board.................................................................... 98 1-2 Joysticks................................................................................ 99 Platform Components..............................................................................104 2-1 Platform.................................................................................104 2-2 Platform Leveling Slave Cylinder.........................................................105 2-3 Platform Rotator.........................................................................106 2-4 Platform Overload System.................................................................108 Jib Boom Components, S-85........................................................................111 3-1 Jib Boom.................................................................................111 3-2 Jib Boom Lift Cylinder...................................................................112 Boom Components..................................................................................113 4-1 Cable Track..............................................................................113 4-2 Boom.....................................................................................116 4-3 Boom Lift Cylinder.......................................................................119 4-4 Extension Cylinders......................................................................121 4-5 Platform Leveling Master Cylinder........................................................123 Engines..........................................................................................124 5-1 RPM Adjustment...........................................................................124 5-2 Flex Plate...............................................................................124 Ground Controls..................................................................................130 6-1 Control Relays...........................................................................130 6-2 Power Relay..............................................................................131 6-3 Terminal Strip...........................................................................131 Hydraulic Pumps..................................................................................132 7-1 Function Pump............................................................................132 7-2 Drive Pump...............................................................................133 Manifolds........................................................................................135 8-1 Function Manifold Components - View 1....................................................135 8-2 Function Manifold Components - View 2....................................................139 8-3 Valve Adjustments - Function Manifold....................................................141 8-4 Brake/Two-speed Manifold Components (from serial number 4436 to 4617 and before 4212)....143 8-5 Brake/Two-speed Manifold Components (from serial number 4212 to 4435 and after 4617).....144 8-6 Turntable Rotation Manifold Components...................................................145 8-7 Jib Boom Select Manifold Components, S-85................................................146 8-8 Axle Select Manifold Components..........................................................147 8-9 2WD Traction Manifold Components (before serial number 3853).............................149 8-10 2WD Traction Manifold Components (after serial number 3852).............................151 8-11 4WD Traction Manifold Components (before serial number 3835)............................153 8-12 4WD Traction Manifold Components (after serial number 3834).............................155 8-13 Drive Oil Diverter Manifold Components (welder option)..................................157 8-14 Valve Adjustments - Traction Manifold...................................................158 8-15 Valve Coils.............................................................................159 Fuel and Hydraulic Tanks.........................................................................162 9-1 Fuel Tank................................................................................162 9-2 Hydraulic Tank...........................................................................163 Turntable Rotation Components....................................................................165 10-1 Turntable Rotation Drive Hub Assembly...................................................165 2WD Steer Axle Components........................................................................168 11-1 Yoke and Hub............................................................................168 11-2 Steer Cylinder..........................................................................169 11-3 Tie Rod Cylinder........................................................................170 4WD Steer Axle Components........................................................................171 12-1 Yoke and Drive Hub......................................................................171 12-2 Drive Motor.............................................................................172 12-3 Drive Hub...............................................................................173 12-4 Steer Cylinders.........................................................................173 12-5 Tie Rod Cylinder........................................................................174 Non-steer Axle Components........................................................................175 13-1 Drive Motor.............................................................................175 13-2 Drive Hub...............................................................................175 Oscillating Axle Components......................................................................176 14-1 Oscillate Axle Cylinders................................................................176 14-2 Valve Adjustments - Oscillate Directional Valve.........................................177 Extendable Axle Components.......................................................................179 15-1 Extendable Axles........................................................................179 15-2 Axle Extension Cylinder.................................................................181 Fault Codes..........................................................................................183 Fault Codes - Controls System ...................................................................184 Engine Fault Codes- GM and Ford Models...........................................................188 Schematics...........................................................................................195 Electrical Symbols Legend........................................................................196 Hydraulic Symbols Legend.........................................................................197 Ford LRG-425 EFI Engine Wiring Harness...........................................................200 GM 3.0L Engine Wiring Harness....................................................................201 Electrical Schematic, S-80, Deutz F4L 913........................................................204 Ground Control Box Wiring Diagram, S-80, Deutz F4L 913 Models....................................208 Platform Control Box Wiring Diagram, S-80, Deutz F4L 913 Models..................................209 Electrical Schematic, S-80, Deutz BF4L-2011 Models...............................................212 Ground Control Box Wiring Diagram, S-80, Deutz BF4L-2011 Models..................................216 Platform Control Box Wiring Diagram, S-80, Deutz BF4L-2011 Models................................217 Electrical Schematic, S-80, GM 3.0L Models.......................................................220 Ground Control Box Wiring Diagram, S-80, GM 3.0L Models..........................................224 Platform Control Box Wiring Diagram, S-80, GM 3.0L Models........................................225 Electrical Schematic, S-80, Perkins 804-33 Models................................................228 Ground Control Box Wiring Diagram, S-80, Perkins 804-33 Models...................................232 Platform Control Box Wiring Diagram, S-80, Perkins 804-33 Models.................................233 Electrical Schematic, S-80, Ford LRG-425 EFI Models..............................................236 Ground Control Box Wiring Diagram, S-80, Ford LRG-425 EFI Models.................................240 Platform Control Box Wiring Diagram, S-80, Ford LRG-425 Models...................................241 Electrical Schematic, S-85, Deutz F4L 913 Models.................................................244 Ground Control Box Wiring Diagram, S-85, Deutz F4L 913 Models....................................248 Platform Control Box Wiring Diagram, S-85, Deutz F4L 913 Models..................................249 Electrical Schematic, S-85, Deutz BF4L 2011 Models...............................................252 Ground Control Box Wiring Diagram, S-85, Deutz BF4L 2011 Models..................................256 Platform Control Box Wiring Diagram, S-85, Deutz BF4L 2011 Models................................257 Electrical Schematic, S-85, GM 3.0L Models.......................................................260 Ground Control Box Wiring Diagram, S-85, GM 3.0L Models..........................................264 Platform Control Box Wiring Diagram, S-85, GM 3.0L Models........................................265 Electrical Schematic, S-85, Perkins 804-33 Models................................................268 Ground Control Box Wiring Diagram, S-85, Perkins 804-33 Models...................................272 Platform Control Box Wiring Diagram, S-85, Perkins 804-33 Models.................................273 Electrical Schematic, S-85, Ford LRG-425 EFI Models..............................................276 Ground Control Box Wiring Diagram, S-85, Ford LRG-425 EFI Models.................................280 Platform Control Box Wiring Diagram, S-85, Ford LRG-425 EFI Models...............................281 Connector Pin Legend- View 1.....................................................................284 Connector Pin Legend- View 2.....................................................................285 Dual Battery Option..............................................................................288 Belt Drive Generator Option......................................................................289 CE Option........................................................................................292 Platform Level Cutout, CTE Option................................................................293 12 kW Hydraulic Generator Wiring Diagram.........................................................296 12 kW Hydraulic Generator Option.................................................................297 Hydraulic Schematic, 2WD Models..................................................................300 Hydraulic Schematic, 4WD Models..................................................................301 Back Cover...........................................................................................303 Return to Index...................................................................................... 0
S.S 05/24
