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Genie S-80 S-85 Service Manual 122149 – PDF DOWNLOAD
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Description
Genie S-80 S-85 Service Manual 122149 – PDF DOWNLOAD
Language : English
Pages : 253
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 Service Manual 122149 – PDF DOWNLOAD
Safety Rules..................................................................................... 7 Table of Contents................................................................................ 9 Specifications................................................................................... 19 Machine Specifications....................................................................... 19 Performance Specifications................................................................... 20 Hydraulic Oil Specifications................................................................. 20 Hydraulic Component Specifications........................................................... 21 Valve Coil Resistance Specifications......................................................... 22 Continental TME27 Engine..................................................................... 23 Deutz BF4L-2011 Engine....................................................................... 24 Perkins 804C-33.............................................................................. 26 Machine Torque Specifications................................................................ 27 Manifold Component Specifications............................................................ 27 Hydraulic Hose and Fitting Torque Specifications............................................. 28 SAE and Metric Fastener Torque Chart......................................................... 29 Scheduled Maintenance Procedures................................................................. 31 Pre-delivery Preparation..................................................................... 33 Maintenance Inspection Report................................................................ 35 Checklist A Procedures....................................................................... 37 A-1 Inspect the Manuals and Decals....................................................... 37 A-2 Perform Pre-operation Inspection..................................................... 38 A-3 Perform Function Tests............................................................... 38 A-4 Perform Engine Maintenance........................................................... 39 A-5 Check the Hydraulic Filter Condition Indicators...................................... 40 A-6 Grease the Extendable Axles.......................................................... 41 A-7 Test the Oscillate Axle.............................................................. 41 A-8 Test the Extendable Axles............................................................ 42 A-9 Perform 30 Day Service............................................................... 43 A-10 Perform Engine Maintenance- Deutz and Continental Models............................ 43 A-11 Inspect the Fuel Filter/Water Separator - Deutz and Perkins Models.................. 44 A-12 Grease the Turntable Rotation Bearing and Rotate Gear............................... 45 A-13 Perform Engine Maintenance.......................................................... 45 A-14 Replace the Drive Hub Oil........................................................... 46 A-15 Perform Engine Maintenance - Perkins Models......................................... 48 Checklist B Procedures....................................................................... 49 B-1 Inspect the Battery(s)............................................................... 49 B-2 Inspect the Electrical Wiring........................................................ 50 B-3 Test the Key Switch.................................................................. 52 B-4 Check the Exhaust System............................................................. 52 B-5 Inspect the Engine Air Filter........................................................ 53 B-6 Check the Engine Oil Cooler and Cooling Fins - Deutz Models.......................... 54 B-7 Confirm the Proper Brake Configuration............................................... 55 B-8 Inspect the Tires, Wheels and Lug Nut Torque......................................... 56 B-9 Check the Drive Hub Oil Level and Fastener Torque.................................... 57 B-10 Check and Adjust the Engine RPM..................................................... 58 B-11 Perform Engine Maintenance.......................................................... 60 B-12 Check the Oscillate Directional Valve Linkage....................................... 61 B-13 Test the Ground Control Override.................................................... 61 B-14 Test the Platform Self-leveling..................................................... 62 B-15 Test the Engine Idle Select Operation............................................... 62 B-16 Test the Fuel Select Operation - Gasoline/LPG Models................................ 63 B-17 Test the Drive Enable System........................................................ 64 B-18 Test the Drive Brakes............................................................... 65 B-19 Test the Drive Speed - Stowed Position.............................................. 66 B-20 Test the Drive Speed - Raised or Extended Position.................................. 66 B-21 Test the Alarm Package (if equipped)................................................ 67 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System.............................. 68 B-23 Perform Hydraulic Oil Analysis...................................................... 69 Checklist C Procedures....................................................................... 75 C-1 Perform Engine Maintenance........................................................... 70 C-2 Grease the Platform Overload Mechanism (if equipped)................................. 71 C-3 Test the Platform Overload System (if equipped)...................................... 71 C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models..................... 74 C-5 Replace the Fuel Filter/Water Separator - Diesel Models.............................. 74 Checklist D Procedures....................................................................... 76 D-1 Check the Boom Wear Pads............................................................. 76 D-2 Check the Extendable Axle Wear Pads.................................................. 77 D-3 Check the Free-wheel Configuration................................................... 78 D-4 Check the Turntable Rotation Bearing Bolts........................................... 79 D-5 Inspect for Turntable Bearing Wear................................................... 80 D-6 Perform Engine Maintenance - Deutz and Perkins Models................................ 82 D-7 Replace the Hydaulic Filter Elements................................................. 83 D-8 Replace the Drive Hub Oil............................................................ 84 D-9 Perform Engine Maintenance - Deutz Models............................................ 86 Checklist E Procedures....................................................................... 87 E-1 Test or Replace the Hydraulic Oil.................................................... 87 E-2 Perform Engine Maintenance - Perkins Models.......................................... 89 E-3 Grease the Steer Axle Wheel Bearings - 2WD Models.................................... 89 E-4 Perform Engine Maintenance - Deutz and Perkins Models................................ 91 Repair Procedures................................................................................ 93 Platform Controls............................................................................ 94 1-1 ALC-500 Circuit Board................................................................ 94 1-2 Joysticks............................................................................ 95 Platform Components.......................................................................... 99 2-1 Platform............................................................................. 99 2-2 Platform Leveling Slave Cylinder.....................................................100 2-3 Platform Rotator.....................................................................101 2-4 Platform Overload System.............................................................103 Jib Boom Components, S-85....................................................................106 3-1 Jib Boom.............................................................................106 3-2 Jib Boom Lift Cylinder...............................................................107 Boom Components..............................................................................108 4-1 Cable Track..........................................................................108 4-2 Boom.................................................................................111 4-3 Boom Lift Cylinder...................................................................114 4-4 Extension Cylinders..................................................................116 4-5 Platform Leveling Master Cylinder....................................................118 Engines......................................................................................119 5-1 RPM Adjustment.......................................................................119 5-2 Flex Plate...........................................................................119 Ground Controls..............................................................................124 6-1 Control Relays.......................................................................124 Hydraulic Pumps..............................................................................125 7-1 Function Pump........................................................................125 7-2 Drive Pump...........................................................................126 Manifolds....................................................................................128 8-1 Function Manifold Components - View 1................................................128 8-2 Function Manifold Components - View 2................................................132 8-3 Valve Adjustments - Function Manifold................................................134 8-4 Brake/Two-speed Manifold Components..................................................137 8-5 Turntable Rotation Manifold Components...............................................138 8-6 Jib Boom Select Manifold Components, S-85............................................139 8-7 Axle Select Manifold Components......................................................140 8-8 2WD Traction Manifold Components.....................................................142 8-9 4WD Traction Manifold Components.....................................................144 8-10 Drive Oil Diverter Manifold Components (welder option)..............................146 8-11 Valve Adjustments - Traction Manifold...............................................147 8-12 Valve Coils.........................................................................148 Fuel and Hydraulic Tanks.....................................................................151 9-1 Fuel Tank............................................................................151 9-2 Hydraulic Tank.......................................................................152 Turntable Rotation Components................................................................154 10-1 Turntable Rotation Drive Hub Assembly...............................................154 2WD Steer Axle Components....................................................................157 11-1 Yoke and Hub........................................................................157 11-2 Steer Cylinder......................................................................158 11-3 Tie Rod Cylinder....................................................................159 4WD Steer Axle Components....................................................................160 12-1 Yoke and Drive Hub..................................................................160 12-2 Drive Motor.........................................................................161 12-3 Drive Hub...........................................................................162 12-4 Steer Cylinders.....................................................................162 12-5 Tie Rod Cylinder....................................................................163 Non-steer Axle Components....................................................................164 13-1 Drive Motor.........................................................................164 13-2 Drive Hub...........................................................................164 Oscillating Axle Components..................................................................165 14-1 Oscillate Axle Cylinders............................................................165 14-2 Valve Adjustments - Oscillate Directional Valve.....................................166 Extendable Axle Components...................................................................168 15-1 Extendable Axles....................................................................168 15-2 Axle Extension Cylinder.............................................................170 Fault Codes......................................................................................175 Fault Codes - Controls System ...............................................................176 Engine Fault Codes- Continental Models.......................................................180 Schematics.......................................................................................183 Electrical Symbols Legend....................................................................184 Hydraulic Symbols Legend.....................................................................185 Electrical Schematic, S-80/85, Deutz BF4L-2011 Models (before S/N 5520)......................188 Electrical Schematic, S-80/85, Deutz BF4L-2011 Models (after S/N 5519) ......................192 Ground Control Box Wiring Diagram, S-80/85, Deutz BF4L-2011 Models...........................196 Platform Control Box Wiring Diagram, S-80/85, Deutz BF4L-2011 (before S/N 5520)..............198 Platform Control Box Wiring Diagram, S-80/85, Deutz BF4L-2011 (after S/N 5519)...............199 Electrical Schematic, S-80/85, Perkins 804-33 Models (before S/N 5520) ......................202 Electrical Schematic, S-80/85, Perkins 804-33 Models (after S/N 5519) .......................206 Ground Control Box Wiring Diagram, S-80/85, Perkins 804-33 Models............................210 Platform Control Box Wiring Diagram, S-80/85, Perkins 804-33 Models (before S/N 5520)........212 Platform Control Box Wiring Diagram, S-80/85 , Perkins 804-33 Models (after S/N 5519)........213 Electrical Schematic, S-80/85, Continental TME27 Models (before S/N 5520) ...................216 Electrical Schematic, S-80/85, Continental TME27 Models (after S/N 5519) ...................220 Ground Control Box Wiring Diagram, S-80/85, Continental TME27 Models.........................224 Platform Control Box Wiring Diagram, S-80/85 , Continental TME27 Models (before S/N 5520)....226 Platform Control Box Wiring Diagram, S-80/85, Continental TME27 Models (after S/N 5519) .....227 Continental TME27 Engine Harness.............................................................230 Joystick Wiring Diagram......................................................................231 Connector Pin Legend- Sheet 1................................................................234 Connector Pin Legend- Sheet 2................................................................235 Dual Battery Option..........................................................................238 Belt Drive Generator Option..................................................................239 CE Option....................................................................................242 Platform Level Cutout, CTE Option............................................................243 12 kW Hydraulic Generator Option.............................................................246 Hydraulic Schematic, 12 kW Generator.........................................................247 Hydraulic Schematic, 2WD Models..............................................................250 Hydraulic Schematic, 4WD Models..............................................................251 Return to Index.................................................................................. 9
S.S 05/24
