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Genie S-80 S-85 Service Manual 72062 – PDF DOWNLOAD
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Genie S-80 S-85 Service Manual 72062 – PDF DOWNLOAD
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Description
Genie S-80 S-85 Service Manual 72062 – PDF DOWNLOAD
Language : English
Pages : 286
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 Service Manual 72062 – PDF DOWNLOAD
Front Cover............................................................................ 1 Safety Rules........................................................................... 3 Table of Contents...................................................................... 5 Section Two Specifications............................................................. 17 Machine Specifications............................................................. 17 Performance Specifications......................................................... 18 Hydraulic Specifications........................................................... 19 Ford LRG-425 Engine Specifications................................................. 20 Deutz F4L 1011F Engine Specifications.............................................. 21 Perkins 704-30 Engine Specifications............................................... 22 Hydraulic Hose and Fitting Torque Specifications................................... 23 Section Three Theory of Operation...................................................... 25 Power Source....................................................................... 25 Hydraulic System................................................................... 25 Electrical System.................................................................. 25 Limit Switches..................................................................... 26 Machine Controls................................................................... 26 Scheduled Section Four Maintenance Procedures.......................................... 27 Maintenance Inspection Report...................................................... 29 Table A Procedures................................................................. 31 A-1 Inspect the Operators and Safety Manuals................................... 31 A-2 Inspect the Decals and Placards............................................ 31 A-3 Inspect for Damage and Loose and Missing Parts............................. 32 A-4 Check the Engine Oil Level................................................. 33 A-5 Check the Engine Coolant Level - Liquid Cooled Models...................... 34 A-6 Check for Fuel Leaks....................................................... 34 A-7 Check the Hydraulic Oil Level.............................................. 35 A-8 Check for Hydraulic Leaks.................................................. 36 A-9 Check the Tire Pressure.................................................... 36 A-10 Test the Extendable Axles................................................. 37 A-11 Test the Platform and Ground Controls..................................... 38 A-12 Test the Auxiliary Power Operation........................................ 39 A-13 Test the Tilt Sensor...................................................... 40 A-14 Test the Limit Switches................................................... 40 A-15 Drain the Fuel Filter/Water Separator - Diesel Models..................... 43 A-16 Inspect the Engine Air Filter............................................. 45 A-17 Perform 30 Day Service.................................................... 46 A-18 Inspect the Radiator - Liquid Cooled Models............................... 46 A-19 Check the Battery......................................................... 47 A-20 Replace the Engine Oil and Filter - Ford Models........................... 48 A-21 Inspect the Electrical Wiring............................................. 50 A-22 Check the Oil Cooler and Cooling Fins - Deutz Models...................... 51 A-23 Check the Engine Belt - Ford and Perkins Models........................... 52 A-24 Replace the Fuel Filters - Ford Models.................................... 54 Table B Procedures................................................................. 56 B-1 Check the Exhaust System................................................... 56 B-2 Check the Hydraulic Tank Return Filter Condition Indicator................. 57 B-3 Inspect the Tires and Wheels (including lug nut torque).................... 58 B-4 Confirm the Proper Brake Configuration..................................... 59 B-5 Check the Oil Level in the Drive Hubs...................................... 60 B-6 Check and Adjust the Engine RPM............................................ 62 B-7 Test the Key Switch........................................................ 63 B-8 Test the Emergency Stop Buttons............................................ 64 B-9 Test the Ground Control Override........................................... 64 B-10 Test the Platform Self-leveling........................................... 65 B-11 Test the Horn............................................................. 65 B-12 Test the Foot Switch...................................................... 66 B-13 Test the Engine Idle Select Operation..................................... 66 B-14 Test the Fuel Select Operation - Ford Models.............................. 67 B-15 Test the Drive Enable System.............................................. 68 B-16 Test the Drive Brakes..................................................... 69 B-17 Test the Drive Speed - Stowed Position.................................... 70 B-18 Test the Drive Speed - Raised or Extended Position........................ 71 B-19 Test the Alarm Package (if equipped)...................................... 72 B-20 Perform Hydraulic Oil Analysis............................................ 73 B-21 Replace the Hydraulic tank Return Filter.................................. 73 B-22 Replace the Drive Loop Hydraulic Filter................................... 74 B-23 Inspect the Fuel Tank Cap Venting System.................................. 75 B-24 Replace the Engine Air Filter Element..................................... 76 B-25 Replace the Spark Plugs - Ford Models..................................... 77 Table C Procedures................................................................. 78 C-1 Check the Engine Belt - Deutz Models....................................... 78 C-2 Check the Engine Valve Clearances - Deutz Models........................... 79 C-3 Replace the Fuel Filter/Water Separator Element - Perkins Models........... 79 C-4 Replace the Fuel Filter Element - Perkins Models........................... 81 C-5 Replace the Engine Oil and Filter - Perkins Models......................... 82 C-6 Check the Starting Aid - Perkins Models.................................... 83 C-7 Check the Specific Gravity of the Engine Coolant - Liquid Cooled Models.... 84 C-8 Replace the PCV Valve - Ford Models........................................ 85 Table D Procedures................................................................. 86 D-1 Check the Boom Wear Pads................................................... 86 D-2 Check the Extendable Axle Wear Pads........................................ 86 D-3 Check the Free-wheel Configuration......................................... 87 D-4 Check the Turntable Rotation Bearing Bolts................................. 88 D-5 Grease the Turntable Rotation Bearing and Rotate Gear...................... 89 D-6 Replace the Drive Hub Oil.................................................. 90 D-7 Replace the Engine Oil and Filter - Deutz Models........................... 91 D-8 Clean the Fuel Pump Strainer - Deutz Models................................ 93 D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz Models.............. 94 D-10 Change the Fuel Hoses - Deutz Models...................................... 95 D-11 Check the Engine Valve Clearances - Perkins Models........................ 96 D-12 Clean the Engine Breather Assembly - Perkins Models....................... 96 Table E Procedures................................................................. 97 E-1 Test or Replace the Hydraulic Oil.......................................... 97 E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models............ 99 E-3 Change the Fuel Hoses - Ford Models........................................100 E-4 Replace the Engine Air Breather - Perkins Models...........................102 E-5 Grease the Steer Axle Wheel Bearings - 2WD Models..........................102 E-6 Check the Fuel Injectors - Perkins Diesel Models...........................104 Section Five Troubleshooting Flowcharts................................................105 Fault Code Chart...................................................................107 Chart 1 Engine Will Not Crank Over.................................................112 Chart 2 Engine Cranks Over But Will Not Start - Ford Models........................114 Chart 2A Engine Runs While Cranking Then Dies - Ford Models........................116 Chart 3 Engine Cranks Over But Will Not Start - Diesel Models......................117 Chart 4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models.....120 Chart 5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models.....122 Chart 6 Engine High Idle Inoperative - Ford Models.................................123 Chart 7 Engine Low Idle Inoperative - Ford Models..................................124 Chart 8 Engine High Idle Inoperative - Diesel Models...............................125 Chart 9 Engine Low Idle Inoperative - Diesel Models................................127 Chart 10 All Functions Inoperative, Engine Starts and Runs.........................128 Chart 11 All Lift and Steer Functions Inoperative, Drive Functions Operational.....129 Chart 12 Ground Controls Inoperative, Platform Controls Operate Normally...........130 Chart 13 Platform Controls Inoperative, Ground Controls Operate Normally...........131 Chart 14 Boom Up Function Inoperative..............................................132 Chart 15 Boom Down Function Inoperative............................................135 Chart 16 Boom Extend Function Inoperative..........................................138 Chart 17 Boom Retract Function Inoperative.........................................141 Chart 18 Turntable Rotate Left Function Inoperative................................143 Chart 19 Turntable Rotate Right Function Inoperative...............................147 Chart 20 All Platform Leveling Functions Inoperative...............................151 Chart 21 Platform Level Up Function Inoperative....................................152 Chart 22 Platform Level Down Function Inoperative..................................154 Chart 23 Platform Rotate Left Function Inoperative.................................156 Chart 24 Platform Rotate Right Function Inoperative................................158 Chart 25 Jib Boom Up Function Inoperative, S-85 Models.............................160 Chart 26 Jib Boom Down Function Inoperative, S-85 Models...........................162 Chart 27 Drive Chassis Jack Function Inoperative...................................164 Chart 28 Axle Extend/Retract Function Inoperative..................................166 Chart 29 Steer Left Function Inoperative...........................................167 Chart 30 Steer Right Function Inoperative..........................................169 Chart 31 All Drive Functions Inoperative, All Other Functions Operate Normally.....171 Chart 32 Drive Forward or Reverse Function Inoperative.............................174 Chart 33 Traction Function Inoperative.............................................175 Chart 34 Machine Will Not Drive At Full Speed......................................176 Chart 35 Machine Drives At Full Speed With Platform Raised or Extended.............177 Chart 36 Drive Enable System is Malfunctioning.....................................178 Chart 37 Auxiliary Functions Inoperative...........................................179 Section Six Schematics.................................................................181 Electrical Components..............................................................182 Electrical Symbols Legend..........................................................184 Abbreviation Legend................................................................185 Ford LRG-425 EFI Engine Wiring Harness.............................................186 Electrical Schematic - Ford Models.................................................187 Ground Control Box Wiring Diagram - Ford Models....................................189 Platform Control Box Wiring Diagram - Ford Models..................................190 Electrical Schematic - Deutz Models................................................191 Ground Control Box Wiring Diagram - Deutz Models...................................193 Platform Control Box Wiring Diagram - Deutz Models.................................194 Electrical Schematic - Perkins Models..............................................195 Ground Control Box Wiring Diagram - Perkins Models.................................197 Platform Control Box Wiring Diagram - Perkins Models...............................198 Hydraulic Symbols Legend...........................................................199 2WD Hydraulic Schematic............................................................200 4WD Hydraulic Schematic............................................................201 Section Seven Repair Procedures........................................................202 Platform Controls..................................................................203 1-1 Joystick Controllers.......................................................203 1-2 Horsepower Limiter Board...................................................210 1-3 Foot Switch................................................................212 1-4 Toggle Switches............................................................213 Platform Components................................................................214 2-1 Platform...................................................................214 2-2 Platform Leveling Slave Cylinder...........................................214 2-3 Platform Rotator...........................................................216 Jib Boom Components, S-85 Models...................................................219 3-1 Jib Boom...................................................................219 3-2 Jib Boom Lift Cylinder.....................................................220 Boom Components....................................................................222 4-1 Cable Track................................................................222 4-2 Boom.......................................................................225 4-3 Boom Lift Cylinder.........................................................228 4-4 Extension Cylinders........................................................229 4-5 Platform Leveling Master Cylinder..........................................231 Turntable Covers...................................................................232 5-1 Turntable Covers...........................................................232 Deutz F4L 1011F Engine.............................................................233 6-1 RPM Adjustment.............................................................233 6-2 Flex Plate.................................................................233 6-3 Oil Temperature and Oil Pressure Gauges....................................234 Perkins 704-30 Engine..............................................................235 7-1 RPM Adjustment.............................................................235 7-2 Flex Plate.................................................................235 7-3 Coolant Temperature and Oil Pressure Gauges................................236 Ford LRG-425 EFI Engine............................................................237 8-1 Timing Adjustment..........................................................237 8-2 Flex Plate.................................................................237 8-3 Coolant Temperature and Oil Pressure Gauges................................238 Ground Controls....................................................................240 9-1 Control Relays.............................................................240 9-2 Power Relay................................................................241 9-3 Toggle Switches............................................................242 9-4 Wago® Components...........................................................242 9-5 Engine Fault Codes - Ford Models...........................................242 Hydraulic Pumps....................................................................244 10-1 Lift/Steer Pump...........................................................244 10-2 Drive Pump................................................................245 Manifolds..........................................................................247 11-1 Function Manifold Components..............................................247 11-2 Valve Adjustments - Function Manifold.....................................251 11-3 Turntable Rotation Manifold Components....................................253 11-4 Chassis Jack Manifold Components..........................................254 11-5 Axle Extend Dump Manifold Components......................................255 11-6 Steer Manifold Components.................................................256 11-7 2WD Drive Manifold Components.............................................257 11-8 Valve Adjustments, 2WD Drive Manifold.....................................258 11-9 4WD Drive Manifold Components.............................................259 11-10 Valve Adjustments, 4WD Drive Manifold....................................261 11-11 Jib Boom / Platform Rotate Manifold Components, S-85 Models..............262 11-12 Brake/Two Speed Manifold Components......................................263 Fuel and Hydraulic Tanks...........................................................264 12-1 Fuel Tank.................................................................264 12-2 Hydraulic Tank............................................................265 Turntable Rotation Components......................................................268 13-1 Rotation Hydraulic Motor..................................................268 2WD Steering Axle Components.......................................................271 14-1 Yoke and Hub..............................................................271 14-2 Steering Cylinders........................................................273 14-3 Tie Rod Cylinder..........................................................274 4WD Steering Axle Components.......................................................275 15-1 Yoke and Hub..............................................................275 15-2 Steering Cylinders........................................................276 15-3 Tie Rod Cylinder..........................................................276 Extendable Axle Components.........................................................277 16-1 Extendable Axles..........................................................277 16-2 Drive Chassis Lift Jacks..................................................281 16-3 Hydraulic Limit Switches..................................................281 Non-steering Axle Components.......................................................283 17-1 Drive Motor...............................................................283 17-2 Drive Hub.................................................................284 17-3 Wheel Brake...............................................................285 Rear Cover.............................................................................286
S.S 05/24
