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Genie S-80 S-85 Service Manual 77832 – PDF DOWNLOAD
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Description
Genie S-80 S-85 Service Manual 77832 – PDF DOWNLOAD
Language : English
Pages : 295
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 S-85 Service Manual 77832 – 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 Manifold Component Specifications........................................................................ 21 GM 3.0L EFI Engine....................................................................................... 22 Deutz F4L 913 Engine..................................................................................... 23 Perkins 704-30 Engine.................................................................................... 24 Machine Torque Specifications............................................................................ 25 Hydraulic Hose and Fitting Torque Specifications......................................................... 26 SAE and Metric Fastener Torque Chart..................................................................... 27 Scheduled Maintenance Procedures............................................................................. 29 Pre-delivery Preparation................................................................................. 31 Maintenance Inspection Report............................................................................ 33 Checklist A Procedures................................................................................... 35 A-1 Perform Pre-operation Inspection................................................................. 35 A-2 Perform Function Tests........................................................................... 35 A-3 Perform Engine Maintenance- All Models........................................................... 36 A-4 Check the Hydraulic Filter Condition Indicators.................................................. 37 A-5 Test the Oscillate Axle.......................................................................... 38 A-6 Test the Extendable Axles........................................................................ 38 A-7 Perform 30 Day Service........................................................................... 39 A-8 Perform Engine Maintenance- Deutz Models......................................................... 40 A-9 Inspect the Fuel Filter/Water Separator - Deutz and Perkins Models............................... 40 A-10 Grease the Turntable Rotation Bearing and Rotate Gear........................................... 41 A-11 Perform Engine Maintenance- All Models.......................................................... 42 A-12 Perform Engine Maintenance- Deutz Models........................................................ 43 A-13 Replace the Drive Hub Oil....................................................................... 43 A-14 Perform Engine Maintenance - GM and Perkins Models.............................................. 45 Checklist B Procedures................................................................................... 46 B-1 Inspect the Battery(s)........................................................................... 46 B-2 Inspect the Electrical Wiring.................................................................... 47 B-3 Test the Key Switch.............................................................................. 49 B-4 Check the Exhaust System......................................................................... 49 B-5 Inspect the Engine Air Filter.................................................................... 50 B-6 Check the Engine Oil Cooler and Cooling Fins - Deutz Models...................................... 51 B-7 Confirm the Proper Brake Configuration........................................................... 52 B-8 Inspect the Tires, Wheels and Lug Nut Torque..................................................... 53 B-9 Check the Drive Hub Oil Level and Fastener Torque................................................ 54 B-10 Check and Adjust the Engine RPM................................................................. 55 B-11 Perform Engine Maintenance- All Models.......................................................... 57 B-12 Check the Oscillate Directional Valve Linkage................................................... 58 B-13 Test the Ground Control Override................................................................ 58 B-14 Test the Platform Self-leveling................................................................. 59 B-15 Test the Engine Idle Select Operation........................................................... 59 B-16 Test the Fuel Select Operation - GM Models...................................................... 60 B-17 Test the Drive Enable System.................................................................... 61 B-18 Test the Drive Brakes........................................................................... 62 B-19 Test the Drive Speed - Stowed Position.......................................................... 63 B-20 Test the Drive Speed - Raised or Extended Position.............................................. 63 B-21 Test the Alarm Package (if equipped)............................................................ 64 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System.......................................... 65 B-23 Perform Hydraulic Oil Analysis.................................................................. 66 B-24 Perform Engine Maintenance - GM Models.......................................................... 67 Checklist C Procedures................................................................................... 68 C-1 Perform Engine Maintenance - Deutz and Perkins Models............................................ 68 C-2 Grease the Platform Overload Mechanism (if equipped)............................................. 69 C-3 Test the Platform Overload System (if equipped).................................................. 69 C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models................................. 72 C-5 Replace the Fuel Filter/Water Separator - Diesel Models.......................................... 72 C-6 Perform Engine Maintenance - GM Models........................................................... 74 Checklist D Procedures................................................................................... 75 D-1 Check the Boom Wear Pads......................................................................... 75 D-2 Check the Extendable Axle Wear Pads.............................................................. 76 D-3 Check the Free-wheel Configuration............................................................... 77 D-4 Check the Turntable Rotation Bearing Bolts....................................................... 78 D-5 Inspect for Turntable Bearing Wear............................................................... 79 D-6 Perform Engine Maintenance - Deutz and Perkins Models............................................ 81 D-7 Replace the Hydaulic Filter Elements............................................................. 82 D-8 Replace the Drive Hub Oil........................................................................ 83 D-9 Perform Engine Maintenance - Deutz Models........................................................ 85 Checklist E Procedures................................................................................... 86 E-1 Test or Replace the Hydraulic Oil................................................................ 86 E-2 Perform Engine Maintenance - Perkins Models...................................................... 88 E-3 Grease the Steer Axle Wheel Bearings - 2WD Models................................................ 88 E-4 Perform Engine Maintenance - Deutz and Perkins Models............................................ 90 Repair Procedures............................................................................................ 93 Platform Controls........................................................................................ 94 1-1 ALC-500 Circuit Board............................................................................ 94 1-2 Joysticks........................................................................................ 95 Platform Components......................................................................................100 2-1 Platform.........................................................................................100 2-2 Platform Leveling Slave Cylinder.................................................................101 2-3 Platform Rotator.................................................................................102 2-4 Platform Overload System.........................................................................105 Jib Boom Components, S-85................................................................................108 3-1 Jib Boom.........................................................................................108 3-2 Jib Boom Lift Cylinder...........................................................................109 Boom Components..........................................................................................110 4-1 Cable Track......................................................................................110 4-2 Boom.............................................................................................113 4-3 Boom Lift Cylinder...............................................................................116 4-4 Extension Cylinders..............................................................................118 4-5 Platform Leveling Master Cylinder................................................................120 Turntable Covers.........................................................................................121 5-1 Turntable Covers.................................................................................121 Engines..................................................................................................122 6-1 RPM Adjustment...................................................................................122 6-2 Flex Plate.......................................................................................122 6-3 Engine Fault Codes - GM Models...................................................................126 Ground Controls..........................................................................................127 7-1 Control Relays...................................................................................127 7-2 Power Relay......................................................................................128 7-3 Terminal Strip...................................................................................129 Hydraulic Pumps..........................................................................................130 8-1 Function Pump....................................................................................130 8-2 Drive Pump.......................................................................................131 Manifolds................................................................................................133 9-1 Function Manifold Components - View 1............................................................133 9-2 Function Manifold Components - View 2............................................................137 9-3 Valve Adjustments - Function Manifold............................................................139 9-4 Turntable Rotation Manifold Components...........................................................141 9-5 Brake/Two-speed Manifold Components..............................................................142 9-6 Jib Boom Select Manifold Components, S-85........................................................143 9-7 Axle Select Manifold Components..................................................................145 9-8 2WD Traction Manifold Components.................................................................147 9-9 4WD Traction Manifold Components.................................................................149 9-10 Valve Adjustments - Traction Manifold...........................................................151 9-11 Valve Coils.....................................................................................152 Fuel and Hydraulic Tanks.................................................................................154 10-1 Fuel Tank.......................................................................................154 10-2 Hydraulic Tank..................................................................................155 Turntable Rotation Components............................................................................157 11-1 Turntable Rotation Drive Hub Assembly...........................................................157 2WD Steer Axle Components................................................................................160 12-1 Yoke and Hub....................................................................................160 12-2 Steer Cylinder..................................................................................161 12-3 Tie Rod Cylinder................................................................................162 4WD Steer Axle Components................................................................................164 13-1 Yoke and Drive Hub..............................................................................164 13-2 Drive Motor.....................................................................................165 13-3 Drive Hub.......................................................................................166 13-4 Steer Cylinders.................................................................................166 13-5 Tie Rod Cylinder................................................................................167 Non-steer Axle Components................................................................................168 14-1 Drive Motor.....................................................................................168 14-2 Drive Hub.......................................................................................168 Oscillating Axle Components..............................................................................169 15-1 Oscillate Axle Cylinders........................................................................169 15-2 Valve Adjustments - Oscillate Directional Valve.................................................170 Extendable Axle Components...............................................................................172 16-1 Extendable Axles................................................................................172 16-2 Axle Extension Cylinder.........................................................................174 Fault Codes..................................................................................................177 Fault Codes - Controls System ...........................................................................178 Fault Code Chart.........................................................................................179 Schematics...................................................................................................183 Electrical Symbols Legend................................................................................184 Hydraulic Symbols Legend.................................................................................185 Connector Pin Legend.....................................................................................188 GM 3.0L Engine Wiring Harness............................................................................189 Ground Control Box Wiring Diagram, S-80, Deutz F4L 913 Models (before serial number 3577)................192 Platform Control Box Wiring Diagram, S-80, Deutz F4L 913 Models (before serial number 3577)..............193 Electrical Schematic, S-80, Deutz F4L 913 (after serial number 3576).....................................196 Electrical Schematic, S-80, CE Models, Deutz F4L 913 (after serial number 3576)..........................200 Ground Control Box Wiring Diagram, S-80, Deutz F4L 913 Models (after serial number 3576).................204 Platform Control Box Wiring Diagram, S-80, Deutz F4L 913 Models (after serial number 3576)...............205 Ground Control Box Wiring Diagram, S-80, CE Models (after serial number 3576)............................208 Platform Control Box Wiring Diagram, S-80, CE Models (after serial number 3576)..........................209 Ground Control Box Wiring Diagram, S-80, GM 3.0L Models (before serial number 3577)......................212 Platform Control Box Wiring Diagram, S-80, GM 3.0L Models (before serial number 3577)....................213 Electrical Schematic, S--80, GM 3.0L Models (after serial number 3576)...................................216 Ground Control Box Wiring Diagram, S-80, GM 3.0L Models (after serial number 3576).......................220 Platform Control Box Wiring Diagram, S-80, GM 3.0L Models (after serial number 3576).....................221 Ground Control Box Wiring Diagram, S-80, Perkins 704-30 Models (before serial number 3577)...............224 Platform Control Box Wiring Diagram, S-80, Perkins 704-30 Models (before serial number 3577).............225 Electrical Schematic, S-80, Perkins 704-30 Models (after serial number 3576).............................228 Ground Control Box Wiring Diagram, S-80, Perkins 704-30 Models (after serial number 3576)................232 Platform Control Box Wiring Diagram, S-80, Perkins 704-30 Models (after serial number 3576)..............233 Ground Control Box Wiring Diagram, S-85, Deutz F4L 913 Models (before serial number 3577)................236 Platform Control Box Wiring Diagram, S-85, Deutz F4L 913 Models (before serial number 3577)..............237 Electrical Schematic, S-85, Deutz F4L 913 Models (after serial number 3576)..............................240 Electrical Schematic, S-85, CE Models, Deutz F4L 913 Models (after serial number 3576)...................244 Ground Control Box Wiring Diagram, S-85, Deutz F4L 913 Models (after serial number 3576).................248 Platform Control Box Wiring Diagram, S-85, Deutz F4L 913 Models (after serial number 3576)...............249 Ground Control Box Wiring Diagram, S-85, CE Models, Deutz F4L 913 Models (after serial number 3576)......252 Platform Control Box Wiring Diagram, S-85, CE Models, Deutz F4L 913 Models (after serial number 3576)....253 Ground Control Box Wiring Diagram, S-85, GM 3.0L Models (before serial number 3577)......................256 Platform Control Box Wiring Diagram, S-85, GM 3.0L Models (before serial number 3577)....................257 Electrical Schematic, S-85, GM 3.0L Models (after serial number 3576)....................................260 Ground Control Box Wiring Diagram, S-85, GM 3.0L Models (after serial number 3576).......................264 Platform Control Box Wiring Diagram, S-85, GM 3.0L Models (after serial number 3576).....................265 Ground Control Box Wiring Diagram, S-85, Perkins 704-30 Models (before serial number 3577)...............268 Platform Control Box Wiring Diagram, S-85, Perkins 704-30 Models (before serial number 3577).............269 Electrical Schematic, S-85, Perkins 704-30 Models (after serial number 3576).............................272 Ground Control Box Wiring Diagram, S-85, Perkins 704-30 Models (after serial number 3576)................276 Platform Control Box Wiring Diagram, S-85, Perkins 704-30 Models (after serial number 3576)..............277 Dual Battery Option......................................................................................279 Hydraulic Schematic, 2WD Models (before serial number 3583) .............................................282 Hydraulic Schematic, 4WD Models (before serial number 3583).............................................283 Hydaulic Schematic, 2WD Models (after serial number 3582) ...............................................286 Hydraulic Schematic 4WD Models (after serial number 3582) ...............................................287 Electrical Schematic, S-80, Deutz F4L 913 Models (before serial number 3577).............................290 Electrical Schematic, S-80, GM 3.0L Models (before serial number 3577)...................................291 Electrical Schematic, S-80, Perkins 704-30 Models (before serial number 3577)............................292 Electrical Schematic, S-85, Deutz F4L 913 Models (before serial number 3618).............................293 Electrical Schematic, S-85, GM 3.0L Models (before serial number 3577)...................................294 Electrical Schematic, S-85, Perkins 704-30 Models (before serial number 3577)............................295 Back Cover...................................................................................................289 Return to Index.............................................................................................. 0
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