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Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1280490 – PDF
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Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1280490 – PDF DOWNLOAD
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Description
Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1280490 – PDF DOWNLOAD
Language : English
Pages : 213
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1280490 – PDF DOWNLOAD
Front Cover...................................................................................................... 1 Important Information............................................................................................ 2 Find a Manual for this Model..................................................................................... 2 Revision History................................................................................................. 3 Serial Number Legend............................................................................................. 4 General Safety Rules............................................................................................. 5 Table of Contents................................................................................................ 7 Specifications................................................................................................... 13 Machine Specifications....................................................................................... 13 Performance Specifications................................................................................... 14 Hydraulic Oil Specifications................................................................................. 14 Hydraulic Component Specifications........................................................................... 17 Manifold Component Specifications............................................................................ 18 Deutz TD2011 L04i Engine Specifications...................................................................... 19 Deutz TCD 2.2 L3 Engine Specifications....................................................................... 20 Deutz TD 2.9 Engine Specifications........................................................................... 21 Perkins 404D-22T Engine Specifications....................................................................... 22 Perkins 404F-E22TA Engine Specifications..................................................................... 23 Machine Torque Specifications................................................................................ 24 Machine Component Weights.................................................................................... 24 Hydraulic Hose and Fitting Torque Specifications............................................................. 25 Torque Procedure............................................................................................. 26 Repair Procedures................................................................................................ 28 Introduction................................................................................................. 28 Control System............................................................................................... 30 1-1 ALC-600 Platform Control Module...................................................................... 30 1-2 ALC-600 Service Mode................................................................................. 30 1-3 Full Machine Calibration............................................................................. 31 1-4 Machine Functions.................................................................................... 32 How to Adjust the Machine Maximum Speed Setting...................................................... 32 How to Adjust the Joystick Ramp Rate Setting......................................................... 33 How to Adjust the Joystick Threshold Setting......................................................... 34 1-5 How to Enter ALC600 Software Update Mode............................................................. 34 1-6 Display Module Menus................................................................................. 35 1-7 How to Replace the Display Controller (DISCON) Module................................................ 40 1-8 How to Replace the Ground Control Overlay............................................................ 41 Platform Components.......................................................................................... 44 2-1 Platform............................................................................................. 44 2-2 Platform Leveling Slave Cylinder..................................................................... 45 How to Remove the Platform Leveling Slave Cylinder................................................... 45 How to Bleed the Slave Cylinder...................................................................... 45 2-3 Platform Rotator..................................................................................... 46 How to Remove the Platform Rotator................................................................... 46 How to Bleed the Platform Rotator.................................................................... 47 2-4 Platform Overload System............................................................................. 48 How to Perform a Zero Load Platform Calibration...................................................... 48 How to Perform a Full Load Platform Calibration...................................................... 49 How to Replace the Platform Overload Load Cell....................................................... 51 Jib Boom Components.......................................................................................... 52 3-1 Jib Boom............................................................................................. 52 3-2 Jib Boom Lift Cylinder............................................................................... 53 Boom Components.............................................................................................. 54 4-1 Cable Track.......................................................................................... 54 How to Remove the Cable Track, S-80.................................................................. 54 How to Repair the Cable Track........................................................................ 56 4-2 Boom................................................................................................. 56 How to Shim the Boom................................................................................. 56 How to Remove the Boom............................................................................... 57 4-3 Boom Lift Cylinder................................................................................... 60 4-4 Boom Extension Cylinder.............................................................................. 61 4-5 Boom Extend/Retract Cables........................................................................... 63 How to Adjust the Extend/Retract Cables.............................................................. 63 How to Replace the Boom Extend/Retract Cables........................................................ 65 4-6 Platform Leveling Master Cylinder.................................................................... 67 4-7 Primary Boom Angle Sensor Calibration................................................................ 68 4-8 Boom Length Sensor................................................................................... 69 Engines...................................................................................................... 70 5-1 RPM Adjustment....................................................................................... 70 5-2 Flex Plate........................................................................................... 70 How to Remove the Flex Plate......................................................................... 70 How to Install the Flex Plate........................................................................ 73 How to install the Pump and Bell Housing Assembly.................................................... 74 _5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3.............................................. 75 Hydraulic Pump............................................................................................... 76 6-1 Function Pump........................................................................................ 76 6-2 Drive Pump........................................................................................... 77 How to Prime the Drive Pump.......................................................................... 78 Manifolds.................................................................................................... 79 7-1 Function Manifold.................................................................................... 79 7-2 Valve Adjustments - Function Manifold................................................................ 81 How to Adjust the System Relief Valve................................................................ 81 How to Adjust the Boom Down Relief Valve............................................................. 81 How to Adjust the Boom Extend Relief Valve........................................................... 82 7-3 Brake/Two-Speed Manifold Components.................................................................. 83 7-4 Turntable Rotation Manifold Components............................................................... 84 7-5 Platform Rotate Manifold Components.................................................................. 85 7-6 Platform Manifold Components, S-80 XC................................................................ 86 7-7 Platform Manifold Components, S-85 XC................................................................ 87 7-8 4WD Traction Manifold Components..................................................................... 89 7-9 Valve Adjustments - Traction Manifold................................................................ 91 7-10 Generator Manifold Components....................................................................... 92 7-11 Valve Coils......................................................................................... 93 Valve Coil Resistance Specifications................................................................. 93 Fuel and Hydraulic Tanks..................................................................................... 95 8-1 Fuel Tank............................................................................................ 95 8-2 Hydraulic Tank....................................................................................... 96 Turntable Rotation Components................................................................................ 98 9-1 Turntable Rotation Drive Hub Assembly................................................................ 98 How to Remove the Turntable Rotation Drive Hub Assembly.............................................. 98 How to Remove the Turntable Rotation Hydraulic Motor................................................. 99 How to Adjust the Turntable Rotation Gear Backlash...................................................100 How to Calibrate the Turntable Tilt Sensor...........................................................101 Steer Axle Components........................................................................................103 10-1 Yoke and Drive Hub..................................................................................103 10-2 Drive Motors........................................................................................104 10-3 Drive Hubs..........................................................................................104 Generators...................................................................................................105 11-1 Hydraulic Generator.................................................................................105 Fault Codes......................................................................................................106 Introduction.................................................................................................106 Control System Fault Codes...................................................................................107 How to Retrieve Control System Fault Codes...............................................................107 Control System Fault Codes - Models with Revision G Software or Lower....................................108 Control System Fault Codes - Models with Revision H Software or Higher...................................125 Engine Fault Codes...........................................................................................142 Deutz TD 2.9 L4 Engine Fault Codes...........................................................................143 Deutz TCD 2.2 L3 Engine Fault Codes..........................................................................154 Perkins 404-22 Engine Fault Codes............................................................................164 GM 3.0L Engine Fault Codes...................................................................................166 Schematics.......................................................................................................171 Introduction.................................................................................................171 Electrical Symbol Legend.....................................................................................172 Hydraulic Symbols Legend.....................................................................................173 Limit Switch Location Legend.................................................................................174 Engine Relay Layout - Deutz TD2.9............................................................................175 Engine Relay Layout - Deutz TD2011L04i.......................................................................176 Engine Relay Layout - Perkins 404D-22T.......................................................................177 Engine Relay Layout - GM 3.0L................................................................................178 Connector Pin Legend.........................................................................................179 Electrical Schematics........................................................................................181 Electrical Schematic, TCON (to Serial number S80XCH-513, S85XCH- 518)....................................182 Electrical Schematic, Platform Controller (to Serial number S80XCH-513, S85XCH- 518).....................183 Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to 1399)..........186 Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)....187 Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400).......190 Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)........191 Electrical Schematic, Deutz TCD 2.2 L3 Engine............................................................194 Electrical Schematic, Deutz TD 2.9 L4 Engine.............................................................198 Electrical Schematic, Deutz TD2011 L04i Engine...........................................................199 Electrical Schematic, Perkins 404D-22T Engine............................................................202 Electrical Schematic, Perkins 404F-E22TA Engine..........................................................203 Electrical Schematic, GM 3.0L Engine.....................................................................206 Electrical Schematic, 12 kW Welder Generator and 3 kW Generator..........................................207 Hydraulic Schematics.........................................................................................209 Hydraulic Schematic, S-80 XC Models......................................................................210 Hydraulic Schematic, S-85 XC Models.....................................................................211 Back Cover.......................................................................................................213
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