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Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1315679 – PDF DOWNLOAD
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Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1315679 – PDF DOWNLOAD
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Description
Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1315679 – PDF DOWNLOAD
Language : English
Pages : 197
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-80 XC S-80 HF S-85 XC S-85 HF Service & Repair Manual 1315679 – 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 GM 3.0L 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................................................................................ 35 1-6 Display Module Menus.................................................................................................... 36 1-7 How to Replace the Display Controller (DISCON) Module................................................................... 41 1-8 How to Replace the Ground Control Overlay............................................................................... 42 Platform Components............................................................................................................. 45 2-1 Platform................................................................................................................ 45 2-2 Platform Leveling Cylinder.............................................................................................. 46 How to Remove the Platform Leveling Slave Cylinder...................................................................... 46 How to Bleed the Platform Leveling Cylinder............................................................................. 46 2-3 Platform Rotator........................................................................................................ 47 How to Remove the Platform Rotator...................................................................................... 47 How to Bleed the Platform Rotator....................................................................................... 48 2-4 Platform Overload System................................................................................................ 49 How to Perform a Zero Load Platform Calibration......................................................................... 49 How to Perform a Full Load Platform Calibration......................................................................... 50 How to Replace the Platform Overload Load Cell.......................................................................... 52 2-5 Platform Level Sensor................................................................................................... 53 Jib Boom Components............................................................................................................. 54 3-1 Jib Boom................................................................................................................ 54 3-2 Jib Boom Lift Cylinder.................................................................................................. 55 Boom Components................................................................................................................. 56 4-1 Cable Track............................................................................................................. 56 How to Remove the Cable Track, S-80..................................................................................... 56 How to Repair the Cable Track........................................................................................... 58 4-2 Boom.................................................................................................................... 58 How to Shim the Boom.................................................................................................... 58 How to Remove the Boom.................................................................................................. 59 4-3 Boom Lift Cylinder...................................................................................................... 62 4-4 Boom Extension Cylinder................................................................................................. 63 4-5 Boom Extend/Retract Cables.............................................................................................. 65 How to Adjust the Extend/Retract Cables................................................................................. 65 How to Replace the Boom Extend/Retract Cables........................................................................... 67 4-6 Primary Boom Angle Sensor Calibration................................................................................... 69 4-7 Boom Length Sensor...................................................................................................... 70 Engines......................................................................................................................... 71 5-1 RPM Adjustment.......................................................................................................... 71 5-2 Flex Plate.............................................................................................................. 71 How to Remove the Flex Plate............................................................................................ 71 How to Install the Flex Plate........................................................................................... 74 How to install the Pump and Bell Housing Assembly....................................................................... 75 _5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3, TD 2.9 L4 Stage IV Engines..................................... 76 Hydraulic Pump.................................................................................................................. 77 6-1 Function Pump........................................................................................................... 77 6-2 Drive Pump.............................................................................................................. 78 How to Prime the Drive Pump............................................................................................. 79 Manifolds....................................................................................................................... 80 7-1 Function Manifold....................................................................................................... 80 7-2 Valve Adjustments - Function Manifold................................................................................... 82 How to Adjust the System Relief Valve................................................................................... 82 How to Adjust the Boom Down Relief Valve................................................................................ 82 How to Adjust the Boom Extend Relief Valve.............................................................................. 83 7-3 Brake/Two-Speed Manifold Components..................................................................................... 84 7-4 Turntable Rotation Manifold Components.................................................................................. 85 7-5 Platform Rotate Manifold Components..................................................................................... 86 7-6 Platform Manifold Components, S-80 XC, S-80 HF.......................................................................... 87 7-7 Platform Manifold Components, S-85 XC, S-85 HF.......................................................................... 88 7-8 4WD Traction Manifold Components........................................................................................ 90 7-9 Valve Adjustments - Traction Manifold................................................................................... 92 7-10 Generator Manifold Components.......................................................................................... 93 7-11 Valve Coils............................................................................................................ 94 Valve Coil Resistance Specifications.................................................................................... 94 Fuel and Hydraulic Tanks........................................................................................................ 96 8-1 Fuel Tank............................................................................................................... 96 8-2 Hydraulic Tank.......................................................................................................... 97 Turntable Rotation Components................................................................................................... 99 9-1 Turntable Rotation Drive Hub Assembly................................................................................... 99 How to Remove the Turntable Rotation Drive Hub Assembly................................................................. 99 How to Remove the Turntable Rotation Hydraulic Motor....................................................................100 How to Adjust the Turntable Rotation Gear Backlash......................................................................101 How to Calibrate the Turntable Tilt Sensor..............................................................................102 Axle Components.................................................................................................................104 10-1 Yoke and Drive Hub.....................................................................................................104 10-2 Drive Motors...........................................................................................................105 10-3 Drive Hubs.............................................................................................................105 Generators......................................................................................................................106 11-1 Hydraulic Generator....................................................................................................106 Fault Codes.........................................................................................................................108 Introduction....................................................................................................................108 Control System Fault Codes......................................................................................................109 How to Retrieve Control System Fault Codes..................................................................................109 Control System Fault Codes..................................................................................................110 Engine Fault Codes..............................................................................................................128 Deutz TD 2.9 L4 Teir IV Engine Fault Codes......................................................................................129 Deutz TCD 2.2 L3, TD 2.9 L4 Stage IV Engine Fault Codes.........................................................................140 Perkins 404-22 Engine Fault Codes...............................................................................................150 GM 3.0L Engine Fault Codes......................................................................................................152 Schematics..........................................................................................................................157 Introduction....................................................................................................................157 Electrical Symbol Legend........................................................................................................158 Hydraulic Symbols Legend........................................................................................................159 Limit Switch Location Legend....................................................................................................160 Engine Relay Layout - Deutz TD 2.9 L4, TCD 2.2 L3...............................................................................161 Engine Relay Layout - Deutz TD2011L04i..........................................................................................162 Engine Relay Layout - Perkins 404D-22T..........................................................................................163 Engine Relay Layout - GM 3.0L...................................................................................................164 Connector Pin Legend............................................................................................................165 Electrical Schematics...........................................................................................................167 Electrical Schematic, Turntable Controller - Models without Recovery Module (from S80XCH-3101, S85XCH-3091, S85XCD-2002)....168 Electrical Schematic, Turntable Controller - Models with Recovery Module (from S80XCH-3101, S85XCH-3091, S85XCD-2002).......169 Electrical Schematic, Platform Controller (from S80XCH-3101, S85XCH-3091, S85XCD-2002)......................................172 Electrical Schematic, Deutz TCD 2.2 L3 Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..................................173 Electrical Schematic, Deutz TCD 2.2 L3 Tier IV Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..........................176 Electrical Schematic, Deutz TCD 2.2 L3 Stage V Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..........................177 Electrical Schematic, Deutz TD2011 L04i Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002).................................180 Electrical Schematic, Deutz TD 2.9 L4 Tier IV Engine (from S80XCH-3101, S85XCH-3091, SX85XCD-2002)..........................181 Electrical Schematic, Deutz TD 2.9 L4 Stage IV Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..........................184 Electrical Schematic, Deutz TD 2.9 L4 Stage IV Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..........................185 Electrical Schematic, Perkins 404D-22T Engine (from S80XCH-3101, S85XCH-3091, S85XCD-2002)..................................188 Electrical Schematic, GM 3.0 Engine (from S80XCH-3101, S80XCH-3091, S85XCD-2002)............................................189 Electrical Schematic, Generator Options (from S80XCH-3101, S85XCH-3091, S85XCD-2002)........................................192 Hydraulic Schematics............................................................................................................193 Hydraulic Schematic, S-80 XC, S-80 HF Models (from S80XCH-3101).............................................................194 Hydraulic Schematic, S-85 XC, S-85 HF Models (from S85XCH-3091).............................................................195 Back Cover..........................................................................................................................197
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