Genie S-80 - Service And Repair Manual

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Service and Repair Manual

Serial Number Range

S-80

from S8015-12264 to

S8016H-

13999

from S8515-12264

S8516H-13999

This manual

includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S-85

from S80X15-12264 to

S80X16H-

13999

from S8015D-

101 to

S8016D-339

S-80X

from S80X15D-101 to

S80X16D-

339

from S80H-14000

from S85H-

14000

from S80XH-

14000

from S80D-340

from S85D-

340

from S80XD-

340

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1269074

Rev A3

October 2016

Main Page

Default Chapter2
- October2
- Find a Manual for this Model2
- October4
- Serial Number Legend4
Safety Rules5
- Table of Contents7
Specifications17
- Machine Specifications17
- Performance Specifications18
- Hydraulic Component Specifications21
- Manifold Component Specifications22
- Continental TME27 Engine Specifications23
- Deutz Td2011L04I Engine Specifications24
- Deutz TD 2.9 Engine Specifications25
- Machine Torque Specifications28
- Hydraulic Hose and Fitting Torque Specifications29
- Torque Procedure30
- October31
Repair Procedures32
- Section 3 Repair Procedures32
- About this Section33
Platform Controls34
- ALC-500 Circuit Board34
  - How to Remove the ALC-500 Circuit Board34
- Joysticks35
Platform Components41
- Platform41
  - How to Remove the Platform Leveling Slave Cylinder42
  - How to Bleed the Slave Cylinder42
- Platform Rotator43
  - How to Remove the Platform Rotator43
  - How to Bleed the Platform Rotator44
- Platform Overload System45
Jib Boom Components48
- Jib Boom48
- Jib Boom Lift Cylinder49
Boom Components50
- Cable Track50
  - How to Remove the Cable Track, S-8050
  - How to Repair the Cable Track52
- Boom52
  - How to Shim the Boom52
  - How to Remove the Boom53
- Boom Lift Cylinder55
- Boom Extension Cylinder57
- Boom Extend/Retract Cables59
  - How to Adjust the Extend/Retract Cables59
  - How to Replace the Boom Extend/Retract Cables61
- Platform Leveling Master Cylinder63
- Primary Boom Angle Sensor, S-80X64
Engines66
- RPM Adjustment66
- Flex Plate66
Ground Controls71
- Control Relays71
Hydraulic Pumps72
- Function Pump72
- Drive Pump73
  - How to Prime the Pump74
Manifolds75
- Function Manifold75
- October75
- Valve Adjustments - Function Manifold77
- Brake/Two-Speed Manifold Components79
- Turntable Rotation Manifold Components80
- Platform Rotate Manifold Components81
- Platform Manifold Components, S-8082
- Platform Manifold Components, S-8583
- 2WD Traction Manifold Components84
- 4WD Traction Manifold Components85
- Drive Oil Diverter Manifold Components (Welder Option)87
- Valve Adjustments - Traction Manifold88
- Valve Coils89
  - Valve Coil Resistance Specifications89
Fuel and Hydraulic Tanks91
- Fuel Tank91
- Hydraulic Tank92
- October93
Turntable Rotation Components94
- Turntable Rotation Drive Hub Assembly94
Steer Axle Components98
- Yoke and Drive Hub98
- Drive Motors99
- Drive Hubs99
- Steer Cylinders100
Non-Steer Axle Components101
- Drive Motor101
- Drive Hub101
Oscillating Axle Components102
- Oscillate Axle Cylinders102
- Oscillate Directional Valve103
  - How to Adjust the Oscillate Relief Valve103
  - How to Set up the Directional Valve Linkage104
Fault Codes105
- Section 4 Fault Codes105
Control System Fault Codes106
- How to Retrieve Control System Fault Codes106
- Control System Fault Codes107
Fault Code Display - Deutz and Perkins Models111
- How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models111
- 22 Models111
- Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models113
- October113
- Main Menu Structure - Deutz D 2.9 L4 Models114
- Main Menu Structure - Perkins 404F-22 Models115
Deutz D 2.9 L4 Engine Fault Codes116
Perkins 404F-22 Engine Fault Codes127
Continental TME27 Engine Fault Codes129
- How to Retrieve Continental Engine Fault Codes129
- How to Clear Engine Fault Codes from the ECM129
- Continental TME27 Engine Fault Codes130
- October131
Schematics135
- Section 5 Schematics135
- Electrical Symbol Legend136
- Hydraulic Symbols Legend137
- Relay and Fuse Panel Legend - Deutz Td2011L04I138
- Relay and Fuse Panel Legend - Perkins 804D-33139
- Connector Pin Legends140
- Continental TME27 Engine Harness144
- S-80X Ground Control Box Wiring Diagram146
- Deutz TD2.9 L4 Engine Harness148
- Perkins 404F-22T Engine Harness150
Electrical Schematics, S-80X - ANSI and CSA Models152
Electrical Schematics, S-80, S-85 - ANSI and CSA Models193
- Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)193
- Ground Control Box, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)197
- Platform Control Box, S-80 / S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)200
- Electrical Schematic, S-80 / S-85 - Deutz Td2011L04I Models (ANSI / CSA)201
- Ground Control Box, S-80 / S-85 - Deutz Td2011L04I Models (ANSI / CSA)205
- Platform Control Box, S-80 / S-85 - Deutz Td2011L04I Models (ANSI / CSA)208
- Electrical Schematic, S-80 / S-85 - Perkins 404F-22T Models (ANSI / CSA)209
- Ground Control Box, S-80 / S-85 - Perkins 404F-22T Models (ANSI / CSA)213
- Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models216
- Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)217
- Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)221
- Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (ANSI / CSA)224
- Electrical Schematic, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)225
- Ground Control Box, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)229
- Platform Control Box, S-80 / S-85 - Continental TME27 Models (ANSI / CSA)232
Electrical Schematics, S-80, S-85 - CE Models233
- Electrical Schematic, S-80 / S-85 - Deutz TD2.9 L4 Models (CE)233
- Ground Control Box, S-80 / S-85 Deutz TD2.9 L4 Models (CE)238
- Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)240
- Electrical Schematic, S-80 / S-85 - Deutz Td2011L04I Models (CE)241
- Ground Control Box, S-80 / S-85 - Deutz Td2011L04I Models (CE)245
- Platform Control Box, S-80 / S-85 - Deutz Td2011L04I Models (CE)248
- Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (CE)249
- Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (CE)253
- Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (CE)256
- Electrical Schematic, S-80 / S-85 - Continental TME27 Models (CE)257
- Ground Control Box, S-80 / S-85 - Continental TME27 Models (CE)261
- Platform Control Box, S-80 / S-85 - Continental TME27 Models (CE)264
Electrical Schematics, S-80, S-85 - as Models265
- Electrical Schematic, S-80 / S-85 - Deutz Td2011L04I Models (AS)265
- Ground Control Box, S-80 / S-85 - Deutz Td2011L04I Models (AS)269
- Platform Control Box, S-80 / S-85 - Deutz Td2011L04I Models (AS)272
- Electrical Schematic, S-80 / S-85 - Perkins 804D-33 Models (AS)273
- Ground Control Box, S-80 / S-85 - Perkins 804D-33 Models (AS)277
- Platform Control Box, S-80 / S-85 - Perkins 804D-33 Models (AS)280
- Electrical Schematic, S-80 / S-85 - Continental TME27 Models (AS)281
- Ground Control Box, S-80 / S-85 - Continental TME27 Models (AS)285
- Platform Control Box, S-80 / S-85 - Continental TME27 Models (AS)288
Schematics - Options289
- Continental Options Schematic289
- Deutz and Perkins Options Schematic291
- Platform Level Cutout, CTE Option293
- 12 Kw Hydraulic Generator Wiring Diagram295
- 12 Kw Hydraulic Generator Electrical Schematic297
- Belt Driven Generator Option299
- Hydraulic Schematic, 2WD Models301
Hydraulic Schematics301
- Hydraulic Schematic, 4WD Models303
- October304

Genie S-80 - Service And Repair Manual

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