Genie S-85 - Ground Control Box, S-80 • S-85 - Perkins 804 D-33 Models (AS)

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February 2017 Service Manual

311

Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)

Table of Contents

Introduction2
- Find a Manual for this Model2
- Revision History3
- Serial Number Legend5
Safety Rules6
- Table of Contents8
Specifications21
- Machine Specifications21
- Performance Specifications22
- Hydraulic Oil Specifications22
- Hydraulic Component Specifications25
- Manifold Component Specifications26
- Continental TME27 Engine Specifications27
- Deutz Td2011L04I Engine Specifications28
- Deutz TD 2.9 Engine Specifications29
- Machine Torque Specifications32
- Hydraulic Hose and Fitting Torque Specifications33
- Torque Procedure34
- February35
Scheduled Maintenance Procedures36
- Pre-Delivery Preparation Report39
- Maintenance Inspection Report40
Checklist a Procedures42
- Inspect the Manuals and Decals42
- Perform Pre-Operation Inspection43
- Perform Function Tests43
- A-5 Perform Engine Maintenance – Deutz Models44
- Test the Oscillate Axle45
- Check the High Pressure Hydraulic Filter Condition Indicator46
- Perform 30-Day Service46
- Perform Engine Maintenance - Continental Models47
- Grease the Turntable Rotation Bearing and Rotate Gear48
- Replace the Drive Hub Oil48
Checklist B Procedures49
- Inspect the Batteries49
- Inspect the Electrical Wiring50
- Check the Exhaust System52
- Inspect the Engine Air Filter53
- Perform Engine Maintenance - Continental Models54
- Perform Engine Maintenance - Perkins Models54
- Confirm the Proper Brake Configuration55
- Inspect the Tires, Wheels and Lug Nut Torque55
- Check the Drive Hub Oil Level and Fastener Torque56
- Check the Oscillate Directional Valve Linkage57
- Test the Ground Control Override57
- Test the Platform Self-Leveling58
- Test the Engine Idle Select58
- February58
- Test the Drive Brakes60
- Test the Drive Speed - Stowed Position61
- Test the Drive Speed - Raised or Extended Position61
- Inspect the Fuel and Hydraulic Tank Cap Venting Systems63
- Perform Hydraulic Oil Analysis64
- Inspect the Boom Extend/Retract Cables65
- Test the Emergency Power System67
Checklist C Procedures68
- Perform Engine Maintenance - Continental Models68
- Perform Engine Maintenance - Deutz Models68
- Perform Engine Maintenance - Perkins Models69
- Replace the Engine Air Filter Element69
- Check and Adjust the Engine RPM70
- Grease the Platform Overload Mechanism (if Equipped)72
- Test the Platform Overload System (if Equipped)72
- Check the Safety Envelope Limit Switches and Angle Sensor, S80X74
- February75
Checklist D Procedures77
- Check the Boom Wear Pads77
- Check the Free-Wheel Configuration78
- Check the Turntable Rotation Bearing Bolts80
- Inspect for Turntable Bearing Wear81
- Replace the Hydraulic Filters82
- Replace the Drive Hub Oil83
- Perform Engine Maintenance - Continental Models85
- Perform Engine Maintenance - Deutz Models85
- Perform Engine Maintenance - Perkins Models86
- Inspect the Boom Extend/Retract Cables86
Checklist E Procedures88
- Test or Replace the Hydraulic Oil88
- Perform Engine Maintenance - Perkins Models90
- Perform Engine Maintenance - Deutz Models90
- Perform Engine Maintenance - Perkins Models91
- Perform Cooling System Maintenance - Perkins 404F Models91
- Remove and Inspect the Boom Extend/Retract Cables92
  - Cable Replacement Criteria94
Repair Procedures95
Platform Controls97
- ALC-500 Circuit Board97
  - How to Remove the ALC-500 Circuit Board97
- Joysticks98
Platform Components104
- Platform104
  - How to Bleed the Slave Cylinder105
- Platform Leveling Slave Cylinder105
- Platform Rotator106
  - How to Remove the Platform Rotator106
  - How to Bleed the Platform Rotator107
- Platform Overload System108
Jib Boom Components111
- Jib Boom111
- Jib Boom Lift Cylinder112
Boom Components113
- Cable Track113
  - How to Remove the Cable Track, S-80113
  - How to Repair the Cable Track115
- Boom115
  - How to Shim the Boom115
  - How to Remove the Boom116
- Boom Lift Cylinder118
- Boom Extension Cylinder120
- Boom Extend/Retract Cables122
  - How to Adjust the Extend/Retract Cables123
  - How to Replace the Boom Extend/Retract Cables124
- Platform Leveling Master Cylinder126
Engines127
- RPM Adjustment127
- Flex Plate127
Ground Controls132
- Control Relays132
Hydraulic Pumps133
- Function Pump133
- Drive Pump134
  - How to Prime the Pump135
Manifolds136
- Function Manifold Components136
- Valve Adjustments - Function Manifold138
- Brake/Two-Speed Manifold Components140
- Turntable Rotation Manifold Components141
- Platform Rotate Manifold Components142
- Platform Manifold Components, S-80143
- Platform Manifold Components, S-85144
- 2WD Traction Manifold Components145
- 4WD Traction Manifold Components146
- Drive Oil Diverter Manifold Components (Welder Option)148
- Valve Adjustments - Traction Manifold149
- Valve Coils150
  - Valve Coil Resistance Specifications150
Fuel and Hydraulic Tanks152
- Fuel Tank152
- Hydraulic Tank153
Turntable Rotation Components155
- Turntable Rotation Drive Hub Assembly155
Steer Axle Components159
- Yoke and Drive Hub159
- Drive Motors160
- Drive Hubs160
- Steer Cylinders161
Non-Steer Axle Components162
- Drive Motor162
- Drive Hub162
Oscillating Axle Components163
- Oscillate Directional Valve164
  - How to Adjust the Oscillate Relief Valve164
  - How to Set up the Directional Valve Linkage165
Fault Codes167
Control System Fault Codes168
- How to Retrieve Control System Fault Codes168
- Control System Fault Codes169
Fault Code Display - Deutz and Perkins Models173
- How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models173
- 22 Models173
- Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models175
- February175
- Main Menu Structure - Deutz D 2.9 L4 Models176
- Main Menu Structure - Perkins 404F-22 Models177
Deutz D 2.9 L4 Engine Fault Codes178
Perkins 404F-22 Engine Fault Codes189
Continental TME27 Engine Fault Codes191
- How to Retrieve Continental Engine Fault Codes191
- How to Clear Engine Fault Codes from the ECM191
- Continental TME27 Engine Fault Codes192
- February193
Schematics198
- Section 6 Schematics198
- Electrical Symbol Legend199
- Hydraulic Symbols Legend200
- Relay and Fuse Panel Legend - Deutz Td2011L04I201
- Relay and Fuse Panel Legend - Perkins 804D-33202
- Connector Pin Legends203
- Continental TME27 Engine Harness207
- S-80X Ground Control Box Wiring Diagram209
- Deutz TD2.9 L4 Engine Harness211
- Perkins 404F-22T Engine Harness213
Electrical Schematics, S-80X - ANSI and CSA Models215
Electrical Schematics, S-80, S-85 - ANSI and CSA Models255
- Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)255
- Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)259
- Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)262
- Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)263
- Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)267
- Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)270
- Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)271
- Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)275
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)279
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)283
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)265286
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)287
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)291
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)294
Electrical Schematics, S-80, S-85 - CE Models295
- Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (CE)295
- Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (CE)299
- Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (CE)302
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)303
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)307
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)310
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)311
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)315
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)318
- February318
Electrical Schematics, S-80, S-85 - as Models319
- Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (AS)319
- Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (AS)323
- Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (AS)326
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)327
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)331
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)334
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)335
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)339
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)342
Schematics - Options343
- Continental Options Schematic343
- Deutz and Perkins Options Schematic345
- Platform Level Cutout, CTE Option347
- 12 Kw Hydraulic Generator Wiring Diagram349
- 12 Kw Hydraulic Generator Electrical Schematic351
- Belt Driven Generator Option353
- Hydraulic Schematic, 2WD Models355
Hydraulic Schematics355
- Hydraulic Schematic, 4WD Models357

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