Genie S-80 Installations- und Betriebsanleitung

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

Service and Repair Manual October 2016

Introduction

ii S-80 • S-85 • S-80XPart No. 1269074

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1269074 Rev A, September 2015

First Edition, First Printing

"Genie" and "S" are registered trademarks of Terex South

Dakota, Inc. in the USA and many other countries.

October 2016 Service and Repair Manual

Introduction

Part No. 1269074 S-80 • S-85 • S-80X iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 9/2015

Initial Release

A1 7/2016 Repair Procedures Added 4-7, Primary Boom Angle Sensor, S80X

A2 9/2016 Introduction Serial Number Legend

A3 10/2016 Repair; Schematics Hydraulic Drive Manifolds, Hydraulic Schematics

Reference Examples: Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual October 2016

Introduction

iv S-80 • S-85 • S-80X Part No. 1269074

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (located under cover)

6 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

October 2016 Service and Repair Manual

Safety Rules

Part No. 1269074 S-80 • S-85 • S-80X v

Section 1 Safet y Rul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual October 2016

Safety Rules

vi S-80 • S-85 • S-80X Part No. 1269074

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal

words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or

moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazar

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extinguisher with

in easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lift

ing or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

properly ventilated and well lit.

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X vii

Introduction Introduction...........................................................................................................ii

Important Information .............................................................................................ii

Find a Manual for this Model..................................................................................ii

Serial Number Legend ..........................................................................................iv

Section 1 Safety Rules..........................................................................................................v

General Safety Rules .............................................................................................v

Section 2Specifications.......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications....................................................................................2

Hydraulic Specification...........................................................................................2

Hydraulic Component Specifications......................................................................5

Manifold Component Specifications.......................................................................6

Continental TME27 Engine Specifications.............................................................7

Deutz TD2011L04i Engine Specifications..............................................................8

Deutz TD 2.9 Engine Specifications.......................................................................9

Perkins 804D-33 Engine Specifications...............................................................10

Perkins 404F-22T Engine Specifications .............................................................11

Machine Torque Specifications............................................................................12

Hydraulic Hose and Fitting Torque Specifications ...............................................13

Torque Procedure ................................................................................................14

October 2016

Table of Contents

viii S-80 • S-85 • S-80X Part No. 1269074

Section 3 Repair Procedures.............................................................................................16

Introduction ..........................................................................................................16

Platform Controls...............................................................................................18

1-1 ALC-500 Circuit Board...................................................................................18

How to Remove the ALC-500 Circuit Board...................................................18

1-2 Joysticks ........................................................................................................19

How to Adjust the Joystick Max-out Setting ...................................................20

How to Adjust the Joystick Ramp Rate Setting ..............................................21

How to Adjust the Joystick Threshold Setting ................................................22

How to Calibrate the Boom Angle Sensor......................................................23

Platform Components .......................................................................................25

2-1 Platform..........................................................................................................25

2-2 Platform Leveling Slave Cylinder...................................................................26

How to Remove the Platform Leveling Slave Cylinder...................................26

How to Bleed the Slave Cylinder....................................................................26

2-3 Platform Rotator.............................................................................................27

How to Remove the Platform Rotator.............................................................27

How to Bleed the Platform Rotator.................................................................28

2-4 Platform Overload System.............................................................................29

Jib Boom Components......................................................................................32

3-1 Jib Boom........................................................................................................32

3-2 Jib Boom Lift Cylinder....................................................................................33

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X ix

Boom Components ............................................................................................34

4-1 Cable Track....................................................................................................34

How to Remove the Cable Track, S-80 ..........................................................34

How to Repair the Cable Track.......................................................................36

4-2 Boom..............................................................................................................36

How to Shim the Boom ...................................................................................36

How to Remove the Boom ..............................................................................37

4-3 Boom Lift Cylinder..........................................................................................39

4-4 Boom Extension Cylinder...............................................................................41

4-5 Boom Extend/Retract Cables.........................................................................43

How to Adjust the Extend/Retract Cables.......................................................43

How to Replace the Boom Extend/Retract Cables.........................................45

4-6 Platform Leveling Master Cylinder.................................................................47

4-7 Primary Boom Angle Sensor, S-80X..............................................................48

Engines................................................................................................................50

5-1 RPM Adjustment ............................................................................................50

5-2 Flex Plate .......................................................................................................50

How to Remove the Flex Plate........................................................................50

How to Install the Flex Plate............................................................................53

How to install the Pump and Bell Housing Assembly .....................................54

Ground Controls.................................................................................................55

6-1 Control Relays................................................................................................55

Hydraulic Pumps................................................................................................56

7-1 Function Pump...............................................................................................56

7-2 Drive Pump.....................................................................................................57

How to Prime the Pump..................................................................................58

October 2016

Table of Contents

x S-80 • S-85 • S-80X Part No. 1269074

Manifolds ............................................................................................................59

8-1 Function Manifold ..........................................................................................59

8-2 Valve Adjustments - Function Manifold .........................................................61

How to Adjust the System Relief Valve ..........................................................61

How to Adjust the Boom Down Relief Valve...................................................61

How to Adjust the Boom Extend Relief Valve.................................................62

8-3 Brake/Two-Speed Manifold Components......................................................63

8-4 Turntable Rotation Manifold Components.....................................................64

8-5 Platform Rotate Manifold Components..........................................................65

8-6 Platform Manifold Components, S-80............................................................66

8-7 Platform Manifold Components, S-85............................................................67

8-8 2WD Traction Manifold Components.............................................................68

8-9 4WD Traction Manifold Components.............................................................69

8-10 Drive Oil Diverter Manifold Components (welder option) ............................71

8-11 Valve Adjustments - Traction Manifold........................................................72

8-12 Valve Coils...................................................................................................73

Valve Coil Resistance Specifications .............................................................73

Fuel and Hydraulic Tanks .................................................................................75

9-1 Fuel Tank.......................................................................................................75

9-2 Hydraulic Tank...............................................................................................76

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