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S-80X
Genie S-80X Manuals
Manuals and User Guides for Genie S-80X. We have
7
Genie S-80X manuals available for free PDF download: Service Manual, Service And Repair Manual, Operating Manual, Operator's Manual, Operator's Manual Supplement
Genie S-80X Service Manual (359 pages)
Brand:
Genie
| Category:
Boom Lifts
| Size: 46 MB
Table of Contents
Introduction
2
Find a Manual for this Model
2
Revision History
3
Serial Number Legend
5
Safety Rules
6
Table of Contents
8
Specifications
21
Machine Specifications
21
Performance Specifications
22
Hydraulic Oil Specifications
22
Hydraulic Component Specifications
25
Manifold Component Specifications
26
Continental TME27 Engine Specifications
27
Deutz Td2011L04I Engine Specifications
28
Deutz TD 2.9 Engine Specifications
29
Machine Torque Specifications
32
Hydraulic Hose and Fitting Torque Specifications
33
Torque Procedure
34
February
35
Scheduled Maintenance Procedures
36
Pre-Delivery Preparation Report
39
Maintenance Inspection Report
40
Checklist a Procedures
42
Inspect the Manuals and Decals
42
Perform Pre-Operation Inspection
43
Perform Function Tests
43
A-5 Perform Engine Maintenance – Deutz Models
44
Test the Oscillate Axle
45
Check the High Pressure Hydraulic Filter Condition Indicator
46
Perform 30-Day Service
46
Perform Engine Maintenance - Continental Models
47
Grease the Turntable Rotation Bearing and Rotate Gear
48
Replace the Drive Hub Oil
48
Checklist B Procedures
49
Inspect the Batteries
49
Inspect the Electrical Wiring
50
Check the Exhaust System
52
Inspect the Engine Air Filter
53
Perform Engine Maintenance - Continental Models
54
Perform Engine Maintenance - Perkins Models
54
Confirm the Proper Brake Configuration
55
Inspect the Tires, Wheels and Lug Nut Torque
55
Check the Drive Hub Oil Level and Fastener Torque
56
Check the Oscillate Directional Valve Linkage
57
Test the Ground Control Override
57
Test the Platform Self-Leveling
58
Test the Engine Idle Select
58
February
58
Test the Drive Brakes
60
Test the Drive Speed - Stowed Position
61
Test the Drive Speed - Raised or Extended Position
61
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
63
Perform Hydraulic Oil Analysis
64
Inspect the Boom Extend/Retract Cables
65
Test the Emergency Power System
67
Checklist C Procedures
68
Perform Engine Maintenance - Continental Models
68
Perform Engine Maintenance - Deutz Models
68
Perform Engine Maintenance - Perkins Models
69
Replace the Engine Air Filter Element
69
Check and Adjust the Engine RPM
70
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, S80X
74
February
75
Checklist D Procedures
77
Check the Boom Wear Pads
77
Check the Free-Wheel Configuration
78
Check the Turntable Rotation Bearing Bolts
80
Inspect for Turntable Bearing Wear
81
Replace the Hydraulic Filters
82
Replace the Drive Hub Oil
83
Perform Engine Maintenance - Continental Models
85
Perform Engine Maintenance - Deutz Models
85
Perform Engine Maintenance - Perkins Models
86
Inspect the Boom Extend/Retract Cables
86
Checklist E Procedures
88
Test or Replace the Hydraulic Oil
88
Perform Engine Maintenance - Perkins Models
90
Perform Engine Maintenance - Deutz Models
90
Perform Engine Maintenance - Perkins Models
91
Perform Cooling System Maintenance - Perkins 404F Models
91
Remove and Inspect the Boom Extend/Retract Cables
92
Cable Replacement Criteria
94
Repair Procedures
95
Platform Controls
97
ALC-500 Circuit Board
97
How to Remove the ALC-500 Circuit Board
97
Joysticks
98
How to Adjust the Joystick Max-Out Setting
99
How to Adjust the Joystick Ramp Rate Setting
100
How to Adjust the Joystick Threshold Setting
101
How to Calibrate the Boom Angle Sensor
102
Platform Components
104
Platform
104
How to Bleed the Slave Cylinder
105
Platform Leveling Slave Cylinder
105
Platform Rotator
106
How to Remove the Platform Rotator
106
How to Bleed the Platform Rotator
107
Platform Overload System
108
Jib Boom Components
111
Jib Boom
111
Jib Boom Lift Cylinder
112
Boom Components
113
Cable Track
113
How to Remove the Cable Track, S-80
113
How to Repair the Cable Track
115
Boom
115
How to Shim the Boom
115
How to Remove the Boom
116
Boom Lift Cylinder
118
Boom Extension Cylinder
120
Boom Extend/Retract Cables
122
How to Adjust the Extend/Retract Cables
123
How to Replace the Boom Extend/Retract Cables
124
Platform Leveling Master Cylinder
126
Engines
127
RPM Adjustment
127
Flex Plate
127
How to Remove the Flex Plate
127
How to Install the Flex Plate
130
How to Install the Pump and Bell Housing Assembly
131
Ground Controls
132
Control Relays
132
Hydraulic Pumps
133
Function Pump
133
Drive Pump
134
How to Prime the Pump
135
Manifolds
136
Function Manifold Components
136
Valve Adjustments - Function Manifold
138
How to Adjust the System Relief Valve
138
How to Adjust the Boom down Relief Valve
138
How to Adjust the Boom Extend Relief Valve
139
Brake/Two-Speed Manifold Components
140
Turntable Rotation Manifold Components
141
Platform Rotate Manifold Components
142
Platform Manifold Components, S-80
143
Platform Manifold Components, S-85
144
2WD Traction Manifold Components
145
4WD Traction Manifold Components
146
Drive Oil Diverter Manifold Components (Welder Option)
148
Valve Adjustments - Traction Manifold
149
Valve Coils
150
Valve Coil Resistance Specifications
150
Fuel and Hydraulic Tanks
152
Fuel Tank
152
Hydraulic Tank
153
Turntable Rotation Components
155
Turntable Rotation Drive Hub Assembly
155
How to Remove the Turntable Rotation Drive Hub Assembly
155
How to Remove the Turntable Rotation Hydraulic Motor
156
How to Adjust the Turntable Rotation Gear Backlash
157
February
158
Steer Axle Components
159
Yoke and Drive Hub
159
Drive Motors
160
Drive Hubs
160
Steer Cylinders
161
Non-Steer Axle Components
162
Drive Motor
162
Drive Hub
162
Oscillating Axle Components
163
Oscillate Directional Valve
164
How to Adjust the Oscillate Relief Valve
164
How to Set up the Directional Valve Linkage
165
Fault Codes
167
Control System Fault Codes
168
How to Retrieve Control System Fault Codes
168
Control System Fault Codes
169
Fault Code Display - Deutz and Perkins Models
173
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models
173
22 Models
173
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
175
February
175
Main Menu Structure - Deutz D 2.9 L4 Models
176
Main Menu Structure - Perkins 404F-22 Models
177
Deutz D 2.9 L4 Engine Fault Codes
178
Perkins 404F-22 Engine Fault Codes
189
Continental TME27 Engine Fault Codes
191
How to Retrieve Continental Engine Fault Codes
191
How to Clear Engine Fault Codes from the ECM
191
Continental TME27 Engine Fault Codes
192
February
193
Schematics
198
Section 6 Schematics
198
Electrical Symbol Legend
199
Hydraulic Symbols Legend
200
Relay and Fuse Panel Legend - Deutz Td2011L04I
201
Relay and Fuse Panel Legend - Perkins 804D-33
202
Connector Pin Legends
203
Continental TME27 Engine Harness
207
S-80X Ground Control Box Wiring Diagram
209
Deutz TD2.9 L4 Engine Harness
211
Perkins 404F-22T Engine Harness
213
Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
215
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
219
Platform Control Box, S-80X Deutz TD2.9 L4 Models (ANSI / CSA)
221
Electrical Schematic, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
223
Ground Control Box, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
227
Platform Control Box, S-80X Deutz Td2011L04I Models (ANSI / CSA)
229
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)
231
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
235
Platform Control Box, S-80X Perkins 404F-22T Models (ANSI / CSA)
237
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)
239
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
243
Platform Control Box, S-80X Perkins 804D-33 Models (ANSI / CSA)
245
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)
247
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
251
Platform Control Box, S-80X Continental TME27 Models (ANSI / CSA)
253
February
254
Electrical Schematics, S-80X - ANSI and CSA Models
215
Electrical Schematics, S-80, S-85 - ANSI and CSA Models
255
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)265
286
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 Models
295
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
February
318
Electrical Schematics, S-80, S-85 - as Models
319
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 - Options
343
Continental Options Schematic
343
Deutz and Perkins Options Schematic
345
Platform Level Cutout, CTE Option
347
12 Kw Hydraulic Generator Wiring Diagram
349
12 Kw Hydraulic Generator Electrical Schematic
351
Belt Driven Generator Option
353
Hydraulic Schematic, 2WD Models
355
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Genie S-80X Service Manual (353 pages)
Brand:
Genie
| Category:
Lifting Systems
| Size: 4 MB
Table of Contents
Table of Contents
9
Introduction
2
Serial Number Information
2
Serial Number Legend
5
Safety Rules
7
Table of Contents
9
Table of Contents
20
Machine Specifications
21
Hydraulic Oil Specifications
22
Performance Specifications
22
Hydraulic Component Specifications
23
Valve Coil Resistance Specifications
24
Continental TME27 Engine Specifications
25
Deutz Td2011L04I Engine Specifications
26
Perkins 804D-33 Engine Specifications
27
Machine Torque Specifications
28
Manifold Component Specifications
28
Hydraulic Hose and Fitting Torque Specifications
29
Pre-Delivery Preparation
33
Maintenance Inspection Report
35
Checklist a Procedures
37
Inspect the Manuals and Decals
37
Perform Engine Maintenance
38
Perform Pre-Operation Inspection
38
Perform Function Tests
39
Test the Oscillate Axle
39
Check the High Pressure Hydraulic Filter Condition Indicator
40
Perform 30 Day Service
40
Inspect the Fuel Filter/Water Separator - Diesel Models
41
Perform Engine Maintenance - Deutz and Continental Models
41
Grease the Turntable Rotation Bearing and Rotate Gear
43
Perform Engine Maintenance
44
Replace the Drive Hub Oil
45
Perform Engine Maintenance - Perkins Models
47
Checklist B Procedures
48
Inspect the Battery(S)
48
Inspect the Electrical Wiring
49
Check the Exhaust System
51
Test the Key Switch
51
Inspect the Engine Air Filter
52
Check the Oil Cooler and Cooling Fins - Deutz Models
53
Confirm the Proper Brake Configuration
54
Inspect the Tires, Wheels and Lug Nut Torque
54
Check the Drive Hub Oil Level and Fastener Torque
55
Check and Adjust the Engine RPM
56
Check the Oscillate Directional Valve Linkage
58
Perform Engine Maintenance
58
Test the Ground Control Override
59
Test the Platform Self-Leveling
59
Test the Engine Idle Select Operation
60
Test the Fuel Select Operation - Gasoline/Lpg Models
61
Test the Drive Enable System
62
Test the Drive Brakes
63
Test the Drive Speed - Stowed Position
63
Test the Drive Speed - Raised or Extended Position
64
Test the Alarm Package (if Equipped) and the Descent Alarm
65
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
66
Inspect the Boom Extend/Retract Cables
67
Perform Hydraulic Oil Analysis
67
Checklist C Procedures
69
Grease the Platform Overload Mechanism (if Equipped)
69
Test the Platform Overload System (if Equipped)
70
Replace the Fuel Filter/Water Separator Element - Diesel Models
73
Check the Safety Envelope Limit Switches and Angle Sensor, S-80X
75
Check the Boom Wear Pads
78
Checklist D Procedures
78
Check the Free-Wheel Configuration
79
Check the Turntable Rotation Bearing Bolts
80
Inspect the Turntable Bearing Wear
81
Perform Engine Maintenance
83
Replace the Drive Hub Oil
84
Perform Engine Maintenance - Deutz Models
86
Checklist E Procedures
87
Test or Replace the Hydraulic Oil
87
Perform Engine Maintenance - Deutz and Perkins Models
89
Perform Engine Maintenance - Perkins Models
89
Remove and Replace the Boom Extend/Retract Cables
90
Circuit Board
92
Platform Controls
92
Joysticks
93
Platform
99
Platform Components
99
Platform Leveling Slave Cylinder
100
Platform Rotator
101
Calibrate the Platform Overload System
103
Jib Boom
106
Jib Boom Components
106
Jib Boom Lift Cylinder
107
Boom Components
108
Cable Track
108
Boom
111
Boom Lift Cylinder
114
Boom Extension Cylinders
115
Boom Extend/Retract Cables
118
Platform Leveling Master Cylinder
122
Flex Plate
123
RPM Adjustment
123
Control Relays
128
Ground Controls
128
Function Pump
129
Hydraulic Pumps
129
Drive Pump
130
Function Manifold Components
132
Valve Adjustments - Function Manifold
134
Brake/Two-Speed Manifold Components
136
Turntable Rotation Manifold Components
137
Platform Rotate Manifold Components
138
Platform Manifold Components, S-80
139
Platform Manifold Components, S-85
140
2WD Traction Manifold Components
141
4WD Traction Manifold Components (before Serial Number 8581)
143
4WD Traction Manifold Components (after Serial Number 8580)
145
Drive Oil Diverter Manifold Components (Welder Option)
147
Valve Adjustments - Traction Manifold
148
Valve Coils
149
Fuel and Hydraulic Tanks
151
Fuel Tank
151
Hydraulic Tank
152
Turntable Rotation Components
154
Turntable Rotation Drive Hub Assembly
154
2 WD Steer Axle Components
157
Yoke and Hub
157
Steer Cylinder
158
4 WD Steer Axle Components
159
Yoke and Drive Hub
159
Drive Motor
160
Drive Hub
161
Steer Cylinders
161
Non-Steer Axle Components
162
Drive Motor
162
Drive Hub
162
Oscillating Axle Components
163
Oscillate Axle Cylinders
163
Oscillate Directional Valve
164
Fault Codes - Control System
168
Electrical Symbols Legend
180
Hydraulic Symbols Legend
181
Connector Pin Legend - View 1
184
Connector Pin Legend - View 2
185
Deutz Td2011L04I Models
188
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / as Deutz Td2011L04I Models
196
Electrical Schematic, S-80 and S-85 (CE Deutz Td2011L04I Models (before Serial Number 8111)
200
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (before Serial Number 8111)
204
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (before Serial Number 8111)
205
Platform Control Box Wiring Diagram, S-80 and S-85 (CE)
207
Platform Control Box Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (before Serial Number 8111)
208
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (before Serial Number 8111)
209
Deutz Td2011L04I Models (after Serial Number 8110)
211
Deutz Td2011L04I Models (after Serial Number 8110)
212
Electrical Schematic, S-80 and S-85 (CE Deutz Td2011L04I Models (after Serial Number 8110)
212
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (after Serial Number 8110)
216
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (after Serial Number 8110)
217
Deutz Td2011L04I Models (after Serial Number 8110)
220
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Deutz Td2011L04I Models (after Serial Number 8110)
221
Electrical Schematic, S-80X
223
Deutz Td2011L04I Models
223
Ground Control Box Terminal Strip Wiring Diagram, S-80X
227
Deutz Td2011L04I Models
227
Ground Control Box Switch Panel Wiring Diagram, S-80X
229
Deutz Td2011L04I Models
229
Platform Control Box Wiring Diagram, S-80X
231
Deutz Td2011L04I Models
231
Deutz Td2011L04I Models
232
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS)
235
Perkins 804D-33 Models
235
Electrical Schematic, S-80 and S-85 (ANSI / CSA / as Perkins 804D-33 Models
236
And S-85 (ANSI / CSA / AS), Perkins 804D-33 Models
239
Perkins 804D-33 Models
244
Electrical Schematic, S-80 and S-85 (CE)
247
Perkins 804D-33 Models (before Serial Number 8111)
247
Electrical Schematic, S-80 and S-85 (CE Perkins 804D-33 Models (before Serial Number 8111)
248
Perkins 804D-33 Models (before Serial Number 8111)
252
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (before Serial Number 8111)
253
Platform Control Box Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (before Serial Number 8111)
256
Electrical Schematic, S-80 and S-85 (CE Perkins 804D-33 Models (after Serial Number 8110)
260
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after Serial Number 8110)
264
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after Serial Number 8110)
265
Platform Control Box Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after Serial Number 8110)
268
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Perkins 804D-33 Models (after Serial Number 8110)
269
Electrical Schematic, S-80X Perkins 804D-33 Models
272
Ground Control Box Terminal Strip Wiring Diagram, S-80X Perkins 804D-33 Models
276
Platform Control Box Wiring Diagram, S80X Perkins 804D-33 Models
280
Platform Control Box Switch Panel Wiring Diagram, S80X Perkins 804D-33 Models
281
Continental TME27 Models
284
Ground Control Box Terminal Strip Wiring Diagram S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
288
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / as Continental TME27 Models
292
Electrical Schematic, S-80 and S-85 (CE Continental TME27 Models (before Serial Number 8111)
296
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before Serial Number 8111)
300
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before Serial Number 8111)
301
Platform Control Box Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before Serial Number 8111)
304
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (before Serial Number 8111)
305
Electrical Schematic, S-80 and S-85 (CE Continental TME27 Models (after Serial Number 8110)
308
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after Serial Number 8110)
312
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after Serial Number 8110)
313
Continental TME27 Models (after Serial Number 8110)
316
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE Continental TME27 Models (after Serial Number 8110)
317
Electrical Schematic, S-80X Continental TME27 Models
320
Ground Control Box Terminal Strip Wiring Diagram, S-80X Continental TME27 Models
324
Platform Control Box Wiring Diagram, S-80X Continental TME27 Models
328
Continental TME27 Engine Harness
332
Platform Level Cutout, CTE Option
333
Continental Options Schematic
336
Deutz and Perkins Options Schematic
337
Kw Hydraulic Generator Wiring Diagram
340
Kw Hydraulic Generator Electrical Schematic
341
Belt Driven Generator Option
344
Relay and Fuse Panel Legend
345
Hydraulic Schematic, 2WD Models
348
Hydraulic Schematic, 4WD Models
349
Kw Hydraulic Generator Hydraulic Schematic
351
Genie S-80X Service And Repair Manual (301 pages)
from S80/85/80X15-12264
Brand:
Genie
| Category:
Boom Lifts
| Size: 30 MB
Table of Contents
Introduction
2
Find a Manual for this Model
2
September
2
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
15
Machine Specifications
15
Performance Specifications
16
Hydraulic Component Specifications
18
Manifold Component Specifications
19
Continental TME27 Engine Specifications
20
Deutz Td2011L04I Engine Specifications
21
Deutz TD 2.9 Engine Specifications
22
Machine Torque Specifications
25
Hydraulic Hose and Fitting Torque Specifications
26
Torque Procedure
27
September
28
Repair Procedures
29
Section 3 Repair Procedures
29
About this Section
30
Platform Controls
31
ALC-500 Circuit Board
31
How to Remove the ALC-500 Circuit Board
31
Joysticks
32
How to Adjust the Joystick Max-Out Setting
33
How to Adjust the Joystick Ramp Rate Setting
34
How to Adjust the Joystick Threshold Setting
35
How to Calibrate the Boom Angle Sensor
36
Platform Components
38
Platform
38
How to Remove the Platform Leveling Slave Cylinder
39
How to Bleed the Slave Cylinder
39
Platform Rotator
40
How to Remove the Platform Rotator
40
How to Bleed the Platform Rotator
41
Platform Overload System
42
Jib Boom Components
45
Jib Boom
45
Jib Boom Lift Cylinder
46
Boom Components
47
Cable Track
47
How to Remove the Cable Track, S-80
47
How to Repair the Cable Track
49
Boom
49
How to Shim the Boom
49
How to Remove the Boom
50
Boom Lift Cylinder
52
Boom Extension Cylinder
54
Boom Extend/Retract Cables
56
How to Adjust the Extend/Retract Cables
56
How to Replace the Boom Extend/Retract Cables
58
Platform Leveling Master Cylinder
60
Engines
61
RPM Adjustment
61
Flex Plate
61
How to Remove the Flex Plate
61
How to Install the Flex Plate
64
How to Install the Pump and Bell Housing Assembly
65
Ground Controls
66
Control Relays
66
Hydraulic Pumps
67
Function Pump
67
Drive Pump
68
How to Prime the Pump
69
Manifolds
70
September
70
Function Manifold
72
Valve Adjustments - Function Manifold
72
How to Adjust the System Relief Valve
72
How to Adjust the Boom down Relief Valve
72
How to Adjust the Boom Extend Relief Valve
73
Brake/Two-Speed Manifold Components
74
Turntable Rotation Manifold Components
75
Platform Rotate Manifold Components
76
Platform Manifold Components, S-80
77
Platform Manifold Components, S-85
78
2WD Traction Manifold Components
79
4WD Traction Manifold Components
80
Drive Oil Diverter Manifold Components (Welder Option)
82
Valve Adjustments - Traction Manifold
83
Valve Coils
84
Valve Coil Resistance Specifications
84
How to Test a Coil Diode
85
Fuel and Hydraulic Tanks
86
Fuel Tank
86
Hydraulic Tank
87
Turntable Rotation Components
89
Turntable Rotation Drive Hub Assembly
89
How to Remove the Turntable Rotation Drive Hub Assembly
89
How to Remove the Turntable Rotation Hydraulic Motor
90
How to Adjust the Turntable Rotation Gear Backlash
91
September
92
Steer Axle Components
93
Yoke and Drive Hub
93
Drive Motors
94
Drive Hubs
94
Steer Cylinders
95
Non-Steer Axle Components
96
Drive Motor
96
Drive Hub
96
Oscillating Axle Components
97
Oscillate Axle Cylinders
97
Oscillate Directional Valve
98
How to Adjust the Oscillate Relief Valve
98
How to Set up the Directional Valve Linkage
99
Fault Codes
101
Section 4 Fault Codes
101
Control System Fault Codes
102
How to Retrieve Control System Fault Codes
102
Control System Fault Codes
103
Fault Code Display - Deutz and Perkins Models
107
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models
107
Fault Code Display - Flashing and Solid Led's Deutz D 2.9 L4 and Perkins 404F-22 Models
108
Deutz D 2.9 L4 and Perkins 404F-22 Models
109
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
109
Main Menu Structure - Deutz D 2.9 L4 Models
110
Main Menu Structure - Perkins 404F-22 Models
111
Deutz D 2.9 L4 Engine Fault Codes
112
Perkins 404F-22 Engine Fault Codes
123
Continental TME27 Engine Fault Codes
125
How to Retrieve Continental Engine Fault Codes
125
How to Clear Engine Fault Codes from the ECM
125
Continental TME27 Engine Fault Codes
126
September
127
Schematics
131
Section 5 Schematics
131
Electrical Symbol Legend
132
Hydraulic Symbols Legend
133
Relay and Fuse Panel Legend - Deutz Td2011L04I
134
Relay and Fuse Panel Legend - Perkins 804D-33
135
Connector Pin Legends
136
Continental TME27 Engine Harness
141
S-80X Ground Control Box Wiring Diagram
143
Deutz TD2.9 L4 Engine Harness
145
Perkins 404F-22T Engine Harness
147
Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
149
Electrical Schematics, S-80X – ANSI and CSA Models
149
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
153
Platform Control Box, S-80X Deutz TD2.9 L4 Models (ANSI / CSA)
155
Electrical Schematic, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
157
Ground Control Box, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
161
Platform Control Box, S-80X Deutz Td2011L04I Models (ANSI / CSA)
163
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)
165
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
169
Platform Control Box, S-80X Perkins 404F-22T Models (ANSI / CSA)
171
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)
173
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
177
Platform Control Box, S-80X Perkins 804D-33 Models (ANSI / CSA)
179
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)
181
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
185
Platform Control Box, S-80X Continental TME27 Models (ANSI / CSA)
187
September
188
Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
189
Electrical Schematics, S-80, S-85 – ANSI and CSA Models
189
Deutz TD2.9 L4 Models (ANSI / CSA)
190
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
193
Platform Control Box, S-80 • S
195
Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
196
Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)
197
Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)
201
Deutz Td2011L04I Models (ANSI / CSA)
202
Platform Control Box, S-80 • S
203
Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (ANSI / CSA)
204
Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)
205
Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)
209
Perkins 404F-22T Models (ANSI / CSA)
210
Platform Control Box, S-80 • S
211
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)
213
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)
217
Perkins 804D-33 Models (ANSI / CSA)
218
Platform Control Box, S-80 • S
219
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)
220
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
221
Continental TME27 Models (ANSI / CSA)
222
Ground Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
225
Platform Control Box, S-80 • S
227
Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
228
September
228
Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)
229
Electrical Schematics, S-80, S-85 – CE Models
229
Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (CE)
230
Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (CE)
233
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)
234
Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (CE)
236
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)
245
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
249
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
252
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)
253
Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)
257
Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)
260
Electrical Schematic, S-80 • S-85 - Deutz Td2011L04I Models (AS)
261
Electrical Schematics, S-80, S-85 – as Models
261
Ground Control Box, S-80 • S-85 - Deutz Td2011L04I Models (AS)
265
Platform Control Box, S-80 • S-85 - Deutz Td2011L04I Models (AS)
268
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)
269
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
273
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
276
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)
277
Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)
281
Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)
284
Continental Options Schematic
285
Schematics - Options
285
Deutz and Perkins Options Schematic
287
Platform Level Cutout, CTE Option
289
12 Kw Hydraulic Generator Wiring Diagram
291
12 Kw Hydraulic Generator Electrical Schematic
293
Belt Driven Generator Option
295
Hydraulic Schematic, 2WD Models
297
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Genie S-80X Service And Repair Manual (305 pages)
Brand:
Genie
| Category:
Boom Lifts
| Size: 28 MB
Table of Contents
October
2
Find a Manual for this Model
2
October
4
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
17
Machine Specifications
17
Performance Specifications
18
Hydraulic Component Specifications
21
Manifold Component Specifications
22
Continental TME27 Engine Specifications
23
Deutz Td2011L04I Engine Specifications
24
Deutz TD 2.9 Engine Specifications
25
Machine Torque Specifications
28
Hydraulic Hose and Fitting Torque Specifications
29
Torque Procedure
30
October
31
Repair Procedures
32
Section 3 Repair Procedures
32
About this Section
33
Platform Controls
34
ALC-500 Circuit Board
34
How to Remove the ALC-500 Circuit Board
34
Joysticks
35
How to Adjust the Joystick Max-Out Setting
36
How to Adjust the Joystick Ramp Rate Setting
37
How to Adjust the Joystick Threshold Setting
38
How to Calibrate the Boom Angle Sensor
39
Platform Components
41
Platform
41
How to Remove the Platform Leveling Slave Cylinder
42
How to Bleed the Slave Cylinder
42
Platform Rotator
43
How to Remove the Platform Rotator
43
How to Bleed the Platform Rotator
44
Platform Overload System
45
Jib Boom Components
48
Jib Boom
48
Jib Boom Lift Cylinder
49
Boom Components
50
Cable Track
50
How to Remove the Cable Track, S-80
50
How to Repair the Cable Track
52
Boom
52
How to Shim the Boom
52
How to Remove the Boom
53
Boom Lift Cylinder
55
Boom Extension Cylinder
57
Boom Extend/Retract Cables
59
How to Adjust the Extend/Retract Cables
59
How to Replace the Boom Extend/Retract Cables
61
Platform Leveling Master Cylinder
63
Primary Boom Angle Sensor, S-80X
64
Engines
66
RPM Adjustment
66
Flex Plate
66
How to Remove the Flex Plate
66
How to Install the Flex Plate
69
How to Install the Pump and Bell Housing Assembly
70
Ground Controls
71
Control Relays
71
Hydraulic Pumps
72
Function Pump
72
Drive Pump
73
How to Prime the Pump
74
Manifolds
75
Function Manifold
75
October
75
Valve Adjustments - Function Manifold
77
How to Adjust the System Relief Valve
77
How to Adjust the Boom down Relief Valve
77
How to Adjust the Boom Extend Relief Valve
78
Brake/Two-Speed Manifold Components
79
Turntable Rotation Manifold Components
80
Platform Rotate Manifold Components
81
Platform Manifold Components, S-80
82
Platform Manifold Components, S-85
83
2WD Traction Manifold Components
84
4WD Traction Manifold Components
85
Drive Oil Diverter Manifold Components (Welder Option)
87
Valve Adjustments - Traction Manifold
88
Valve Coils
89
Valve Coil Resistance Specifications
89
Fuel and Hydraulic Tanks
91
Fuel Tank
91
Hydraulic Tank
92
October
93
Turntable Rotation Components
94
Turntable Rotation Drive Hub Assembly
94
How to Remove the Turntable Rotation Drive Hub Assembly
94
October
94
How to Remove the Turntable Rotation Hydraulic Motor
95
How to Adjust the Turntable Rotation Gear Backlash
96
Steer Axle Components
98
Yoke and Drive Hub
98
Drive Motors
99
Drive Hubs
99
Steer Cylinders
100
Non-Steer Axle Components
101
Drive Motor
101
Drive Hub
101
Oscillating Axle Components
102
Oscillate Axle Cylinders
102
Oscillate Directional Valve
103
How to Adjust the Oscillate Relief Valve
103
How to Set up the Directional Valve Linkage
104
Fault Codes
105
Section 4 Fault Codes
105
Control System Fault Codes
106
How to Retrieve Control System Fault Codes
106
Control System Fault Codes
107
Fault Code Display - Deutz and Perkins Models
111
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models
111
22 Models
111
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
113
October
113
Main Menu Structure - Deutz D 2.9 L4 Models
114
Main Menu Structure - Perkins 404F-22 Models
115
Deutz D 2.9 L4 Engine Fault Codes
116
Perkins 404F-22 Engine Fault Codes
127
Continental TME27 Engine Fault Codes
129
How to Retrieve Continental Engine Fault Codes
129
How to Clear Engine Fault Codes from the ECM
129
Continental TME27 Engine Fault Codes
130
October
131
Schematics
135
Section 5 Schematics
135
Electrical Symbol Legend
136
Hydraulic Symbols Legend
137
Relay and Fuse Panel Legend - Deutz Td2011L04I
138
Relay and Fuse Panel Legend - Perkins 804D-33
139
Connector Pin Legends
140
Continental TME27 Engine Harness
144
S-80X Ground Control Box Wiring Diagram
146
Deutz TD2.9 L4 Engine Harness
148
Perkins 404F-22T Engine Harness
150
Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
152
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
156
Platform Control Box, S-80X Deutz TD2.9 L4 Models (ANSI / CSA)
159
Electrical Schematic, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
161
Ground Control Box, S-80X - Deutz Td2011L04I Models (ANSI / CSA)
165
Platform Control Box, S-80X Deutz Td2011L04I Models (ANSI / CSA)
167
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)
169
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
173
Platform Control Box, S-80X Perkins 404F-22T Models (ANSI / CSA)
175
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)
177
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
181
Platform Control Box, S-80X Perkins 804D-33 Models (ANSI / CSA)
183
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)
185
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
189
Platform Control Box, S-80X Continental TME27 Models (ANSI / CSA)
191
October
192
Electrical Schematics, S-80X - ANSI and CSA Models
152
Electrical Schematics, S-80, S-85 - ANSI and CSA Models
193
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 Models
216
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 Models
233
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 Models
265
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 - Options
289
Continental Options Schematic
289
Deutz and Perkins Options Schematic
291
Platform Level Cutout, CTE Option
293
12 Kw Hydraulic Generator Wiring Diagram
295
12 Kw Hydraulic Generator Electrical Schematic
297
Belt Driven Generator Option
299
Hydraulic Schematic, 2WD Models
301
Hydraulic Schematics
301
Hydraulic Schematic, 4WD Models
303
October
304
Genie S-80X Operating Manual (68 pages)
Brand:
Genie
| Category:
Boom Lifts
| Size: 6 MB
Table of Contents
Table of Contents
2
Introduction
3
Symbol and Hazard Pictorials Definitions
6
General Safety
8
Personal Safety
14
Work Area Safety
15
Legend
25
Controls
26
Inspections
34
Operating Instructions
48
Transport and Lifting Instructions
60
Maintenance
63
Specifications
66
Genie S-80X Operator's Manual (7 pages)
Brand:
Genie
| Category:
Lifting Systems
| Size: 0 MB
Table of Contents
Safety Rules
3
Construction Specifications
4
Workplace Inspection
6
Instructions for Use
7
Genie S-80X Operator's Manual Supplement (7 pages)
Panel Cradle
Brand:
Genie
| Category:
Boom Lifts
| Size: 0 MB
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