Home

Service Manual - Genie Industries

Contents

1. TURNTABLE ROTATE PLATFORM LEVEL PLATFORM JIB BOOM CYLINDER g 3 11 4 L min BOOM EXTEND RETRACT CYLINDERS ROTATE S 85 OPTION 16 gpm 61 L min EXTEND S Sse PRIMARY LIFT CYLINDER 1 7 gpm 26 5 L min RETRACT I L R 15 gpm 57 L min UP i 8 gum 30 L min DOWN SLAVE A 3 nU ee CYLINDER t BRAKE 2 SPEED MEDIUM Am 0 0 s He EN A Lo MANIFOLD 51 psi PRESSURE FUNCTION EN 1 11 t ce 1 E i AU O 0 025 in
2. N e LO C78 BR x 5 YL gt F BR S18 PRIMARY BOOM ANGLE C6 33 SENSOR SAFETY C123PBS RD BK lt lt C123PBS RD BK Is p C6 34 SNSR GND BR SNSR GND BR 5 BK 517 2 9 6 35 PRIMARY BOOM ANGLE P109ANG GN WH 289 PASANG lt PI09ANG GNWH RD SENSOR OPERATIONAL 9 gt C2 8 5 3 598 2 16 ROBK 2215 eese 15720 STOWED ANGLE 8 d DRIVE SPEED REDUCTION 5 be are si 04218 ORIRD E22 x
3. GND BR N e LO GND BR mae YL 21 gt BR S18 gt pon w PRIMARY BOOM ANGLE C123PBS_RD BK lt lt C123PBS RD BK a gt Bt SENSOR SAFETY C210 SNSR GND BR 98 34 gt SNSR GND BR 817 C29 P109ANG GR WH 939 P109ANG GR WH I RD MH PRIMARY BOOM ANGLE SENSOR OPERATIONAL 9 C2 8 cS 5 510 9 RD Eos
4. GND BR N LO cra GND BR lw YL Y 518 OR PRIMARY BOOM ANGLE C123PBS RDBK lt amp C123PBS RD BK BL SENSOR SAFETY SNSR GND BR 22 SNSR GND BR gt BK 0210 17 m P109ANG GR WH EEE lt lt piogANG GR WH 1 PRIMARY BOOM ANGLE are SENSOR OPERATIONAL C2 8 5 9 50 10 S RD 15720 g 6605 BR o 4 ANGLE STOWED osx am en re 43 4215 OR
5. CHECK ENGINE LED ES0503D HOURMETER PRESSURE COMP VALVE FUNCTION ENABLE RPM POWER RELAY RPM CONTROL RELAY RPM SOLENOID FUEL PUMP GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID CONTROL RELAY FUEL SOLENOID AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP POWER RELAY AUXILIARY PUMP IGNITION STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION FLASHING BEACONS OPTION 5 80 S 85 5 80 ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY a 3 5 o c
6. N e LO C7 3 BR x 5 YL S18 N PRIMARY BOOM ANGLE C6 33 SENSOR SAFETY C123PBS RD BK lt lt C123PBS RD BK Is p C6 34 SNSR GND BR SNSR GND BR 5 BK 517 C29 6 35 PRIMARY BOOM ANGLE 59535 RD SENSOR OPERATIONAL P109ANG GN WH amp P109ANG GN WH 29 C2 8 5 _ e _ 598 2 10 ROBK 2215 Qu 9 alleele 18120 STOWED ANGLE a d DRIVE SPEED REDUCTION BEL ag e eg 02 si 04218 ORIRD 06 22 x 5 Bk s LIMIT SWITCH e C29MS RD WH 28 S a C6 40 2 2 5 X LED BURD 1 lt 6 C40LS OR 7 TTeleale 198180 BOOM RETRACT a BR ed DRIVE ROTATE
7. C132PLI BK C28TTA RD BK 1 LS18A P26ESTP BK t P26ESTP BK LS18 I 5 C9P 1 ps 20 D10 P24FS WH 5 7 psa BK a S P25FS RD S gt P25FS RD Bb e P24FS WH P24FS WH Capes TS1 TS2 TS4 TS3 4 AUXILIARY ENGINE ENGINE FUEL PBOX GND E Sa PUMP START lt A n RPM SELECT 5 9 E U35 o ia g I x A R20 l 5 e Wo 8 Me U 2 SEC 59 Sg 2 SEC o 2 T NO NO 10A 2 p HORN T EX g UM 8 5 EA 5 5 L4 3 8 Bs Di2Y 5 2 mg D39 PBOX GND 8 5 x D40 PBOX GND 9 9 g Q 9 CB2 a 15 AMP 1 mp _ 18134 0 8 8 2 2 B 2 32 a A BD RD N FUNCTION sts ENABLE Kai 8 23 3 22 TS52 So 3 4 K 9 TS54 TS53 9 pe PLAT 5 9 1357 Q ENGINE Q ENGINE 8 FUEL 8 GND 9 y START 8 D68 7 1904 3 SELECT 5 18 8 41 5
8. C73 BR Ux 5 je 1 gt F BR 818 T Chay poou anete 0129888 RDIBK lt lt 0129088 gt p BL C6 34 SNSR GND BR SNSR GND BR T 2 BK C29 06 35 PRIMARY BOOM ANGLE 963850 P109ANG GN WH lt PIOYANG GNIWH gt V ED 9 5 C2 8 10 24 3 lt Hi ROBK 2215 8 9 5 Qu 3 LST20 STOWED ANGLE 2 C6 22 ay 154 DRIVE SPEED REDUCTION Paes 46 gt e 04218 OR RD 7 amp 04215 OR RD N as al LIMIT SWITCH e cams ROWH 28 9 d 5 2 2 E C6 40 RD LED BL RD 1 lt lt 41 C40LS OR cons OR 1 LSB1RO BOOM RETRACT 1 BR 15126 DRIVE ROTATE SPEED u lt P134PWR RD BK LIMIT SWITCH 5 5 WH m E s um P134PWR RD T 22 CIA4DER BUWH EK 4 1 1 BURD S 13 C13DRE BURD BR
9. N C73 BR Fx 5 gt F YL la r 88 818 SENSOR SAFETY 06 38 RD BK e 0128088 RD BK _ p 0123088 C6 34 0 SNSR GND BR amp SNSR GND BR arr 817 0210 2 9 6 35 PRIMARY BOOM ANGLE O P109ANG GNWH SENSOR OPERATIONAL gt 58 C2 8 5 lt 2 10 HI ROBK 2215 a 9 5 QU 3 alg ele LST20 STOWED ANGLE 5 ad DRIVE SPEED REDUCTION 5 PS 4 lt lt 4 04215 OR RD 922 lt C42LS BK LIMIT SWITCH C29MS RDWH 228 3 LSB1RO BOOM RETRACT 1 LED BURD CALS OF 58 40 catch gt wa 144 DRIVE ROTATE SPEED P134PWR RD BK LIMIT SWITCH WH 5 3 m re ET P134PWR RD CIADER BLWH EKQ coc s C13DRE BURD 9 13 lt C13DRE BURD BR E DAVE ENABIE 2 LIMIT SWITCH
10. N LO BR 4 x 5 I r BR 818 PRIMARY BOOM ANGLE St C6 33 C123PBS X C123P BS RD BK Is p BL SENSOR SAFETY 6 34 c2 10 SNSR GND lt SNSR GND BR 817 2 9 C6 35 PRIMARY BOOM ANGLE P109ANG GNWH RD lt F AOBANGONANTE gt SENSOR OPERATIONAL 9 C2 8 5 lt 10 AT RDBK 2215 a o 5 Qu 9 LST20 STOWED ANGLE 2 a d DRIVE SPEED REDUCTION si C42LS 6 22 lt 4215 ORRD 5 BK LIMIT SWITCH 4 46 5 C29MS RD WH 28 3 C6 40 02 2 5 LED BURD 56 1 41 C40LS OR Cors on 1 ie eleglo LSB1RO BOOM RETRACT 1 4 DRIVE ROTATE SPEED u E P134PWR RD LIMIT SWITCH WH 3 2 2 an P134PWR RD isno CIAMDER BLWH gt BX 7 e 013085 BRD lt lt C13DRE BL RD a Zd DRIVE ENABLE RIGHT 2 BK Z LIMIT SWITCH LEFT
11. a N x 5 c 9 o lt Z Ege 5 E Sos 8 5 8 8 FAA 2 0 85 cz zu d 6 eck SSeS iu 5 a ES ee 1 5 amp cole 0031 m 05 11 o g 3 a w e e x RS ar C132PLI2 BK all E 8 5 x C44 a z C5 19 E V155PCE OR RD V155PCE OR RD w 8 05 P ds F 50 88 c 25 HOLD gt HIGH 1 9 C35RPM BK RD SEE ES 35 252 PULLIN SEHR 95 5 s EGG red a 5 gt NO ON N NN PL L ES Oza OO a 6 1 5 Faestow Se 25 en lee HIGH 8 IT E 8 Kr 20 B 2 s 2 5 F g 4 8 amp qiu 85 9 8 85 4 amp amp 20 05 x Baa ore C34SA BKWH 8 Coen 11 4 4 2 893 B 4 X p i R34SA BK WH lt fs 5
12. N M L K H G F D C B A CONTROL HARNESS 1 0 2 w 2 2 mom 0 m 9 3 25 225 22 5 2 0 x 5 S E 5 5 2 955 5 53 E RR mA ES c E 85853532 R95 299 g d 2g 5 255 s 455 59589 955 9 c on Be 9 9 2001 0 D lt 5 aS o 9 m oS c 9 L 7 8 5 589 5 gt 3 5 VS i T 2 TS4 9 TS15 5 n S 5 4 9 9 2 N PRO pes 47 4 PE JC3 7 1 1 1 de TS2 TS6 8 1 7 1 1 lt Qd 608 1 4 x m 3 ig 0 M L1 9j 1 1 4 9 en MB 5 TS7 TS14 0 I u 7 a aa OQ fogo PO N 3 Ne 48 L51 TS75 L50 5 RD BK BK BK RD RD 0 ES0504D CHERCHER IMEEM n Ins SS SS
13. N M L K J H G 0 Deutz TD2011L04i 0 2 nL mE T LABEL DESCRIPTION 5 8 7 8 NOT USED CR1 START RELAY G pgdrzhg 2 CR2 IGNITION FUEL RELAY CR3 HIGH IDLE RELAY CR17 X x m CR2 E CR5 HORN RELAY Ly pom 15 GLOW PLUG RELAY I 17 HYDRAULIC OIL COOLER RELAY 4 orn H 1 CR39 AUXILIARY PUMP RELAY R21IGN CR39 AUXILIARY PUMP RELAY H ri H ri F7 FUSE 30A OIL COOLER FAN HORN X CR39 J 685 CRI CRIS U CR3 F17 FUSE 30A ENGINE AUXILIARY PUMP ae F20 FUSE 20A ENGINE RPM SOLENOID EI u Au E 2 E 22 FUSE 60A GLOW PLUGS O Perkins 804D 33 0 m y mn Pilg us 7 LABEL DESCRIPTION 1 1 20 CIRCUIT BREAKER 10A ENGINE RPM SOLENOID 5 6 7 8 1 h 7 G F2 L H CR1 START RELAY CR2 IGNITION FUEL RELAY CR17 L cre 0 CR4 CR3 HIGH IDLE RELAY zy PES ENGINE RPM SOLENOID RELAY I u l L CR5 HORN RELAY J 1 15 GLOW PLUG RELAY CR17 HYDRAULIC OIL COOLER RELAY L r CR39 AUXILIARY PUMP RELAY R 685 En en CR39 ES cha F
14. RD E STOP o RD 1618 CABLE P134PWR RD E 1 P134PWR RD re R20 e ZO x RD H1 I 3 256 9 ON 82 51 8 oo 0 2 5 x 88 P26ESTP BK E STOP R26ESTP BK C9P 1 BR GND e e TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 e 2 d o TS1 V155PCE OR RD 4 x TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS8 C43JU GR C4P 7 E TS8 C44JD GR BK C4P 8 9 OJ TS9 C14PLU OR 2 TS9 C15PLD OR BK C4P 3 H1 C133PLA GR BK 12 m L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C2P 10 J1 P109ANG GR WH 2 9 ay TS3 C39LP BL RD C2P 1 P3 C46HRN GR C2P 5 5 BK P2 E apr C C40LS OR 2 2 2 s C6TRF WH RD 6 8g 9 9 C123PBS RD BK C2P 8 7 1 C C13DRE BL RD
15. i MRNA QNM DEES MEME dM MM CM _ ______ _ 9 8 21 5 u 1 RD E STOP XALI RD L818 CABLE 5 8 220 P134PWR RD Bil lt lt Ie 9 P134PWR RD o R20 e 9 9 5 aso 47000 Ne ZED i 1 8 8 O Z P26ESTP E STOP R26ESTP BK C9P 1 s BR GND e TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 mo I TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 1 J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 1 P2 P23PWR WH C7P 2 P2 P22PWR C7P 1 TS1 V155PCE 4 qe TS48 C49DLITE WH BK 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK 8 TS9 C14PLU OR 2 TS9 C15PLD C4P 3 1 H1 C133PLA GR BK C3P 12 5 L47 C59CNK BL BK
16. N e LO C78 BR x 5 19 YL BR S18 PRIMARY BOOM ANGLE C6 33 ENSOR SAFETY 128088 RD BK T lt lt 0129088 RDIBK BL SENSOR S C6 34 mE SNSR GND BR lt SNSR GND BR BK Sm C29 35 PIOSANG GN WH ER P109ANG GNWH gt gt RD PRIMA 9 5 C2 8 10 2 lt 4 AT RoK 7218 s 9 5 Qu 3 TT 18120 STOWED ANGLE C24 E c6 22 BR 1 DRIVE SPEED REDUCTION 4 lt lt lt a 4215 OR RD 7 4215 OR RD eq BK al LIMIT SWITCH 22849 8 5 2 2 C6 40 gt LED BURD 1 lt 4015 OR C40LS OR RC e LSBIRO BOOMIRETHAGT a BR 144 DRIVE ROTATE SPEED u lt P134PWR RD BK 5 x LIMIT SWITCH 3 WH m s 06 25 P134PWR RD T 22 CIA4DER BLWH x Cet e C13DRE BL RD 9919 lt C13DRE BURD BR I 1 DRIVE ENABLE PS RIGHT 2 af LIMIT SWITCH LEFT 555 WH C143DEL BUBK 5 5 C6 37 2 8 C37STCC 378 STEER CCW Q o x 5 17 0 C36STC BL mE C36STC BL STEER CW 8 n x ope 926 C6TRF WH RD g EK c35 C5TRR WH BK C34 T C4TRL WH 8 1 4 cime wii TURNTABLE ROTATE
17. du enD NEU gt GBOX 220 50HZ GFI OUTLET NEU gt GBOX A B 0 D E F gt R20BAT RD d 1 Fd 5 gt NEUTRAL WH 3 GND BR IE L5 LINE 2 gt FIELD BKWH BELT DRIVEN 2 GENERATOR LINE e LINE BK CTTW NEUTRAL WH lt GND GR N FIELD GR e CR46 CB6 87 NEUTRAL WH P20BAT e je 301 3 et 187 3 552 m gt Tas e GND BR 120 VAC 60 HZ with Regulator 4 5 gt R20BAT RD d Fd Rs gt NEUTRAL WH d GND BR Lu 55 d gm LINE BK 2 gt FIELD BK WH 6 BELT DRIVEN le ee GENERATOR LINE BK rJ 22 LINE BK N NEUTRAL WH wee GND GR 7 AN FIELD GR TGA e CR46 CB6 87A t NEUTRAL WH P20BAT of Ye 30A 80 e 4 187 4 EN m gt F e GND BR ues 8 2212 2020 Genie 6 166 220 50 HZ with Regulator 5 80 5 85 S 80X PartNo 122985
18. N M L G F E D C B A CONTROL HARNESS TO PLATFORM BOX 1 gt I fos m w SE 8 2 8 8388 TE 38382 88 5 23 S gt x c 8 82 22552 34 2 983829 9 8 6 2 9 9 x 8 58 8 3 5 2 7 e 2 9 o 5 97 Rom a SR lt Som e mx m 2 amp gt 25 0 a 2 a 9 n t 5 2 gt TS4 S Er S 9 TS3 5 TS15 1 1 gt S D12 PR 29 JC7 JC3 3 4 1 10 we TS2 AH BO L1 4 1 2 2 E ES D43 5 9 TS14 148 O 2 ER Ps 9 J O u 9 MED i P3 a 27 ES 0 27 OO zc 2 BK 6 RD RD O ESO505D ee ee A ee oh eee ee ee ee Mere COMPONENT INDEX 7 CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION AUXILIARY TOGGLE SWITCH NOTE DASHED LINES INDICATE OPTIONS CR30 LIFT DRIVE SELECT LIMIT SWITCH CI
19. CHECK ENGINE LED ES0504A HOURMETER PRESSURE COMP VALVE FUNCTION ENABLE RPM CONTROL RELAY RPM SOLENOID RPM MODULE GLOW PLUG TIME DELAY 30 SECONDS GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID CONTROL RELAY FUEL SOLENOID AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP POWER RELAY AUXILIARY PUMP IGNITION STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION FLASHING BEACONS OPTION G S 80 S 85 S 80X ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY a N x d f i 9 amp 5 5 Eu SER 2 8 8 8 58 6 5 g 3 E 65 eos Em NN Sa 5 PIE SS 8 p lt s sx 6 sje vie e le m amp mie gt 2 5 11 4 C4 10 o C4 10 3 o 5 5 lt lt oll 1192 a lgo 3 m C44 A 05 19 E 15 OR RD 155005 OR RD u as a i 288 LOW afiyv frase 60 58 T 25 gt 55 rx BAIE mm BREE 63 p S as Se Ea ON 1
20. K L M N C5 ENGINE DEUTZ PERKINS CONTINENTAL 2011L04i 804 TME27 PIN CIRCUIT COLOR CIRCUIT COLOR CIRCUIT COLOR 1 P24PWR RD P24PWR RD P23PWR WH 2 C41RPM OR BK CHRPM 41 3 C21IGN WH C21IGN WH 4 5 C33STR BK C33STR BK C33STR 6 C27AUX RD C27AUX RD C27AUX RD 7 6 GR C46HRN GR C46HRN GR 8 C127TSW GR 9 C35RPM BK RD 10 C39LP 11 R21IGN WH 14 R21IGN WH 14 R21IGN WH 14 12 13 0108551 BL WH 14 15 C24TSPS WH C24TSPS WH P24PWR RD 16 17 R24PWR RD 18 5 BK RD C35RPM BK RD 19 V155PCE OR RD V155PCE OR RD V155PCE OR RD 20 C31EDC WH BK C31EDC WH BK C31EDC WH BK 21 C30EDC WH C30EDC WH C30EDC WH 22 0345 BK WH 0345 BK WH 23 C32BRK WH RD C32BRK WH RD C32BRK WH RD 24 029 58 RD WH C29MS RD WH C29MS RD WH C7 C9 12V POWER TO PLAT FOOTSWITCH C7 DTPO06 4S C9 FS DTO4 4P COLOR CIRCUIT PIN COLOR CKT PIN BK P22PWR 1 BK P26ESTP 1 WH P23PWR 2 WH _ P24FS 2 BR BATGND 3 RD P25FS 3 PLUG 4 PLUG 4 ES0507C 9L J J3 El J1 J2
21. September 2015 Electrical Schematic S 80 and S 85 ANSI CSA AS Deutz TD2011L04i Models Section 6 Schematics CHECK ENGINE LED x x 8 ES x x 9 205 5 lt lt x 5 8 8 8 INN A 666 2 a z a lt a SEE 452 8 Es Fa 9 5 5 z m len 5 5248 lt s i 9999999999 4 m HOURMETER ale 8 5 11 4 TN NR 8 8 z C5 19 E PRESSURE COMP VALVE V155PCE OR RD 5 155 OR RD 1 x a FUNCTION ENABLE u 39g 2 RPM CONTROL RELAY I a rats Low 265 EB ES 8 gt mx RPM SOLENOID C35RPM BK RD 2225 52 2 80 N 28 amp rh gt ATAM ON N AW fle L 9 z OO oo 8 1 5 lt
22. T N e C7 3 BR x 5 YL M BR S18 PRIMARY BOOM ANGLE C6 33 SENSOR SAFETY C123PBS RD BK lt lt C123PBS RD BK Is p 2 C6 34 SNSR GND BR SNSR GND BR 5 BK 517 2 9 6 35 PRIMARY BOOM ANGLE 289 P109ANG PASANG lt PI09ANG GNWH RD SENSOR OPERATIONAL gt 9 5 C2 8 10 2 598 _ e _ ROBK 2215 a 9 5 8 ele LST2O STOWED ANGLE a d DRIVE SPEED REDUCTION BEL ag e eg 02 04218 oR RD E22 5 5 Bk xl LIMIT SWITCH RDWH 28 8 5 2 2 C6 40 X LED BURD 1 lt 6 C40LS OR 7 BOTT 188180 BOOM RETRACT wa ed DRIVE ROTATE SPEED u P134PWR RD BK 5 x LIMIT SWITCH 2 5 WH 2 of 8 LST10 1440 BLWH x E a C13DRE BURD 26136 1 BURD 712154 DRIVEENABIE PS RIGHT gt 2 1 LIMIT SWITCH LEFT WH C143DEL E C1 11 6 37 rac C37STCC BL BK G C37STCC BL BK STEER CCW cs e C1 10 C6 36 Sei T gt lt C36STC BL C36STC BL STEER CW 8 n gt me 6 C6TRF WH RD 8 EK 035 CSTRR WH BK C94 WH 8 xa 1 C64 TURNTABLE ROTATE r 25 TURNTABLE ROTATE De 4 g teow i
23. u a Oz ri a 8 lt 2 8 2 5 Q 5 n Or o 5 m 0 zi x Z o z 5 aes 8 2 T ala 6 6 5 S lt 2 5 Hels 5 o 5 5 5 ol 6 F 5 5 5 zr 50626 clo 9 5 o F ullu 28856 2 u 5 E ez 2 gt 669 T gt c F lt z s u u u E z lt 2 gt 25 9 G GO 5 5 E 5 5 6 07856 x 6 6 5 6 lt ul m zz t 5 5 5 z 2 50 0 2 5 5 Li Our x 0 5 5 2 S ou o O B ka ZZ rr gt 2 o u 5 a 665 Gr Z Cr gt m gt m gt z eE E E EF lt u 8 95 05 2 599 lt E lt lt 2 5 5 z o sa mG x k gt 2 22 2 2024 0650 0 ui 5 F 8 m lt 5 E 5555 8 413 3 EIP B e P 5 k 90018 NOLLWNINYAL 58
24. 2 5 Deutz TD2011L04i Engine Specifications 2 6 Perkins 8040 33 Engine Specifications 2 7 Machine Torque Specifications 2 8 Manifold Component Specifications sse 2 8 Hydraulic Hose and Fitting Torque Specifications 2 9 SAE and Metric Torque Specifications sese 2 10 Genie Part No 122985 5 80 S 85 S 80X vii September 2015 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction ee ee as ERBE en 3 1 Pre Delivery Preparation 3 3 Maintenance Inspection Report u 3 5 ChecklistA Procedures A 1 Inspectthe Manuals and Decals 3 7 2 Perform Pre operation Inspection 3 8 A 3 Perform Engine Maintenance 3 8 4 Perform Function Tests nennen nnne nnns 3 9 5 Test the Oscillate Axle enne nnne 3 9 A 6 Check the High Pressure Hydraulic Filter Condition Indicator 3 10 A 7 Perform 30 Day Service 3 10 A 8 Perform Engine Maintenance Deutz and Con
25. 19 6951 asralog Ho 01 INSI HM 1 289 08 06581 2951 d 5 qsegr qu xg 7951 On 21 Q c8 L HM 2 14651 S8 r uO d8 9r1 u8 81 66 1 8 ave lal dd dOLS 3 90 08 T c9S 1L QH HM q98 L QH HM 26951 2 1951 4 WrLd 1 q8rral Ho 951 vedo vie 18 ES0503D Genie S 80 5 85 S 80X 6 63 Part No 122985 September 2015 Section 6 Schematics 63 Ground Control Switch Panel Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models 64 65 Section 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models CONTROL HARNESS TO PLATFORM SWITCH PANEL TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6
26. PartNo 122985 S 80 S 85 S 80X 6 4 Section 6 Schematics Perkins 804D 33 Models Electrical Schematic S 80X September 2015 N e LO ers GND BR z si S18 5 coss gt oR Ww PRIMARY BOOM ANGLE RD BK C123PBS RD BK BL SENSOR SAFETY 0128088 SNSR GND
27. N C78 BR sx 5 gt F YL gt F BR S18 5 SENSOR SAFETY C123PBS RD BK lt lt C123PBS RD BK 82 BL C6 34 C210 SNSR GND BR amp SNSR GND BR arr BK 17 C6 35 PRIMARY BOOM ANGLE 29 P409ANG GN WH Ro e lt gt 1 e SENSOR OPERATIONAL 9 C2 8 5 2 10 HT ROBK 2215 a Qu 9 RDT LST20 STOWED ANGLE C24 C6 22 gt a BR DRIVE SPEED REDUCTION 4 456 lt e CA2LS OR RD amp 04215 OR RD oq BK amp LIMIT SWITCH cams RDWH 22849 3 2 2 C6 40 5 LED BURD g 1 9 0405 OR C40LS OR ROC ae LSBIROSBOOMRETRACT rw BR DRIVE ROTATE SPEED u P134PWR RD BK x LIMIT SWITCH WH lt 3 8 2 C6 25 oll T en P134PWR RD isto 125152 DANE ENABLE BLWH 7 EXC lt a C13DRE 613 c13DRE BLIRD 22 2 s z LIMIT SWITCH _ 58 F WH C143DEL BL BK 5 1 11 C6 37 5 rec C37STCC BL BK C37STCC STEER CCW 8 oa o T x TZ C36STC BL 66 86 C36STC BL ni STEER cw 5 n e 6 C6TRF WH RD EK C35 CSTRR WH BK 9 foc C4TRL WH 8
28. OSCILLATE VALVE S 80 S 85 S 80X PartNo 122985 pra BOOM EXTEND RETRACT CYLINDERS JIB BOOM CYLINDER PRIMARY LIFT CYLINDER 16 61 Limin EXTEND 771 EA Lar e OPTION 7 gpm 26 5 L min RETRACT 15 gpm 57 L min UP 1 R F 8 30 L min DOWN SLAVE 3 isses 5 BRAKE 2 SPEED Am A MEBIUM FUNCTION MANIFOLD mud 222222 m 0 025 inch 3 5 PRESSURE ENABLE VALVE M E en legt JE ra H 4 pog p Up ee 211 Bo BB ce t HIGH PRESSURE 7 Lope 0 030 inch mt BST SET 1 ZIN IRB DRIVE PUMP da dU Bd 1 2 1 1 p N ERBEN EN 1 MASTER BRAKE TEST 1 E v2 CYLINDER 1 1 6 4 2 x L__ 102 psi JB 7 bar 250psi PLM1 PLS1_PLS2 PLM2 PR2 J 4 cT Biber 2276 us 1 T5 SW1 sw2 L1 12 2 4 Fa T X M 5 Ms i 21 NE eg NN 2 5 Rom 2900 psi 77777777 t 1 H 1 1 3750 psi re SEXES
29. C28TTA RD BK N C28TTA RD BK Genie 6 130 5 80 S 85 S 80X PartNo 122985 P26ESTP BK P26ESTP BK P26ESTP BK P24FS WH P2 C9P 3 D10 a 1 P25FS RD P25FS RD _ P24FS WH P24FS WH TS2 TS4 TS3 4 TS1 ENGINE ENGINE FUEL es START lt RPM SELECT o o po 048 re re re Ut T 58 0 m T To ap es 9 79 29 8 Hy HORN Hi E z L48 012 5 2 D40 x gt T CB2 15 AMP Pi TB134 9 9 9 9 9 g 9 8 a BI 2 e TB132 m m A ae 4 1 TB22 8 ut TS52 TS64 Q 3 8 ENGINE 8 FUNCTION 4 me 8 8 eGRND Selen 5 S PUMP gt pele START Q ENABLE 3 mee 2 e E TB20 2 d 2 x 2 az ety IL 59 p P134PWR RD iz 8 Z 8 9 5 m s C41RPM OR BK 7 8 ENGINE ENGINE 5 FUEL
30. ES Q 4215 OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 Q Gy C2PBD 2 gt C36STC BL C1P 10 C3PBF RD WH 3 C37STCC BL BK C1P 11 WH L1 WH C9P 2 C7PBE BK 7 Q C13DRE BL RD C4P 1 C8PBR BK WH 8 C4P BR e C7P 12V BATT 5 C4TRL WH 4 C32BRK WH RD C1P SES 29 caine XM s 2 2 C29MS RD WH C1P 3 C2P BK C1P GY LS18 C132PLI1 BK C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH 1 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 I JC3 5 C159STC BL WH B GE C2P 9 109 GR WH lt 2 2 JC7 4 C165TRS WH RD 4 5 C2P 10SNSRGNDBR FO L JC7 3 C164PES RDAWH 4 NI ES JC7 2 01620042 OR O i JC7 5 C163PES WH BK 8 a JC7 1 JSGND2 BR 5 JC3 4 C160JPL WH RD JE I JC3 2 P162JPW1 OR O mo l JC3 3 1595 L JC3 1 JSGND1 BR TS15 C144DER BL WH i 9 a TS15 C143DEL BL BK lt H L1 C13DRE A BL RD O C28TTA RD BK I TS14 C29MS RD WH 8 T GR BK C3P 12 GR BK L4 RD C2P 6 RD 151
31. m a FZ T I na 2 a 5 o lt 5 855 lu 2 n z asE 9 m 9 9 o 58 Z Q lt 5 2 5 209 5 E 255 z 2 88 882 9 m sz 555 5 B K u 12 a 5 az F uu o 21 68 lt 2 4 mullo 25 2m 5 gi Om 0 1 5825 8 2 888352 lt a z lt o u F 2 B 8 s zlul gt 5 5 5 2 252 802 8 2 0 5 8 O z r F m 3 gt Lu Fu 5 m 5 G gt gt dig tt z gt 5 6 5 5 6 0 lt 2 gt 5 gt 4 5 gt 454 6 lt 0 5 ET 2 ele 0 2008 ele a 5 lt mir 95 0 D A GD GO 0 H a lt O O O 2 0 m 8 01 Gd SEEN 6 2
32. pi a Qu zu zo 24 OF zy I gt Go lt x Z rs 5 20 o 2151 B 5 ciu 5 r 6 gt 2 E u 2 gt u 5 20 5555 215 5852 6 5 5 lt o 9 lt 5 EZkz EIS 22 2515 25 5158 05 zu Q 25282528216 2156 2 8 21 2 5 0 35 3 2 8 aus um 9 29 8 6 5 59 6 5 gt 0 9 5 S 8 85 0 5 xl wu z 5 6 6 0 5 o alala a z elele gt gis lt 2 lt lt 8 5 gt uE 25 2 zz E gt 5 2 lt u x 25 lt lt lt lt lt lt s Es 2 2 gt gt gt gt 5 x 21 2 G Siala a 2 55552 5 a I lt m gt m 888 ezsssstb5sssss gt 2 a HD 0 a4 o O OO O OO F F F F F lt 9 qm 39018 NOLLVNIINH3 L 5
33. DO Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm 5 Flow divider combiner valve uu Controls flow to flow divider combiner valves 19 80 90 ft lbs 108 122 Nm 6 CHECK scenic DD Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm DE us Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm DA Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm Equalizes pressure on both sides of flow divider combiner valve 13 10 Check DG Steer end drive motor circuit 60 70 ft lbs 81 95 Nm 11 Check valve rit DH Steer end drive motor circuit 35 40 ft Ibs 48 54 Nm 12 Shuttle valve 3 position 3 way DJ Charge pressure circuit that directs hot oil out of low pressure side of drive pump 80 90 ft lbs 108 122 Nm 13 Flow divider combiner valve DM Controls flow to steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 14 Check Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm Genie P
34. LAUNE 1 6 COMPONENT INDEX H1 TILT ALARM TS6 GLOW PLUG TOGGLE SWITCH JC3 JOYSTICK DRIVE STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE PLATFORM LEVEL UP DOWN TOGGLE SWITCH L1 LED DRIVE ENABLE TS14 DRIVE SPEED TOGGLE SWITCH 147 LED CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH 7 L48 LED TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH OPTION L50 LED ZONE B 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD L51 LED ZONE A 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON NOTE DASHED LINES INDICATE OPTIONS P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH 1 ROCKER STEER OPTION 8 TS2 ENGINE START TOGGLE SWITCH TS4 RPMSELECT TOGGLE SWITCH Genie PartNo 122985 S 80 S 85 S 80X 6 55 55 September 2015 Section 6 Schematics I Platform Control Box Switch Panel Wiring Diagram S 80X Deutz TD201 Models 56 Section 6 Schematics September 2015 aIK Cc Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models 57 6 58 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models
35. 2951 1 aezal HM 2 1851 S8 r uO ug 9r1 ug 281 qeeal a e dOLS 3 1 89 951 Gq9g8 L qu HM 4 6951 914 2 1981 98191 90 L L9S L HWGH C wH H8 viu vedo S8 5 8 18 ES0505A Genie S 80 5 85 S 80X 6 123 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 123 6 124 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 125 6 126 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111
36. 6 171 12 kW Hydraulic Generator Hydraulic Schematic 6 173 Genie xviii S 80 S 85 S 80X Part No 122985 September 2015 Section 2 Specifications Machine Specifications Specifications Fluid capacities Fuel tank 35 gallons Rough ough Terrain and Non Marking Tires Wheels Deutz and Perkins models 132 5 liters Tire size 18 625 FF Continental models 30 gallons Tire ply rating 16 113 5 liters Overall tire diameter 40 7 LPG tank 33 5 pounds 103 3 cm 15 2 kg Tire pressure Foam filled Hydraulic tank 40 gallons Wheel diameter 24 5 in 151 4 liters 62 2cm Hydraulic system 50 gallons Wheel width 15 in including tank 189 3 liters 38 1 cm Turntable rotation drive hub 40 fl oz Tire weight new foam filled minimum 622 Ib single fill port 1 2 liters 9 282 kg Turntable rotation drive hub 43 fl oz Dual fill ports 1 3 liters High Floatation Tires and Wheels Four wheel drive hubs 30 5 fl oz 0 90 liters Tire size 41 18LLx22 5 wheel drive hubs 23 fl oz Tire ply rating 14 0 68 liters Tire pressure 70 psi Drive hub oil type 4 8 bar SAE 90 multipurpose hypoid gear oil API service classification GL5 Wheel diameter 22 5 in Tue tum 57 For operational specifications refer to the Operator s Manual Wheel width 14 in
37. c SOg8 HO 9 80 NSI QN9718 81 8 015 WOO 22 90 v HcO 27 f Noudo WOO8 1 87 t 8561 76 0 HM 58 6 NMOGNOOSB alf 8 MG D 18 18053000 gt 061 89S1 49 49 avre L 40 HOIVH3N39 OV 66 90 1 820 Sv NHOH 2 99 9 920 9v ovirdd a31318V9 35001 11 90 11 880 6S 9 NOLLOn 3H 03345 1411 19 90 HO Fm 988 HO 21 80 21 6 260 HW 18 aasnNn 21 860 Mg u5 661 8 260 Mg u5 H3MOd HOLIMS 72 99 9 920 Qu vel re 1 260 Z ISY v HOLIMS AIX 96 90 90 90 08 SNOOW3E HM 9 HO 3unss3Hd 61 90 90 GH HO 881 890 9 6951 GH HO v o 0 ncn gt 8 2 260 3 5 8 xa 21 9 IE 599 509181 8 u 8 2 6861 D ONS 5 1561 ug 1 822548 5 5 2 og 1 5 026 81 18 vezal overal dH L 2250 Hwa HARNESS SWITCH PANEL PartNo 122985 CABLE RESTRAINT wo S 80 S 85 S 80X G ES504D 6 14 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80
38. 1 o 116 cae Wa LAWOHOVL 2 O ya ato AvidH1HVIS T Ol ey m gS cH L HM M90 18 1 Va N M 86978 WOOS IHd 1 90 Laco 7 1951 9 IHd 2 92 Mg QH 6 860 2 gt 620 9 1951 M8 QH WOOS IHd 8 99 5 959 MO SLVLOY 474 7 99 HM 860 HM 2 2951 HM F1VLOH 5 99 9 820 8 S 1 2951 1 318VINHAL 9 90 9 860 QU HM 9 v r H 1X3 WOO 2 90 99 1 869038 Z 6951 LOVHLSY WOO IHd 8 99 HMA 9 860 HWE 8 2 2951 HWE MO14 1 1 WOOd 6 99 auma 6 860 auma 6 98 81 99 9 le 2 8 1 6951 HO 13437 WHOSLW 1d SL 2 6951 MO 31VLOH WHOSLW 1d 8 1 SS1 HO MOO 3lv1Ou 1d 9 40 49 48 81 2981 49 49 AlddNS 1 198 Livd 02 2 289 5 AZL 11 90 HM 12 HM E OL HMd HOLIMSA3M 22 050 15 21 9 5 WHO4LV1d OL H3MOd 2 810 21 EZ 2 WSI HM 15 HM 0281 vc 9 82 zz 076 690 1881
39. 01120 06 92 MAD 012120 86 92 H8 GND 1 1 me 177 g au 08320 1 gt o x 1 LA g 38820 1 2951 12574 91424818 5 aoc o ceo r 5 2 9 2 E ou 86 81 38 8 _ 9 5 0998100 Z 2 lt 8 GISSL HM 9 _ 1 20 7 5 e T p amp es Pe 060018 1 e LO S 80 S 85 S 80X PartNo 122985 6 98 Section 6 Schematics September 2015 Perkins 804D 33 Models Ground Control Box Switch Panel Wiring Diagram S 80X SNOILOANNOO lOHLNOO OL 08181 6881 8 18 01 08 9 260
40. gt 0 EE lt 81501 x ol lt 2 ala SE lt m tu Sur 512228 lt o rio 2 2 Kklalz gt 52 34 06 001 5 5 lt i riu lt mo o o o s z i OE lt Z E o 2 gt 5 E m 5 215 5 2615 5181891515 919 015 21218 5 5 68 5 su tt lt 5 9 m cos lt m i mags T St m 486682 254 54555 2 2222 58 0 m 0 G4 T3nd NOI 6 om ul m SSVdA8 A34 8 0 a HMd A3 2 G m 281 9 9 0 in 1 90 08 x S CH N m d NO 01881 10015 6 ea H3l13WOHOVL Z O isar3gHo Lavis C gEZaL HM 32018 NOLLVNIINH3 L 558 pont 8 9 090 9g IHd 1 90 1 850 L 7 1951 N WOOgIHd 2 90 2 8 0 Mg Qu Orval gt 620 9 1951 4g QH WOO8 IHd 5 90 HWGH 9 HWQH MO 31VLOH IIAVLNHNL 7 99 HM 2 2951 HM MOO 9 99 AJ HM 8 860 S 1 2951 M8 HM SLVLOY 9 90 9 QU HM 9 v rLH 1X3
41. Fuel or RPM solenoid FS1 BLK Foot switch P1 T 3 Emergency Stop button normally closed Hydraulic oil cooling fan Auxiliary pump 510 0 Resistor with ohm value Tilt sensor 6 2 S 80 5 85 S 80X Part No 122985 September 2015 Section 6 Schematics 25 psi lt 1 7 bar Filter with bypass valve relief setting Pump fixed displacement ze Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder MAANNM Accumulator 035 0 89 Orifice with size 2 Shut off valve ace Check valve 200 psi 13 8 bar _ Relief valve with pressure setting w A Directional valve mechanically activated Pilot operated 3 position 3 way shuttle valve 50 _ 50 ons Flow divider combiner valve with pressure balancing orifice and flow percentages Differential sensing valve Genie PartNo 122985 Hydraulic Symbols Legend DS Solenoid operated proportional valve Priority flow regulator valve
42. WHY HOSN3S 13131 86 90 8 2 8LO 82 92 59 9 10 6 oda auvwHod 12 50 HM r 819 HM 0 06 90 M8 HM 5 80 8 L 60 90 Qu HM 9 819 ze THAVHL QH HM 1 16 9 90 2 810 66 WSI 2 2951 9 81 9581 6 99 6 810 S 951 610 1 qu xa MO H331S 95 99 18 01 910 18 9 4431S 46 99 LL 8LO aasnnn 1 829 6 8 07 90 HO 2 820 OF aN9 49 2 52 2 20 8 WSI 5 5 INOOS 22 99 7 829 2 4 NOlLdO 008 2 8951 58 8 NMOG NOO8 8 WWWINDSXIQM e0tQ 5 8951 07 HOLVH3N3O OV 66 90 2 820 Sb 28 NHOH 1 80 9 820 11 99 11 86 69 9991 8 8 03308 1411 15 99 HO FIG 98 HO 21 810 251 2 20 HW 21 880 661 8 260 HOLIMS 90 9 751 1 260 2 15 dH v HOLIMS ASM
43. C73 BR 5 gt H YL gt BR 518 PRIMARY BOOM ANGLE C6 33 2b OR SENSOR SAFETY RD BK 2238 0128088 RD BK p 0123088 C6 34 0 SNSR GND lt SNSR GND BR gt t 817 02 10 C6 35 ee P109ANG GNWH P109ANG GN WH RD 58 C2 8 5 BRK 10 HU RDBK 2215 8 gt NT 3 2 LST20 STOWED ANGLE zz 5 Td DRIVE SPEED REDUCTION C42LS ORIRD 059226 C42LS ORRD 5 BK LIMIT SWITCH 46 5 ss a C29MS RD WH 5 a C22 C6 40 5 LED BURD 5 1 C40LS OR C40LS OR 4 8045 LBETROCHOONIRETRAGT BR lt q DRIVE ROTATE SPEED 5 P134PWR RD gt x LIMIT SWITCH WH 3 2 2 Fa Ceres P134PWR RD RD C41 C6 13 T LST10 BLWH EKQ 4 C13DRE BURD 99 13 1 BL RD BR je DANE ENABIE 2 LIMIT SWITCH EA RIGHT 2 gt BK zg 55 WH C143DEL BL BK o E o 8 8 E 9 gt cn 0378100 6 ces C37STCC STEER CCW 2 C36STC BL z 05 36 C36STC BL Al STEER CW e es WH RD 4 r 25 C3 5 2213 9 C5TRR WH BK 14 fox C94 CATRL WH a 8 3535 C64 gt TURNTABLE ROTATE 22295 CW CATRL
44. SNSR GND BR Dr 02 10 17 ce P109ANG EEE progANG GRIWH I nd PRIMARY BOOMANGLE m SENSOR OPERATIONAL C2 8 em 9 5 S10 S RD 2 LST20 6 22 BR le ANGLE STOWED C2 4 C42LS 04315 OR RD Bk d DRIVE SPEED REDUCTION 46 LIMIT SWITCH WH C22 e c40LS OR 0850 C40LS OR gt gt RD 5 LSB1RO 25 lt lt lg 1844 BOOM RETRACT 9 415 DRIVE ROTATE SPEED 66 23 E P134PWR RD 513 5 514 ror 5 B C6 25 3538 ci P134PWR RD AD a istic 55555 2 8 55 ME 5 C13DRE BURD lt lt C13DRE BURD a 384 DRIVE ENABLE 8 8838 y m 00558 H e 536 C6TRF WH RD 9 EK 03 5 CSTRR WH BK 4 3 WH Sen 9 03 4 10 C64 l TURNTABLE ROTATE v E m C6 5 CSTRR WH BK 5 TURNTABLE ROTATE 1 5 8 et C6 6 E TURNTABLE ROTATE H1 RD BK 9 aT READ 0 7 FLOW CONTROL lt III 8 38 QUO 14 03 9 C9PER BK RD 224 a 1 C8PBR C29MS RDWH 22 2 227 BK oc LEDBURD as er PRIMARY BOOM 06 7 gur _ 216 n 5 ork C7PBE BK H 4 Fat s 8 EXTEND C144DER BLIWH 5 8
45. 4 asedl Au Nd 588 21 7954 L cgo du 62841 2 18461 S8 r dO ug 9 1 81 azzal yg Sp1 dd SI SO qu 18 951 9 2 6951 919 1951 q8rral Ho 961 8 28 ES0505D Genie S 80 5 85 S 80X 6 147 Part No 122985 September 2015 Section 6 Schematics M zt Ground Control Box Switch Panel Wiring Diagram S 80X Continental TME27 Models 6 147 6 148 Section 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80X Continental TME27 Models 6 149 6 150 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80X Continental TME27 Models CONTROL HARNESS TO PLATFORM SWITCH PANEL P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 TS48 C49DLITE WH BK C4P 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS9 C14PLU OR C4P 2
46. C36STC BL 10 1 5 5 o Q4 C3PBF RD WH C3P 3 8 oE 9 822 C37STCC BL BK C1P 11 1 Ls CATRL WH C3P 4 oo C32BRK WH RD C1P 6 1 lt C5TRR WH BK C3P 5 C29MS RD WH C1P 3 gt tr N 3 o z TS75 1 P109TS GR WH a _ 12 P109LS BL WH _ 12 C177LS BLWH O P 1 575 2 C184PL WH TS75 3 SNSR BR Ho o C4P BR C3P GR I L51 C169LED1 GR O E 150 C169LED2 GR C2P BK N 7 CAN HI Ho CAN LOW UP C1P GY LS18 C177LS BL RD C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH C1P 8 TS4 C35RPM BK RD C1P 9 o L48 C28TTA RD BK H1 4 om I JC3 5 C159STC BL WH 5 _ 5 C2P 9 P109ANG GRWHO 2 23 4 7 4 C165TRS WH RD mug um 2 10 SNSR GND BRIO 2 at r JC7 3 C164PES RD WH 4 N 7 2 P162JPW2 OR 2 5 JC7 5 C163PES WH BK 4 8 7 1 JSGND2 BR y gt JC3 4 C160JPL WH RD 22 E e D i JC3 2 P162JPW1 OR 8 JC3 3 1598 BLWH 008 1 JSGND1 P I TS15 C144DER BLWH G a I TS15 C143DEL BL BK Nun I L1 C13DRE A BL RD C28TTA i HTS14 C29MS RD WH 5 RD C2P 6 RD LS18 WH TS14 e LIFT DRIVE SELECT OPTION BR BATGND GROUND STUD
47. 3xvH8 62 50 9 812 QU HM 26 LYVLS 3NION3 9 90 2 810 6 EHWSI 6 2561 9 81 ve S 91N HWA 95S L 8 3NION3 81 50 6 810 auma SE 6101 7981 MO 15 96 90 18 01 91019 96 83315 16 99 LL 8LO aasnNn 0919571 HOLIMS 07 99 2 820 HO 09 1 2 50 M8 HO 2 820 Ir ZEINSI 02181 HOLIMS LINIT 2290 GH HO 860 ev aasnnn 4 8 HO er 9 48 49 vr 1 0530 0281 60 1d ut HO1VH3N39 66 50 7 820 SF NE De NHOH 1 80 9 865 58 anayo 35007 1 92 11 890 es 9r7 43385 1411 18 90 98 r HO ZEL Z 9 aasnNn EEL 8 59 49 49 H3AAOd HOLIMS 2 90 9 920 961 8 1 260 2 19 v HOLIMS 2 90 96 90 vre 1431 NOOV38 HM 1 NOOv38 HO 318VN3 34155344 61 59 GH HO 290 7 870 au uo 991 890 8 6981 GH HO 9 a 38324 1 g au 1 011120 08 99 012120 86 92 H8 GND 1 1 1 2 e 0842600 1 gt o 5 a 384 00 1 u 2 Z 8
48. a x 5 m 8 5 gt 5 2255 E 5 lt lt x Orne aga 3 5 5 c gt lt zu 55 amp gt zm HOSS my 59558 to e t oe 999900 4 1 m 2 9 1 8 ai C5 11 aa e 8 a 5 C4 4 a C5 19 gt x V155PCE OR RD gt 4 V155PCE OR RD wo s 5 z im 5 322 z 0 u F gt rs 3 HIGH 1 9 29 t gt C35RPM BK RD 5557 ES 96 a lt Na a 5 R388 88 d Sz 395 0620 amp QOO F i E LOw 1 4 HIGH gt 5 18 1 e m 5 na rasrem 4 n 5 z lt as I E 5 u gt 5 55 B 4 C34SA BK WH 8 03 22 D 5 2 2 883 For R34SA BK WH rs zr s S lt C1 7 ae C33STR BK 5g gt 529 o E 5 15 5 gt 595 C24TSPS WH amp Filo a lt Ca e e Sa le 98 rX2 g 522 8 7 8 5 3 ju 4 t C27AUX RD 3 519 PN e AE 4 r e AUXILIARY 5 PUMP Bt 8 m 2 a we C5 6 5 5 t 5 4 9 lt as Zio cs 22 gg el
49. 1951 681 qg8rrar do 1 1951 999 vedo Joc l 8 18 ES0503A Genie S 80 5 85 S 80X 6 75 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 77 Section 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 81 11 September 2015 RD E STOP Zeil BAS RD LS18 CABLE P134PWR RD P134PWR RD o R20 RD H1 CONTROL HARNESS TO PLATFORM SWITCH PANEL COM NO U35 C3 10 C4 10 P26ESTP BK E STOP R26ESTP BK C9P 1 BR GND e e TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK C4P 8 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 LS18 C132PLI2 BK C3P 10 H1 C1
50. J2 11 JP TS9 C15PLD OR BK C4P 3 J8 P109LS GR WH C3P 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 TS3 C39LP BL RD C2P 1 P3 C46HRN GR C2P 5 TS47 C45GEN GR WH C2P 7 C40LS OR C2P 2 C6TRF WH RD C3P 6 C123PBS RD BK C2P 8 C7PBE BK C3P 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STC BL C1P 10 C3PBF RD WH C3P 3 C37STCC BL BK C1P 11 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK 5 C29MS RD WH C1P 3 1 les e s e s TS75 1 P109TS GR WH 4 1 12 P109LS BL WH C1P 12 C177LS BL WH 4 TS75 2 C184PL WH 7575 3 SNSR BR H 6 1 S o olo L51 C169LED1 GR L50 C169LED2 GR N CAN HI 2 o2 oh o o CAN LOW 1 JC3 5 C159STC BL WH _ C2P 9 P109ANG GR WH 4 7 4 C165TRS WH RD 2 10 SNSR GND r JC7 3 C164PES 4 r JC7 2 P162JPW2 OR JC7 5 C163PES WH BK 4 r JC7 1 JSGND2 BR _ JC3 4 C160JPL WH RD 9 1 LS18 C177LS BL RD C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 4 JC3 2 P162JPW1 OR JC3 3 1598 BL WH I JC3 1 JSGND
51. 01 8785 HM 6 a 99 01281 8 a 255 613 21 99 HM AVTaY NOLLdO o 9 ISP m lt wo S 80 S 85 S 80X G 64 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 SNOILO3NNOO OL 08181 6881 8 18 01 08 0 6 81 08 09 00 971 9 269 61 00 1951 9 I LSY HM S 9 raw 1951 4 z 88 81 08 v rLu Qu HM aval HM 2951 9 78 e N 0 0 06 8 22 e 2951 9 0881 qea L qu ia 21 90 Arral 9 48 4951 290 10 0 09 181 08181 38 6681 18 6681 38 9 2951
52. OR 5 PLATFORM DOWN LEVEL C15PLD OR BK 8 g P UP 5 I se PLAT LEVEL 0 DOWN ae 85 5 9 95 Bm C4 8 PS2 DOWN t CHYD ORBI qe C43JU GR 3 m z Su up 5 85 OPTION 9 8 8 4 Ground C46 PRR GR BK 2 535 Pac C18PRR FRE row m C17PRL GR 2 CCW a ee PLAT ROTATE tow 48 m 8 d veer 7 PLATFORM LEVEL UP o HA mE 2 1 922 12 5 PLATFORM LEVEL DOWN gt al JIB BOOM DOWN 8 2410 5228 2 a a 8 891 J22 5 J22 9 ceo 8 7 JIB BOOM Cee 5 2 x x s e E o EIS 22 2 SESS 22 3 25993 PLATFORM ROTATE CCW 58858 8 8 6 5 E LL PLATFORM ROTATE CW 7 42255 G 5 80 5 85 S 80X 6 35 Part No 122985 September 2015 Section 6 Schematics p WwH Xt Electrical Schematic S 80 and S 85 CE Deutz TD20111041 Models after serial number 8110 36 Section 6 Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Deutz TD2011L041 Models after serial number 8110 37 GROUND STUD ENGINE C5
53. l 1 TS9 i TS14 Ji jl 2 E Ton 43 fogo 1 b E L48 P2 5 RD BK 0 ES0504D x O a S A SS MEME 4 COMPONENT INDEX CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT DRIVE SELECT LIMIT SWITCH CIRCUIT OPTION TS8 JIB BOOM UP DOWN TOGGLE SWITCH S 85 OPTION H1 TILT ALARM TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH JC3 JOYSTICK DRIVE STEER TS14 DRIVE SPEED TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS15 DRIVE ENABLE TOGGLE SWITCH 7 L1 LED DRIVE ENABLE U13 ALC500 JOYSTICK CONTROLLER CARD L4 LED PLATFORM OVERLOAD U35 TIME DELAY RELAY L47 LED CABLE TENSION LED ALARM NOTE DASHED LINES INDICATE OPTIONS LS18 PLATFORM OVERLOAD LIMIT SWITCH P2 EMERGENCY STOP BUTTON 1 ROCKER STEER OPTION P3 HORN BUTTON R20 RESISTOR 47000 TS1 AUXILIARY TOGGLE SWITCH 8 TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH Genie PartNo 122985 S 80 S 85 S 80X 6 43 September 2015 Section 6 Schematics V Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz 2011 041 Models after serial number 8110 6 43 6 44 45 Section 6 Schematics
54. LS 2179 5 OL H3MOd 91 2 820 21 6 2 NSI HM 20 1 157 HM it vozal qu 0 5 9 99 dH 22 4 WSI 1981 GY 0 81 HOSN3S 13A31 82 92 810 xg au 82 5 6 90 5 91 HIWQH 62 003 00 16 90 HM r 810 HM 6 02 59 x8 HM 5 81 M8 HM 16 ayvua 56 90 9 819 ze T3AVHI QU HM LHVLS 9 90 8 2 810 66 ASI 2 2951 MO19 8 81 0 HWE 6 9 91 HW 8 9561 Q33dS 6 90 6 810 6 1 1 7951 qu xa MO 5 95 99 18 01 910 96 MOO 1 18 99 11 81 46 aasnnn 1 860 0310013 8 07 99 Z ZO HO OF 2 1 2 52 9 860 28 NSI ut 57 5 319NV 22 99 86 Qu uO ev 0 7 E pue aPC AAT DR 5 te NOILdO Wood air 1 8 HO 1 8561 HO avera 986 NMOG WOO 49 49 tt 14829310077 e 2 8951 49 49 DZE MIIHM u YOLVHANAD OV 65 99 1 829 SP 8 NHOH 1 80 49 9 860 97 q31318vO 11 90 Nad LL g O 68 r1 03305 1411 16 99
55. 20 25 ft lbs 27 34 Nm 2 Solenoid valve 2 position 3 way BC Two speed motor shift 20 25 ft lbs 27 34 Nm 3 Check valve Brake release circuit 20 25 ft lbs 27 34 Nm 4 Orifice 0 025 inch 0 63 mm BD uus Turntable rotation brake release BA Genie S 80 5 85 8 Part No 122985 September 2015 Section 4 Repair Procedures 8 4 Turntable Rotation Manifold Components MANIFOLDS The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine Index No OO N Schematic Description Item Function Counterbalance valve 1000 psi RA Turntable rotate left Counterbalance valve 1000 psi RB Turntable rotate right Shuttle valve 2 position way Turntable rotation brake release Orifice 0 030 inch 0 8 mm Brake release circuit Genie Torque 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm nr 8 10 ft lbs 10 15 Nm Part No 122985 S 80 S 85 S 80X Section 4 Repair Procedures September 2015 mcm M i MANIFOLDS 8 5 Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator
56. CHECK ENGINE LED ES0503D HOURMETER PRESSURE COMP VALVE FUNCTION ENABLE RPM POWER RELAY RPM CONTROL RELAY RPM SOLENOID FUEL PUMP GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID CONTROL RELAY FUEL SOLENOID AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP POWER RELAY AUXILIARY PUMP IGNITION STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION FLASHING BEACONS OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY G S 80 S 85 S 80X PartNo 122985 6 58 Section 6 Schematics September 2015 Perkins 804D 33 Models Electrical Schematic S 80 and S 85 ANSI CSA AS
57. 5 8 LIMIT SWITCH y e RDWH 28 2 2 C6 40 5 X LED BURD 1 lt 6 C40LS OR 7 TTeleale 198180 BOOM RETRACT ed DRIVE ROTATE SPEED u P134PWR RD BK 5 x LIMIT SWITCH a WH 6 C6 25 u P134PWR RD RD u 5 zlog LSTI C144DER x C13DRE BURD 26186 __ C13DRE BURD BR 129 8 DUE ENABLE 22 BWH E LIMIT SWITCH PS RIGHT 2 LEFT WH C143DEL BUBK oa id 8 Cit C6 37 2 2 rec C37STCC BUBK C37STCC BL BK STEER CCW x 2 gt ze 015 C36STC BL C636 C36STC BL STEER CW 5 5 8 m 03 6 C6TRF WH RD 24 5 gt WH BK 03 5 9 73 c T m WH T g 5555 04 C64 gt TURNTABLE ROTATE 228076 oases cow ccw COW C ORNTABLEROTATE C6 5 TURNTABLE ROTATE 5 23932 git C5TRR WH BK A cw 88886 8 0059 C6 6 SETE WED F TURNTABLE ROTATE 1 MIMIMINIM 8 FLOW CONTROL 89 9 Fe a Ec x 55 C6 1 2019 PRIMARY BOOM 263 UP id UP 58 PRIMARY BOOM 8 c 1 2 9 gE _ t DOWN aH az C2PBD RD BK 24 awa a BOOM 98 og 3 lt 2 a SEI 5 8 z PRIMARY BOOM
58. LEFT 1 RIGHT A 3300 psi 228 F F EN l eon STEER CYLINDER A 3000 psi 207 bar M2 1 sow a ts J LEFT RIGHT 10 070 inch 18mm A ALIA P 12 he 1 1 NUNC SA G t a i IN m 1 LEFT M3 S UT 4 REAR 11 HS0166C 7 Kea OSCILLATE CYLINDERS TRACTION MANIFOLD 200 September 2015 Section 6 Schematics Hydraulic Schematic 4WD Models N M L K J H G F E D 0 8 A
59. l FUNCTION RETURN 211 meris US 0 6 gpm 14 DU PUMP FILTER 1 1 E 23 Umin 38cc Ti 1 1 1 1 ST TA T4 1 I pes 950 psi b doa 4 sq 135 2ber PLATFORM MANIFOLD 25 psi 1113 L min J Abas SU 0 TE i i i a FUNCTION MANIFOLD 30 psi 2 2 e Ost 2 Sri 78 OIL COOLER RESERVOIR osc TEST 5 2 7 4 5 1 HYDRAULIC ROTARY COUPLER 1 l E amp SE A COUNTERBALANCE VALVES Nik ene ee RATIO PRESS 6 1 1 A 1000 psi 69 bar A 151 3000 psi 207 bar ES SS T ren 19 RIGHT a 3500 pisi bar FRONT A 451 1000 psi 69 bar A pl LEFT RIGHT A 451 3500 psi 241 bar Lo l STEER CYLINDERS A 3300 psi 228 bar E 08 A 3000 psi 207 bar n 8 M6 7 E FG t 47 f 50 1 280 psi B Fr 50 4 LEFT RIGHT n 19b ba 27 190 reh M DK 50 50 IN LE som amp 8 11 p D er i DD Dy 1 404 EE 225 IN cni 0 040 inc
60. tW 4 J22 11 PLATFORM LEVELUP gt 9227 5 26 PLATFORM LEVEL DOWN 18 2 1 1228 J22 6 Se 422 10 se JIBBOOM DOWN 7 gt N J22 5 EI 122 9 bE 0 5 JIB BOOM UP 5 E gt x x 5 E o T ao E a 122 2 22 3 85845 PLATFORM ROTATE CCW 8 240 23484 T 5 E 5 PLATFORM ROTATE CW G 5 80 5 85 S 80X 6 119 Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 119 6 120 Section 6 Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 81 11 6 121 6 122 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 C
61. 01 08 1951 L LSM HM vay O9 1951 2951 088 81 0 v rLH QU HM 289 aval HM QZLGL NO 2951 9r u ad 78 1951 eo 06 08 8 O ESHO Md GA 9 0881 6881 a6aL Au Nd 21 90 word td ON 9 ON pe 91 08181 8 OL NSI HM 2 0 qeearoda 2951 9951 1 18 era lt o0 7951 aseal Au Nd aezal HM 2 1451 S8 VEYHO YE 9 281 2281 9 SI sO qu 18 T c9S L dH HM q98 L dH HM 2 6981 914 1951 WrLd 1 1951 98 98 88 ES0503D Genie S 80 5 85 S 80X 6 9 Part No 122985 September 2015 Section 6 Schematics H l Ground Control Box Switc
62. CR30 CR27 C32BRK C1P 6 OR RD C40LS SPLICE TO 0401 5 C2P 2 WH RD C32BRK SPLICE TO 5 80 5 85 S 80X PartNo 122985 6 102 September 2015 Section 6 Schematics jo v b6b e gr z zx gt 1 x x z z 1 1 91 Platform Control Box Switch Panel Wiring Diagram S 80X Perkins 804D 33 Models N M K H G F E D C B A 0 1 CONTROL HARNESS TOPLATFORMBOX 1 ii m w 202 ies iss m S 39 221128 5 3L 2 8 9 5 a 2 25 3 29E RR 9 A E R8 48 BESS 4034 2 2939 8 8 5 88 R 9 5 355 5 2 58 9 3 5 8 o P m 9 o Im 8 G 5 7 5 5 2 o9 RO c 2 0 8 EN ox 82 o sang g 9 zo 5 oz 5 A dw ER amp i 1 1 B n gt 553 TS4 9 TS15 o S Si 7 2 2 QO x DIS JC3 u l 1 1 JC7 TS2 TS6 3 Wad O6 Q Le ot 1 147 Q4 all 4 o
63. RIGHT 2 7 LEFT Se WH C143DEL BUBK C1 11 E C6 37 2 8 C37STCC BL BK C37STCC ga 1 1 STEER CCW lt 18 8 C6 36 5 T TZ C36STC BL s C36STC BL STEER CW e Blur 6 C6TRF WH RD EK 095 C5TRR WH BK 9 Hos CATAL WH C64 8 18 TURNTABLE ROTATE 510 4 ccw 0 cow C4TRL WH 4 gt 4 Tt 255 Sig cow TABLEROTATE 5 219 TURNTABLE ROTATE gt git 8 CSTRR WH BK 7 Ow LET C6 6 TURNTABLE ROTATE 222025 a 2 WHIRD FLOW CONTROL 5 a F N 88856 C6 1 PRIMARY BOOM 53 59 0 0 UP 8 2 C1PUB RD A Up e PRIMARY BOOM a lt 529 o m 29 5 9 u ES 5 ces E PRIMARY BOOM C3PBF RD WH UP DOWN 5 FLOW CONTROL 2 5 ES 87 csa C1PBU RD i M C129DA DESCENT ALARM 3 oz C2PBD RD BK 0 7 1 8 3 5 222 C3PBF RD WH 8 11 IS Sm 2256 GROUND 5 9 88 lace C9PER BK RD 51554 88280 C8PBR BK WH 8 3 8 12 859 0 C37 89 frac lt C7PBE BK 5 E Lo ee C67 BR PRIMARY BOOM 4 EXTEND zug EXTEND 5 8 us g 1 RETRACT 0 SH PRIMARY BOOM RETRACT 5 2 52 25 Fi B
64. 220V 15A 120V CR46 CB4 CB6 30A L M N E GENERATOR VOLTAGE REGULATOR C45GEN gt lt BATTERY D lt BATTERY C C OUTLET 6 GENERATOR PIN COLOR CIRCUIT 1 WH NEUTRAL 2 GR FIELD 3 LINE 4 PLUG Ll Ll Km 1 2 3 4 5 VOLTAGE REGULATOR PIN COLOR CIRCUIT 1 RD12GA R20BAT 2 WH 12GA NEUTRAL 3 BR12GA GND 4 BK12GA LINE 5 BK WH 14GA FIELD
65. 8 99 9 HMA 8 9S L HWE 1 WOOP Idd 6 90 6 880 6 9 6951 61 99 1 dn T3A31 Z8vO 1 1 6851 13A31 9 SL 9 6991 8 MO 31vLOH 9 1 9 981 MOO 31v10H 9 49 49 81 2951 49 49 AlddNS 1 0 00 5 AZL 11 90 HM 5 99 HM E 1 14 OL HMd HO LIMSA3M 22 260 9 19 Zig 5 OL H3MOd 2 80 2 2 WSI HM Za l LSA HM dc 1 v2 2 55 9 90 1815 qu 6 4 690 51 1951 e 80 81 WHV1V HOSN3S 82 90 6 a 75 69 810 68 T 16 90 HM HM 06 5 06 90 M8 HM 910 M8 HM 6 56 50 9 410 Qu HM 66 WHY TV T3AvuL Qu HM amp 1HVlS 9 90 2 810 98 66 1 51 6 2851 MOTO 8 HLO 6 9 9991 6 99 6 10 SE 1 51 qua NO 8 96 90 18 01 910 18 9 MOO 4331S 26 90 6 aasnnn 6 S
66. 91 L AUXILIARY 2 d PUMP E C5 6 SN APU CUT OUT 8 5 gU RELAY m or cs emo E mo sms 4 VOLTAGE DROP uw 5 5 20 RELAY 11 8 m 7 2 5 Si m AUXILIARY PUMP P23PWR WH 5 885 R27AUX RD T AUXILIARY PUMP y4 r lt Cr C28TTA RD BK e T gie 06 28 C28TTA RD BK TILT ALARM C624 P134PWR RD LEVEL SENSOR ee OR x 018468 RD A FLASHING BEACON SD OPTION t P134FB RD 45 9 e m Y E 2 C25 C46HRN GR 05 7 HORN RELAY e gi E 6886 P22PWR 1 1 a HORN 3 2 M 7 qw HYD OIL COOLER 8 TEMP SWITCH 92 x pigapwa RD OPTION Lt gt 5 a 8 2 HYD OILCOOLER 5 Q 2 FAN OPTION lt z 9 4 amp x EY y m amp a m g mie i x e E ao 8 o Le 9 D amp 5 lt ol a 8 CR 2 2 9 ls 5 ALTERNATOR 119 3 8 AUX MAIN IE cot 1408 11 ret 5 4 0 BATTERY SEPERATOR LCS 205 8 RD 4 START BATTERY at o ec 8 a e B1BAT RD CONTROL BATTERY PartNo 122985 5 80 5 85 S 80X 6 142 Section 6 Schematics Continental TME27 Models Electrical Schematic S 80X September 2015
67. BR BATGND GROUND STUD WH TS14 CR30 T CR27 e hl o LIFT DRIVE SELECT OPTION WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD C40LS SPLICE TO CA0LS C2P 2 ES0505A 5 80 5 85 S 80X PartNo 122985 6 126 September 2015 F E D C Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 B A CONTROL HARNESS TO PLATFORM BOX 1 1 1 i 0 UO o uU 2 o DDD 192 Di 2 2 m a DE dD 8 JA 2 5 A Q BO 2 5 lt uo E 5 z 202 8 0 0 9g 6 A i X I 2 2 2 FY y 9 9 2 a GE 202 x m ox ur 1 8 v c c c o 9 Q9 I U P Oo Q o T 0 0 5 7 5 D n 2 j m R 5
68. Bee 1 P23PWR WH Ie R33STR BK 805 5 2 WH RD a t Q 5 lt a a 2 amp lt 2 Z lt a a amp 5 9 a a m 4 C6 28 1 AH 612 C28TTA RD BK C28TTA RD BK zog 3 9 e tn BK 3 8 C624 PI34PWR RD LH m lt r ore C133PLS GR BK 5 m x 025 C46HRN GR St i 25 go z S 5 25 19 ei e GRIBK RAeHRN GR 4 5 P22PWR BK 1 a zo 5 nd i 52 a C1 12 E 7 1 116 WH 4 C132PLI BLWH 350 E C2 6 5 E zo lt P184PWR RD gt gt gz 5 As a 3 xz xl H d 1148 5 1 527 ac 9 RD 5 at P134FB RO dr t OEP P134FB RD _ 4 5 H C52 CA1RPM 1 42 w9 9 57 m 2 5 9 1155 2 189 s S 8 at 1027 PS ERO 0 5 a RD gt 4 a FL 5 m a2 08 1 S C 8 E RD 8 o a e 8 N LO PartNo 122985 6 82 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 A
69. m uA 6 Slain E ol T m 6 5 P 2 gt 0212 2 gt u 2 lt oe oo o 29 2 52 25558 5 20504 15288 amp 2 9 Bag 5 5 8 5 8 5 2 8158 2 pz 5 6 00 O 0 Ai O O O GO T Xj F IF F F F F F F FI IF 2 23123 8 u m 1 05 a NO 6 G 88181 m O 6 5 SSVdA8 A34 8 O q m A33 2 O1 35ezapHM S x AdaLiva 9 Q4 5 O as NO aw LUVLS 04 5 H313AOHOVL Z 67 36 1816 11 SI 06 K z 1 39018 NOLLVNIAH3 L 3SV8 6 8 Fl 0 6 INOOG IHd 1 95 rgeoqu anis WOOS 292 0 890 g QH 2 Orral e 620 9 1951 38 08 7 WOOd Idd 6 92 H 0 Hwqt 06 MO SLWLOY 7 99 HM HM 9 6991 HM MOO 3lviOH 5 92 S 8G O M8 HM S 1 2951 M8 HM 31V LOH 1 9 99 GY HM 9 8 0 QU HM 9 LH 1X3 WOO8 IHd 1 90 X8 1 860 8 2 2951 LOVHL3Y WOOd
70. 98 WHOSLV 1d 61 10 Z L 9 69 51 859 1 N9 49 HOLIMS 72 99 9 920 rer 9 9H Qu v 43MOd HOLIMS A3 96 95 42 90 Vvell e 1431 NOOV38 HM 1H5I8 NOOV38 HO 61 90 0 8 290 Qu uO 991 890 9 2951 qu uo 2 2 8 HMA 2 4 1 LAND 2 6681 5 1551 5 ee 1 4 348 een HM 9 6 82 Xg HM e 0686 81 48 1 E zuo See 191 HMdv ld dH Oz La L HMV 14 vezal 01 9 9 01281 dud 60 90 lt NOLLdO 2 1H I1 9 enie G 8 80 5 85 S 80X PartNo 122985 6 26 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L041 Models before serial number 8111 SNOILOANNOO OL 08181 Qesal tg 1a anas 95 u8 1 1 Yn 5 9 ZE9 HM c L9S1 dH L LSX HM
71. BERE 531888 82598 c Y 585858 3 za gt oa 00 6 z 2 2 2 Elolz u 58 829 22 5 89253 Ex S x 2 9 5 9 0 gt 5 9 6 5 5 6 215 lt 2 FEF 8 2 G gt 05 541025255051 121218 41815 F lt 90 2 gt rr r gt 2 2 5 5 5 5 5 9 1 66 2 gt z 2 2 EU lt 2 6 5 5 5 5 5 lt z gt 2 5 gt 2 eo s 6 5 5 2 56 5 355 58814 x i lt 6 m 55888 Yo 58585 8588 jo 58555555824 009 0 9 55 01 C pag 2 NO 6 Son SSVdA8 8 O A33 2 0 0828 Aual va 9 G a omowa INdNI 18016 CH an 1 Z Csao 1815 3 6998 32018 51 WOO8 IHd 1 90 1 890 1981 2 99 Y9 QU z ae
72. L1 B 4 9 ist tev 22 FR 75 N 9 L fogo e 3 OOO o Ne rae s 9 L48 L51 TS75 L50 P2 QU I 5 RD BK BK BK 1 1 RD RD 9 ES0503D ae ss 4 6 COMPONENT INDEX 1 TILT ALARM TS6 GLOW PLUG TOGGLE SWITCH JC3 JOYSTICK DRIVE STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH L1 LED DRIVE ENABLE TS14 DRIVE SPEED TOGGLE SWITCH 147 LED CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH 7 148 LED TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH OPTION L50 LED ZONE B 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD L51 LED ZONE A 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON NOTE DASHED LINES INDICATE OPTIONS P3 HORN BUTTON AUXILIARY TOGGLE SWITCH 1 ROCKER STEER OPTION TS2 ENGINE START TOGGLE SWITCH 8 TS4 RPM SELECT TOGGLE SWITCH Genie Part No 122985 S 80 S 85 0 6 103 September 2015 Section 6 Schematics Tu Platform Control Box Switch Panel Wiring Diagram S 80X Perkins 804D 33 Models 6 103 6 104 Section 6 Schematics September 2015 sssw sssTsFwwF Electrical Schematic 5 80 5 85 ANSI CSA AS Continental TME27 Models 6 105 6 106 Sep
73. M Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 85 6 86 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 C a ez ne 0 2 5 lt I 5 ol la 5 5 ul ul E 55 5 95 ks 2 lt 8 10 e oz e 9 alaja I 5 O 2 2 real 5 2 5 sie u gl 6 o ES S EZ E 2528 E ub CES al 2 5 2 8 T 3 86 22 22 996 gt 5 9 8 8 5 54 8 296524 5 e m 220 5 F uli z gt 8 55 eik olala 5 lt 0 519 5 lt E Oli s zizi zm rgEeEroStau 5 o 55 gt lt 5958 F gt
74. RD WH UP DOWN a FLOW CONTROL ar X C129DA RD BK DESCENT ALARM lez C3 EE 3 C2PBD RD BK Sk 03 2 7 8 1 zi eus on d CR34 SPEED REDUCTION oi Sn 8 S C3PBF RELAY m zr DONE nn E 6 31 m 9 LST3O BOOM UP DOWN 1 9655 SPEED REDUCTION 3 9 8 EX CORPER BK AD 2m BK LIMIT SWITCH 55542 50 aa as Oh a lt 65 C8PBR BK WH i W Q aly T Sr C7PBE BK 82 rail C6 7 BK RD BR gt PRIMARY BOOM 5 4 EXTEND t retract MARY BOOM C6 8 8 PRIMARY BOOM ok M 7 S RETRACT 5 8 25 Fre C6 9 HIM PRIMARY BOOM C9PERF BK RD EXTEND RETRACT 258 m FLOW CONTROL 8825 22 66 8 3 fa TEZ 1 4 CS C30EDC WH ER 1 4 EDC DRIVE FORWARD 2 2 TEZ C15 65 20 C31EDC 7 4 EDC DRIVE REVERSE te 1 GND BR 21 F C130TA WH RD TRAVELALARM OPTION PFs 22 8 8 5 P24FS WH 4 IX C16 5 29 C32BRK WH RD BRAKE RELEASE P26ESTP BK gt 3 lis gt C5 24 2 SPEED MOTOR STROKE 8 m C I No Bou P134PWR RD cz
75. Rc Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 CE Deutz 2011 041 Models after serial number 8110 CONTROL HARNESS 1 ii l m DD 2 S 2 2 w w 2 22 2 8 2 3L 2 2 DD 8 o 5 a 2 5 5 5 5 2 2 2 2 2 o lt 0 9o lt r 8 59 8 gt Z Z 9 A2 X E 5 0 8 2 go ToT 2 29 9 3 X C o 5 9 55 Ras c W 4 N wm N Ba gt 121 yom x S gt e 5 5 202026 2 2 T 9 E o m 5 a o c o TS4 7815 N Ss gt 2 N S 2 0 w m 1 1 1 1 1 x 012 JC3 1 1 1 1 JC7 0 E x EE TS2 TS6 3 1 T TX wen feo 1 L47 NE f 1 ME 5 1 325 4 NE Q l N Ser 1 EE 4
76. TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 TS48 C49DLITE WH BK C4P 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK C4P 8 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 11 1 1 WH L1 WH C9P 2 J8 P109LS GR WH C3P 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 P3 C46HRN GR C2P 5 TS47 C45GEN GR WH C2P 7 C40LS OR C2P 2 WH RD 6 C123PBS RD BK C2P 8 C7PBE BK C3P 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STC 0 C3PBF RD WH C3P 3 C37STCC BL BK C1P 11 C4TRL WH 4 C32BRK WH RD C1P 6 C5TRR WH BK 5 C29MS RD WH C1P 3 J ALC 500 U13 8 O Q O 0O 01 J7 CAN HI o2 no 1 CAN LOW LS18 C177LS BL RD C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH C1P 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 4 3 5 C159STC BL WH 2 9 P109
77. WH C143DEL BL BK oa 5 9 2 E 0378100 BLIBK fe 06 37 C37STCC g FM STEER CCW x zc BI C36STC BL 65 26 C36STC BL Ibi 4 STEERCW 9 5 8 m 4 Cs C6TRF WH RD 25 13 9 ces C5TRR WH BK 5 5 9 57 E TOZ 084 CATRL WH 8 5 4E C64 TURNTABLE ROTATE 0 cw 8 5 5 5 E lt TURNTABLE ROTATE 5 INTALE ROTATE 22252 T 5 8 C5TRR WH BK 8 E cw 2 000025 L S E 6 H H H 1 FLOW CONTROL 5 m 28 pa PRIMARY BOOM 28 e PRIMARY BOOM a 298 Te DOWN 208 PRIMARY BOOM gt 8 M DOWN 98 85 Zar 2 a lt cs PRIMARY BOOM 8 5 RD WH 4 UP DOWN g FLOW CONTROL ay i 8 ess zT M C129DA DESCENT ALARM Bx PBU C3 2 ee 3 C2PBD RD BK 84 8 7 5 CR34 SPEED REDUCTION gt 5n 8 RD WH r 7 RELAY 244 oc ml sa 6 31 12215 LST30 BOOM UP DOWN 228 C3 9 E SPEED REDUCTION OOPER ED J LIMIT SWITCH 885346 6048 ix C8PBR BK WH
78. o 55 c6 11 15825 EE C59CNK BL BK gus LOOSE CABLE 4 gt Lol LIMIT SWITCH 2 l c3 11 Fl Ln 146 147 LOOSE CABLE LED 4 2 3 5 C14PLU OR 3 PLATFORM T LEVEL DOWN C15PLD OR BK 8 z 8 P UP 5 sf PLAT LEVEL 0 DOWN ae 85 9 95 C4 8 89 PS2 DOWN t GRBK A C43JU GR 3 m z Su up 5 85 OPTION 9 RE 8 4 Ground nee C4 6 B22 low t C18PRR GR BK LEW m C17PRL GR 2 CCW ROTATE ee gy B m 8 d PLATFORM LEVEL UP 322531 7 3227 o HA J228 2 1 922 12 5 PLATFORM LEVEL DOWN gt V J22 6 A 12210 5 x 8 JIB BOOM DOWN 2 2 E J22 5 Em 422 9 2 cio I cr JIB BOOM UP o l u gt 2 T o EE g k J22 3 22 2 SESS B 210 x 8 PLATFORM ROTATE CCW 2384 5 PLATFORM ROTATE CW 21 4224 G 5 80 5 85 S 80X 6 83 Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 83 84 Section 6 Schematics September 2015
79. 0 Q Q D99 3 Y TB21 TB29 35 6 79 TB45 2 124 ohms AIBATTERY 1 d A2SENSOR POWER 5 VDC 098 065 mlo T 124 ohms 8 BIVAVEOFWDCOL 6 V151HG GR B2VALVE 1 NC 9 V150HG GR BK B3DIGITAL OUTPUT BYPASS m g g 9 g 8 5 BK 162 RS232TxD 1 C57 C57 BS gt RS232RxD cr 4 2 X 4 9 4 8 D1ANALOG 0 JOYSTICK x gt D2ANALOG 1 NC 4 D3C41 RPM 4 1 o x 7 c E1NOT USED 545 I 7 PS4 m E2NOT USED pL 5 9 15 USED AS lt B3 Io B m X IS 1 e 22 l F1DIG INO 8 N O 5 F2DIG IN 1 GENERATOR 9 F3DIG IN 2 SX Controller 8 g g PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD m lt m m BR2 o 16 2 DIVERTER MANIFOLD Genie S 80 5 85 S 80X Part No 122985 6 163 September 2015 Section 6 Schematics M 12 kW Hydraulic Generator Electrical Schematic 6 163 6 164 6 165 Section 6 Schematics September 2015 rc F Belt Driven Generator Option 6 166 Section 6 Schematics September 2015 UsuCr Belt Driven Generator Option 120VAC 60HZ LINE GFI OUTLET
80. 02 01 LL L ALC500 POWER VALVE INPUT PIN CIRCUIT COLOR 1 GND BR 2 P24FS WH 3 P26ESTP BK 4 P24FS WH ALC500 INPUT CIRCUIT COLOR 1 C165TRS WH RD 2 C164PES RD WH 3 C163PLS WH BK 4 C160JPL WH RD 5 C159STC BL WH 6 1440 BL WH 7 1 BL BK 8 C29MS RD WH 9 P109ANG GR WH 10 SNSR GND BR 11 P162JPW2 OR 12 JSGND2 BR 13 P162JPW1 OR 14 JSGND1 BR 15 C28TTA RD BK 16 C13DRE A BL RD ALC500 OUTPUT CIRCUIT COLOR 1 4018 OR 2 C123PBS RD BK 3 C13DRE BL RD 4 C42LS OR RD 5 C41RPM OR BK 6 C1PBU RD 7 C2PBD RD BK 8 C3PBF RD WH 9 C4TRL WH 10 C5TRR WH BK 11 C6TRF WH RD 12 C7PBE BK 13 C8PBR BK WH 14 C9PERF BK RD 15 C30EDC WH 16 C31EDC WH BK 17 C36STC BL 18 C37STCC BL BK 19 C32BRK WH RD 20 C29MS RD WH ES0507C September 2015 H G F CONTINENTAL TME27 ENGINE PLUG PIN CIRCUIT 4 COLOR 1 R23PWR WH 2 C21RET WH 3 C38RET BL Ti 4 C38FP BL WH 5 R33STR BK 14 6 CA1RPM OR BK GRAY 7 R21IGN WH 8 5 BK RD 9 C108ESL BL WH lt 10 C127TSW GN 11 C39LP BL RD 12 C26TSR WH RD GAUGE OPTION S 80X MODEL
81. 1 o 0 C3P GR 2 5 ai CAN HI 2 LOW C1P GY LS18 C177LS BL RD 1 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 on I JC3 5 C159STC BUWH L 82 5 62 a C2P 9 P109ANG GR WH O 2 2 JC7 4 C165TRS WH RD 5 8 e 2 10 SNSR 0 F 9 JC7 3 C164PES RD WH 1 8 067 2 P162JPW2 5 E 9 JC7 5 C163PES WH BK 8 SC7 1 JSGND2BR O 2 9 i JC3 4 C160JPL WH RD 5 i JC3 2 P162JPW1 OR A 1 i JC3 3 1595 BL WH m o I JC3 1 JSGND1 BR I TS15 C144DER BL WH 1 3 1 I TS15 C143DEL BL BK I 1 1 BURD J1 C28TTA RD BK I TS14 C29MS RD WH 1 J RD C2P 6 RD 1518 a co 1 QN e Section 6 Schematics A Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 ANSI CSA AS Deutz 2011 041 Models September 2015 RD 1518 BK C7P 1 RD WH C7P 2 og O 1 BK J3 3 CONTROL HARNESS TO PLATFORM BOX WH RD J1 4 BK RD
82. 11 J1 SNSR GND 10 J1 P109ANG GR WH C2P 9 NE TS3 C39LP BL RD C2P 1 E I P3 C46HRN GR C2P 5 E pe TS47 C45GEN GR WH C2P 7 2 e Ar apr e a 4015 2 2 WH RD 6 2 a C123PBS RD BK C2P 8 9 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 SN C42LS OR RD C2P 4 C9PERF BK RD C3P 9 WH L1 C41RPM OR BK C2P 3 C30EDC WH 4 Q C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STC BL C1P 10 gt ur RD WH 3 6 5 C37STCC BLIBK 1 11 gt WH C3P 4 C32BRK WH RD 1 6 gt C5TRR WH BK C3P 5 Q C29MS RD WH 1 3 ES gt co 5 N E 0 Er 515 59 TE 96 DO C4P BR 1 c 0200069 N Ho CAN LOW 2 1 P GY c TS1 C27AUX RD C1P 1 TS2 C33STR C1P 7 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 on I JC3 5 C159STC BL WH a2 5 I e n 1 Oe 5 a C2P 9
83. 2 ele 10A TS43 52 CONTROL BOX TS49 TS48 HEATER WORK LIGHT DRIVE LIGHT re THS1 715 wc 5 5 R21 R22 100 100 Yay SA L o PLATFORM BOX GROUND o e TB21 LA 0 9 5 F19 10A 8 N 1 G3 G2 8 LE Iz 1 m 28 CR23 gt 477 9 026158 lt 12 75 m Vio HARNESS ES0505C it o 204 22 28 82 8 8 3 or 5 m m mz mo a m o 32 9 9 a m 2 4 2 gt 9 o 0 2 2 Genie 6 158 S 80 S 85 S 80X Part No 122985 September 2015 Section 6 Schematics ssscwwa Deutz and Perkins Options Schematic F E D 0 8 A P26ESTP BK P26ESTP BK FSi 3 Sri P25FS RD P25FS RD P25FS RD 1 P22BAT BK P24FS WH P24FS WH P24FS WH 2 F18 ie 10A 1 P134PWR RD e TS43 _ CONTROL BOX TS49 TS48 INC HEATER WORK LIGHT DRIVE LIGHT re pe THS1 2 IA wc R21 R22 100 100 2 130 24 3 PLATFORM BOX GROUND o 9 8 TB21 e TB45 4 C102 R21IGN WH e o 8 5 G1 F19 5 5 10A 9 b G3 G2 9 8 Q 8 5 o e e 5 5 CR23 i 6 5 ES m k 9 10 4 C10 1 C10
84. M M m How to Adjust the Boom Extend Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 3000 psi 0 to 200 bar pressure gauge to the diagnostic nipple Presr port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle Switch to the high idle position and activate and hold the boom extend toggle switch with the boom fully extended Observe the pressure reading on the pressure gauge Refer to Section 2 Hyaraulic Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item SO on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeat steps 2 through 5 to confirm relief valve pressure Section 4 Repair Procedures MANIFOLDS Genie Part No 122985 S 80 5 85 S 80X Section 4 Repair Procedures September 2015 MANIFOLDS 8 3 Brake Two Speed Manifold Components The brake two speed manifold is mounted inside the drive chassis Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way BA Brake release
85. N TURNTABLE ROTATE amp T 87 g 4 06 5 CSTAR WHIBK TURNTABLE ROTATE Te LET 2229298 t C6 6 gt TURNTABLE ROTATE PSPEZ A E CT RE FLOW CONTROL TESTES a 38830 Se pog a lt x 8 0 58 2 C6 1 CiBUS AD gt PRIMARY BOOM m 888 PRIMARY BOOM 3 Bx 45 E ui EG 5 PRIMARY BOOM 5 2 D RD WH UP DOWN FLOW CONTROL 5 ay 85 a C3 1 x ex RD 4 C129DA DESCENT ALARM 3 7 C2PBD RD BK A 222 5 C3 3 8 xer 5n 8 C3PBF RD WH 2 E Om 804 555426 Ground HEH 55 EX cs C9PER BK RD 4 a 88280 09 6 lt 058 lt 08088 BK WH eo 5 nz 90 03 7 C7PBE BK 5 8 Im C67 RD BR f PRIMARY BOOM 4 EXTEND CIEBESEN S PRIMARY BOOM a RETRACT i C6 8 z PRIMARY BOOM C2 8 81 5 RETRACT 2 ER ER B 52 7 a mol PRIMARY BOOM 259 t C9PERF BK RD EXTEND RETRACT 559 g FLOW CONTROL 5 8 5 IEX 1 4 air 65 21 C30EDC WH ER 1 EDC DRIVE FORWARD 2 ets 8 55 29 031800 WH BK gt EDC DRIVE REVERSE r 2 GND BR 21 Er 4 C130TA WH RD TRAVEL ALARM OPTION 4 P24FS WH 2 g 5 s 8 t P24FS WH 4 IK C16 Fite E C32BRK WH RD Sp BRAKE RELEASE P26ESTP BK gt
86. PE gr 422 5 g 422 9 29 S Cee xx Leto aEBeg E 5 8 5485 J22 8 EM J22 2 STERN 2884 SEAR PLATFORM ROTATE CCW Se 22 2410 4221 PLATFORM ROTATE CW 6 11 5 80 5 85 S 80X G Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 ANSI CSA AS Deutz TD201 1L04i Models 11 12 Section 6 Schematics September 2015 VE Is Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011L04I Models 13 6 14 GROUND STUD ENGINE FUNCTIONS 18 22 CABLE 16 22 CABLE 12V TO PLAT September 2015 C Ground Control Box Terminal Strip Wiring Diagram 5 80 and 5 85 ANSI CSA AS Deutz TD2011L04l Models Section 6 Schematics 2 5 8 8 5 5 5 5 gt gt 5 0 3 565 u o z 5 9s 555 858328 9 AME 825
87. Zed DRIVE ENABLE RIGHT 2 gt BK z al LIMIT SWITCH LEFT 555 B 5 WH C143DEL BUBK z 5 g 2 18 911 C37STCC BL BK 7 C37STCC BUEK SH STEER CCW a o x z 5 17 0 036810 BL C36STC BL 9 STEER CW 7 N E gt ma 6 C6TRF WH RD g EK ere C5TRR WH BK TO C34 WH cux 8 sa 1 6 cima wn TURNTABLE ROTAT gt 5 TURNTABLE ROTATE raz ps git 5 06 5 estan WHIBIC 0 TURNTABLE ROTATE 5 55 8 TERE 6 gt TURNTABLE ROTATE 55 5 4 FLOW CONTROL 9 5 9 5 m 22292 8 aF reef a 500538 28 E C6 1 gt PRIMARY BOOM 538 PRIMARY BOOM 8 8 5 m x rdg g e a u EF 5 532 PRIMARY BOOM E RD WH UP DOWN 2 FLOW CONTROL m 1 5 85 ES C34 66 CIPBURD C129DA RD BK z DESCENT ALARM See o e 7 ues C2PBD RD BK 5 Sa 5 CR34 SPEED REDUCTION 215 8 11815 OR 3 8K gt 5 6 08086 RD WH J PELNY z z 5 xr DM 4280 TY 2431 P134PWR RD C631 ADFT eo elo LST30 BOOM UP DOWN Graza 3 9 218 SPEED REDUCTION 55842 nac BK LIMIT SWITCH 58586 u lt WH OE 03 8 C8PBR BK WH 6 C97 So 12 C7PBE BK 82 4 B C67 2 BR gt PRIMARY BOOM 5 i C7PBE BK N
88. i 8 HIGH 1 098 E 82 5 Ug 54 amp 8 ua I 5 3 8 u RPM MODULE m 4 5 gt lt lt B 8 N 85 5 zo GLOW PLUG u 5 TIME DELAY 30 SECONDS 95 5 5 22 GLOW PLUG gt gt 6 7 CONTROL RELAY 843 512 8 R34SA BKIWH T BP duh RE 34 GLOW PLUG w a O 5 C33STR 22 OLI TEMPERATURE 31444 p SWITCH ase 5 15 Sot OIL PRESSURE 2 Juss SWITCH a 5 1 gt 8 5 7 n 92 go 55 5 n p lt 8 5 3 4 FUEL SOLENOID CONTROL RELAY t C27AUX RD 15 R21ING WH gt gt 9 FUEL SOLENOID 1 9 AUXILIARY I 1144 8 Zi PUMP 1 8 7 Sx 9 LF 1 06 AUXILIARY PUMP x 5 CONTROL RELAY 5 AUXILIARY PUMP 9 4 R27AUX POWER RELAY a i B I AUXILIARY PUMP m P23PWR WH 5 zo 1 R tz 8 WH 5 IGNITION STARTER S RELAY jj tet j 9 pcc 5 8 R33STR BK i A B bod Sie uj L3 8 STARTER g i E a eg 4 a a r 9 S d C6 28 C133PLS GR BK TILT ALARM P134PWR RD LH LEVEL SENSOR e dm 2S E 24 C46HRN GR 7 T 4 SERVICE HORN 8
89. 09181 OL WSI HM 2 00 1 2951 1 4 1 od vSSL 80 060681 2 1451 S8 VEHO Ha 8 9 281 1 98 1 91 90 v c9S L QH HM q98 L dH HM 26981 914 2 1981 681 q8rral Ho 1 1951 WH 0 v viH loe 28 ES0504D Genie S 80 5 85 S 80X 6 51 Part No 122985 September 2015 Section 6 Schematics rrr C Ground Control Box Switch Panel Wiring Diagram S 80X Deutz TD201 1LO4l Models 51 52 Section 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80X Deutz TD201 1L04l Models 53 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80X Deutz TD2011L04I Models CONTROL HARNESS TO PLATFORM SWITCH PANEL TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR
90. 1 G 5 260 08 Woog IHd 1 99 1951 anis NMOG WOO8 IHd 2 90 2 860 2 Orval Mg QH e 620 9 1951 WOOd 5 99 HWAH 5 95 HWQH HNVAH MO 31V1OH II8VYLNHNL 1 90 HM HA 2951 HM M29 JIAYLNYNL 990 8 5 Mg HM 8 1 2951 ME HM SLVLOY 18 1 9 90 9 860 QU HM 9 vt GH HM 1X3 WOO8 IHd 1 90 98 L8 0 2 1 6981 LOVYLSY WOO 8 90 HME 8 8 9S L HME 13H LX3 WOO IHd 6 90 6 860 6 9 6951 199 1 80 1 dn T3A31 2 8 vl 1 6951 13A31 Ma HO St g 6SS1 MO 31VLOH 1 1 98 970 L 6 2861 MOO 31VLOH 9 8 49 49 81 1 2551 49 49 AlddNS L1V8 LIV8 02 2 282 AldANS NOILINDI AZL LL 80 HM IZ HM OL HMd HOLIMSA3M 22 660 5 15 5 OL H3MOd 1 90 HM 2 840 ZL HM 6 20 157 HM dc 1 5 H3MOd 9 50 L 8I9 Gu 22 1951 u 0281 INHY1V HOSN3S 13437 86 90 Mg QH 30 00 6 75 59 810 6 16 90 HM aL HM 0
91. 1 tev DE BAT 9 Eo 7 2 tet NO 777 9 E ap i i i 2 5 1 8 m 51 STA RD 12GA w swat bog 8 Wer un no 74 WH 14GA 8 3 T 1 82 1 i i i L S B 1 4 4 4 4 4 o gt 2125 X X gt D gt D lt m 0 TU o X 4m m 8 3 gt 5 gt lt or m Smo mo ms z 9 cm 3 5 mz c i gt 5 d E S5 oho 2 2 22 RE 25 5 2 20 5 5 55 B B 8 p 3 92 822 8 22 8 5 5 5 8 9 52 5 ee 5 7 2 m 22 2 g 4 8 9 58 x m 5 2 gt 70 2 96 9 e 28 2 2 d 2 1 h fn 5 a 5 5 S E 52 8 m m 5 5 3 2 9 5 ES0505A gt m I 2 t m Genie 6 118 S 80 S 85 S 80X PartNo 122985 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Continental TME27 Models before serial number 81 11
92. 2 6 5 LEYE lt lt P134PWR RD gz p 5 1 8 3 xz 0 1 8 1 y ac e RD 2 ae P134FB RD e m E S Va B 5 a f C52 1 CARPM ORBK ga 1 42 1 59 cmn 7 J144 2 N 1185 n 8 188 KUX MAIN ro fs 6 5 e rs lt 6 BIBAT RD as F t os c 8 m RD N LO PartNo 122985 6 22 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Deutz TD201 1L 041 Models before serial number 81 11 C GND BR
93. Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel Genie Part No 122985 S 80 S 85 S 80X 4 61 Section 4 Repair Procedures September 2015 FUEL AND HYDRAULIC TANKS 9 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and de aerate the hydraulic fluid during operation The tank utilizes internal suction strainers for the pump supply hoses and has an external return filter equipped with a filter condition indicator How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See 9 1 How to Remove the Fuel Tank 4 62 Genie S 80 S 85 0 2 Close the two hydraulic tank valves located at the hydraulic tank if equipped Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the cLoseD position or component damage will occur If
94. a 9 Lo EZ Z x x o 52 5 5 ox 8 8 8 6 6 8 s L BK 284 a D gi 2 CONTINENTAL TME27 ENGINE u VEHICLE INTERFACE 1 Ed lo E 8 Noa YYYYY rS I GM IW WA a 5 9 5 5 5 588802 1 5 5 h E Se H ey 5 5 amp amp k c 5 a6 8 8 gt B 5 5 5 Bees 8 8 8 8 8 o o o o c o o 5 5 is zu AS 85a 4 87487841848 6 LP 8 t ca C39LP 8 8 LP gt 4 am 92 884 5 8 FLY C1 9 9 C35RPM BK RD FS 5 FS a LOW RPM HIGH RPM n 5 8 Car CHECK ENGINE LIGHT FUEL PUMP 5 25 ENGINE FAULT CODE 002 TEST SWITCH WH 14GA 8 HOUR METER C5 11 5 STARTER amp m 6 8 E n en a E 5 4 C5 19 PRESSURE COMP VALVE 8 V155PCE ORRD a 2 X gt renum lt ala lt a 81718 IGNITION RELAY 5 9 2 2 gi 5 52888 Eu o i N 6 2 05 15 _ x 2 E s i sis lt a BT ant 8 EH C1 7 825 C33STR BK 9 ges 82 I 2 2 E 8 C55 a Ja x START RELAY g 553 81218 F lt N a t um C27AUX RD oc 4 541 825 0 mi
95. gt 9 OZNA Q 2 P26ESTP E STOP R26ESTP BK C9P 1 BR GND e 1 8 TS7 C18PRR GR BK J22 3 eR TS7 C17PRL GR J22 4 mo I TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU J22 7 TS9 C15PLD J22 8 1 N 422 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 1 1 1 1 P2 P23PWR WH C7P 2 P2 P22PWR C7P 1 TS1 V155PCE OR RD 4 TS48 C49DLITE WH BK 9 TE TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK 8 TS9 C14PLU OR 2 TS9 C15PLD C4P 3 1 H1 C133PLA GR BK C3P 12 L47 C59CNK BL BK 11 I c J1 SNSR GND BR 10 5 9 J1 P109ANG GR WH C2P 9 NE P3 C46HRN GR C2P 5 c Ns TS47 C45GEN GRANH C2P 7 i BK P2 1 oy 532 Nye 1 J e a C40LS OR C2P 2 2 C6TRF WH RD C3P 6 0123085 RD BK C2P 8 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 SN C42LS OR RD C2P 4 C9PERF BK RD C3P 9 WH L1 Q C41RPM OR BK C2P 3 C30EDC WH 4 2 Q C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 a C36STC BL C1P 10 gt ur Q RD WH C3P 3 6 5
96. jDoesnottumonMIL EPR 1171 EPR Delivery Pressure Y Y MJ actual commanded press 4 in H20 Diagnostics than expected gt ee LPG 1172 EPR Delivery Pressure Y Y MJ actual commanded press 4 in H20 than expected 1173 EPR Comm Lost Y Y packets received within 500 ms 1174 Voltage Supply Higa 1175 Voltage SupplyLow 20 1176 Internal Actuator jfautdetection Fr fault detection Id NR fault detection Adaptive Learn Key Cycle Genio 5 10 S 80 5 85 S 80X Part No 122985 September 2015 Section 5 Fault Codes t Cam Crank Crank Loss Sensors FAULT CODES Fault Conditions 5 d z o No cam pulse in 4 cycles and RPM gt 1000 Cam pulses without crank activity gt 6 cam pulses Adaptive Learn Shutdown lt Adaptive Learn KC Trower berate berate ee k within a time window of lt 700 ms nt 442111 _ within a time window of lt 800 ms S Internal 606 COP Failure Processo 1612 RTI1Loss_ v Diagnostics 1613 RTI2Loss TO 1614 RTI Loss Y CH 1616 invalid interrupt PO 601 Flash Checksum Invalid 604 JRAMFalue 1 J1939 1625 Shutdown Request
97. t z x x 2 55 585 5520 zu 8 FNN 52 6 5 g lt lt zu uber 6892 55 2 ats 55552520429 to E tp CO c e lt ejes 0000000000 gt x m 4 amp mie It E C51 LT 497 LI an o 55 C132PLI2 BK 0 5 9 5 x a C5 19 E V155PCE OR RD p gt 155 OR RD u 2 a x 4 382 Fits Low 855 9 22 lt THIGH mE BK RD of 2 88 b a BOS 8686 GO amp 88 2 5 HIGH C5 18 Inl gt 4 2 2 Re x 52 5 7 6 1 BK RD n na 5 x 2 Bie u L 5 ig Pong 018 C34SA 9 D 2 a0 0 888 Poe ir R348A BK WH s RS 5 lt Zk 3 ade C17 59 Piss C33STR BK 2 4 Cries C5 15 Box C24TSPS WH o E s PTS 2 5 7 82 5 n E 5 F lt a 5 3 Im t C27AUX RD 5 9 R21ING WH 4 9 er AUXILIARY 5 5 87 T8 B PUMP ok 5 1227 5 m o 0 lt glo cz n O 2 R27AUX lfj _ 34 zn a 1 85 rd 88 1 d A o x 20 a m gi xz s 188 5 ee u 1 C5 5 4 7 2
98. ul SSVdAd 810 A33 2 G 9 AH311V8 919 in 1 S9 QU S C INS ug 5 01881 0 9 INANI 18918 O H31I3WOHOVL 18416 i JB Sy n n gEZaL HM 32018 NOILVNIIAH3 L 3SVg 5 E WOO8 1 90 raso 1951 amp WOO8IHd 2 90 Mg au 2 Orval He 62 9 1951 4g QH MO14 IHd 6 92 5 98 05 MO 31V 1OH 1 7 99 HM 7 989 9 6981 HM 31VLOH 5 92 9 80 S 1 2951 M8 HM STEVLNYNL 9 99 QH HM 9 860 9 vr QH HM 1X3 WOO8 IHd 1 90 1 8 0 1 L 9S 1 LOVYLSY WOO IHd 8 90 8 HMA 8 2 2951 HMG MO14 13uH 1X3 WOO 8 6 8 0 00 98 6 9 2951 81 99 1 8 1 dn 13A31 2 8 1 6981 HO NMOG 13 31 WHOSLV1d SL 9 6991 8 MO S grO 1 2 2981 MOO WHOSLW1d 9 grO 1 2551 81 Adans LIVd 2 280 AlddNS 11 90 HM 12 999 HM OL HMd HOLIMSASM 22 690
99. 3000 psi 206 8 bar 1 77 3 1 1777 Counterbalance valve with pressure and pilot ratio H H lt 2 position 2 way solenoid valve 5 Fat 4 1 Directional valve pilot operated 2 position 2 way Solenoid operated 2 position 3 way directional valve SA Solenoid operated 3 position 4 way directional valve d 2 position 3 way shuttle valve Hydraulic oil cooler Brake S 80 5 85 S 80X Section 6 Schematics September 2015 p This page intentionally left blank Genie 6 4 S 80 5 85 S 80X Part No 122985 Section 6 Schematics September 2015 Tsssa rvaHsTww sFw Connector Pin Legend View 1 Section 6 Schematics Connector Pin Legend View 1 A 0 C1 DT06 12SA 1 COLOR CIRCUIT RD RD BK RD WH WH WH BK WH RD BK WH BK RD BL BL BK BL WH BL WH C27AUX C28TTA C29MS C30EDC C31EDC C32BRK C33STR C34SA C35RPM C36STC C37STCC C132PLI1 C177LS C1 GRAY L CE MODEL S 80X MODEL C2 DT06 12SB COLOR CIRCUIT BURD OR BK OR RD GR GR BK GR WH GR RD 5 OR WH LT BR C39LP C40LS C41RPM 4215 C46HRN P134PWR C45GEN C123PBS P109ANG SNSR GND PLUG PLUG C2 BLACK Genie S
100. Es 128690 777 a B 164 min r 2400 psi_ ell I 1 p YT rH E AUXILIARY TEST c g 168080 1 19 des ES IDEE T i PUMP 3200 psil Me E ER SP MES E F 221 bar mist al 80 EG se XH D F 2400 psi MPT EL 0 3 gpm 0 8 FUNCTION RETURN SH 165 bar 0 6 1 1 L min Lmin DK ____ 5 4 23 7 PUMP FILTER 4 2802 E 1 4 1 i 1 Ta 1 1 950 psi SM 30 psi 166 bar X 2 bar S80 PLATFORM MANIFOLD BET F SE ETE 2 bar 3 5 Su l SD is I Denen FUNCTION MANIFOLD j Ost ST2 Sri 25 5 RESERVOIR 086 TEST DRE DONNER 2 4 5 Wars uci eer uou pe er ces ee 1 EE HYDRAULIC ROTARY COUPLER r e 9 Lye L lt l COUNTERBALANCE VALVES 8B 18 2A 2c 2B 4 5 PRESS d 1000 psi 69 bar aaa nn A 151 3000 psi 207 bar A ta 3500 psi 241 bar A 451 1000 psi 69 bar A 451 3500 psi 241 bar A 4
101. Index Schematic No Description Item Function Torque 1 Counterbalance valve 3300 psi PA Platform rotate right 37 44 ft lbs 50 60 Nm 2 Counterbalance valve 3300 psi Platform rotate left 37 44 ft lbs 50 60 Nm QFE PA Genie 4 48 S 80 S 85 0 Part No 122985 September 2015 Section 4 Repair Procedures Eee eee LL LL LLL MANIFOLDS 8 6 Platform Manifold Components S 80 The jib boom platform rotate manifold is mounted on the platform end of the boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way EF Platform rotate CW CCW 30 35 ft Ibs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 4 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Needle valve Platform 20 25 ft lbs 27 34 Nm 6 Pressure comp flow control valve EE Platform rotate flow control 33 37 ft lbs 45 50 Nm ED 6 6 EE ECG P O 5 59 Genie Part No 122985 S
102. OL 1 9 qesa tg 18 anis 99 48 1 1 15 9 260 21981 L LSM HM raw 1 assral qu do 2951 245 1 881 9 araL HM 9191 99 V LH HN QH 9ru ad 78 azal 9ru ad 881 61 08 1 09181 01 WSI HM 1 469 0 qaeeart a Qavea L HW a Le NE 2951 9 qsegi qu xg 78 06681 4 2 1451 98 9 GLcal HM azzal yg 91 90 0008 V c9S 1 QH HM q9g L qu HM 6951 1951 Gqe 8 L HWad q8rrar Hdo L L9S L HIWQH 95 u8 ES0504D Genie S 80 5 85 S 80X 6 39 Part No 122985 September 2015 Section 6 Schematics
103. PD TB133 9 T FAULT 2 mM SELECT 12 lt C27AUX RD CODE Dny E 28 D2 TB27 TB33 78155 211 TB35 TB39 GROUND 1 gt _ C27AUX RD GROUND BOX 5 5 gt m P134PWR RD w 5 6 P23PWR WH TB41 8 gt g 8 8 9 8 9 9 9 9 9 4 i amp T 1 4 z a 4 2 17 952 OR BK K6 20 6s P24PWR RD 5 10 BURD 11 g R21ING WH C59 _ BK RD 68 5 lt z B1BAT RD C513 suwn 8 F 2 98 000 3 m BAT 2 APU RD o T 8 5 CRI 995 c gt ig SBA 5134 F7 CR39A CR39B R21ING WH EG B 28 me 5 d R21RET WH 6 gt R6 17 085 5 5 5 E 5100 oe gt 2 gt 8 R33STR BK 6 2 1 2 m 8 2 5 3 1 2 R23PWR WH 2 2 9 i i 8 8 A lt C38FP BLWH lt k4 2 2 9 3 5 C38RET BL Ka cee 8 NOJ Ci 9 i 2 m lt sw4 LES 8 H2 M vua i td e lt e ee e 0 6 4 lt lt e 5 5 gt o me 8 5 gt 5 02 GHz n 8 SE eme 85 8E 3 mz ax 5 6 d gg z gt d Jeo m CD 2 lt x ce Ax gt 58
104. RIGHT I RETRACT E 1 Primary BOOM Y sz 2 3 I 8 C143DEL 72 nee C69 PRIMARY BOOM T C9PERF BK RD T EXTEND RETRACT FLOW CONTROL 8 0 8 Ti i N RD zb al LST3S BOOM ANGLE BR lo d STOWED Sekt 415 34 GROUND BOX ZONE A a SAFETY LIMIT SWITCH pepe 1 8 5 WH 22 7 TZ 03 12 P109LS GR WH C636 m al s LSB1ES BOOM EXTEND BR 72 CAPACITY SAFETY gt E BR BL 5 LIMIT SWITCH 6 38 8 5 gt 2638 _ gt gt on BR 5 C209LED BL i gt 8 C6 30 E 1 C211PLO BUBK RD BKMWH LSB1EO BOOM EXTEND A BK 710 CAPACITY OPERATIONAL z LIMIT SWITCH 5 BLAD 61 12 01778 BLIRD 6691 BR N i 1 I 4 a 1 i BR 58 P134PWR RD RD c LST3O BOOM UP DOWN 5 5 FEN BR GROUND BOX ZONE ZONE SELECT 2 So a 2272 OPERATION AND SPEED z 5 9 T P210PWR BK c6 12 4 WH REDUCTION LIMIT SWITCH 19 WH a 8 2 01840 E are 5 221 pl s 5 ce C1PBU RD gt 4 PRIMARY BOOM UP n
105. e PLATFORM LEVEL DOWN 2 m C43JU GR 047 a 58 C44JD GR BK SEE bg a 9 Fac cw dem 38 C129DA RD BK DESCENT ALARM i 8 2 a C17PRL GR 04 5 C18PRR GR BK 04 6 EE E 5 5 cow pe 889 3 zm J2241 tH s eos 8 PLATFORM LEVEL UP EI J2242 2 PLATFORM LEVEL DOWN 2 8 lt 4229 3 J22 10 lt lt t 8 E 2 xx lt alit PT EM umi z x gt 8 8 PLATFORM ROTATE CW 6 PLATFORM ROTATE CCW 4 gt 2228 Fd 6 95 S 80 5 85 S 80X Part No 122985 95 September 2015 Section 6 Schematics u r ihrm ss Electrical Schematic S 80X Perkins 804D 33 Models 96 Section 6 Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram S 80X Perkins 804D 33 Models 97 6 98 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 80X Perkins 804D 33 Models 0 lt 0 5 2 5 a o ur m m E lt gt ce e u z lt a 5 rs a c jw uu 7 OJT 9 gt lt gt 2 5 O lt o gt 4 6 2 zu zt 5 Mox oz 2 BS as 8
106. lt lt lt P134PWR RD gt gt 1 MEN OIL COOLER FAN OPTION 4 1 Ve P134F8 RD Oe B D FLASHING BEACONS y Ye OPTION 8 4 P134FB RD em 8 5 2 4 4 C41RPM OR BK 9 88 j j C ws ml lt gl EU BLEU Fl A 2 5 8 z l 18 5 ALTERNATOR 9 6 amp I 6 21 43 7 I TE 1 lt _ k 18 e B BATTERY SEPERATOR as 95 25 LCH oa BIBAT 0 S 4 START BATTERY a a lud Sc 5 e BIBAT RD CONTROL BATTERY a gt E N iO PartNo 122985 S 80 S 85 S 80X 6 46 6 47 Section 6 Schematics Electrical Schematic S 80X Deutz TD2011L04I Models September 2015
107. v g F e 9H ME HD 951 9 S LSS L HM HM 1 840248 8 een OsrTM8 05 SAFI NAHM e 66181 48 2 91 Ove Lal HMdr Ld QH 26181 1 Send arvo ozal 2 wo ceo NOILdO LHO9FT3AIHG e i e nio G 8 80 S 85 S 80X PartNo 122985 6 122 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 SNOILOANNOO 1 OL 8181 q6sa1 xg 18 qoear ad 9 9 0 e Ld QH 9 262 1951 15 4 01 00 499181 8 40 WrL4 au HM QS8 L518 HM aval HM 2951 9 0 1 1881 08 1 8 9 ArraLl 19 49 vO ON 1851 24 6661 09 81 08181 38 as aL 49 40 0 8 qeega l ig
108. vy 1951 01481 2951 4991 81 4 40 v rLH QH HM Qqsa L5g8 HM Aral HM 1 49 01 83 20 58 78 vLH HIWOH L 1 9Lu qd 0881 td 9 Q F 885 6451 1 08181 48 01 WSI HM 200 080 1 8 vod 2951 gt AreaLl HMMd 9951 4 1 21 L ecdgo qd 062841 2 1451 98 J9v1 u8 012841 ea 1 8 9 8 1 dc amp ON ON 91 90 2951 981 5 2 1951 WrLd QEaL HWAH peHo 1951 95 u8 98 18 ES0504A Genie S 80 5 85 S 80X 67 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz 020111041 Models before serial number 81 11 Secti
109. w ooo r1 L NE lt D12 JC3 1 1 1 ees i JC7 0 t x x x EE TS2 TS6 3 od TO sgo ogo 1 1 1 L47 NE f 1 E NE Q l 1 gt N z eu 1 EE 4 TS9 No C o Los 2 E 272 y CN KCN NC 4 fogo oe L48 P2 5 RD BK RD RD MEA x ES0503D 1 COMPONENT INDEX CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT DRIVE SELECT LIMIT SWITCH CIRCUIT OPTION TS8 JIB BOOM UP DOWN TOGGLE SWITCH S 85 OPTION H1 TILT ALARM TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH JC3 JOYSTICK DRIVE STEER TS14 DRIVE SPEED TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS15 DRIVE ENABLE TOGGLE SWITCH 7 L1 LED DRIVE ENABLE U13 ALC500 JOYSTICK CONTROLLER CARD L4 LED PLATFORM OVERLOAD U35 TIME DELAY RELAY L47 LED CABLE TENSION Lm CED TIT ALARM NOTE DASHED LINES INDICATE OPTIONS LS18 PLATFORM OVERLOAD LIMIT SWITCH P2 EMERGENCY STOP BUTTON 1 ROCKER STEER OPTION P3 HORN BUTTON R20 RESISTOR 47000 TS1 AUXILIARY TOGGLE SWITCH 8 TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH Genie PartNo
110. 15 At the pivot end of the boom carefully pull the rope with the new retract cable attached 16 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube Remove the rope 17 Repeat steps 14 through 19 for the other boom retract cable Part No 122985 Genie S 80 S 85 0 BOOM COMPONENTS 18 At the platform end of the boom install the retract cables clevis pins and rue rings to the adjustment plate 19 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder 20 Install the new boom retract pulleys to the pivot end of the boom extension cylinder 21 Install the boom extension cylinder assembly into the boom Note Before lowering the extension cylinder into the saddles of the number 1 boom tube wrap the boom retract cables around the pulleys 22 Adjust the boom extend retract cables See Section 4 5 How to Adjust the Boom Extend Retract Cables Section 4 Repair Procedures September 2015 BOOM COMPONENTS 4 6 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the pivot end of the boom How to Remove the Platform Leveling Master Cylinder Note When removing a hose assembly or fitting the O ring
111. 2 Start the engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 4 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 5 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Performance Specifications Note To adjust the speed refer to Repair procedure 1 2 How to Adjust the Joystick Max out Setting Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B 20 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle select toggle switch to foot switch activated high idle rabbit and foot switch symbo
112. 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 4 Locate the fuel filter water separator next to the oil filter for leaks Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures 5 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Note Do not completely drain the filter a fuel filter water separator b drain valve 6 Clean up any fuel that may have spilled 7 Startthe engine from the ground controls and check the fuel filter water separator for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener Part No 122985 Genie S 80 S 85 0 CHECKLIST C PROCEDURES C 6 Check the Safety Envelope Limit Switches and Angle Sensor S 80X Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the
113. 92 59 6 dz VOzal du 003 12 69 HM 0 8 HM 6 2 5 3SH3A3H 02 52 M8 HM 9 810 M8 HM 16 0 91 66 90 9 810 QU HM ZE 1HVLS SNIDNA 5 69 2810 8 EHWSI 5 2551 8 810 6 9951 ANIDNA 81 50 8 6 810 6 1 1 7951 8 MO 88215 96 90 18 01 810 18 9 MOOH3als 16 99 LL 8LO 8 6 OHL8S1 HOLIMS 07 99 HO 2 820 IWNDIS 1 2 50 820 8 Z INSI 021571 HOLIMS LINIT 22 99 820 GH HO zr 2 80 0 9 49 aasnnn 8 70 48 49 vv 1 0510 0261 0 NS 2 OV 65 99 HIWHO 7 820 HWH MT Be NHOH 1 80 5 20 9 58 1 92 11 860 6S 9 NOLLONGaY 03346 1411 15 99 FIG 98 PEHO HO aasnNn ZEL aasnnn EEL 8 Z 9 49 49 H LIMS 72 99 9 860 81 8 1 60 2 19 v HOLIMS 96 90 96 90 1431 NOOV3 amp HM NOOV38 HO 318VN3 3unsS3ud 61 59 GH HO 9q r grO SSL 90 5 2961 GH HO 38824 1
114. BL RD J1 16 WH C9P 2 BL BK J1 7 0 GJ _ 1515 22 L1 BL WH J1 6 L48 RD C9P 3 RD BK H1 D40 2j OOO Qo TS4 PR TS6 TS1 BK WH C1P 8 OR RD C4P 4 D12 TS2 8 TS14 RD BK RD C1P 9 BK C1P 7 RD C1P 1 RD WH J1 8 GRIBK C4P 8 J22 6 GR C4P 7 22 5 BR GND STUD L47 BL BK C3P 11 GR C4P 5 J22 4 GR BK C4P 6 J22 3 RD WH J1 2 OR J1 11 BR J1 12 WH BK J1 3 WH RD J1 1 8 oo JC7 C P3 OR C4P 2 J22 7 ES0504D OR BK C4P 3 J22 8 a GR C2P 5 6 19 S 80 5 85 S 80X Genie Part No 122985 PLATFORM LEVEL UP DOWN TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH DRIVE SPEED TOGGLE SWITCH DRIVE ENABLE TOGGLE SWITCH ALC500 JOYSTICK CONTROLLER CARD ROCKER STEER OPTION TS8 TS9 TS14 TS15 U13 1 NOTE DASHED LINES INDICATE OPTIONS COMPONENT INDEX JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE LED DRIVE ENABLE LED CABLE TENSION LED TILT ALARM PLATFORM ROTATE TOGGLE SWITCH JOYSTICK DRIVE STEER EMERGENCY STOP BUTTON ENGINE START TOGGLE SWITCH RPM SELECT TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH HORN BU
115. INJECTOR 2 INJECTOR 1 NOTE INJECTORS CONNECT TO ECM PINS PER 1 3 4 2 FIRING ORDER 4 BLACKALT GREEN 18 YELLOW GRAY 18 ECT o Pressure swiTcH BLACK LT GREEN 18 7 TAN 18 ORANGE18 LTGREENRED 18 2 TMAP DKGREEN18 TX g LT GREEN 18 4 cou SPLICE WITHIN 6 OF CONNECTOR LTGREENRED18 sv BLKILT GREEN 18 BLACKILT GREEN 18 DK GREEN ORANGE 18 8 PINKIDK GREEN 16 6 PRE CAT HEGO BLACKWHITE 16 GREEN 18 JANDKGREEN B 6 cer HEGO PINK DK GREEN 16 t BLACKYELLOW 16 BLUEWHTE 1811 WHITE ORANGE 18 TERM WHITE ORANGE 8 cans BLACK 16 5 GROUND WHITE ORANGE 18 PINKYELLOW 16 7 BLUEIWHITE 18 TWIST WIRES 10 TURNS 360 DEGFOOT FULL LENGTH BLUE WHITE 18 1 GREEN ORANGE 18 ht WHITE ORANGE 18 2 N18 N 3 Da 5 PUBPLELT BLUE 18 LT GREENRED 18 SPLICE WITHIN e FROM CONNECTOR PURPLEIWHITE 18 PURPLEWHITE 18 CRANK SENSOR 4 9 DK BLUE 18 E 02 WHITE PURPLE 18 WHITE PURPLE 18 10 LOW 18 TWIST WIRES 10 TURNS 360 DEG FOOT FULL LENGTH 12 ERAN GREEN 18 15 BLUEANHITE 18 ph JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR 16 H h N Kor xA WHITE RED 18 BLACK LT GREEN 18 LPG TEMP 21 PURPLEIWHITE 18 RAT LT GREEN RED 23 GRAY BROWN 18 GRAY BROWN 18 PURPLEORANGE 18 NA 5 CAM SENGOR 4 PURPLE
116. M 20 Ou EC a gt 2 92546941 E 5 e m gt TS3 TS4 5 TS15 SN S A oO N N 1 Q 0 2 R O 7 I I D12 nn 14 Dod 4 469 3 12 21 EE D10 JC7 Ld nom 1 TS2 toot oF I 1 147 TEE 1 L1 4 4 I I o l 1 l NE MEE 21 11 LZ j 11 9 J I lt TS9 5 T 1 814 0 L48 1 NC e R 0 N j a Ns CS 1 OG Q 6 1 P2 RD BK RD RD 6 T 1 T 1 Q 1 50505 EEEE ect fC cr bho aa 6 4 4 COMPONENT INDEX CiP 18 22 CONTROL CABLE GREY P3 HORN BUTTON 7 18 22 CONTROL CABLE BLACK R20 RESISTOR 47000 085 16 22 CONTROL CABLE GREEN AUXILIARY TOGGLE SWITCH 16 22 CONTROL CABLE BROWN TS2 ENGINE START TOGGLE SWITCH C7P 12VDC POWER TO PLATFORM 753 FUEL
117. Section 6 Schematics ol 8 JE 5 5 6 65 5 2 5 95 5 x ols lt zu E m Su o 5 5 Ole 2 ot u 5 EIS P SK 2 s z RT 5 5 5 6 iz 5 68 2958 88 a lt o u su 558 5 uju 9 m lt oz z 5 216 eu o lt lt lt 6 6 8 m oO u e 035 E 2 6 F gt u 50 mi lt z 4 5 215 5 5 lt 5 5 55 ur 5 n s 9 2 lt 22268 2 5 212 Ho 2 355 55 9 2 8 3 2 99 16 6165 612102222 lt gt mnm XZ e E E E E sunt rius Tie ooo oo 52 8088 5 9885 5 2 9 5 29 52 5 225 2 I Bag zs 9988 ai m 3588 5882 5 P X G4 Oz o NO T3n NSI 6 e em SSVdAd 8 O HMd 2 eo zi AYSLLVE 9 9668 O1 L 82 QH S 9 no ua m
118. 03 2 7 a 1 Zs 5 CR34 SPEED REDUCTION C3 3 11818 OR or 21 8 RD WH RELAY zr DONE T ei E C631 9 LST3O BOOM UP DOWN 5 C3 9 2 SPEED REDUCTION 8 LIMIT SWITCH BIRD gt BK 85346 WH 2 22200 x C8PBR 8 lt 0059 ac 03 7 C7PBE BK 5 B9 g Bn PRIMARY BOOM 2 Se Le C67 4 EXTEND RETRACT MARY BOOM C6 8 8 PRIMARY BOOM ok M 7 S 5 C8PBR BK WH PRIMA 35 FE m i5 2 54 PRIMARY BOOM 9 C9PERF BK RD EXTEND RETRACT 258 g FLOW CONTROL 502 22 66 8 eh EXC mE 5221 030500 WH ER 1 4 EDC DRIVE FORWARD D 2 8 m 081500 P EDC DRIVE REVERSE 64 E te 1 GND BR 21 F C130TA WH RD TRAVEL ALARM OPTION P24FS 22 g 8 BRAKE RELEASE t 4 Tee 1 6 r 65 23 C32BRK WH RD P26ESTP 86 25 8 5 lx 4 5 24 UU 5 2 SPEED MOTOR STROKE 8 m I No Bou P134PWR RD cz 55 c6 11 15825 EE C59CNK BL BK Sus LOOSE CABLE Lol TT LIMIT SWITCH D 3 l c3 11 Fl Ln 146 147 AS 9 LOOSE CABLE LED 4 2 3 5 i
119. 1 aseal au Nd vSSL L 2ego qd aezal HM 2 1451 0 98 7600 J gv1 u8 281 Gqeeala 9 1 9 8 T c9S 1L dH HM q98 L dH HM 8 2 1951 4 681 081181 1 1951 iNH u8 vEYO joe 98 98 28 ES0505D Genie S 80 5 85 S 80X 6 135 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 81 10 6 135 6 136 Section 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 6 137 6 138 September 2015 WH TS14 itl CR30 LIFT DRIVE SELECT OPTION WH TS7 WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD C40LS SPLICE TO 0401 5 C2P 2
120. 1 6 1881 1 14 9 470 1948 8 1 2551 AlddNS Live L1v8 11v8 02 2 280 AlddNS NOLLINDI AZL 11 90 HM 12 INH HM OL HOLIMSA3M 22 2 0 163 ut INHOA LYId OL 1 59 HM 2 840 2VHM 68 1 15 HM vocal qu vz 550 H3MOd 9 90 qu 22 1981 80c81 dH INHYTV HOSN3S 82 90 8 2 812 82 92 9 9 810 6 18 50 HM 815 HM 06 oda asuaAau 02 50 M8 HM 9 910 4g HM 5 56 90 QU HM 9 815 66 T3AVHL QH HM 8 5 50 1 810 6 g zss1 9 81 6 6 50 8 6 810 Gua 6 ELQ I v5S1 MO 88315 9 90 18 01 810 18 9 4331S 16 99 11 810 6 109198 dVsvo 01 50 1 860 i ess 1 s 1 WOOS 07 92 920 HO OF m O 2 SO M8 HO 9 860 Xg uO LP 20 5 319NV WOO8 22 99 GH HO 860 Qu uO r F 99999 dnwoogair 0 2 8 1 8951 HD 98 5 alr 8 IH 082530007 _ e 858 1 HOIlVH3N35 OV 66 90 42 820 Sr NHOH 1 80 HO 5 820 9 d
121. 10 x 10 x 152 cm under the long link arm across the turntable covers 5 Slowly lower the boom until the long link arm contacts the wood block Do not rest the entire weight of the boom on the block Turn the machine off Component damage hazard The turntable covers can become damaged if the weight of the boom is allowed to rest on the block 6 Place wood blocks between the short link arm and the turntable weldment for support 7 Insert a 1 125 x 12 inches 32 x 300 mm eye bolt through each hole located on the top surface of the counterweight Secure the eye bolts in position with flat washers and nuts 8 Securely attach lifting straps or chains with a minimum rating of 5 tons 5000 kg to the lifting points on the top of the turntable counterweight Attach the lifting straps or chains to a 5 ton 5000 kg overhead crane Note A spreader bar and other hardware may be needed to safely remove the counterweight Genie S 80 S 85 0 9 Slowly operate the overhead crane to apply tension to the lifting straps Do not attempt to lift the machine with the overhead crane 10 Locate and remove the counterweight retaining fastener at the center of the counterweight Carefully lift the counterweight upwards and remove the counterweight from the machine Set the counterweight on the ground Do not leave the counterweight suspended above the ground Crushing hazard The turntable counterweight will fall
122. 2 C6TRF WH RD C3P 6 0123085 RD BK C2P 8 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 SN C42LS OR RD C2P 4 C9PERF BK RD C3P 9 WH L1 Q C41RPM OR BK C2P 3 C30EDC WH 4 2 Q C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 a C36STC BL C1P 10 gt ur Q RD WH C3P 3 6 5 C37STCC 1 11 gt C4TRL WH 4 PES C32BRK WH RD C1P 6 gt 5 WH BK C3P 5 i C29MS RD WH 1 3 i 5 gt 0 co E 59 5 TE 96 DO o o C4P BR 1 1 1 C2P Bk 5 a CAN HI Ho CAN LOW CIP GY TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH 1 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 I JC3 5 C159STC BL WH 5 I e n 1 5 2e a C2P 9 P109ANG GR WHO 2 21 7 4 C165TRS WH RD Bo 2 10 SNSRGNDBR at r JC7 3 C164PES RDWH 5 N 7 2 PI62JPWEOR 9 Yi 4 7 5 C163PES WH BK 5 4 7 1 JSGND2BR FO q 2 JC3 4 C160JPL WH RD 5 18 I JC3 2 P162JPW1 OR gt 9 amp JC3 3 1598 S 10341 488 01 1
123. 9 90 3290 I8 51 vg WOOS IHd 1 99 1 860 1981 WOOS Idd 2 90 yg qu 2 8 0 05 vz8 89uO xg au g WOOS IHd 5 99 8 0 HWQH 0597900 a aeca l HM MO 31V1OH 378 1 7 99 HM v EO HM 2981 HM 2 060 38 MOO SLWLOY 1 S 90 8 HM 5 M8 HM S 1 6981 48 HM gt anis dN5 u8 31V1Ot 1 9 90 GH HM 9 8E9 9 V r lH N 1X3 WOO8 IHd 1 90 1 8 0 xg Z VZ8 69H9 lovHl3H WOOSIHd 8 90 HWE 8 8 0 HWM8 8 E E9SL HWA 134 1X3 6 90 GHA 6 880 6 V viu auma 1 99 L 13A31 2 v 1 6951 13A31 1 1 grO 8 SL 2 6951 9 0 MO ALWLOY WHOALW 1d 0 9 8 HO 1 6 1881 MOO 31VLOH 1 1 9 8 81 1 881 8 9 Alddns 118 1 8 1 zL QH 2 200 AlddNS AZL 11 90 HM 18 HM WHOSLW1d 01 HMd HOLIMSASY 2 690 9 8 INHOd 1V1d OL H3MOd 2 810 21 24151 HM ca 1 15 HM H3MOd vc H3MOd 9 90 1 810 zz He 9a Y NSI 1981 82 90 910 xg au 82
124. C37STCC 1 11 gt C4TRL WH 4 PES C32BRK WH RD C1P 6 gt 5 WH BK C3P 5 i C29MS RD WH 1 3 i 5 gt 0 co E 59 5 TE 96 DO o o C4P BR 1 1 1 C2P Bk 5 a CAN HI Ho CAN LOW CIP GY TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH 1 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 I JC3 5 C159STC BL WH 5 I e n 1 5 2e a C2P 9 P109ANG GR WHO 2 21 7 4 C165TRS WH RD Bo 2 10 SNSRGNDBR at r JC7 3 C164PES RDWH 5 N 7 2 PI62JPWEOR 9 Yi 4 7 5 C163PES WH BK 5 4 7 1 JSGND2BR FO q 2 JC3 4 C160JPL WH RD 5 18 I JC3 2 P162JPW1 OR gt 9 amp JC3 3 1598 S 10341 488 01 10 2 I TS15 C144DER BL WH I TS15 C143DEL BL BK 41 I L1 C13DRE A BYRD 0 814 29 5 RDWH GR BK C3P 12 GR BK 14 i RD 2 6 RD 1618 QN e PartNo 122985 u G S 80 S 85 S 80X 6 42 September 2015 Section 6 Schematics
125. Dual fill port rotator motor b drive hub drive hub mounting bolts d fil ports If necessary add oil Refer to Section 2 Specifications 4 Apply pipe thread sealant to the plug and install the plug in the drive hub 5 Checkthe torque of the turntable rotate drive hub mounting fasteners Refer to Section 2 Specifications Genie 3 26 8 80 8 85 S 80X B 10 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Continental models Note The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact the Genie Industries Service Department Deutz TD2011L04i models 1 Connecta tachometer to the engine Start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures Deutz models a high idle adjustment b low idle adjustment Skip to step 4 if the low idle
126. FUNCTIONS C6 18 22 CABLE 4 C2B 16 22 CABLE C7B 12V TO PLAT CABLE RESTRAINT September 2015 C PartNo 122985 H6 5 80 5 85 S 80X G u ES t 28 I 8 5 u k 5 5 o 5 B E 5 lt o o u I 5 a 584488 Es 5 z 56559 3 5 582 5 2258 25 Q zug u 2 z E u s z a 15 6 gt 5555 9 gt BEES ESz8 8 52 2 u azg E 2 awu e aj uu 5 2 gt SB 6 5 59 550 59954 5 5 5 5 53245835 gt 2 2 ulu 9 Ez 2 gt 2 9559 5 599 210 iu Fu zn z a lt 514 5 am
127. GROUND cow C18PRR GR BK 989 FRE 8 row 045 C17PRL GR 3 5 PLAT ROTATE E tw m S al PLATFORM LEVEL UP 240 3227 5 2 J22 12 n PLATFORM LEVEL DOWN 2 1 3228 o o E a x JIBBOOM DOWN 2 922 10 7 12259 2 Ov g 89 J22 5 5 J22 9 r uo 1 cto 5 0 Tob m e JIB BOOM UP 6 55 228 2 OX E J22 3 509 22 2 SESS 9 PLATFORM ROTATE CCW 8 x 240 5884 E 5 n 42221 PLATFORM ROTATE CW 224 G 5 80 5 85 S 80X 6 59 Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models 59 60 September 2015 Section 6 Schematics Ground Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models 61 GROUND STUD ENGINE FUNCTIONS 18 22 CABLE 16 22 CABLE 12V TO PLAT September 2015 C Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models
128. How to Remove a Steer Cylinder There are two identical steer cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod cylinder maintains equal movement of the tires Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pin retaining fasteners from the steer cylinder pivot pins Remove the pivot pin from each end of the steer cylinder 3 Remove the steer cylinder from the machine Part No 122985 September 2015 Section 4 Repair Procedures 4WD Steer Axle Components 12 1 Yoke and Drive Hub How to Remove the Yoke and Drive Hub Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rem
129. J22 6 E J22 10 8 2 8 Sr J22 5 gt 22 9 4 u a 9 5 x x gt lt 422 3 J22 2 SERE x m 1 88 PLATFORM ROTATE CCW T gt 322 1 PLATFORM ROTATE CW G 5 80 5 85 S 80X 6 131 Part No 122985 September 2015 Section 6 Schematics M Electrical Schematic S 80 and S 85 CE Continental TME27 Models after serial number 8110 6 131 6 132 Section 6 Schematics September 2015 EE Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 81 10 6 133 6 134 GROUND STUD ENGINE FUNCTIONS 18 22 CABLE 16 22 CABLE 12V TO PLAT September 2015 C PartNo 122985 S 80 and S 85 CE Continental TME27 Models after serial number 8110 Ground Control Box Terminal Strip Wiring Diagram Section 6 Schematics m Oz ES 5 28 a a
130. Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Part No 122985 September 2015 Section 4 Repair Procedures Fuel and Hydraulic Tanks 9 1 4 Tag disconnect drain and plug the supply and return fuel hoses Cap the fittings on the fuel Fuel Tank tame How to Remove the Fuel Tank Remove the fuel tank retaining fasteners 6 Remove the fuel tank from the machine ADANGER Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach ADANGER Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Component damage hazard When installing the plastic fuel tank do not overtighten the retaining fasteners Note Clean the fuel tank and inspect for damage before installing it onto the machine 1 Turn the manual fuel shutoff valve to the closed position if equipped Remove the fuel filler cap from the tank 3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to capacity specifications
131. To Unlatch MAP voltage must be gt 0 5 vdc Y ECTvotage 495vdc y ECTvotage O 05vdc gt 210 gt 600 _ gt 230 gt 600 _ _ _ gt 4 95 lt 0 05 Y gt 2007 and gt 1000 127 IAT higher than 2 Y gt 2107 gt 1000 2229 Pressure High gt t6ps 129 BPPressuetow BPpressure lt 83psi_ Battery 563 Voltage Hin Y v jVotage i8vdc j Voltage 562 VottageLow jVolage 9 5vdcand RPM 1500 5V 643 5VE1High Voltage gt External 642 5VEtLowVoltage sVEt 46vic O TPS 123 TPStHign voltage TPStvotage 48vdc 122 TPS1 Low Voltage TPStvolage 02vdc 223 TPS2 High Voltage Y TPS2voltage 222 TPS2 Low Voltage Y TPS2volage 02vdc 221 TPSi gt thanTps2 v j TPStpercent TPS2 percent gt 20 121 TPS1 lt thanTPs2 j TPSt percent TPS2 percent lt 20 2112 Unabletoreach gt TPS j argetTPS actuM TPS gt 20 2111 Unabletoreach lt TPS Y target TPS actual TPS lt 20
132. k onm 7 m 2 L o PS l si 5 2 5 0 0 5 5 P gt amp 3 5 8 ok TS4 TS15 S 4 Sok _ a 5 I l N l 5 8 PRO Q L4 D12 4 MEM E 8 JC7 TS2 TS6 un 1 os Po G 925 1 L47 ME AE L1 I 4 0 1 1 ME 1 i TS9 5 NO TS14 L48 gt 4 13 J R O O 2 O OO O q 2 BK RD RD 6 Q 0 ES0504A ane A ODED jT COMPONENT INDEX CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION 1518 PLATFORM OVERLOAD LIMIT SWITCH TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH 7 CR30 LIFT DRIVE SELECT LIMIT SWITCH CIRCUIT OPTION P2 EMERGENCY STOP BUTTON TS14 DRIVE SPEED TOGGLE SWITCH H1 TILT ALARM P3 HORN BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH J22 PLATFORM MANIFOLD R20 RESISTOR 47000 U13 ALC500 JOYSTICK CONTROLLER CARD JC3 JOYSTICK DRIVE STEER TS1 AUXILIARY TOGGLE SWITCH 034 TIME DELAY RELAY 2 SECONDS 10A JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT T
133. s 876 E on Illustration 3 22 Step on the footswitch at the platform Result The Valve Power LED should not illuminate W Result The Valve Power LED is illuminated Remove the machine from service and contact the Genie Service Department 23 Securely install the red wire disconnected in step 20 onto terminal 5 of the relay timer 24 Step on the footswitch at the platform Result The Valve Power LED should illuminate W Result The Valve Power LED is not illuminated Remove the machine from service and contact the Genie Service Department 25 Using a suitable lifting device place a test weight equal to that of the available capacity at the center location shown in Illustration 1 Genie S 80 5 85 S 80X 26 Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound and the Valve Power LED should not light The platform overload indicator lights should be flashing at both the ground and platform controls 27 Working from outside the platform and standing next to the platform rotator locate the orange wire which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire Tag and disconnect the connectors Refer to Illustration 2 28 Using a multimeter set to read resistance ohms securely install a lead from the multimeter to the c
134. 0 a PEE iow 5 B 8 THIGH m C35RPM BK RD S e Low THIGH 55 2 9 CHECK ENGINE LIGHT FUEL PUMP 2 355 ENGINE FAULT CODE 222 7 TEST SWITCH P 6 HOUR METER c5 11 4 STARTER m 8 5 9 x 8 C4 4 C5 19 hi PRESSURE COMP VALVE E 4 VI55PCE OR RD 5 V155PCE OR RD EUNCTONENABIE 8 z 5 5 52 x x 2 amp IGNITION RELAY zt 5 2 8 2 82 ei C33STR BK F od Soc gt D 8 8 5 zo T er s 5 7 t css START RELAY 5 pag 8 41 u t C27AUX RD PUMP AUXILIARY C5 1 5 far Blo 2 5 2 2 RD C5 6 N 4 APU CUT OUT x 8 8 s RELAY a 5 m 4 VOLTAGE DROP RELAY 8 8 i ToT ge i C72 P23PWR WH 2 RO7AUX RD AUXILIARY PUMP RELAY 8 EE 4 AUXILIARY PUMP x m WH z 8 eva C28TTA RD BK 9 8 5 C6 28 a 28 RDIBK TILT ALARM 862 P134PWR LEVEL SENSOR C3 12 P134FB RD KS ctoeLs GR WH FLASHING BEACON OPTION P134FB RD x 2 MT RN 8 e A B es C25 C46HRN GR 5 7 11 4 HORN RELAY o 8 GN WH 59 5 tn era P22PWR BK 1 E R46HRN GR 9 HORN 4 2 MR C142 me 1 od 72 zo lt lt C177LS BURD T pe H
135. 1 1951 9 1 1 8 n 2951 9rg ad Arral 19 49 Qqsraloug uo 08181 8 qeear au ia 06681 8 qseal qu ta 28 4 06281 2 1451 S8ftv H0 H8 Jor 1T ug8 1 9 L SO HW IH vY c9S L QH HM 2 2951 OLY 245 7 8 0681 vedo L L9S L HWQH LLL zd 8 18 ES0505D Genie S 80 5 85 S 80X 6 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 5 80 and 5 85 ANSI CSA AS Continental TME27 Models 6 111 6 112 Section 6 Schematics September 2015 E Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models 6 113 6 114 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Continental
136. 122985 September 2015 eee TABLE OF CONTENTS Section6 Rev Schematics continued Platform Control Box Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models after serial number 8110 6 42 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models after serial number 8110 6 43 Electrical Schematic 5 80 2 20111041 0 5 6 46 Ground Control Box Terminal Strip Wiring Diagram S 80X Deutz 02011104 900 6 50 Ground Control Box Switch panel Wiring Diagram S 80X 2 20111041 0 5 6 51 Platform Control Box Wiring Diagram S 80X Deutz TD2011L04i Models 6 54 Platform Control Box Switch Panel Wiring Diagram S 80X 2 20111041 0 5 6 55 Electrical Schematic 5 80 5 85 ANSI CSA AS Perkins 8040 33 Models 6 58 Ground Control Box Terminal Strip Wiring Diagram 5 80 and 5 85 ANSI CSA AS Perkins 8040 33 Models 6 62 Ground Control Box Switch Panel Wiring Diagram 5 80 5 85 ANSI CSA AS Perkins 8040 33 Models 6 63 Platform Control Box Wiring Diagram 5 80 5 85 ANSI CSA AS Perkins 8040 33 6 66 Platform Control Box Switch Panel Wiring Diagram 5 80 5 85 ANSI CSA AS Perki
137. 5 9 C1 7 5 Pine C33STR BK 2 31444 55 5 15 2 n 5994 C24TSPS WH 5 e o 4 lt 1 6 No de f t i 82 255 4 8 5 9 5 a 27 fo 5 3 1 4 t eu C27AUX RD C51 5 2 e L R21ING WH ex Ey re AUXILIARY 41447 3144 8 5 8T 8 8 Sk 1 cs Pe 3 o gio e 2 n 5 R27AUX en 1 1 10 shes COH 5 x on 58 9 4 5 u G z xz 1192 5 129 a 5 5 11 S 8 Eo P23PWR WH 8 R33STR BK E s4 ER WH n RD 5 2 amp lt e E 4 a 5 4 6 28 W 3 C28TTA RD BK C28TTA RD BK lt lt x a 2 L 3 8 T RD IBK P134PWR RD LH C3 12 C133PLA GR BK m C25 C46HRN GR z Co 11 g 9 z 2 m C74 29 mE lt R46HRN GR 15 P22PWR 1 8 8 8 Te 82 a Lie C112 C132PLI BUWH e gt 1 M C2 6 S Eo amp lt C P184PWR RD gt gt Giz Gal i 116400 OR E L l r 2 ree SB RD Pe B ATA ge 2 5 x H C41RPM ORBK ko J144 1 l
138. C33 8 s lt RD WH 2 8 9 5 21 156 1 4 e C30EDC WH DRIVE EDC FORWARD a 5 16 lt gt 5 20 C31EDC WH BK gt 4 DRIVE REVERSE E 8 n E een 378 BL BK mE C37STCC BLIBK STEER CCW GND BR 3 5 1 8 C6 36 4 P24FS WH _ 036970 BL i C36STC BL A STEER CW 8 8 P24Fs 4 54 248 5 23 S cce C32BRK WH RD BRAKE RELEASE P26ESTP BK gt 3 p 2 eset C29MS RD WH MOTOR STROKE 8 lot 8 82 28 P134PWR RD 06 24 l 55 ES 26 c6 11 5 5628 C59CNK BUBK WU LOOSE CABLE 35 u We LIMIT SWITCH s t 55 28 g g 8 5 c3 11 P enw 4 C59CNK BLK 4 LOOSE CABLE LED S c42 C14PLU OR 19 o 4 9 Cra C15PLD OR BK o 2 5 912 ak E 858 PLATFORM LEVEL DOWN me p 047 C43JU GR gt a t C44JD GR BK 5588 43 Pag cw t E EIC C129DA RD BK O DESCENT ALARM 045 C17PRL GR mE C18PRR GR BK z BEE 30 h 422 7 S 422 11 p ew PLATFORM LEVEL UP 5 2 s J22 8 gt bi J22 12 4 PLATFORM LEVEL DOWN 125 4229 lt VE x x B 8 J22 6 cou 8 5 27 2210 0255 tg 2 22855 8 o 5 4224 22 1 55 54 7 8 AA PLATFORM ROTATE CW E A e
139. Chevron Rando HD MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD MV oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optionalfluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Part No 5 September 2015 Section 2 Specifications Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below 18 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use SPECIF
140. L JC7 3 C164PES RDAWH 4 NI ES JC7 2 01620042 OR O i JC7 5 C163PES WH BK 8 a JC7 1 JSGND2 BR 5 JC3 4 C160JPL WH RD JE I JC3 2 P162JPW1 OR O mo l JC3 3 1595 L JC3 1 JSGND1 BR TS15 C144DER BL WH i 9 a TS15 C143DEL BL BK lt H L1 C13DRE A BL RD O C28TTA RD BK I TS14 C29MS RD WH 8 T GR BK C3P 12 GR BK L4 RD C2P 6 RD 1518 S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 Platform Control Box Wiring Diagram Section 6 Schematics BR BATGND GROUND STUD WH TS14 e LIFT DRIVE SELECT OPTION CR30 27 C40LS 2 2 WH TS7 WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD 4015 SPLICE TO PartNo 122985 u G S 80 S 85 S 80X ES0503A 6 78 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111
141. The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor 3 Attach a suitable lifting device to the lifting eyes located near the drive motor 4 Remove the drive hub mounting bolts Carefully remove the turntable rotate drive hub assembly from the machine AWARNING Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device Part No 122985 Genie S 80 S 85 0 CHECKLIST D PROCEDURES 5 Remove the plug the drive hub Drain the oil from the hub into a suitable container Single fill port rotator a motor b fillport drive hub mounting bolts d drive hub Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES Dual fill port rotator motor b drive hub c drive hub mounting bolts d fill ports 6 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications 7 Fillthe drive hub with oil Refer to Section 2 Specifications Apply pipe thread sealant to the plug Install the plug 8 Adjustturntable rotation gear backlash Refer to Repair Procedure 10 1 How to Adjust the Turntable Rotation Gear Backlash Genie S 80 S 85 S 80X D 8 Perform Engi
142. connector from the platform load sense module 3 Remove the hose and cable cover from the side of the jib boom 4 Remove the hose and cable clamp from the jib boom pivot pin Lay all hoses and cables to the side Component damage hazard Hoses and cables can become damaged if they are kinked or pinched Genie S 80 S 85 S 80X 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage 8 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING hazard The jib boom could fall when the slave cylinder rod end pivot pin is removed if not properly attached to the overhead crane 9 Remove the pin retaining fastener from the jib boom bellcrank to primary boom pivot pin 10 Use a soft metal drift to remove the pin and carefully remove the jib boom assembly from the primary boom AWARNING C vshing hazard The jib boom could become unbalanced and fall when removed from the machine if not proper
143. h TURNTABLE ROTATE 55 5 a E 8 226 2 2 6 6 gt TURNTABLE ROTATE OLEI 5 COTHE WHRD 8 FLOW CONTROL iM 23932 5 me 2200 09 ee EE B a 00 9 55 C6 1 PRIMARY BOOM 553 UP RD pine m 888 PRIMARY BOOM 8 o u 5 8 _ PRIMARY BOOM 5 RD WH UP DOWN 2 FLOW CONTROL 5 ay ox ex A RD i M C129DA DESCENT ALARM 3 5 1 7 632 C2PBD RD BK 2 5 8 gt C3 3 a Sn 8 55 5 oj zz 2528 1 Ground a Y lt ceo C9PER BK RD 884 50 90 595970559 lt 938 C8PBR BK WH ao C3 7 0 gt N C7PBE E m x h C67 OPBE IK RD BR gt PRIMARY BOOM u 8 S EXTEND PRIMARY BOOM 5314 RETRACT C6 8 PRIMARY BOOM 9k 25 8 8 5 RETRACT 8 55 Qu u 569 PRIMARY BOOM D C9PERF BK RD EXTEND RETRACT 898 2 FLOW CONTROL 2 2 4 8 2 8 TEZ 1 4 Fe CS C30EDC WH ER 1 4 EDC DRIVE FORWARD 2 2 TEZ C15 65 20 C31EDC 7 4 EDC DRIVE REVERSE te 1 GND BR 21 F C130TA WH RD TRAVELALARM OPTION PFs 22 8 8 P24FS WH 4 IX C16 Fe 5 29 C32BRK WH RD BRAKE RELEASE P26ESTP BK gt 23 1 3 5 24 2 SPEED 8
144. installation or the flex plate teeth may become damaged Part No 122985 September 2015 Section 4 Repair Procedures ENGINES Perkins 804C 33 Perkins Deutz and Continental Pump Mounting Plate Flex Plate Continental Pump Mounting Plate Deutz BF4L 2011 Pump Mounting Plate Genie Part No 122985 S 80 5 85 S 80X 4 37 Section 4 Repair Procedures September 2015 Ground Controls 6 1 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect all the wiring from the relay to be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a and 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a and 30 no continuity infinite Q terminal 87 to 30 continuity zero Q 87 1 87
145. platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw on the rotator but do not remove it AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 122985 September 2015 Section 4 Repair Procedures 4 Move the function enable button to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING C shing haz
146. specific gravity of each battery cell with a hydrometer Note the results Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery i Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions an
147. 0 Pull the hub off the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Section 4 Repair Procedures September 2015 2WD STEER AXLE COMPONENTS How to Install the Hub and Bearings 2WD Models Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 5 Place the outer bearing into the hub 6 Install the washer and castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearing Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one turn and then torque to 35 ft lbs 47 Nm 9 Install a new cotter pin Bend the cotter pin to secure the castle nut Note Always use a new cotter pin when installing a castle nut 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Genie S 80 S 85 S 80X 11 2 Steer Cylinder
148. 1 q9gr qu HM c 9S1 dH 914 91 08 1 q8rral Ho 951 9 ES0503D Genie S 80 5 85 S 80X 6 87 Part No 122985 September 2015 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 Section 6 Schematics September 2015 l uma O tI lt Qs Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 89 6 90 September 2015 WH TS14 itl CR30 LIFT DRIVE SELECT OPTION WH TS7 WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD C40LS SPLICE TO 0401 5 C2P 2 Platform Control Box Wiring Diagram 5 80 and S 85 CE Perkins
149. 1 e 10 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 SNOILOANNOO 1 OL qesa g 18 anis 99 48 qvera r ad c Ld QH 9 260 1951 L LSM HM raw 01 08 assral qu do 2951 PAY v rLH QH HM 0881 8 araL HM 2181 49 1 83 914 1 1651 1951 1 281 38 9 8841 1 gerar uo5 10 0 QNM T7 avrar Ho asraloug uo 01 WSI HM 2 69 qeea ig 2851 Qqaveal HAw a aseaL au Nd 21 aezal HM 2 1451 98 8 9 1281 2081 Sv7 du 91 99 95
150. 10 Inspect the turntable area for burnt chafed and pinched cables 11 Lower the boom to the stowed position and turn the engine off 12 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the boom Cables on the boom and jib boom Jib rotate level manifold Inside of the platform control box Genie 3 20 5 80 5 85 0 13 Inspect for a liberal coating of dielectric grease in the following location All wire harness connectors to platform control box 14 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray 15 Swing the engine tray in towards the machine 16 Install the engine tray retaining fasteners AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury PartNo 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 3 Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation
151. 122985 S 80 S 85 5 80 6 1 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models after serial number 81 10 Section 6 Schematics September 2015 Electrical Schematic S 80X Perkins 804D 33 Models 93 6 4 September 2015 Section 6 Schematics Electrical Schematic S 80X Perkins 804D 33 Models e x 5 5 w s x x gt 8 oc 0 lt E 5 z 2 8 5 o T lt lt aga APINA Eu S amp 2 OOO 9 2 2 5 8 a a abs 52 8 zz zo 555 5 5 ele 8 am lt 895525 588 2 4 o o 5 lo 4 x m gie HOUR METER 4 5 8 9 5 C5 19 x V155PCE OR RD V155PCE mE EE x g 5 58 POWER RELAY 5 5 LOW RPM m 2 1 to 2 8 C1 9 8658 88 de RPM BK RD x Z HGHRPM 5 5 EB 60 5 FS z 20 oz 5 gi 88518838 88 a a LOW RPM 2 il 8 m HIGH RPM C5 18
152. 2 zi v A xc JIBBOOMDOWN 8 5 J22 5 E t J22 9 55 p JIB BOOM UP 5 ZZ x x ee lt Bae 422 3 Se J22 2 PLATFORM ROTATE CCW 8 8 28 8 8 He Hans 1 Jaen 4 PLATFORM ROTATE CW tx G 6 28 S 80 5 85 S 80X Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Deutz TD201 1L 04i Models before serial number 81 11 28 24 Section 6 Schematics September 2015 M 5 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Deutz TD2011L041 Models before serial number 81 1 1 25 6 26 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram 5 80 and 5 85 CE Deutz TD2011L041 Models before serial number 8111 C
153. 28 6 gt Feige SIE 2 m z gt 5 lt 2 9 5 2 50 2686812555255 29944 55 15 49291290 25555 ial EEL FE F F Genie S 80 5 85 S 80X 6 67 Part No 122985 September 2015 Section 6 Schematics p J J H est Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 8040 33 Models 67 68 69 Section 6 Schematics September 2015 Electrical Schematic S 80 and 85 Perkins 804D 33 Models before serial number 8111 C132PLI BK September 2015 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models before serial number 81
154. 2951 10 8 99 HME 8 8 0 HMA 8 6951 HW 8 L3H LX3 WOO 6 90 6 90 00 08 6 9 2951 Qu a8 61 99 raro 1 13A31 HO rt 6951 NMOG 13431 WHO4 1VId 9 70 8 0 SI 5 6954 8 MO 31V LOH WHOSLW1d 0 9 8 21 9 981 MOO 31VLOH 0 9 8 48 49 84 2561 48 49 AlddNs L va LIV8 2 290 5 AZL 11 52 HM IZ HM E OL HO LIMSA3M 22 000 9 8 WNHOJ Y d OL H3MOd Z 91N 2 84 ZUHM 6 2 WSI HM l LSA HM ae 1 ve 55 H3MOd AYYTIXNY 9 90 L dioqH 976 690 v amp WSI QH 1951 008 HOSN3S 96 90 2 810 82 72 9 9 810 HIWQH 68 17 90 HM 819 HM 08 06 90 M8 HM 9 00 M8 HM 16 62 60 QH HM 9 812 22 WHY V T3AVHL QH HM LYVLS 5 69 1 810 6 NSI 9 0981 MO19 8 80 6 S 910 HWW 9 9981 6 59 6 810 auma 6 610 961 Quia MO 15 9 99 18 01 919 18 96 MOO 1 26 92 NaN 6 qasnNn 00 78 6 s1 8 07 90 z 820 OF
155. 3 LC s VA cul CR46 v29 7 ES0503D ES0504D e 5 g 8 5 2 5 2 9 8 m S 8 g Sn 2 lt dzg oF 53 om omg mo mz mm 22 222 59 5 5 2 22 ms 4 2 i 5 om 96 EJ 8 m EJ gt a 9 22 m E m m 8 8 Genie Part No 122985 S 80 S 85 S 80X 6 159 September 2015 Section 6 Schematics pu M nt Deutz and Perkins Options Schematic 6 159 6 160 6 161 Section 6 Schematics September 2015 12 kW Hydraulic Generator Wiring Diagram 6 162 Section 6 Schematics September 2015 12 kW Hydraulic Generator Wiring Diagram A B C D E F G H 12 5 KW HYDRAULIC GENERATOR 1 NEUTRAL BUSS BAR lt QO M 2 Y x 9 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI 1 E 208 VAC 1 OUTLET 3 6 RED RED ez 3 5 7 4 ORANGE gt 1 WHITE LA 6 E BLACK 4 BLACK BLACK 12GA I GREEN GREEN 20 AMP CIRCUIT NEMA 4 CONTROL BOX Ns BREAKER GROUND STUD ON 5 PA
156. 3 position 3 way DJ Charge pressure circuit that directs hot oil out of low pressure side of drive pump 80 90 ft lbs 108 122 Nm 13 Flow divider combiner valve DM Controls flow to steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 14 Check Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm Genie Part No 122985 S 80 S 85 8 Section 4 Repair Procedures September 2015 MANIFOLDS DN DA DL Genie 4 54 S 80 S 85 0 Part No 122985 September 2015 Section 4 Repair Procedures 8 10 MANIFOLDS 4WD Traction Manifold Components after serial number 8580 The drive manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item Function Torque 1 Relief valve 280 psi 19 3 bar DE Charge pressure circuit 35 40 ft lbs 48 54 Nm 2 Flow divider combiner valve DB Controls flow to non steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 3 Check DF Steer end drive motor circuit 35 40 ft lbs 48 54 Nm 4 Check valve
157. 5 u im a Qa I D 2 5 6 5 282 2 2 5 88 0 5 I oz 5 2 s zg uru 5 5 S 58 k Siz Z 5 9 gt 8 1 0 9 lu 2 8 E 958 5 2 0 22825113 28 41 5 5 55558 55 x lt u n lt m a lt Ex 58 8 zz 5 2150 a Quiz 5 Q gt x 6 az lt gt 2 lt 9 aS y 2856566 85 0 25 25 gt lt OG GO I E F FE E amp o 5 2 Pier lt S Z S Z o o 525 9830288 82 50010535 52288 85 Sl EI 55909 m T e Bag 2 55865651829 y 14 5 N m en 2 m ageca l HM x90 18 NOLLVNIINH3 L O 6 9 68 dn IHd 1 90 1 880 1981 ANLS AND UE NMOG WOOS 2 99 8 0 2 G O 2 Orval 6 01 9 1951 8 5 99 HWAH 9 860 068 MO 31VLOH JIAYLNYNL 7 99 HM 50 HM 9 6981 HM 9 90 9 60 M8 HM S 1 2951 S
158. 53 5 4 5 24 5 2 SPEED Boc Qn MOTOR STROKE m Mi CR34 SPEED REDUCTION RELAY 2 o z z C6 31 29 LST3O BOOM UP DOWN C118LS OR G acs SPEED REDUCTION 8 LIMIT SWITCH No P134PWR RD 2 5 56 C6 11 8 15828 SE CS9CNK BL BK LOOSE CABLE TW LIMIT SWITCH Si 2 4 C3 11 El 146 147 S LOOSE CABLE LED 4 2 3 3 C14PLU OR PLATFORM 8 DOWN LEVEL pes C15PLD OR BK 4 8 0 el UP I PLAT LEVEL 5 85 DOWN d 9 82 22 C4 8 892 nom 04440 GR BK LER Tup AT C43JU GR i 8 4 gt DOWN JIBBOOM 5 85 OPTION 2 5 UP 9 nee C4 6 B22 sow M C18PRR GR BK FRE 4 m C17PRL GR 3 sccw PLAT ROTATE ud B m E S door gt 322311 PLATFORM LEVEL UP o ze 3228 21 4 PLATFORM LEVEL DOWN ge J22 6 E n 422 10 1 8 x 422 5 gt m 422 9 8 5 lt z 5 2 x x E e 2545 J22 8 EIS J22 2 SENN 2344 8 PLATFORM ROTATE CCW o 3226 gt lp gez PLATFORM ROTATE CW G 5 80 5 85 S 80X 6 107 Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 ANSI CSA AS Continental TME27 Models 6 107 6 108 Section 6 Schematics September 2015 ea Ground Contro
159. 80 S 85 S 80X Genie Remove the upper rollers from the replacement section of cable track Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Connect the ends of the replacement cable track section to the existing cable track using the snap rings Install the rollers onto the new section of cable track Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Part No 122985 September 2015 Section 4 Repair Procedures 4 2 Boom How to Shim the Boom 1 Measure each wear pad Note Replace the pad if thickness is less than minimum specification If thickness is more than minimum specification perform the following procedure Refer to Section 3 D 1 Check the Boom Wear Pads 2 Extend the boom until the wear pads are accessible 3 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 5 Tighten the mounting fasteners 6 Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Note Always maintain squareness between the outer and inner boom tubes Part No 122985 BOOM COMPONENTS How to Remove the Boom ADANGER Tlp over hazard This procedure requires the removal of t
160. 9 WOO IHd 1 90 1 860 1981 qu IHd 2 99 xg au Orral gt 05 VZ8 89HO m WOOS IHd 8 99 069050 HWAH eu MO SLVLOY 1 1 7 99 HM 860 HM r Z9SL HM m MOO ALVLOY STAVLNHNL 9 90 Mg8 HM 5 M8 HM S 2961 48 HM m 31VLOH 1 1 9 90 GH HM 9 59 9 V rLH o 1X3 1 90 1 8 0 Z VZ8 69HO 8 LOVHISH WOO Idd 8 99 HWE 8 8 2 2951 HW IHd 6 99 6 860 6 8 318vN33AlHd 6 90 8 EL 13A31 WHOSLW1d 2 879 HO 1 6981 HO NMOQ 13A31 WHO41V1d 8VO 489 40 SL 6581 of a 77 MO 1108 INHOd1V 1d 0 9 8 HD 1 6 1881 mol a1V1OH INHOd1V 1d 9 8vO 81 1 581 48 49 SE seo Alddns Liva Liva Liva 02 2 24 anis AldANS 11 90 HM 12 INH HM WHOd41V1d OL 22 690 0 8 WHO41V d OL H3MOd Z 91N 2 840 UHM 20 1 5 HM 2 H3MOd 9 90 12 1981 73477 8290 yg qu 910 xg au 82 72 0 8LO 62 903 10 90 HM 810 HM 06 Od3 3SH3AdH 02 0 9
161. C3 7 N 12 lt lt 7 O2 C67 rp 214 PRIMARY BOOM a 4 EXTEND SUR 1 EXTEND S PRIMARY BOOM 8 t RETRACT C6 8 Ibi PRIMARY BOOM pl RETRACT 54 56 t t F E PRIMARY BOOM 9 C9PERF BK RD EXTEND RETRACT 8 FLOW CONTROL 92 sch NRE EE 2 ci 5560 5 2 m C30EDC WH EDC DRIVE FORWARD 15 2 4 Cis C520 081800 WH BK 34 EDC DRIVE REVERSE 162 5 r GND BR C130TA WH RD TRAVEL ALARM OPTION P24FS WH 2 4 4 m gt 2 WHi 224 1 05 23 C32BRK WH RD BRAKE RELEASE 1 P26ESTP BK 3 N 24 Bi 3 CMS ROM HH MOTOR STROKE 3 So u P134PWR RD L T cz 9 15825 5 C59CNK BL BK Ss LOOSE CABLE LIMIT SWITCH 5 gt g C3 11 L 146 147 4 o LOOSE CABLE LED s C4 2 3 iu C14PLU OR 5 Ul PLATFORM DOWN LEVEL m CI5PLD OR BK 8 UP PLAT LEVEL 8k DOWN d C44JD GRIBK 22 DOWN IE ED e UP C47 C43JU GR i 8 0 DOWN BOOM u UP S 85 OPTION 8 5 cih
162. EXTEND EUN EXTEND 7 MARY BOOM 6 8 0 MARY BOOM og git C8PBR 24 C2 3 81 E RETRACT FE 6 gru C69 PRIMARY BOOM C9PERF BK RD EXTEND RETRACT FTE E FLOW CONTROL 5 g 5 2 am Irc mE mE C30EDC WH 51 4 EDC DRIVE FORWARD y 2 16 lt 56 6 65 20 C31EDC WH BK EDC DRIVE REVERSE Q A r GND BR 21 C130TA WH RD TRAVEL ALARM OPTION P24FS WH 2 g 4 n e P23F9 WH 4 19 ers Fe 6523 C32BRK WH RD SH 1 BRAKE RELEASE 9 P26ESTP BK 258 C1 3 C5 24 Spt 2 SPEED 20 MOTOR STROKE m z P134PWR RD 55 6 58 8 18828 E C59CNK BL BK gus LOOSE CABLE ESI TM LIMIT SWITCH 5 2 c3 11 L46 L47 gt Ye 7 LOOSE CABLE LED 5 C4 2 3 5 C14PLU OR PLATFORM 8 DOWN LEVEL CISPLD OR BK D 5 P UP PLAT LEVEL 5 DOWN EE oo 85 9 C4 8 m 55 DOWN t C44JD GR BK 5 5 wur mE GR i m 5 7 ALS DOWN JIBBOOM Eu tup S850PTON 9 ROUND E em E 0 ERSTER Pug C18PRR GR BK ETES tew 645 C17PRL GR T Ccw Hl 9 99 77 PLAT ROTATE E TOW 5 e mE In sen PLATFORM LEVEL UP o 22 8 EI 422 12 1 PLATFORM LEVEL DOWN 222 6 EIS J22 10 v 247 1 5 JIBBOOMDOWN
163. Genie S 80 5 85 S 80X 6 15 Part No 122985 September 2015 15 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 5 80 5 85 ANSI CSA AS Deutz TD2011L04I Models 16 Section 6 Schematics September 2015 III EE III Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011L04I Models 17 6 18 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram 5 80 and S 85 ANSI CSA AS Deutz 2011 041 Models A ER MD CUNEO C RO GNO ee DRE 1 i ui QO oy 5 amp A z 8 SIE z 9 ion sN 155 gt lt 2 I 55 8 185 E lt O lt Fs 85 EL s 8 O 5 i 2 523 21 9 amp 0 e u 4 22 1 TS7 C18PRR GR BK J22 3 clog 9 8 TS7 C17PRL GR J2
164. Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz 2011 041 Models after serial number 81 10 6 9 6 40 Section 6 Schematics September 2015 1 1 1 Platform Control Box Wiring Diagram S 80 and S 85 CE Deutz TD2011L041 Models after serial number 8110 41 6 42 September 2015 WH TS14 itl CR30 LIFT DRIVE SELECT OPTION WH TS7 WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD C40LS SPLICE TO 0401 5 C2P 2 Platform Control Box Wiring Diagram 5 80 and 5 85 CE Deutz 2011 041 Models after serial number 8110 Section 6 Schematics C RR RM ME SCRA 1 9 aie 1 i RD E STOP ww IX RDLS18 CABLE 4 5 e lt P134PWR RD i 2 lt 5 81 P134PWR RD R20 9 9 2 55 47000 Ne i ZED 5
165. Ibs 80 Nm 12 135 ft lbs 183 Nm 12 85 ft lbs 115 Nm 16 200 ft lbs 271 Nm 16 110 ft lbs 150 Nm 20 250 ft lbs 334 Nm 20 140 ft Ibs 190 Nm 24 305 ft Ibs 414 Nm 24 180 ft lbs 245 Nm Genie Part No 122985 5 80 5 85 S 80X 2 9 Section 2 Specifications September 2015 SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 trengt Grade 5 Grade 8 22 Black Oxide Bolts LUBED LUBED LUBED _in ibs 11 3 110 12 4 10 1 13 5 120 135 LUBED DRY LUBED 1 gt 140 160 15 8 18 lt INS ft lbs 176 23 19 N 312 352 47 4 50 1 E 555 773 101 6 86 7 1084 176 170 149 2 217 210 284 176 240 325 515 350 320 433 430 583 10 560 12 770 718 840 800 970 1315 1290 7 1090 908 1440 19 1220 24 1530 2074 1700 2304 3620 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 mm BED LUBED LUBED LUBED Nm ins ias inis inis Nm 11241 a 4e3 54 58 663 78 884 68 775 91 103 407 69 787 93 105 100 113 122 15 116 132 155 175 RY ft tbs fttbs fttbs fttbs Nm 23 6 274 830
166. LST20 0 BR 104 ANGLE STOWED 4 3 C2 4 1 4215 OR RD CA2LS OR RD 47 z REDUCTION 24 022 C40LS OR 0530 C40LS OR gt gt RD 8 s LSBIRO p 5 gt gt BOOM RETRACT 513 P134PWR RD C6 23 4 9 Bk ae DRIVE ROTATE SPEED 8 amp AYYRN s WH LIMIT SWITCH Tr 5 T 5 5 5 5 4 6925 P134PWR RD AD 8 T 9 5 9 8 CI3DRE BL RD 9 13 6 C13DRE BURD lo DRIVE ENABLE 85 8 a z 8 s 5 LIMIT SWITCH ras 03 8 WH RD 9 2 3 5 4 Joo amp CSTRR WH BK 104 WH 2 n 9 B C64 TURNTABLE ROTATE E C4TRL WH H cw o u 4 1 cow 1 5 enw TURNTABLE ROTATE 4 b 2 C6 6 E TURNTABLE ROTATE H1 T H FLOW CONTROL ms 8 g z c3 9 8 14 lt lt C9PER BK RD PES 13 C8PBR BK WH C3 7 RDWH 228 112 C7PBE BK 8a LED BURD a 9 8 gt 16 _ 252b 4 C67 Z pn SH PRIMARY BOOM E 5 BER 4 C7PBE BK ZUR A EXTEND CHADER ea EXTEND 5 SN 4 RIGHT 19 RETRACT E 6 8 e PRIMARY BOOM e C8PBR BK WH RETRACT u 5 BX 8 8 CMSDEL BLBK 2 PRIMARY BOOM 223 e el 5 PS 99 C9PERF BK RD J EXTEND RETRACT 1 8 FLOW CONTROL al gi gi 81 1
167. MO 31VLOH WHOSLV1d 0 9 8 21 LSSL MOO WHOSLW1d 9 80 48 49 81 1 1951 AlddNs LIV8 8 1 8 02 280 AlddNS NOLLINSI AZL 11 80 HM 12 999 HM OL HMd HOLIMSA3M 22 080 8 15 OL H3MOd 1 69 HM 2 840 21 6 18 NSI HM 1 15 HM 0281 ve u3MOd AYVITIXNY 9 90 gro 22 764 690 vi WSI 1991 WHV1V HOSN3S 82 90 8 0 xg qu 82 5 92 59 9 15 6 oda auvMdo4 16 90 HM T HLO HM 0 oda asua au 02 52 M8 HM 8 810 M8 HM 16 82 59 QH HM 9 819 Qu HM 26 WHv1v T3AVH L QH HM 1 15 9 90 1 810 x8 6 WSI 2 2951 MOTD 8 910 HMMA S 91N 9 9991 6 99 Qu M8 6 810 auma SE 951 810 1 u331S 95 99 18 01 812 18 9 215 46 90 LL 8LO aasnnn 6 een 1 1 8 07 90 920 OF 8 E 2 50 Xg HO 5 95 8 6 NSI 48 HO wg __S103MOLS WOO 22 99 r 829 Qu uO ev Ovre uw DE 10 dn Wood dif 0 2 1 88461 98 5 NMOG 008 alr 9 005300007 gt e 2
168. Models Engine specifications require that this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 Genie S 80 S 85 0 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST E PROCEDURES E 4 Replace the Boom Extend Retract Cable
169. NR September 2015 Checklist E Y NR C 1 Engine maintenance E 1 Hydraulic oil C 2 Grease platform overload if equipped C 3 Test the platform overload if equipped C 4 Air filter element C 5 Replace filter separator Deutz and Perkins models C 6 Safety envelope S 80X Checklist D Y NR D 1 Boom wear pads D 2 Free wheel configuration D 3 Turntable rotation bearing bolts 0 4 Turntable bearing wear D 5 Engine maintenance D 6 Replace hydraulic filters 0 7 Drive hub oil Perform every 1500 hours D 8 Engine maintenance Deutz models Comments Genie E 2 Engine maintenance Perkins models Perform every 3000 hours E 3 Engine maintenance Deutz and Perkins models Perform every 10 years E 4 Replace the Boom Extend Retract Cables S 80 S 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed daily Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition
170. ORANGE 18 PURPLE ORANGE 18 o Ke TWIST WIRES 10 TURNS 360 DEG FOOT FULL LENGTH 29 BLK LT GREEN 18 31 YELLOW 18 JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR 1309583 ww 34 NIE 1 1 BLACK LT GREEN 18 35 LT GREENMWHITE 18 gt 8 ex LTGREEN RED 18 3 GASOLINE SENSOR INTERFACE 38 1 WHITE LT GREEN 18 4 38 TAN 18 hh 40 a2 TANIBROWN 18 bot 43 48 PINKITAN 18 rn 2 48 DK BLUE YELLOW 18 hA 4 LIGREENAED 18 VEHICLE INTERFACE 2 18 DBW THROTTLE CONNECTOR DEUTSCH DT06 PLUG LTBLUE DK BLUE 18 4 5 PURPLE LT BLUE 18 LT GREEN RED 18 L 51 BLUE 18 8 VREF 52 GRAYWHITE 18 2 FPP1 SS LL GREENT ACK TE BLACKLTGREEN 18 RETURN DK TS 4 AUXANAPUT PURPLEYELLOW 18 5 55 ORANGE 18 BLUEIGREEN 145 START IN AUTOCRANK N Mm 167 GROUND 1 M NOTUSED PLUGGED 60 REDMAN TS h 4 2 49 NOT USED PLUGGED WHITEIOR NGETB lio CAN nian ir m N 1 2 nun BLUEWHITE 18 44 CANLOW 63 16 12 NOT USED PLUGGED 16 66 67 Des 69 BLACK 16 ry WHITEBLUE E M 2 i BLACK YELLOW ARCA VEHICLE INTERFACE 1 75 WHITEIBLACK 18 2 7 DEUTSCH DTO4 RECEPTACLE 78 2 hp 1 PINK 18 _ f1 vsw 8 L 5 AA
171. PIN CIRCUIT 4 WIRE 1 P109LS GR WH 2 C184PL WH J8 3 NC 4 NC 5 C169LED2 BL 6 P109LS GR WH 7 617718 BL RD 8 SNSRGND BR 5 9 NC 10 C169LED1 GR Section 6 Schematics Fr Connector Pin Legend View 2 C B A DEUTZ 2011LO4i ENGINE PLUG 1 PIN CIRCUIT 4 COLOR 1 C41RPM OR BK J144 2 C107AF WH 3 C26TSR WH RD 4 8 WH 5 C25PSR WH BK 6 8 WH 2 7 R21IGN WH 14 BR 1 9 10 3 4 PLATFORM MANIFOLD 5 422 DT04 12PA PIN CIRCUIT COLOR 1 GND BR GND BR 3 C18PRR GR BK 4 C17PRL GR 5 GR 6 6 C44JD GR BK 422 7 8 C15PLD OR BK 9 GND BR 10 GND BR 11 GND BR 12 GND BR 7 8 Genie Part No 122985 S 80 S 85 S 80X September 2015 Section 6 Schematics m Hn Connector Pin Legend View 2 Section 6 Schematics September 2015 Ps Electrical Schematic 5 80 5 85 ANSI CSA AS Deutz TD201 1L04i Models C28TTA RD BK C28TTA RD BK s L2
172. R27AUX RD N A A g er er 1 a 8 g 1 2 5 1 aa 7 2 P23PWR WH d D IO Lee az Aa 8 WH C55 11 4 L W Eo 12 C28TTA RD BK wie R33STR BK 5 RD E Tog gt lt 8 amp d C6 28 ha 109 5 al N 7 C624 P134PWR RD LY 5 2 2 00 2 025 C46HRN GR 5 i go 8 GR BK R46HRN GR 4 C71 fo P22PWR BK 1 2 8 1 HE ge T T 2 91 12 C BURD 5 i ML AD C2 6 1 8 2 2 lt lt RD 512 5 i 1 x 2 2 5 RD 21 PI34FB RD 8 O 8 ale 4 P184FB ATA 1 C52 1 C41RPM ORBK 1 32 ao 59 e l 1 m m l 9 4 E 55 PIR 5 8g 9 15 man 5 NE a o 55 nec La 8 BIBAT RD 4 4 as 5 6 8 m RD N LO
173. Remove the pin retaining fasteners from both the steering cylinder and the tie rod cylinder pivot pins Use a soft metal drift to remove the pins Loosen the wheel lug nuts Do not remove them Block the non steer wheels and center a lifting jack of ample capacity under the steer axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts Remove the tire and wheel assembly Remove the pin retaining fasteners from the yoke pivot pins Support and secure the yoke and hub assembly to a lifting jack Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out Remove the yoke and hub assembly from the machine ACAUTION Crushing hazard The yoke and hub assembly may become unbalanced and fall if not properly supported and secured to the lifting jack when it is removed from the machine Part No 122985 and Bearings 1 5 Loosen the wheel lug nuts Do not remove them Block the non steer wheels and center a lifting jack of ample capacity under the steer axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts Remove the tire and wheel assembly Remove the dust cap cotter pin and castle nut Note Always replace the cotter pin with a new one when installing the castle nut 6 Genie S 80 S 85
174. Repair Procedures 8 8 2WD Traction Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end of the machine Index Schematic No Description Item 1 Relief Valve 280 psi 19 3 bar DE 2 Flow Divider Combiner Valve DB Check Valve DC Check Valve DD 5 Shuttle Valve position way DF 6 Orifice Plug 0 070 inch 1 8 mm DA Part No 122985 S 80 5 85 8 MANIFOLDS Function Torque Charge pressure circuit 30 35 ft lbs 41 47 Nm ps Controls flow to drive motors in forward and reverse 90 100 ft Ibs 120 133 Nm Drive circuit 30 35 ft lbs 41 47 Nm 2 Drive circuit 90 35 ft lbs 41 47 Nm beets Controls flow to drive motors in forward and 6 8786 50 55 ft lbs 67 73 Nm AN Equalizes flow across flow divider combiner valve BY Genie Section 4 Repair Procedures September 2015 WW ET MANIFOLDS DE Genie 4 52 S 80 S 85 0 Part No 122985 September 2015 Section 4 Repair Procedures 8 9 MANIFOLDS 4WD Traction Manifold Components before serial number 8581 The drive manifold is mounted inside the drive chassis at the non steer end of the machine Index Schemati
175. S 85 S 80X PartNo 122985 6 74 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 SNOILO3NNOO lOHLNOO OL a8LaL 19 49 qesal g 1a anas 99 48 Qvera c au 9H248 H5 0 0 9 269 1951 18 vay 1951 0 481 4991 81 08 40 2951 W FL4 aAU HM 0881 8 aval HM 181 9 L 9Lu qu 5 es 1951 4 1 1 NA 9r u ag 0881 2951 9 Qvria l Ho Qe DE 4951 289 o 12 081 81 48 01 WSI HM 1 469 08 06681 2851 Qvega L HM a era 8681 Coty d 2 7951 L ego ad 06281 c ISSL HM 98 veHO ud Jor ug GLC8 L HM azzal yg OPS ON 90 08 6951 00 53 914
176. SELECT TOGGLE SWITCH Co FOOT SWITCH 164 SELECT TOGGLE SWITCH CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT DRIVE SELECT LIMIT SWITCH CIRCUIT OPTION 158 JIB BOOM UP DOWN TOGGLE SWITCH 8 85 OPTION 1 TILT ALARM TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH 122 PLATFORM MANIFOLD 1514 __ DRIVE SPEED TOGGLE SWITCH 8 303 JOYSTICK DRIVE STEER 1515 DRIVE ENABLE TOGGLE SWITCH 407 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE Ui8 ALC500 JOYSTICK CONTROLLER CARD LED DRIVE ENABLE U34 TIME DELAY RELAY 2 SECONDS 10A 6 LED PLATFORM OVERLOAD U35 TIME DELAY RELAY 2 SECONDS 304 bar HED CABLE TENSION NOTE DASHED LINES INDICATE OPTIONS 148 LED TILT ALARM i ROCKER STEER OPTION 1518 PLATFORM OVERLOAD LIMIT SWITCH EMERGENCY STOP BUTTON Genie Part No 122985 S 80 5 85 S 80X 6 127 September 2015 Section 6 Schematics r Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serialnumber8111 6 127 6 128 Section 6 Schematics September 2015 n Electrical Schematic S 80 and S 85 CE Continental TME27 Models after serial number 8110 6 129 6 130 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Continental TME27 Models after serial number 8110 D A B C
177. SPEED 5 u P134PWR RD BK 5 x LIMIT SWITCH a 5 WH m C6 25 P134PWR RD RD DUE ENABLE GE CIMDER BLWH 7 33 ee si C13DRE C99 C13DRE BR E LIMIT SWITCH PS RIGHT 2 LEFT SS WH C143DEL BUBK oa E 8 o 2 gt rec E 0878100 06 37 C37STCC BUBK STEER CCW 2 x 2 gt C36STC BL C636 C36STC BL STEER CW 110 lt 17 8 8 C36 C6TRF WH RD 24 5 gt C35 2213 9 C5TRR WH BK T m WH T g 5555 04 C64 514 TURNTABLE ROTATE cow D C4TRL WH 05052 TURNTABLE ROTATE lt 25058 cow i h TURNTABLE ROTATE 2114 88842 i cw 0 024040 O O 0 2 p m e 6 6 gt TURNTABLE ROTATE 2 7 FLOW CONTROL 8 8 H H 5 H 88 8 B cn N g 8 55 C6 1 2019 PRIMARY BOOM 263 UP o3 UP 53 PRIMARY BOOM 8 c 1 2 9 u 85 t DOWN alr 02 C2PBD RD BK 38 og 8 5 eg 5 39 8 lt 2 a wt 5 z PRIMARY BOOM RD WH A UP DOWN a FLOW CONTROL ar X C3 1 CIPBU RD C129DA RD BK DESCENT ALARM 8 C2PBD RD BK Sk
178. September 2015 Electrical Schematic S 80X Deutz TD201 1L04l Models 6 46 September 2015 Section 6 Schematics Electrical Schematic S 80X Deutz TD2011L04I Models a x 5 5 w s m ie a 0 lt E 5 z 2 8 5 o lt aaa a 5 8 gy S 2 0000 95 2 8 a 5 abs 9853 8 2 8 52 35 5 I 895525 588 2 4 o o 5 lo 4 x m gie HOUR METER 4 5 8 a 8 5 3 C5 19 PRESSURE COMP VALVE 4 V155PCE OR RD RS V155PCE OR RD FUNCTION ENABLE ae 0 4 58 4 POWER RELAY 5 LOW RPM m 2 1 o 2 a 5 5 i 1 9 8558 5 d RPM BK RD x 2 HIGHRPM 5557 ES 26 SLE FS a 855 88 amp rk 5 228 o Fur OO a LOW RPM 2 e 8 m HIGH RPM C5 18 g tma Le f RPMRELAY BS 2 2 805 8 5 5 i 4113 52215 3 8 po H RPM SOLENOID 5 5 S Zu 5 8 1 52 QU E FUEL PUMP 8 88 a 22 er E C1 8 Te c5 s
179. TME27 Models CONTROL HARNESS TO PLATFORM SWITCH PANEL TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 TS48 C49DLITE WH BK C4P 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 11 1 1 J8 P109LS BL WH 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 TS3 C39LP BL RD C2P 1 P3 C46HRN GR C2P 5 TS47 C45GEN GR WH C2P 7 C40LS OR C2P 2 WH RD 6 C123PBS RD BK C2P 8 C7PBE BK C3P 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C36STC BL C1P 10 C3PBF RD WH C3P 3 C37STCC BL BK C1P 11 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK 5 C29MS RD WH C1P 3 P 08 91919 J7 o2 no CAN CAN LOW LS18 C132PLI RD C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD
180. TPS1 2 simultaneous Y Uses same parameters as individual voltages out of range TPS1 2 voltage fault detection above Adaptive Learn Key Cycle Code Fault Name gt Adaptive Learn KC MAP Pressure High MAP Voltage Low ECT Voltage High ECT Voltage Low ECT higher than expected 1 ECT higher than expected 2 Y IAT Voltage High Genie 5 8 S 80 S 85 S 80X Part No 122985 September 2015 Section 5 Fault Codes Fault Name FPP 2122 1 High Voltage 1 voltage gt 4 8 0 2123 1 Low Voltage mee Y FPP1 voltage lt gt vdc Engine 219 Max Govern Speed Override RPM gt 3400 Speed 1111 Rev Fuel RPM 3600 1112 Spark Rev Y 3800 Oil Oil Pressure Low Oil pressure pulled up input with a Pressure threshold voltage of 2 5 vdc and RPM 500 and run time 30 s Adaptive 171 AL High Gasoline Bank 1 AL BM gt 30 and RPM between 0 9999 Learn 0 and MAP between 0 99 psi 172 AL Low Gasoline Bank 1 AL_BM lt 30 and RPM between 0 9999 AL High LPG AL_BM gt 30 and RPM between 0 9999 ji a a AL BM gt 30 and RPM between 0 9999 MAP between 0 99 psi Closed CL High Gasoline Bank 1 CL_BM gt 40 and RPM between 0 9999 5 CL Low Gasoline Bank 1 CL_BM lt 40 and RPM between 0 9999 ET CL High LPG CL gt 35 and RPM betwe
181. WH H cow 0 TURNTABLE ROTATE 5 0 5 T 99 g ie mE 5 WH BK E 28858 m 00045 C6 6 WHR Eu TURNTABLE ROTATE 1 Im 2 8 FLOW CONTROL 89 8 zo 7 5 ui bz 5 B 55 sup C1PUB RD 4 PRIMARY BOOM 529 e PRIMARY BOOM 8 c x I gt PRIMARY BOOM 514 7 DOWN aE c62 88 d DOWN x a 49 55 nel 5 PRIMARY BOOM a 0954 RD WH gt UP DOWN FLOW CONTROL zg i aF x x DESCENT ALARM C341 CIPBU RD C129DA RD BK RT Y 3 C2PBD RD BK 34 032 7 1 Sasse 5 CR34 SPEED REDUCTION gt 11 8 C3PBF RD WH RELAY sa PIS4PWR RD m 06 31 812215 LST3O BOOM UP DOWN 5 2 uote 8 3 9 E SPEED REDUCTION CAPER BAD 5 LIMIT SWITCH lt 552836 WH 22299 8 C8PBR BK WH 2 00047 C37 N 22 lt C7PBE 5 aS N kof In lt m Q BR PRIMARY BOOM H C67 5 a 4 EXTEND amp SN EXTEND um 5 t PRIMARY BOOM des 8 aaa Pn g LRETRACT C8PBR BKWH gt Bx 21 E 26 D 2 PRIMARY BOOM 82 COPERF BK
182. a function proportional valve can open and allow the function to operate Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Push in the red Emergency Stop button to the off position at the platform controls 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 8 times Result There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode Result The alarm does not sound Repeat steps 3through 7 8 Startthe engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold Genie 4 6 S 80 S 85 0 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the joystick back to the neutral position Just before the function stops moving move the drive enable toggle switch to either side to set the threshold Result The alarm should sound indicating a successful calibration 12 Repeat s
183. before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramping can be set Note Perform this procedure with the engine off 1 Open the platform control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for a moment then move the joystick full stroke in the opposite direction Hold for 5 seconds O Result The alarm should sound indicating successful joystick calibration Result The alarm does not sound Check the electrical connections or replace the joystick Part No 122985 Genie S 80 S 85 0 4 3 PLATFORM CONTROLS 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine fuction should operate while performing the joystick calibration procedure How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick controlled machine function Whenever a hydrau
184. bete c eee agn ei 4 69 12 2 Drive MotOr 44er 4 70 12 2 Drive Hub 4 70 12 4 Steer Cylinders u n ns a ea en 4 71 Non steer AxleComponents 13 1 Drive Motor eee oie ae ee 4 72 13 2 Drive HUD u y ine ER atten editt ee ania 4 72 Oscillating Axle Components 14 1 Oscillate Axle Cylinders 4 73 14 2 Oscillate Directional Valve 4 74 Section5 Rev FaultCodes Introduction a ee een per need 5 1 Fault Codes Control 5 2 Engine Fault Codes Continental 0 5 7 Section6 Rev Schematics Introduction ea tei dee Loeb Gane ein 6 1 Electrical Symbols Legend 6 2 6 3 6 6 0 7 Connector Pin Legend View 2 nennen nennen 6 7 Genie PartNo 122985 3 80 S 85 S 80X xiii September 2015 TABLE OF CONTENTS Section 6 Rev Schematics continued Electrical Schematic S 80 and 5 85 ANSI CSA AS Deutz TD2011LO4i Models 11 u 6 10 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011L04i Models 6 14 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011L04i Models 6 15 Platform Control
185. bolts Carefully remove the turntable rotate drive hub assembly from the machine AWARNING Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device 5 Remove the plug the drive hub Drain the oil from the hub into a suitable container b Dual fill port rotator a motor b drive hub c drive hub mounting bolts d fill ports 6 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications 7 Fill the drive hub with oil Refer to Section 2 a c Specifications Apply pipe thread sealant to the plug Install the plug Single fill port rotator a motor 8 Adjustturntable rotation gear backlash Refer to b fil port Repair Procedure 10 1 How to Adjust the c drive hub mounting bolts Turntable Rotation Gear Backlash d drive hub Genie 3 16 S 80 S 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures A 13 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedu
186. floor O Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls O Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls O Result All platform control functions should operate normally Genie Part No 122985 S 80 S 85 0 4 15 Section 4 Repair Procedures September 2015 Jib Boom Components S 85 3 1 Jib Boom How to Remove the Jib Boom Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform Note Models equipped with platform overoad system If the platform overload components are disassembled and or removed from the platform support the platform overload system will need to be calibrated See 2 4 How to Calibrate the Platform Overload System 2 Models equipped with platform overload system Tag and disconnect the electrical
187. in place Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 8 Install the filter housing cap 9 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filer housing Medium and high pressure filters Note The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit 10 Open the engine side turntable cover and locate the two filters Note The high pressure filter is located toward the bulkhead with a condition indicator The medium pressure filter is located nearest the operator 11 Place a suitable container under the filters 12 Remove the filter housing by using a wrench on the nut provided on the bottom of the housings 13 Remove the filter element from the housings 14 Inspect the housing seals and replace them if necessary 15 Install the new medium and high pressure filter elements into the housings and tighten them securely 16 Clean up any oil that may have spilled during the installation procedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 18 Start the engine from the ground controls 19 Inspect the filter housings and related components to be sure that there are no leaks Genie S 80 S 85 S 80X D 7 Replace the Drive Hub Oil G
188. injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Genie 3 18 5 80 5 85 0 Be sure that the battery hold downs and cable connections are tight Be sure that the battery separator wire connections are tight if equipped Fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the
189. level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks Genie S 80 S 85 0 4 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to drive the rod end pivot pin out AWARNING C vshing hazard The jib boom could fall when the slave cylinder rod end pivot pin is removed if not properly supported 5 Remove the external snap rings from the barrel end pivot pin 6 Use a soft metal drift to drive the barrel end pivot pin ou
190. life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine ona firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 12 Grease the Turntable Rotation Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 4 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the boom to full height Do not extend the boom Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a horizontal position Genie 7 Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good w Result The measurement is more than 0 063 inch 1 6 mm The
191. m 4 e F Ea c6 2 C2PBD RD BK 2 Al 4 PRIMARY BOOM DOWN 88 gt gt be ora 8 Fos 5 gt ES PRIMARY BOOM 1 FLOW CONTROL gt E eg 15 eg 5 ET CR34 PRIMARY BOOM 220525 s 8 5 5 SPEED REDUCTION RELAY 85548 m 88888 ORS 1183 E 8 s lt GA CIPBU RD Jo eo fou 9 GROUND 5 3 2 5 C2PBD RD BK 4 75 8 x e 25 5 B 63 3 7 C3PBF RD WH 8 8 9 8 e Se 5 5548 x 0521 C30EDC WH gt N _ DRIVE EDC FORWARD al 4 55 e E 5 20 Bu WH BK DRIVE EDC REVERSE 031500 815 lt 16 5 8 8 C6 37 4 EK cin C37STCC BUBK C37STCC BLIBK STEER CCW GND BR C1 10 C6 36 4 P2AFS 8 17 C36STC BL C36STC BL STEER CW 4 e e Xu 5 en 19 lt lt C16 5 m C32BRK WH RD BRAKE RELEASE 26 3 4 ers G m C29MS RD WH zi 4 MOTOR STROKE lt lt 20 8 lg 5 8 58 P134PWR RD 06 24 Zs o Pore 9 15825 52 C59CNK BL BK WH zu BK LOOSE CABLE z s LIMIT SWITCH 55 ke 2 E g 59 BUBK LOOSE CABLE LED S oro OR C15PLD OR BK 8 5 g
192. m gt c m 5 3 m 2 850 25 82 B E XZ of 2 5 20 2 5 42 E 20 2 gt gt 0 gt m m w 2 z zo o 5 m m AC 5 5 b d 8 78 2 223 5 28 z 4 2 ES0505D gt m m 5 8 98 m o U U gt 2 5 o 2 2 2 m c 50 si 28 5 2 m n z z 2 x z gt m lt D m m o 5 5 2 os 5 3 5 P d 2 8 9 gt 5 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Continental TME27 Models after serial number 8110 N
193. muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket Part No 122985 Genie S 80 S 85 0 ENGINES 21 Remove the relay housing from the muffler mount Do not disconnect the relays 22 Disconnect and remove the ECM from the muffler mount 23 Close the shutoff valve on the Liquid Petroleum Gas LPG tank by turning it clockwise if equipped 24 Unbolt the EPR valve from the muffler mount Leave the hoses attached to the EPR valve 25 Remove the muffler mount 26 Support the drive pump with an appropriate lifting device Remove all of pump plate mounting fasteners 27 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 28 Remove the flex plate mounting fasteners Remove the flex plate from the engine flywheel Section 4 Repair Procedures September 2015 ENGINES How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Apply Loctite removable thread sealant to the mounting screws Note Torque the flex plate mounting bolts in two stages Continental model Torque the flex plate mounting bolts in sequence to 20 8 ft Ibs 28 Nm Deutz model Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Perkins model Torque the flex plate mountin
194. rpm is correct 2 Loosenthe locknut on the low idle adjustment screw 3 Adjust the low idle adjustment screw until low idle meets specification Tighten the locknut 4 Push and hold the function enable high speed button Note the engine rpm on the display Refer to Section 2 Specifications If the high idle is correct disregard adjustment step 5 5 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES Perkins models 1 Connect a tachometer to the engine Start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rom or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm EE E aS EI Perkins models solenoid boot yoke lock nut low idle adjustment screw low idle lock nut yoke high idle adjustment nut 3 Move the function enable rpm select toggle switch to the high idle rabbit symbol position Refer to Section 2 Specif
195. safety envelope system regularly is essential to safe machine operation Continued use of an improperly operating safety envelope could result in the system not restricting the range of motion Machine stablity could be compromised resulting in the machine tipping over Note Perform this procedure with the machine ona firm level surface with all weight tools and equipment removed from the platform Note Start this procedure with the boom fully retracted and in the stowed position Ground controls 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Start the engine from the ground controls Section 3 Scheduled Maintenance Procedures September 2015 E CHECKLIST C PROCEDURES 3 Turn and hold the function enable switch to the 7 MeasuringTape restricted maximum platform capacity and raise the primary boom until it is fully elevated Measure the distance between the center of the pivot pins as shown 201 75 inches 512 cm 2 0 inch 5 cm Digital Protractor 1000 Ibs 500 Ibs Place the digital protractor on the turntable 454 kg 227 kg chassis and reset the protractor to 0 Place the protractor on top of the primary boom The protractor should display 58 2 W Result The primary boom angle is not within 1 specifications Consult Genie Industries Service Department a restricted maximum platform capacity b unrestricted maxi
196. sounds indicating a fault Not calibrated FAULT CODES Cycle power off then on after problem has been corrected Cycle power off then on after problem has been correted Calibrate valve threshold Cycle power off then on after problem has been corrected Cylcle power off then on after problem has been corrected Calibrate joystick as Continued on next page PartNo 122985 Genie S 80 S 85 S 80X 5 5 Section 5 Fault Codes September 2015 FAULT CODES Value too high Value too low Frozen at zero and neutral Genie Limited speed and direction problem has been directions is zero Drive frozen at zero and neutral Alarm sounds indicating a fault Motor speed in the low state Alarm sounds indicating a fault Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after Cycle power off then on after problem has been correted Cycle power off then on after problem has been corrected Cylcle power off then on after problem has been corrected Calibrate joystick problem has been corrected S 80 S 85 0 PartNo 122985 September 2015 Section 5 Fault Codes Continental Engine Models How to Retrieve Continental Engine Fault Codes The ECM constant
197. stamped on chassis PN 77055 Genie PartNo 122985 S 80 S 85 0 iii September 2015 This page intentionally left blank Genie iv S 80 5 85 S 80X Part No 122985 September 2015 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 80 and Genie S 85 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance andrepair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine M 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 Genie Part No 122985 5 80 5 85 S 80X Section 1 Safety Rules September 2015 SAFETY RULES 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
198. the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor a motor b drive hub mounting bolts AWARNING Bodily injury hazard Spraying c drive hub with brake hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the hydraulic tube that connects from the counterbalance manifold to the brake Cap the fittings on the brake and manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the motor brake mounting fasteners Carefully remove the motor from the brake 5 Clean up any oil that may have spilled Genie Part No 122985 S 80 5 85 S 80X 4 65 Section 4 Repair Procedures TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap betwee
199. the function manifold item SB Use a wrench to hold the relief valve and remove the cap using an allen wrench 4 Adjust the internal hex socket Turn it clockwise to increase the pressure or counter clockwise to reduce the pressure Install the relief valve cap Component damage hazard Do not adjust the relief valve higher than specified 5 Repeat step 2 to confirm relief valve pressure 6 Removethe pressure gauge Genie S 80 S 85 0 How Adjust the Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the diagnostic nipple located next to the auxiliary pump 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle Switch to the high idle position and activate and hold the boom down toggle switch with the boom fully lowered Observe the pressure reading on the pressure gauge Refer to Section 2 Hydraulic Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item SN on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase pressure or counterclockwise to decrease pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valves higher than specified 6 Repeatsteps 2 through 5 and confirm relief valve pressure Part No 122985 September 2015 _ e
200. to squirt or spray Note Two persons will be required to safely perform some troubleshooting procedures Genie PartNo 122985 5 80 5 85 S 80X 5 1 Section 5 Fault Codes September 2015 FAULT CODES Fault Codes Control System How to Retrieve Control System Fault Codes Note At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes Note Perform this procedure with the engine off the key switch turned to platform controls and both red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Open the platform control box lid AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Locate the red and yellow fault LEDs on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard Electrostatic discharge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap Genie 5 80 5 85 S 80X Determine the error source The red LED indidates the error source and will flash two separate codes The first code will indicate th
201. um z z m Oo gt 5 lt lt tr nm 5 gt m gt 5 351010 E EEE si ru m o 9 595 lt z lt 2 8 2 lt 5 5 2 klak o S GIA 2 gt a F G m 9 u 5 ialo tin olal Ele B a S 2 2 2 81 4 88 00109 010 a F E FE FF x aeza LHM 32018 NOLLWNINYAL 3Sv8 N Fu en 1 90 1 99 1981 anis WOOS 2 99 2 Orr8l 48 QH e 620 9 1961 WOO Idd 5 99 HWY 5 959 05290 MO ALVLOY STEVLNYNL 7 99 HM 85 9 6981 HM MOO 3lviOH 1 5 90 Y8 HM 9 860 Mg HM S 1 0991 Mg HM SLVLOY 9 99 QU HM 9 8 9 QU HM 9 QH HM 1X3 WOO 1 90 Z aeo 1 1 951 1 1 8 90 HWE 8 860 8 9S HWA 1 13 WOO IHd 6 99 8 6 dEO 6 9 951 61 90 1 WHOSLW1d 2 8 91 1 6981 13 31 9 8 28 80 S 9 6991 MO 1 1 S grO
202. used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Used to indicate the presence of a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie vi S 80 5 85 S 80X Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could
203. w 0 w w ow 2 22 5 5 2002 D E 2 AOE A 9 5 gt 5 2 X 59 5 5 AA 5 O9 o 5 5 lt 5 R 9 5 o 2 DDO So 2 i 5 5 5 5 59 o or NES NE 4 5 r 5 5 32 A I 2 9 i 99 o Eod Q9 X 0 ae N o 7 ry c cvs tac 49 1 a a 2 k Wo 1 5 nm gt P 3 amp n v 5 P o 5 ao c TS amp TS4 TS15 S x S 5 you oW wh 3m Qo DRO 26 2 227 E m 2 22 2 2 L 4 D12 A JC3 il JC7 D10 TS2 3 i aN T 3 4 TS9 TS1 TS14 MON 1 os NC i 187 QO QO 1 000 P3 A ud 6 i 1 L48 L51 TS75 L50 pl J BK BK RD 5 BK RD RD C 4 ES0505D 5 7 77 7 555 1 6 COMPONENT INDEX CR27 BRAKE CIRCUIT LIFT DRIVE OPTION TS2 ENGINE START TOGGLE SWITCH CR30 LIMIT SWITCH LIFT DRIVE OPTION TS3 FUEL SELECT TOGGLE SWITCH H1 TILT ALARM TS4 RPM SELECT TOGGLE SWITCH J
204. wire strands Kinks the cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Cables are on all pulleys Extend cable break limit switch arm is centered in the pivot plate Cables have equaltension Cables atend of adjustment range e No broken or damaged pulleys e No unusual or excessive pulley wear All fasteners in place and secure Note A flashlight and inspection mirror may be necessary to thoroughly inspect the above items Note A pulley groove gauge should be used to check the condition of the pulleys 9 Install the cover at the pivot end of the boom Install the access panels on the sides of the boom Start the engine from the ground controls and fully retract and lower the boom to the stowed position Turn the key switch to the platform controls 10 Extend the boom approximately 2 feet 0 6 m 11 Retract the boom While retracting the boom visually inspect the number 2 and number 3 boom tubes Result The number 2 boom tube should not move more than 1 2 inch 13 mm before the number 3 boom tube begins to retract Note If the number 2 boom tube moves more than inch 13 mm before the number boom tube begins to retract the boom extend retract cables need to be adjusted See Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables Genie S 80 5 85 S 80X PartNo 122985 September 2015 Section 3 Sch
205. 0 6 Orrgl 060 v48 89HO WOOS IHd 90 8 0 0597500 gecal HM MO 31V1OH 378 1 7 99 HM 860 HM 2951 HM S zgO y8 MOO 31V1OH STAVINYNL 9 99 S H O X8 HM S L Z9S1 48 HM an s SLVLOY 1 1 9 90 QH HA 9 8 O QU HM 9 1X3 WOO 1 90 X8 1 8 0 ua 2 289 6980 LOVHLSY WOOSIHd 8 90 HWE 8 60 8 2 2951 HWE 134 1X3 WOO IHd 6 90 8 6 880 6 qua 81 99 1 dn 13A31 2 8 1 6861 NMOG 13A31 4 9 80 48 40 SL 6 6861 MO WHOS 4 0 9 HO 1 9 981 MOO 31VLOY 4 9 8 2 49 49 81 1 881 49 49 AlddNS Live 11v8 02 2 280 1 11 80 HM HM WHOSLV 1d OL HMd HOLIMSASY 22 699 15 2 48 WHOd1V1d OL au 2 840 UHM 6 Z INSI HM cq i 1893 HM 9 90 GH zz 6 T NWSI 1991 WHV1V 13437 82 90 910 82 92 59 9 810 HWQH 6 vozal au 903 16 90 HM 815 HM 0 5 02 50 M8 HM 9 81 M8 HM 16 0281
206. 0 2 I TS15 C144DER BL WH I TS15 C143DEL BL BK 41 I L1 C13DRE A BYRD 0 814 29 5 RDWH GR BK C3P 12 GR BK 14 i RD 2 6 RD 1618 QN e PartNo 122985 u G S 80 S 85 S 80X 6 90 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 CONTROL HARNESS 1 1 21 DD 2 w w O W 2 2 2 gt 25398 2 2 I 2 2 0 D X 2 gt 5 5 5 22 5 A o 8 58 s s 8 53585 d 2g XE 3 45 8 o 9 c on te oF UG P oe o o 5 5 5 Ras S D 22 a 9 Rz E f 48 x ins m 5 302098 2 202 5 a o 8 TS4 7815 S X 9 5 2 D gt SEN 6
207. 00 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner s Manual Genie part number 111901 Genie 1 5 80 5 85 S 80X To access the engine Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures A 12 Replace the Drive Hub Oil Manufacturer specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil after the initial 150 hours of use may cause the machine to perform poorly and continued use may cause component damage Drive hubs 1 Select the drive hub to be servi
208. 05 A NN 29g 6626 46 OO gi 3 88 a 5 So THIGH y C5 18 1 59 2 E 2 5 g 7g E ED u 39 4 5 52 eau 285 9 gua 5 D 8 UJ 20 295 5 5 22 Poa i C34SA 8 4 e 19 883 roa 4 S BK WH 55 Sx Zk 5 2 zo 885 917 C33STR BK 59 44 4 ec 1 20 15 xdi Boa C24TSPS WH j ar F a 1 7 ga 1 t oz e 555 4 gt e gost 8 3 1 t n C27AUX RD dsi 519 4 R21ING WH ex ey AUXILIARY 41447 1448 eo y 8T T8 gie 1 1 d 8 EE a 1 5 6 Du 1 aa 12 D i R27AUX r i Jo FOH 8 Fo iis 1 5 9 9 82 o 8 o 1165 gr g Lx 5 C5 5 8 8 7 2 P23PWR WH 1 ie HISSTRUBK 2 s z WH 4 HD EA EH a I lt e a lt 5 e 2 C6 28 WH 1 57 AH 1 2 C28TTA RD BK C28TTA RD BK r 8 RD gt 3 4082 P134PWR RD LY 4 lt o qa a cae C133PLS GR BK 5 8 025 C46HRN GR gt Cr 11 4 TRE E S 5 gg 5 9 GRK M RAeHRN GR C74 P22PWR BK 1 E u h e o 8 as C1 12 C132PLI BUWH fe 5 2 NC 1 HL nen
209. 09ANG GR WH 7 4 C165TRS WH RD 2 10 SNSR GND BR 1 4 7 3 C164PES 4 7 2 P162JPW2 OR JC7 5 C163PES WH BK 1 r JC7 1 JSGND2 BR JC3 4 C160JPL WH RD 9 1 4 3 2 P162JPW1 OR JC3 3 C159STC BL WH I JC3 1 JSGND1 BR 4 t TS15 C144DER BL WH IIS Ne t TS15 C143DEL BL BK I L1 C13DRE A BL RD 514 0295 RD WH 1 BATGND J3 1 C1P 2 C28TTA RD BK BATGND C7P 3 r J22 1 2 9 10 11 AND 12 OPTION C9 C7P 12V 9 2 5 40 41 28 RD BK RD C2P 6 RD 1518 2 lt Z X m z 8 5 eo m 0 e 2 N e a 2 5 u c o see SER 5 I Bg 8 esa 88 558 Te N 1 Y 2 1 5 9 1 0 9 e zu g 9 20 oO lt 0 st 1 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80X Deutz TD201 1LO4l Models
210. 1 7 59 Piss C33STR BK 52 1 OLI TEMPERATURE 4 lt SWITCH ask 5 15 gt gt lt d Boe C24TSPS WH lt OW a Pad 9 E 5 58 22 em 4 FUELSOLENOID ei v CONTROL RELAY C27AUX RD 519 4 R21ING WH gt 9 FUEL SOLENOID 3 rei AUXILIARY 8 T 5 ie PUMP 84 4 cs 1 N nn a 0 15 5 6 AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP 2 R27AUX RD H Wu M 8 5 E AUXILIARY PUMP a a 5 8 of 2 8 gt 8 2 9 28 83 9 E 5 ET 8 C5 5 IGNITION STARTER 8 RELAY C72 E Eg 2 el L R33STR BK TEY s gt 59 T RD STARTER La c a 1 c 5 c lt 4 a a B 4 C6 28 C28TTA RD BK C28TTA RD BK lt TILT ALARM a 8 8 C6 24 F 5 P134PWR RD LEVEL SENSOR C3 12 C133PLS GR BK m 5 ac C2 5 CA6HRN GR gt 5 7 5 1 SERVICE HORN e 2 n 59 3 22 E GR BK RAeHRN GR 9 SERVICE HORN P22PWR BK 1 8 n 8 n M p zz 1 A 0 12 E 14 OIL COOLER TEMP SWITCH gt 01920 BLWH 1 OPTION 5 T gt 926 py34pwR RD Ir prosessen 1_ Qj OIL COLLER FAN R OPTION b maa 1185 te
211. 1 BR I TS15 C144DER BL WH HTS15 C143DEL BL BK I L1 C13DRE A BL RD I TS14 C29MS RD WH RD C2P 6 BATGND J3 1 J22 1 2 9 10 11 AND 12 C1P 2 C28TTA RD BK e T ES0505D TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 J22 C9 C7P 12V BATTERY C3P GR C2P BK GROUND J1 C28TTA RD BK RD LS18 BR BATGND GROUND STUD WH TS14 CR27 CR30 gt hl SPLICE TO C32BRK C1P 6 WH TS7 WH RD C32BRK OR RD C40LS LIFT DRIVE SELECT OPTION SPLICE TO 4015 C2P 2 5 80 5 85 S 80X PartNo 122985 6 150 September 2015 Section 6 Schematics A Platform Control Box Switch Panel Wiring Diagram S 80X Continental TME27 Models N M L K J H G F E D 0 B A CONTROL HARNESS TO PLATFORM BOX 1 0 v 20 0 00 w m w m m D w
212. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control 3 Check all machine function from the ground controls Result All machine functions should not operate 4 Turn the key switch to ground control 5 Check all machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES B 4 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may result in severe burns To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNI
213. 10 10 RD LST3S BOOM ANGLE BR d STOWED a W m GROUND BOX ZONE ai amp 3 SAFETY LIMIT SWITCH 8 WH 5 9 2 GRWH ca12 P109LS GR WH C616 WH I al 8 m p ig 79 CAPACITY SAFETY 8 ass BR BL LIMIT SWITCH 8 a 4 lt s212PLo GREKE oR C209LED BL 55 8 x 5 5 5 C630 o11PLO BUBK l 7 BK WH d 1 BK 6 Qed 158150 BOOM EXTEND 15570 9702 CAPACITY OPERATIONAL lt C208LED GR 5 LIMIT SWITCH C177LS BURD BURD gt BR 8 8 1 Sen a u RZ BR i P134PWR RD RD P LST30 BOOM UP DOWN ERS E28 V o GROUND BOX ZONE A 1 9 9 ZONE SELECT 11545 OPERATION AND SPEED 1 P109TS GRIWHI 26 9 P210PWR BK C6 12 5 WH REDUCTION LIMIT SWITCH WH gt 2 1 1 14 Belle 4 01080 RD H 9 PRIMARY BOOM UP e m 5 amp amp 6 2 C2PBD RD BK gt 4 PRIMARY BOOM DOWN 53 85 0 aa gt 1 S Gra 6 an non E prawn poou 212 EN 55 22555 PRIMARY BOOM z 5 8 SPEED REDUCTION RELAY 885318 22228 55528 8 cats OOS 8 5 1 C1PBU RD e g crounp 8 m C2PBD RD BK 4 x 25
214. 10 M8 HM L 60 90 QH HM 9 819 GH HM ZE 1015 9 90 2 810 6 2861 aasnNn 81 50 8 6 419 auma se 51 MO 5 95 99 18 01 8LO 18 95 15 16 99 11 810 5 m 103138 5 9 01 59 1 860 6 2 0 189 HOLIMS 07 90 HO 0 0 81 HOWL WdH 5 50 X8 HO 82O 85 02157 HOLIMS 22 90 860 ler 4 80 er 5 8 Mg HO vv WHV IV 0530 0261 620 NOLLdO HOLVHANAD OV 66 90 1 820 HWHO 9 nod E NHOH 1 80 H5 9 20 HO or YS qan a18vo 35007 11 90 11 880 65 9981 2E 03345 WOO 18 99 HO BLL 9847900 HO overdo Om aasnnn eet 5 259 026381 c aasnnn eer 8 260 MEO ovr du O H3MOd HOLIMS 2 90 9 820 ret 1 260 9 4 v H3MOd HOLIMS AIX 55 99 96 90 1437 NOOV3 HM D 209 8 SO H 318VN3 3HnSS3Hd 61 59 QH HO 0 290 881 890 9 2951 7 8 5 anis 0420 1 O1LLZO 08 99 MA HD 012120 85 99 l
215. 1055 682 925 909 1233 24 27 1 25 27 44 49 70 33 9 36 6 59 6 66 4 94 7 108 4 149 162 203 230 21 38 51 5 37 50 1 67 8 81 3 1084 122 162 61 110 120 150 93 105 130 140 126 142 176 EE um 8 5 1551 S i 244 271 433 474 m m N 200 No gt 759 1044 1139 1477 1654 5 ojo ojo 9 i 5 6 7 51 7 Ala Holo o m gt N Qo gt _ co za N ala o i gt IN a a N to a 6 to ol N N Ol ofja N Bm coo gt Njo AID A 5 t A oJ NJN 9 gt DIN lt Ao 19 ip 61 99 ev ES o o E 4 A N E Aa 2 BIN jen 95 65 Oyo g a EN en gt ayo 157 1 20 Genie 2 10 5 80 5 85 S 80X Part No 122985 September 2015 Sec
216. 11 QW ccw PLATFORMLEVEL UP ra m gt 42272 PLATFORM LEVEL DOWN _ lt lt 4229 125 a 5 gy 8 LS g 08 5 5 g 225855 o 5 422 4 Sell 122 1 SZERK 5 PLATFORM ROTATE CW 8 8 8 2 S RSS PLATFORM ROTATE CCW 422 2 5 2223 6 143 5 80 5 85 S 80X Part No 122985 September 2015 Section 6 Schematics m M 1 Electrical Schematic S 80X Continental TME27 Models 6 143 6 144 Section 6 Schematics September 2015 aaTqI r m Ground Control Box Terminal Strip Wiring Diagram S 80X Continental TME27 Models 6 145 6 146 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 80X Continental TME27 Models 0
217. 11 Section 6 Schematics a N 5 By gun n CHECK ENGINE LED sa Orc 2255 Ent lt lt Bos 8 5 8 Eu Z 2000 8 5 5 8 E gt s a B m 8 995 8 gt gt gu EE ERQES 5 2 Eo E Eo gt zes gt ejejeje eee 1 m HOURMETER al 7 m C5 11 z lt 4 C4 10 C4 10 oz 5 Lu o E 126 N m 4 4 a C5 19 E PRESSURE COMP VALVE 155005 OR RD V155PCE OR RD FUNCTION ENABLE 5 gt gt amp 52 RPM POWER RELAY 22 0 LER ELLON 855 22 HIGH 1 9 28 cx 58 C35RPM BK RD 55 58 25 x 258 88 go 825 OO a i 5 THIGH 5 mE 11 RPM CONTROL RELAY 8 m st o ii 52 E r 42 5 BK RD RPM SOLENOID 5 e 8 85 OT z 4 FUEL PUMP z 5 a 993 C1 8 5 22 GLOW PLUG E H CONTROL RELAY 888 zo 9 6 Poza 4 s R34SA oe lt is GLOW PLUG a ze
218. 190 85 terminal 878 N C terminal no 85 coil negative terminal no 30 common terminal no 86 coil positive terminal no 87 N O Control Relay Schematic Genie 4 38 S 80 S 85 S 80X Part No 122985 September 2015 Section 4 Repair Procedures Hydraulic Pumps 7 1 2 Tag disconnect and plug the hydraulic hoses Function Pump from the function pump Cap the fittings on the pump How to Remove the Function AWARNING injury hazard Spraying hydraulic oil can penetrate and Pump burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting 3 Remove the pump mounting fasteners Torque Specifications Carefully remove the pump 1 Close the two hydraulic tank valves located at Component damage hazard the hydraulic tank Be sure to open the two hydraulic tank valves if equipped and prime the pump after installing the pump See 7 2 How to Prime the Pump Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves
219. 1G3lovuldu WOOG 07 99 2 820 07 nn E 2 59 Z9 49 40 Lv 28 NSI 5 S103MOLS 319NV WOO 22 99 920 27 vernm DE NOLLdO dn Wood 0 2 8951 Qvreruo 9 985 NMOG WOOS air 9 1080530099 e gss1 49 49 1 OV 66 92 HWH9 42 820 NHOH 1 80 5 820 9 a31319V9 38001 8 LL 8 O 68 NOILONGaY 43385 141 19 90 98 5 21 80 21 Z 9 51 959 49 99 1 49 49 0 H3MOd 5 72 99 9 860 vel re 9H au 9 g v 43MOd HOLIMS A33 55 99 48 90 qu vrell e 6 SNOOV38 HA aunssaud 61 60 Qu uO 290 4 9 qu uo 99 894 8 2951 qu uo 0 8 2 07 o Ka 0 e QN9 H8 8 Doo 01 980 5 overal du 6 850 HM 5 000189 gt UMdbEld GY 0 H qu Olea ae Se e 614 SO HM o ceo tO 6 1
220. 2 4 Soo amp TS8 C43JU GR J22 5 5 x SES TS8 C44JD GR BK J22 p 595 e TS9 C14PLU OR J22 7 58 583 TS9 C15PLD J22 8 J22 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 i P2 P23PWR WH C7P 2 P2 P22PWR C7P 1 TS1 V155PCE OR RD 4 TS48 C49DLITE WH BK C4P 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS9 C14PLU OR 2 1 TS9 C15PLD OR BK C4P 3 i J8 P109LS GR WH C3P 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 TS3 C39LP BL RD C2P 1 P3 C46HRN GR C2P 5 ene 1847 0458 2 7 28 Tox C40LS OR C2P 2 C6TRF WH RD C3P 6 C123PBS RD BK C2P 8 7 C13DRE BL RD 1 C8PBR BK WH 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 Q C41RPM OR BK C2P 3 C30EDC WH C1P 4 9 C1PBU RD C3P 1 C31EDC WH BK C1P 5 7 C2PBD RD BK 2 C36STC BL 10 Q RD WH C3P 3 5 C37STCC BL BK C1P 11 7 134 C4TRL WH 4 C32BRK WH RD C1P 6 7 C5TRR WH BK C3P 5 LO C29MS RD WH C1P 3 gt c 5 8 Slo 2 S o
221. 313718vo3S0O1 LL 99 11 889 68 9 1411 15 99 HO 21 10 551 5 259 HW18 21 86 551 8 220 49 49 H3MOd HOLIMS 6 90 9 860 vel re v HAMOd HOLIMS 5 99 96 90 1431 NOD V38 HM 61 90 GH HO 0 290 7 00 80 sS 894 8 2981 0 0 v g 5 a 659 21 Naum 096181 8 3 9 2 6 80 5 561 Em 1 08 2 3804 dW 01 02241 38 0691 81 08 I 2 LHDM 31 wo S 80 S 85 S 80X G 6 110 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models C TO GROUND CONTROL BOX CONNECTIONS 81 91 9 99 anis 971 i 9 260 2 50 L LSX HM gg 890 EQ O9 1551 2 01681 2951 088 81 v rLH QH HM QS81 48 HM 92191 99 L 9LU qu OS
222. 3138 01 59 1 822 2551 WOOS 07 99 HO 2 820 OF 5 6 90 4g8 HO M8 HO LF uz 8 50 49 d3MOLS 2295 7 829 Qu uO ov mE WOO8 alr 2 18554 HS d vve1 u0 anis aN9 ug 8 alr I 1309300007 BH e 2 8951 49 49 NOILdO HOLVH3N39 68 99 2 829 Sr NHOH 1 80 49 G dZ9 9v 35001 11 90 11 850 6S 9r1 141 16 90 98 21 919 ZEL 260 1 14 21 860 49 49 EEL H3MOd HOLIMS 0 6 9 820 vti 9H Sv1 v HOLIMS A3 90 90 52 99 vrell e z ven SNOOV3 amp HM 318VN3 61 59 Qu uO 0 290 7 Qu uo 881 890 5 2951 V 8 2 a r 01 952 8 8 QNO Wd 56 een FIOHM aL v overal 7 5 5 18 7 6181 HMdvELd QH 1
223. 33PLA GR BK C3P 12 L47 C59CNK BL BK C3P 11 a T 0 m a e o J1 SNSR GND BR C2P 10 J1 P109ANG GR WH C2P 9 P3 C46HRN GR 2 5 iacao TS47 C45GEN GRANH C2P 7 yal E x C40LS OR C2P 2 E s C6TRF WH RD C3P 6 8 E 123 RD BK 2 8 ES Q 4215 OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 Q Gy C2PBD 2 gt C36STC BL C1P 10 C3PBF RD WH 3 C37STCC BL BK C1P 11 WH L1 WH C9P 2 C7PBE BK 7 Q C13DRE BL RD C4P 1 C8PBR BK WH 8 C4P BR e C7P 12V BATT 5 C4TRL WH 4 C32BRK WH RD C1P SES 29 caine XM s 2 2 C29MS RD WH C1P 3 C2P BK C1P GY LS18 C132PLI1 BK C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C34SA BK WH 1 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 I JC3 5 C159STC BL WH B GE C2P 9 109 GR WH lt 2 2 JC7 4 C165TRS WH RD 4 5 C2P 10SNSRGNDBR FO
224. 35 6 cm Lugs and Lug Nut Torque Wheel lugs 10 3 4 16 Lug nut torque dry 420 ft lbs 569 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Genie Part No 122985 S 80 5 85 S 80X Section 2 Specifications September 2015 SPECIFICATIONS Performance Specifications Drive speed maximum Hydraulic Oil Specifications Hydraulic Oil Specifications 40 ft 7 9 8 5 sec 12 2 m 7 9 8 5 sec Stowed position RT Tires 40 ft 11 13 sec 12 2 m 11 13 sec Stowed position Flotation Tires 40 ft 40 45 sec 12 2 40 45 sec Raised or extended position Braking distance maximum High range on paved surface 3ft 90 cm Gradeability Refer to the Operators Manual Boom function speeds maximum from platform controls Jib boom up S 85 25 to 35 seconds Jib boom down S 85 15 to 25 seconds Boom up ANSI CSA AS models 57 to 65 seconds Boom up CE models 75 to 83 seconds Boom down ANSI CSA AS models 61 to 69 seconds Boom down CE models 75 to 83 seconds Boom extend 59 to 67 seconds Boom retract 57 to 65 seconds Turntable rotate 360 95 to 103 seconds boom fully stowed Turntable rotate 360 210 to 250 seconds boom raised or extended Platform rotate 160 8 to 12 seconds Platform level up 50 to 60 seconds Platform level down 40 to 50 seconds Genie S 80 S 85 S 80X Hydraulic oil type Viscosity grade
225. 4 21 8 gt SE 9 RPM RELAY 418 8 5 een 5 3 ps 9i 214 H RPM SOLENOID s 5 2 5 8 Dee a m 8 Le 9 lt as 2 QU E FUEL PUMP e 4833 C1 8 5 22 81118 4 GLOW PLUG 5 af RELAY zi 5 a R34SA az 805 NS zo 5 8 0 2 z E 5 x GLOW PLUG 925 zer eier C33STR BK 5 9 WATER TEMPERATURE SWITCH 338 1 1 55 C5 15 Sees wi 2 OIL PRESSURE gt gt swrcH T 842 it XxX2 amp Pag 8 5 8 5 25 2 8 0 8 IGNITION POWER RELAY t C27AUX RD eu 2 E R21IGN WH 1 6 0 4 FUEL SOLENOID e 4 8 9 5 o 8 7 ga 4 AUXILIARY 8 PUMP hE i 5 6 AUXILIARY PUMP v RELAY tn ET El cs o AUXILIARY PUMP a RE7AUX 1 POWER RELAY 8 8 2 C72 4 AUXILIARY PUMP P23PWR WH 9 z E e 5 81518 IGNITION START RELAY g 3 C1 2 28 RD BK s POWER RELAY 3 z 8 4 STARTER MOTOR E E 5 gt c 5205 lt 4 TILT ALARM 5 9 amp 8 a e pr C6 28 C28TTA RDIBK lt lt WH 4 COH P134PWR RD noL BK LEVEL SENSOR z a 5 2 5 C57 SIS SERVICE HORN C46HRN GR 7 RELAY Fo 8 Sy U R
226. 4000 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures September 2015 H T This page intentionally left blank Genie 3 4 S 80 S 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R Checklist B N R A 1 Inspect the manuals B 1 Battery s Serial number and decals B 2 Electrical wiring Date A 2 Pre operation B 3 Key switch n B 4 Exhaust system 1 Hour meter 2 5 Engine air filt
227. 46HRN GR SERVICE HORN 7 1 m 80 P22PWR 1 9 8 Cd cr pose LL M 28 OIL COOLER 8 WH 2 e lt TEMPERATURE SWITCH 91 is 2 OPTION 8 1 925 pisapwR RD 1 OIL COOLER 1 4 1 n DC E vun 26 P134F8 RD ib B D FLASHING BEACONS y a OPTION P134FB 9 EX og uay pi ee 1 4 C41RPM OR BK 9 88 s Ia ac Cc CC Rl C C C s o 7 2 8 5 lt z 1 4 Et 5 5 a x 8 a 5 5 5 ALTERNATOR o 3 9 6 IS Y x el x 1 I T lt i 4 5 ____ etH 5 BATTERY SEPERATOR EOS 8 m BIBAT START BATTERY a a ER 8 e BIBAT RD 2 CONTROL BATTERY a gt N N LO
228. 47 KW 2600 rpm Firing order 1 3 4 2 Compression ratio 22 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi or bar of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Low idle 1650 rpm Frequency 335 5 Hz High idle 2300 rpm Frequency 467 7 Hz Governor mechanical all speed Valve clearance cold Intake 0 0098 in 0 25 mm Exhaust 0 0098 in 0 25 mm Lubrication system Oil pressure 2000 rpm 40 60 psi 2 8 4 1 bar Oil capacity 10 6 quarts including filter 10 liters Cil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Part No 122985 Genie S 80 S 85 S 80X SPECIFICATIONS Injection system Injection pump make Zexel Injection pump pressure 1707 to 1849 psi 117 7 to 127 5 bar Injector opening pressure 2000 psi 138 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Enginecoolant Capacity 12 5 quarts 11 8 liters Batteries Type 12V DC Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 6 25 rate 200 minutes Alternator output 90A 12V DC Fan belt deflection 3 8 to 1 2 9 to 12 mm 2 7 Section 2 Specifications September 2015 SPECIFICATIONS Machine Torque Specific
229. 5 8 2 PRIMARY BOOM 9 BK RD EXTEND RETRACT 2358 FLOW CONTROL 8 4885 Brass 8 Sa5 r 8 2 5 21 C30EDC WH EDC DRIVE FORWARD 5 4 152 C15 081800 7 EDC DRIVE REVERSE s s 5 m r 3 GND BR 21 C130TA WH RD I 4 TRAVEL ALARM OPTION 24 5 WH 2 8 a 3 BRAKE RELEASE P24FS WH 4 18 1 6 esos C32BRK WH RD P26ESTP 83 C5 24 St 2 SPEED 043 C29MS RD WH 1 MOTOR STROKE 20 m B ii CR34 SPEED REDUCTION RELAY 5 2 5 6 31 22 LST3O BOOM UP DOWN 1 C118LS OR ats SPEED REDUCTION LIMIT SWITCH P134PWR RD 89 u 555 C6 11 g LSB2S C59CNK BL BK 2 LOOSE CABLE ESI SW LIMIT SWITCH ed 8 l C3 11 el 146 147 N We LOOSE CABLE LED C14PLU OR 3 0422 3 UP PLATFORM LEVEL 4 DOWN 043 CI5PLD OR BK 2 8 z 8 P UP m PLAT LEVEL se DOWN aie 85 cag C44JD GR B 825 59 DOWN 475 UP m GR 3 8 z A5 DOWN jig BOOM Su up S85OPTION 19 EE 8 C4 6 55 jow C18PRR GR BK 8 8 C45 C17PRL GR 8 5 PLAT ROTATE e
230. 56 N i 8 4 Eu re 3 ENGINE 0 3 E P134PWR RD TB20 3 S 2 5 5 m lt C41RPM OR BK 71 5 5 5 5 8 69 S z 6 8 04 TB133 2 2 2 5 7 3 ny 1 C27AUX FE RD 12 8 e 1 C27AUX RD 28 i TB33 E TB27 2 TB TB39 LE WH 02 9 i e 35 39 GBOX C27AUX RD pakid 4 gt 9 o e P134PWR RD H6 as TB46 e P23PWR WH 6 2 o v m S8 o a 05 2 p 5 2A gt OR BK 6 5 10 Os P24PWR RD lt 1 C5 9 i R21IGN WH C35RPM BK RD lt lt 8 5 8 gt P20BAT RD C108ESL 68 5 1 lt 5 8 Ci27TSW 10 22 4 BAT2 APU N Io M ESSA ae F7 3 CR39A CR39B R21IGN WH 7 ma 6 20 gt Fo DN R6 8 2 m 1 I gt I 1 CR17 CRS 5 d 9 5100 iy 3 s gt R33STR BK s z 1 i 1 o 2 l l ia 3 u 3 R23PWR WH 1 1 1 E a 2 d 5 lt 4 1 2 9 8 8 5 8 4 EXCT 3 201 2 WH 8 Ma X3 HARNESS m ERO LE ci LN Le t 9
231. 59 03 2500 rpm Fuel flow rate 0 42 gpm 44 kW 2500 rpm 1 59 L min Firing order 1 3 4 2 Batteries Compression ratio 8 2 1 12V DC Compression pressure Group 31 Pressure psi or bar of the lowest cylinder must be at Quantity 1 least 75 of the highest cylinder Cold cranking ampere 1000A Low idle computer controlled 1600 rpm Frequency 53 33 HZ Reserve capacity 6 25A rate 200 minutes High idle computer controlled 2500 rpm Alternator output 65A 13 8V DC Frequency 83 33 Hz Fan belt deflection 1 2 inch Valve clearance warm 12mm Intake 0 014 in 0 36 mm Exhaust 0 018 in 0 46 mm Lubrication system Oil pressure 40 60 psi 2 8 4 1 bar Oil capacity 7 quarts including filter 6 65 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Part No 122985 Genie S 80 S 85 S 80X Section 2 Specifications September 2015 SPECIFICATIONS Deutz TD2011L04i Engine Displacement 189 6 cu in 3 1 liters Number of cylinders 4 Bore and stroke 3 7 x 4 409 inches 94 112 mm Horsepower Continuous 69 1 2500 rpm Net intermittent 72 8 2500 rpm Continuous 51 5 KW 2500 rpm Net intermittent 54 3 KW 2500 rpm Firing order 1 3 4 2 Lowidle 1300 rpm Frequency 331 5 Hz Highidle 2350 rpm Frequency 599 3 Hz Compression ratio 17 5 1 Compr
232. 7 FUSE 30A OIL COOLER FAN HORN 17 FUSE 30A ENGINE AUXILIARY PUMP 1 bes Hl Hl L F22 FUSE 60A GLOW PLUGS Er September 2015 Section 6 Schematics Relay and Fuse Panel Legend F E D C B A 1 u Lg Le m 4 Le 5 6 or er 7 o j 1 EIE 4125 1 I ct 2 1 R21PIGN ers t 082 55 08394 1 m lir ig rA is l Mm m E y Ly 3 Continental TME27 LABEL DESCRIPTION CR1 START RELAY 4 CR2 IGNITION FUEL RELAY CR5 HORN RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39A AUXILIARY PUMP RELAY CR39B AUXILIARY PUMP ENGINE CUTOUT RELAY F7 FUSE 30A OIL COOLER FAN HORN F17 FUSE 30A ENGINE AUXILIARY PUMP 5 6 7 8 Genie Part No 122985 S 80 S 85 S 80X 6 167 September 2015 Section 6 Schematics i Relay and Fuse Panel Legend 6 167 6 168 6 169 Section 6 Schematics September 2015 rrrrr r Hydraulic Schematic 2WD Models 6 170 Section 6 Schematics eee Hyd
233. 8 02 52 48 HM 9 10 Mg HM 16 62 50 9 819 56 WHVTV T3AVHL QH HM 1 15 9 90 1 810 8 66 2451 8 910 HWA FE Q33dS 6 90 6 10 SE 210 1 7951 0 8 MO 88315 99 90 18 01 910 18 9 MOO 18 76 92 11 80 8 109135 1 5 9 01 59 1 60 110 1 6981 WOOS 07 99 2 820 O 1VNOIS 2 0 8 2 820 ut 9 25 57 5 WOOS 22 92 9 0 Qu uO ev O VFEL HM gu E 5 9 90 dn 21 970 1 9951 YD VrEL HM o I anas 9895 WOO amp 8 8 Mg HO vy WHT 10925300002 9 8981 Mg H9 61 0 HOLVH3N39 OV 68 99 1 820 Sr O2 48 HM NHOH 1 80 9 820 9 Ovi ad 1 92 11 860 68 9 NOILOnQ3H 1417 15 99 HO 8LL 98 PEHO HO 21 810 ZEL 5 659 HW 18 61 860 99 x8 u5 U3MOd HOLIMS 90 9 860 961 9 9H s71 v HOLIMS 55 99 96 90 vrele 1441 NOOV38 HM 3unsSaud 61 59 Qu uO 90 v avo GH HO 881 890 5 2951
234. 8 5 80 and 5 85 CE Deutz 020111041 Models before serial number 8111 Platform Control Box Wiring Diagram Section 6 Schematics BR BATGND GROUND STUD WH TS14 e LIFT DRIVE SELECT OPTION CR30 27 C40LS 2 2 WH TS7 WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD 4015 SPLICE TO PartNo 122985 u G S 80 S 85 S 80X ES0504A 6 0 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 CE Deutz 2011 041 Models before serial number 8111 B A CONTROL HARNESS TO PLATFROM BOX 1 x 9 m DVD o 2 m m JJ 5 2 J D 2 5 5 D 2 gt 2 D 2 5 2 5 5 E UE 202 gt A 2 2 28 825553 443 22654329 29892 x 88 8 58 8 9 0 2 con 9 Q PV c Xo e oe 5 5 c v Y Oo a En g
235. 8 12 Valve Adjustments Traction Manifold How to Adjust the Hot Oil Shuttle Relief Valve Note The pressure differential between the charge pump relief valve located in the drive pump and the hot oil shuttle relief valve located in the traction manifold is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling This pressure differential must be maintained at 40 psi 14 5 bar Note The following procedure will require two people 1 Open the engine side turntable cover and connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump 2 Start the engine from the platform controls and allow the engine to run at low idle Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple located on the traction manifold Genie S 80 S 85 0 4 Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge 5 Turn the engine off and remove the hot oil shuttle relief valve cap item BJ Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 6 Repeat steps 4 and 5 until a pressure differential between the charge pump reading and the hot oil shuttle relief valve of 40 psi 14 5 bar is ob
236. 8 18 55245818 wi 5 5 283 zu 5B Ex 1888 5 9 8 5 5 5 9 515 0 gt 9 6 Sog 5 22 F 6 Els lt 55 6S elslQlsiciz 5 Sr es x u gt 5258 r s 5 415121 2 2 S gt u o lt 68 22 0 lt gt 55 2 5 52 94 25 25229 ola az 52 5 2 5 55 2 98 58 22582929929 le ai m 51815 6518 2 2 za 55 E 2 a 0 G4 oa 6 G SSVdA8 A33 8 eo A33 2 G cuu o AH3LIV8 9 Saad LHM 4 S CH 82 09 a NO 018281 o INdNI LHVLS Sg H313WOHOVI Z C paar AY Tad 18418175 G m i 1 NOILLVNINYSL ASVE IHd 1 99 deo au 1961 ans NOOS Idd 292 9 2 Orval 0 620 9 1951 6 90 HIWQH 9 90 HWQH 0587900 HWGH MO 31V1OH FI8V LNUNL 7 99 HM 860 HM 2951 HM MOO 31V1OH SISVLNYNL S99 8 HM 9 860 M8 HM S 1 6961 M8 HM 18 1 9 99 GH HM 9 8 9 V rLH 1X3 WOOG Iud 1 90 2 800 2
237. 80 S 85 0 4 49 Section 4 Repair Procedures September 2015 mcm M i MANIFOLDS 8 7 Platform Manifold Components S 85 The jib boom platform rotate manifold is mounted on the platform end of the boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way EF_ Platform rotate CW CCW 30 35 ft Ibs 41 47 Nm 2 Solenoid valve 3 position 4 way Platform level up down 30 35 ft lbs 41 47 Nm 3 Solenoid valve 3 position 4 way Jib 30 35 ft lbs 41 47 Nm 4 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 6 Needle valve Platform 20 25 ft lbs 27 34 Nm 7 Pressure comp flow control valve EE Platform rotate flow control 33 37 ft lbs 45 50 Nm 8 Pressure comp flow control valve EG Platform rotate flow control 33 37 ft lbs 45 50 Nm EF 3 3 O p 4 5 Genie 4 50 S 80 S 85 0 Part No 122985 September 2015 Section 4
238. 804D 33 Models after serial number 8110 Section 6 Schematics C RR RM ME SCRA 1 9 JR 1 i RD E STOP ww IX RDLS18 CABLE 4 5 e gt P134PWR RD i 2 lt o P134PWR RD R20 9 9 2 55 47000 Ne i ZED 5 gt 9 OZNA Q 2 P26ESTP E STOP R26ESTP BK C9P 1 BR GND e 1 8 TS7 C18PRR GR BK J22 3 eR TS7 C17PRL GR J22 4 mo I TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU J22 7 TS9 C15PLD J22 8 1 N 422 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 1 1 1 1 P2 P23PWR WH C7P 2 P2 P22PWR C7P 1 TS1 V155PCE OR RD 4 TS48 C49DLITE WH BK 9 TE TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK 8 TS9 C14PLU OR 2 TS9 C15PLD C4P 3 1 H1 C133PLA GR BK C3P 12 L47 C59CNK BL BK 11 I c J1 SNSR GND BR 10 5 9 J1 P109ANG GR WH C2P 9 NE P3 C46HRN GR C2P 5 c Ns TS47 C45GEN GRANH C2P 7 i BK P2 1 oy 532 Nye 1 J e a C40LS OR C2P 2
239. 8951 49 49 HOIVH3N3D OV 68 99 21 829 Sr Ovt du NHOH 1 80 HD 9 860 9v 379 35001 11 90 11 860 68 5971 Q33dS 1411 18 99 HO 988 HO QvO1 WHOL 1d 21 9102 ZEL 5 659 WHV1V 21 8 O 1 H3MOd HOLIMS 72 90 9 860 961 9H 5 1 qu v HOLIMS A3 2 90 90 90 Wrel e z ven SNOOV3 amp HM HO 318VN3 3unsSaud 61 59 294 8 GH HO 68 890 5 2951 GH HO V 8 9 0 zL 8 s 9H ME HD 01 989 OreaL HMA 1 5 een KIC HM Overal qu 7 48 6 8 W8 HM 5 5 6 2201 YMdveld dd 1 ISNI OL 65 151 HM 6 99081 2 a 25 550 HM 2259 Hua 5 8 5 80 and 5 85 CE Deutz TD2011L041 Models after serial number 8110 Ground Control Box Terminal Strip Wiring Diagram Section 6 Schematics 6 38 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram 5 80 and 5 85 CE Deutz TD2011L041 Models after serial number 8110 SNOILO3NNOO
240. A RA 4 RED BLACK18 2 IGN OUT 79 BUM 4 al MA ho h ROR FUEL PUMP EB hp 1 2 12 GROUND ANE hd LT BLUE PINK 14 15 EUM AN 82 PINKWHITE N 0 4 YELLOWILT GREEN 18 6 TACH 33 TANORANGE 18 h h GRAVOK BLUE 8 GOV SELECT 1 85 GRAYWHITE j GOV SELECT 2 86 BLACKIHED TEN NA UTBLUE BLACK 18 WHITE BLACK 18 ORANGE 18 10 ESL TEST SWITCH RR T PINK TAN 18 FUEL LOCKOFF A TAN BROWN 18 FUEL SELECT 90 7 18 12 TEMP SENDER WHITE 14 WHITE ORANGE 18 BLUE WHITE 18 TWIST WIRES 10 TURNS 360 DEG FOOT FULL LENGTH PINKYELLOW 16 30 9 87 PINKIYELLOW 16 PINK YELLOW 16 14 86 15 1 aH 1 WHITE BLUE 18 s 11 EPR RELAY rT We 87 LT BLUE PINK 14 14 87 BLUE GREEN 14 PINK TAN 18 s n g em PINK BLACK 18 85 T8 STARTER RELAY E 5 E 28 8 PFE 3 3 8 8 RED 14 30 m gu 8 ou 0 49 87 PINK YELLOW 16 EE PINK YELLOW 16 e 9 8 5 e 9 B 5 e 35 5 3 5 n z 5 3 9 95 amp EE gi dz 8 TANIBLACK 18 85 i FUEL PUMP RELAY EEE PERE dai HERE g A B D 6 D A B 6 A B CD 5 RED 14 30 2 0 z 2 COIL1 5 87 PINKDK GREEN 16 PINKDK GREEN 16 Es NOTE COIL FIRING ORDER 1 3 4 2 ECM PINS FIRED 1 2 418 28 RED TAN 14 15A PINKIDK GREEN 16 AAA H POWER RE
241. ANG GR WH 7 4 C165TRS WH RD 2 10 SNSR GND BR 1 4 7 3 C164PES 4 7 2 P162JPW2 OR JC7 5 C163PES WH BK 1 r JC7 1 JSGND2 BR JC3 4 C160JPL WH RD 4 3 2 P162JPW1 OR 9 1 JC3 3 C159STC BL WH I JC3 1 JSGND1 BR 4 IIS Ne t TS15 C144DER BL WH t TS15 C143DEL BL BK I L1 C13DRE A BL RD 514 0295 RD WH 1 BATGND J3 1 C1P 2 C28TTA RD BK BATGND C7P 3 r J22 1 2 9 10 11 AND 12 OPTION OPTION 12V D40 J1 28 RD BK RD C2P 6 RD 1518 BR BATGND GROUND STUD WH TS14 CR27 e Hl CR30 SPLICE TO C32BRK C1P 6 WH TS7 WH RD C32BRK OR RD 4015 LIFT DRIVE SELECT OPTION SPLICE TO 0401 5 C2P 2 u G S 80 S 85 S 80X PartNo 122985 6 66 Section 6 Schematics September 2015 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models A RD 1518 26 BK C7P 1 mE za rz 77 ME nb tel I 5 C 5 WH C7P 2 9 G gg Le BK C9 1 5 J3 3 WH RD J1 4 BL WH J1 5 OR J1 13 5 14 BK RD
242. B MTRA G1 6 71 ol o 5 5 7 885 gt O O ae m 21 GPM 79 5 L min G2 a n I GENERATOR HS0166C 12 5 KW Genie PartNo 122985 S 80 S 85 S 80X 6 173 September 2015 Section 6 Schematics pu 12 kW Hydraulic Generator Hydraulic Schematic 6 173 6 174 Genie Scandinavia Phone 46 31 57 00 Fax 46 31575104 Genie France Phone 33 2 37 26 09 99 Fax 33 2 37 26 09 98 Genie Iberica Phone 34 93 572 5090 Fax 34 93 572 5091 Genie Germany Phone 0800 180 9017 Phone 49 4221 491 810 Fax 49 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 0 Fax 81 35445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of Califo
243. BK C7P 1 TS1 V155PCE OR RD C4P 4 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR 5 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 J8 P109LS GR WH 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 P3 C46HRN GR C2P 5 11 1 TS47 C45GEN GR WH C2P 7 1 C40LS OR C2P 2 WH RD 6 C123PBS RD BK C2P 8 C7PBE BK C3P 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 WH L1 C41RPM OR BK C2P 3 C30EDC WH C1P 4 WH C9P 2 C1PBU RD C3P 1 C31EDC WH BK C1P 5 U13 ALC 500 C2PBD RD BK C3P 2 C36STC 0 C3PBF RD WH C3P 3 C37STCC BL BK C1P 11 C4TRL WH 4 C32BRK WH RD C1P 6 C5TRR WH BK 5 C29MS RD WH C1P 3 TS48 C49DLITE WH BK C4P 9 8 11 02 J 6 I L T975 1 P109TS GR WH I L C3P 12 P109LS BL WH 4 I T C1P 12 C177LS BL WH 1 1975 2 C184PL WH 1575 3 SNSR BR H 1516 C169LED1 GR L50 C169LED2 GR 1 0 CAN HI no CAN LOW LS18 C177LS BL RD C1P 12 TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS6 C348A BK WH C1P 8 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 4 3 5 C159STC BL WH 2 9 P1
244. BK H1 3 5 C159STC BL WH 2 9 P109ANG GR WH r JC7 4 C165TRS WH RD 2 10 SNSR GND r JC7 3 C164PES JC7 2 P162JPW2 OR JC7 5 C163PES WH BK 1 JC7 1 JSGND2 BR JC3 4 C160JPL WH RD 4 3 2 P162JPW1 OR 9 1 JC3 3 C159STC BL WH I JC3 1 JSGND1 BR t TS15 C144DER BL WH t TS15 C143DEL BL BK I L1 C13DRE A BL RD 814 29 5 RD WH 1 UNS BATGND J3 1 C1P 2 C28TTA RD BK BATGND C7P 3 r J22 1 2 9 10 11 AND 12 ION len C9 gt ES0505D 12V BATTERY C4P BR C3P GR 2 01 P GY 7 e GROUND D40 J1 C28TTA RD BK BR BATGND GROUND STUD WH TS14 LIFT DRIVE SELECT OPTION CR27 EIE CR30 EE WH RD C32BRK SPLICE TO C32BRK C1P 6 OR RD C40LS SPLICE TO 0401 5 C2P 2 RD C2P 6 RD 1518 G 5 80 5 85 S 80X PartNo 122985 6 114 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models
245. BL RD J1 16 WH C9P 2 BL BK J1 7 TS15 L1 BLANH J1 6 L48 RD C9P 3 RD BK H1 D40 b TS4 TS6 Left TS1 BK WH 1 8 OR RD 4 D12 RD BK RD C1P 9 BK C1P 7 RD C1P 1 RD WH J1 8 C4P 8 J22 6 4 GR C4P 7 J22 5 1 BR GND STUD BL BK C3P 11 GR C4P 5 J22 4 GRIBK C4P 6 J22 3 RD WH J1 2 OR J1 11 BR J1 12 WH BK J1 3 WH RD J1 1 TS9 NO C P3 OR C4P 2 J22 7 ES0503D OR BK C4P 3 J22 8 O GR C2P 5 COMPONENT INDEX z OX 215 SE a 54 8 1 0 ul O 2 8 Ble S tz OQ D ul 2 ago 8 2 56069 E E 5856 as F u e 5 5 u m 2 gt lt u 25 W ui a amp 3 E Sa gt o 9 2 a olo u 5 F F 9 u 5 lt F 2 x gt ES 0 lt cc a gt u F x 2 T Mas T 5 r 2 8 z mio e 8 9 49508 2 2 o gt uo m 39925 22250 arg als z s
246. Box Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011LO4i Models uu u u usia 6 18 Platform Control Box Switch Panel Wiring Diagram 5 80 5 85 ANSI CSA AS Deutz TD2011L04i Models 6 19 Electrical Schematic S 80 and S 85 CE Deutz TD2011L04i Models before serialnumber8111 6 22 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models before serial number 8111 6 26 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models before serial number 81 11 6 27 Platform Control Box Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models before serial number 8111 6 30 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models before serial number 8111 6 31 Electrical Schematic S 80 and S 85 CE Deutz TD2011L04i Models after serial number 8110 6 34 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models after serial number 8110 6 38 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L04i Models after serial number 8110 6 39 Genio xiv S 80 S 85 S 80X Part No
247. C3 JOYSTICK DRIVE STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH L1 LED DRIVE ENABLE 7514 DRIVE SPEED TOGGLE SWITCH 7 L47 LED CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH L48 LED TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH L50 LED ZONE B 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD ZONE 1000 CAPAS NOTE DASHED LINES INDICATE OPTIONS P2 EMERGENCY STOP BUTTON P3 HORN BUTTON 1 ROCKER STEER OPTION TS1 AUXILIARY TOGGLE SWITCH 8 Genie Part No 122985 5 80 S 85 S 80X 6 151 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram 80 Continental TME27 Models 6 151 6 152 6 153 Section 6 Schematics September 2015 saticUtrr Continental TME27 Engine Harness 6 154 Section 6 Schematics Continental TME27 Engine Harness A EGO 1 EGO2 EGOS EGO 4 TPS1 STEP2 TPS2 STEP2 MAP AUX ANAPD1 FPP FPP2 IVS AUX ANA PD2 AUX CAN 1 TERM 1 2 CAN CAN 2 TERM XT V SWITCH AUX PU1 AUX ANA PU2 AUX PUS SV EXT 5V RTN GOV 1 GOV 2 OIL P AUX ANA PUD1 PC TX PC RX PULSE IN TACH V BAT PROT 5 INJ1 LS INJ2LS FUEL LOCKOFF BUZZ AUX PWMS AUX RECIRC
248. C4P 1 5 08088 BK WH C3P 8 04218 OR RD 2 4 E C9PERF BK RD 9 a lt WHL1 C C41RPM OR BK C2P 3 5 C30EDC WH C1P 4 N 1 WH C9P 2 C1PBU RD C3P 1 Eme C31EDC WH BK C1P 5 7 C2PBD RD BK C3P 2 C36STC BL C1P 10 pro C3PBF RD WH C3P 3 5 0375100 C1P 11 WH 4 C32BRK WH RD C1P 6 Jh 4 5 WH BK C3P 5 lt lt SAI 3 C29MS RD WH C1P 3 C2P BK mamy CIP GY LS18 C132PLI RD 1 12 m TS1 C27AUX RD C1P 1 TS2 C33STR BK C1P 7 TS4 C35RPM BK RD C1P 9 L48 C28TTA RD BK H1 o I JC3 5 0 01595 BL WH 2 ds 8 C2P 9 P109ANG GRWH O ee JC7 4 C165TRS WH RD I 2 10 SNSRGNDBR 8 JC7 3 C164PES RD WH lt H 32 JC7 2 0162002 OR 5 JC7 5 C163PES WH BK 8 r JC7 1 JSGND2 gt 1 1 3 4 C160JPL WH RD 1 2 3 JC3 2 PIEIPWIOR 0 2 2 JC3 3 C159STC BL WH L JC3 1 JSGND1 BR P TS15 C144DER BL WH g a TS15 C143DEL BL BK Nez lt L1 C13DRE A BURD 9 C28TTA RD SK I TS14 C29MS RD WH o 8 GR BK 12 GR BK L4 RD C2P 6 RD 1518 N LO
249. Continental TME27 Models Electrical Schematic S 80 and S 85 CE Continental TME27 Models before serial number 81 11 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 81 11 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 81 11 Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 81 11 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 81 11 Electrical Schematic S 80 and S 85 CE Continental TME27 Models after serial number 8110 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 Genie Part No 122985 5 80 S 85 S 80X September 2015 TABLE OF CONTENTS Section6 Rev 5 Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models aft
250. Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 Genie S 80 S 85 0 CHECKLIST D PROCEDURES D 6 Replace the Hydraulic Filters Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank 2 Remove the cap from the filter housing 3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing 4 Remove the filter element from the filter housing Install the new filter element into the filter housing 6 Push the filter element down to be sure the O ring on the element is fully seated into the housing 7 Rotate the filter element clockwise to lock it
251. D CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH 148 LED TILTALARM 013 ALC500 JOYSTICK CONTROLLER CARD P2 EMERGENCY STOP BUTTON P3 HORN BUTTON NOTE DASHED LINES INDICATE OPTIONS AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH ROCKER STEER OPTION 8 153 FUELSELECT TOGGLE SWITCH Genie Part No 122985 S 80 S 85 S 80X 6 139 September 2015 Section 6 Schematics M xsmcrssrrrr rn Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 6 139 6 140 Section 6 Schematics September 2015 Electrical Schematic S 80X Continental TME27 Models 6 141 6 142 C28TTA RD BK C28TTA RD BK September 2015 Electrical Schematic S 80X Continental TME27 Models Section 6 Schematics xc m 5
252. D2011 Operation Manual Genie part number 139320 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures A 4 Perform Function Tests Genie specifications require that this procedure be performed daily Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 122985 Genie 5 80 S 85 S 80X 3 9 CHECKLIST A PROCEDURES A 5 Test the Oscillate Axle Genie specifications require that this procedure be performed daily Proper axle oscillation is essential to safe machine operation If the axle oscillation system
253. DC WH EDC DRIVE FORWARD T 25 cts E 05 20 C31EDC WH BK gt EDC DRIVE REVERSE 162 re a m r GND BR 21 1 C130TA WH RD TRAVEL ALARM OPTION P2AFS 2 2 P24FS WH 5 19 1 6 7 05 23 C32BRK WH RD ELE BRAKE RELEASE P26ESTP gt 3 1 8 5 24 Sn 2 SPEED Boc Qn CSOMS DANH U MOTOR STROKE m CR34 SPEED REDUCTION RELAY 3 C6 31 29 LST30 BOOM UP DOWN SPEED REDUCTION OR 1188 S LIMIT SWITCH N P134PWR RD 258 6 11 9 15825 CS9CNK BL BK STE LOOSE CABLE TW LIMIT SWITCH 9 l 4 C3 11 El kesi 146 147 AS LOOSE CABLE LED i re C14PLU OR 3 UP PLATFORM T 1 LEVEL t DOWN C15PLD OR BK 8 8 P UP PLAT LEVEL I z 08 DOWN sr C4 8 5 a 5 t potere cup 7 C43JU GR i m 7 5 DOWN JIB BOOM 9 685 Es C4 6 5 B22 cow C18PRR GR BK de 045 C17PRL GR 8 Ccw 5 PLAT ROTATE E mw R8 wee 24 PLATFORM LEVEL UP 5 24 If 422 12 PLATFORM LEVEL DOWN 122 8 e J22 6 Sm 422 10
254. Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 73 6 74 September 2015 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 C u a 2 5 gt ne I 9 B o 5 25 2 E 2 5 lt 5 5 oc 0 gt Z oz E O a s u 6 218 5 2 lt 5 SE QS 6 ol z 5 5 5 E Z S E lt z Or 5 5 Eg 2 2995 255 x lQ Q z u luO iss gt lt lt 01 96868611 jam lt an 2 8 25 5 2 lt WW z lt a 6 2512 583 5 o 5 59 lt 6 2 a 2 2 5 5
255. E Dash size Torque 4 14 ft lbs 18 9 Nm 6 23 ft Ibs 31 2 Nm 8 36 ft lbs 48 8 Nm 10 62 ft Ibs 84 1 Nm 12 84 ft lbs 113 9 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 250 Nm SAE O ring Boss Port SPECIFICATIONS Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 15 ft lbs 20 3 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 30 ft Ibs 40 Nm 8 60 ft Ibs 81 3 Nm 8 40 ft Ibs 55 Nm 10 100 ft Ibs 135 6 Nm 10 60 ft
256. ERGENCY STOP BUTTON TS14 DRIVE SPEED TOGGLE SWITCH H1 TILT ALARM P3 HORN BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH J22 PLATFORM MANIFOLD R20 RESISTOR 47000 U13 ALC500 JOYSTICK CONTROLLER CARD JC3 JOYSTICK DRIVE STEER AUXILIARY TOGGLE SWITCH 034 TIME DELAY RELAY 2 SECONDS 10A JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS2 ENGINE START TOGGLE SWITCH 035 TIME DELAY RELAY 2 SECONDS 30A L1 LED DRIVE ENABLE TS4 RPM SELECT TOGGLE SWITCH L4 LED PLATFORM OVERLOAD TS6 GLOW PLUG TOGGLE SWITCH NOTE DASHED LINES INDICATE OPTIONS 8 147 LED CABLE TENSION TS7 PLATFORM ROTATE TOGGLE SWITCH ROCKER STEER OPTION 48 LED ALARM TS8 JIBBOOM UP DOWN TOGGLE SWITCH S 85 OPTION Genie Part No 122985 S 80 S 85 S 80X 6 79 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 81 11 81 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110
257. Genie A TEREX BRAND Serial Number Range 5 80 from S8008 8000 to 58013 11875 85 from S8508 8001 to 58513 11875 5 0 from 580 110 8500 5 Part 122985 Rev D1 September 2015 Introduction September 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes 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
258. ICATIONS Hydraulic Component Specifications Drive pump Type bi directional variable displacement piston pump Displacement 0 to 2 8 cu in 0 to 46 cc Flow rate 2300 rpm 0 to 30 3 gpm 0 to 114 7 L min Drive pressure maximum 3750 psi 259 bar Charge pump Type gerotor Displacement 0 85 cu in 13 9 cc Flow rate 2300 rpm 9 gpm 34 1 L min Charge pressure 2300 rpm 310 psi Neutral position 21 4 bar Function pump Type variable displacement piston pump Displacement 0 to 2 3 cu 0 to 38 cc Flow rate 2300 rpm 0 to 23 gom 0 to 87 L min Auxiliary pump Type fixed displacement gear pump Displacement static 0 151 cu in 2 47 cc Genie PartNo 122985 5 80 S 85 0 2 3 Section 2 Specifications September 2015 SPECIFICATIONS Function manifold System relief pressure 3200 psi measured at PTEST port 221 bar Boom down relief pressure 2400 psi measured at PTEST port 165 bar Boom extend relief pressure 2400 psi measured at PTEST port 165 bar Steer axle extend 3 5 gpm flow regulator 13 2 L min Oscillate relief pressure 950 psi 65 5 bar Drive manifold Hot oil relief pressure 280 psi 19 3 bar Brake release pressure Wheel drive hubs 240 psi 16 5 bar Drive motors Displacement per revolution variable 0 9 to 2 7 cu in 2 speed motor 14 7 to 45 cc Hydraulic filters High pressure filter Beta 3 lt 0 High pressure filt
259. LAY WHITE BLUE 18 85 8 PINK TAN 8 PINK 18 BROWNWHITE 16 x BROWN GREEN 16 Fi RED TAN 14 RED 14 RED 12 BROWN YELLOW 16 20 RED 14 September 2015 Section 6 Schematics TssrsnO mssuh rm Platform Level Cutout CTE Option G F E D C B A PLATFORM BOX 1 4 4 e 2 9 9 a gt m E 2 4 C42LS OR RD C2P 4 3 ipo Se In 9620 NO o NO o 4 9 9 a r 3 3 5 gt x N N m N A 6 Y19 Y20 7 4 3 sz gt 26 5 GROUND 8 m m lt lt m r r GROUND BOX MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED Genie PartNo 122985 S 80 S 85 S 80X 6 155 September 2015 Section 6 Schematics GC Oi zu ________ Platform Level Cutout CTE Option 6 155 6 156 6 157 Section 6 Schematics September 2015 Tu s Continental Options Schematic 6 158 Section 6 Schematics September 2015 Continental Options Schematic A P22BAT BK C P134PWR RD e R21IGN WH N e P26ESTP BK e P26ESTP P2 FSI C9P 3 7 BK 1 P25FS RD P25FS RD POSFS RD P24FS WH P24FS WH P24FS WH
260. LVLOY 1 9 90 QH HM 9 9 vrtu 1X3 WOO8 IHd 1 90 1 8 0 1 2951 xg 8 99 HME 9 860 8 9 6981 HWA 1 1 WOOd 6 99 8 6 86 6 9 E9S1 S1318VN3 81 99 1 dn 13A31 6951 HO NMOG vO Mg uO SL 2 6951 MO 31VLOH 9 21 9 2981 MOO 31109 WHO4 VId 9 48 49 1 1 881 Mg u5 Alddns 02 2 200 AlddNS NOLLINSI AZL 11 59 HM 999 HM OL HMd 5 22 060 LSM uz WHOSLV1d OL 1 90 HM 2 840 ZUHM Z za l LSA HM dc 1 ve 5 Auvrnixnv 9 82 22 1981 u Bored HOSN3S 82 90 810 82 a33dS 6 90 8LO HIWQU 62 oaa auvMHdod 16 90 HM r 810 HM 0 02 59 M8 HM 9 81 M8 HM 6 ayvug 62 52 9 815 66 THAVHL QH HM 1 18 9 90 2 810 2SS 1 aasnnn 10 9 9334 6 99 6 819 SE ELQ L vSS L qug MO H3als 95 99 18 01 910 9 4331S 46 99 LL 8LO 10
261. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the drive motor mounting fasteners 5 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine Refer to Section 2 Specifications Part No 122985 September 2015 Section 4 Repair Procedures 12 3 Drive Hub How to Remove a Drive Hub Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 12 2 How to Remove a Drive Motor 2 Loosen the wheel lug nuts Do not remove them 3 Center a lifting jack of ample capacity under the non steer axle 4 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack 7 Remove the drive hub mounting fasteners that attach the drive hub to the axle Remove the drive hub AWARNING Crushing hazard The drive hub could become unbalanced and fall if not properly supported and secured to the lifting jack when removed from the machine Note Do not re use the dr
262. MARY BOOM 52435 SPEED REDUCTION RELAY 5 5 5 55 8 5 89 888898 55589 or 11818 2 8 C3 1 lol fou 1 C1PBU RD GROUND 5 8 C2PBD RD BK x o 5 s lt 63 3 RD WH 8 gt 8 2 2 a 17 5 5558 y u 558 0521 C30EDC WH FORWARD NET 58555 rec lt 815 5 05 20 C31EDC WH BK 2 0 4 4 DRIVE EDC REVERSE pim 3 8 C6 37 sen C37STCC BLK 2 C37STCC BUBK STEER CCW 82 GND C140 C6 36 314 WH 552 17 086870 BL 036810 BL STEER CW 4 9 e m 21 354 pars C32BRK WH RD BRAKE RELEASE 2 19 gt P26ESTP 3 N 1 3 5 05 24 C29MS RD WH Ihi 4 MOTOR STROKE 6 8 u P134PWR RD C64 2 5 cen 8 15825 EE C59CNK BUBK WH BK LOOSE CABLE LIMIT SWITCH Ue 8 55 2 a 1 C59CNK him LOOSE CABLE LED S m C14PLU OR C15PLD OR BK 8 P PLATFORM LEVEL 9 1 amp DOWN 2 E per C43JU GR ay oes C44JD GR BK lt 43 sow RR 48 C129DA RD BK DESCENT ALARM E 8 C17PRL GR 045 C18PRR GR BK 046 BEE 4 850 J22 7 SI J22
263. MOTOR STROKE a m CR34 SPEED REDUCTION 3 RELAY 5 E C6 31 29 18130 BOOM UP DOWN 011815 OR aus SPEED REDUCTION LIMIT SWITCH No Bou P134PWR RD cz o 55 c6 11 8 15825 4 EE C59CNK BL BK gus LOOSE CABLE gt Lol ye LIMIT SWITCH _ l c3 11 Fl Ln 146 147 LOOSE CABLE LED 3 C4 2 5 OR PLATFORM T LEVEL 8 DOWN C15PLD OR BK g z 5 P UP I s PLAT LEVEL 0 5 85 DOWN ae 9 95 Bm C4 8 PS2 DOWN t ae C43JU GR 3 m t r DOWN JIB BOOM Su S 85 OPTION 2 me Bid 535 CAS C18PRR GR BK 2 Pag FRE LEW m C17PRL GR 2 CCW ROTATE gy B m d 3227 7 322531 PLATFORM LEVEL UP o HA J228 2 1 922 12 5 PLATFORM LEVEL DOWN J22 6 gt J22 10 1 8 of u S 5 J22 5 gt J22 9 1552 5 lt gt 55 ob 3 J22 3 J22 2 2384 B 210 x 8 PLATFORM ROTATE CCW 5 E 4224 7 PLATFORM ROTATE CW G 5 80 5 85 S 80X 6 71 Part No 122985 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models before serial number 81 11 71 72 Section 6 Schematics September 2015 e a Ground Control Box Terminal Strip Wiring
264. Models 3 43 C 5 Replace the Fuel Filter Water Separator Element Diesel Models 3 43 C 6 Check the Safety Envelope Limit Switches and Angle Sensor S 80X 3 45 Genie Part No 122985 S 80 S 85 S 80X ix September 2015 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued ChecklistD Procedures D 1 Check the Boom Wear 7 3 48 0 2 Free wheel Configuration 3 49 D 3 Check the Turntable Rotation Bearing Bolts 3 50 0 4 Inspectthe Turntable Bearing Wear 3 51 0 5 Perform Engine Maintenance 3 53 D 6 Replace the Hydraulic Filter Elements 3 53 D 7 Replace the Drive Hub 0 0 3 54 D 8 Perform Engine Maintenance Deutz 3 56 A ChecklistE Procedures E 1 Testor Replace the Hydraulic 3 57 E 2 Perform Engine Maintenance Perkins Models 3 59 E 3 Perform Engine Maintenance Deutz and Perkins Models 3 59 E 4 Remove and Replace the Boom Extend Retract Cables 3 60 Section4 Rev RepairProcedures Introduction en ei 4 1 Platform Controls 1 1 ALC 500 Circ
265. Models after serial 8110 6 90 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models after serial number 8110 6 91 Electrical Schematic S 80X Perkins 8040 33 6 94 Ground Control Box Terminal Strip Wiring Diagram 5 80 8040 33 Models u u 6 98 Ground Control Box Switch Panel Wiring Diagram S 80X Perkins 8040 33 ModelS 6 99 Platform Control Box Wiring Diagram S80X Perkins 8040 33 6 102 Platform Control Box Switch Panel Wiring Diagram S80X Perkins 8040 33 Models u u 6 103 Genie Xvi 5 80 S 85 S 80X Part No 122985 September 2015 eee Section 6 TABLE OF CONTENTS Rev Schematics continued Electrical Schematic S 80 and S 85 ANSI CSA AS Continental TME27 Models 6 106 Ground Control Box Terminal Strip Wiring Diagram 5 80 and 5 85 ANSI CSA AS Continental TME27 00668 Ground Control Box Switch Panel Wiring Diagram 5 80 5 85 ANSI CSA AS Continental TME27 Models Platform Control Box Wiring Diagram 5 80 and 5 85 ANSI CSA AS Continental TME27 Models sse Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 ANSI CSA AS
266. N M L G F E D C B A CONTROL HARNESS TO PLATFROM BOX 1 9 2 Q 2 20 0 I 2 S 9 259 295 2 5 D m 5 9 5 5 5 22 222 2 8 32 355532 4405 52643209 x 58 9 S 5 D o 8 6 E lt o 2 0 9 Poe Pe 5 gt lt m 9 o a En Ka 9 lt m 2 c 5 pec 5 9 70 a 9 an 25 8 5 4 5 TS15 S S 7 amp 6 8 1 1 1 2 0 1 EE D12 E E JC3 L 8 JC7 MEE TS2 TS6 1 l l 14880 p bs 3 1 4 L1 ME 5 3 0 TS1 5 TS14 8 one P gt x Leo 0 Y e e LETS e 1 1 1 OO 21 1 P2 BK RD 6 ES0503A 1 COMPONENT INDEX CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPTION 1518 PLATFORM OVERLOAD LIMIT SWITCH TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH 7 CR30 LIFT DRIVE SELECT LIMIT SWITCH CIRCUIT OPTION P2 EM
267. NEL BLACK 1264 SILVER T 8 4 CONDUCTOR GA 5 CONDUCTOR e BRASS l a Z 120 VAC GFI 6 GREEN 12GA 12 GA3 CONDUCTOR 7 110 VAC GFI ENCLOSURE N SILVER DN WHITE 8 Ne GREEN 2 BLACK X 7 ES0506B 12 CONDUCTOR BRASS Genie 6 162 S 80 S 85 S 80X Part No 122985 September 2015 Section 6 Schematics 12 kW Hydraulic Generator Electrical Schematic K J H G F E D 0 B A 1 po FOOTSWITCH P26ESTP BK P25FS RD ALC 500 P22PWR BK P P24FS WH TS4 m gt GENERATOR z ez 2 D12 C32BRK WH RD 9 Q 10 v P 5 1 4 2 2 J 8 Q 8 8 9 Q Ds a 5 5 2 S 3 m 7 z m 6 2 o 5 i 8 E 5 5 Q 8 N C 2 Q w m m w 1 0 e 4 2 COM 8 5 3GND sswINPUT 24 A n 9 9 TIME DELAY 5 5 45 5
268. NG Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES 2 Be sure that all nuts and bolts are tight 3 Inspect all welds for cracks 4 Inspect for exhaust leaks i e carbon buildup around seams and joints 5 Swing the engine pivot plate in towards the machine 6 Install the bolts that were just removed into the original holes to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolts into the engine pivot plate to secure it from moving could result in death or serious injury Genie S 80 S 85 S 80X B 5 Inspect the Engine Air Filter Continental Deutz and Perkins Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap Remove the filter element 4 Cleanthe inside of the canister and the end cap with a damp cloth 5 Inspectthe air filter elemen
269. Nn 1 860 6 1 1 1 WOOg 07 909 2 820 ue WNDIS 290 gZ9 LF 28 INSIMg HO ee mE __5 5 STONY W008 22 92 865 00 80 ev 0 7 20 NOILdO Wood 2 v 8951 17 96 986 alf 8 1092530099 gt e 0 2 8951 Oc wg HM YOLVHANAD OV 65 99 1 820 HIWHO St Orr au NHOH 1 80 HD 9 820 319 35001 11 90 11 889 69 03345 1411 15 99 HO 98 LAdNI QvO1 WHOSLW 1d 15 61 ZEL 5 659 21 860 49 49 1 49 48 H3MOd HOLIMS AIM 2 90 9 860 rer re 9H v 43MOd HOLIMS 96 95 42 90 Wree 1437 NOOV38 HM LH9IH NOOV38 HO 61 90 0 290 qu uO 991 890 9 2951 qu uo 9 a eL Oo 8 4 2 551 B dH S LGS I HM M LLL E 1 8 0 38 een HM gt C sv 138 45 6 HVO X8 HM 66181 48 8281 48 OvElal UMdvEld GH 6181 18 Term 9 4 614 eo 2 LH917 7 enie G S 80
270. No 122985 Genie S 80 S 85 0 BOOM COMPONENTS 4 4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Extension Cylinder AWARNING P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position Section 4 Repair Procedures September 2015 BOOM COMPONENTS 2 Remove the boom end cover retaining fasteners and remove the cover 3 Remove the access covers from both sides of the boom at the pivot end 4 Fully loosen the lock nuts on the extend cables Do not remove the nuts a cable guard b retaining block 4 26 S 80 6 85
271. Number of shutdown requests gt 1 Network 1626 CAN Tx Failure TXemorcouter 100 1627 CAN Px Failure 100 1628 Address Conflict Failure jAddressconfictcounter 5 Adaptive Learn Key Cycle Genie Part No 122985 5 80 5 85 5 80 5 11 Section 5 Fault Codes September 2015 pu 1 This page intentionally left blank Genio 5 12 S 80 S 85 S 80X PartNo 122985 September 2015 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use PartNo 122985 Genie S 80 S 85 S 80X 6 1 Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuit
272. OX 1 21333133 11111233 33 1 TT TE T RR 8 81155 34334113 58 8 58 288 3 29 S5 e 9p 3 9 3E c v A 8 BT 2 55547107 5 uS 9 c o U C G 3 D 97 vu 9 o 5 a o Sox 5 TS3 TS4 TS15 5 S 2 29555 5 2 S A E x i i 012 I E JC3 2 lt i pod D10 i 1 TS2 3 I I 45 SD i 1 1 L47 1 N e Ole 2 d 2 8 l 4 0 1 E 4 D43 Ts9 2 iod ISP E E I 3 e PE K CR G 137090 o Q o 22 1 T DE as Quo x 01 148 2 E X 1 i a O 0 5 RD e BK RD RD 1 U ES0505D NN NN NR RC NEM ee 5 5 6 COMPONENT INDEX Hi TILT ALARM TS4 RPM SELECT TOGGLE SWITCH 468 JOYSTICK DRIVE STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS8 JIB BOOM DOWN TOGGLE SWITCH LED DRIVE ENABLE TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH LA LED PLATFORM OVERLOAD TS14 DRIVE SPEED TOGGLE SWITCH 7 147 LE
273. P109ANG GR WHO 2 22 7 4 C165TRS WH RD 4 C2P 10 SNSR GNDBR O 5 1 7 3 C164PES RD WH 5 N 7 2 PI62JPWEOR 9 Yi i JC7 5 C163PES WH BK 4 7 1 JSGND2 BR 2 hy 2 JC3 4 C160JPL WH RD 5 18 JC3 2 P162JPW1 OR gt 9 JC3 3 1598 S I JC3 1 JSGND1 o JP t TS15 C144DER BL WH S I TS15 C143DEL BL BK i HL1 C13DRE A BLIRD 6 RD EK I TS14 C29MS RD WH i GR BK C3P 12 GR BK L4 i RD 2 6 RD 1818 5 80 5 85 CE Continental 27 Models after serial number 8110 Platform Control Box Wiring Diagram Section 6 Schematics PartNo 122985 5 80 5 85 S 80X 6 138 September 2015 Section 6 Schematics E Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 N M L K J l H G F E D 0 B A CONTROL HARNESS PLATFORMB
274. RCUIT OPTION TS2 ENGINE START TOGGLE SWITCH ROCKER STEER OPTION H1 TILT ALARM TS3 FUEL SELECT TOGGLE SWITCH JC3 JOYSTICK DRIVE STEER TS4 RPM SELECT TOGGLE SWITCH JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TS7 PLATFORM ROTATE TOGGLE SWITCH L1 LED DRIVE ENABLE TS8 JIB BOOM UP DOWN TOGGLE SWITCH S 85 OPTION 8 L47 LED CABLE TENSION TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH 148 LED TILT ALARM 514 DRIVE SPEED TOGGLE SWITCH P2 EMERGENCY STOP BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH P3 HORN BUTTON U13 ALC500 JOYSTICK CONTROLLER CARD Genie Part No 122985 S 80 S 85 S 80X 6 115 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 ANSI CSA AS Continental TME27 Models 6 115 6 116 Section 6 Schematics September 2015 I2 I1 2 2 Electrical Schematic S 80 and S 85 CE Continental TME27 Models before serial number 81 11 6 117 6 118 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Continental TME27 Models before serial number 8111 A B C D N
275. RD C42LS OR RD BK WH X fel C40LS OR 0540 C40LS OR gt gt AD 8 e LSB1RO 54 r 251 gt gt Br to BOOM RETRACT 513 P134PWR RD 06 23 1 zf z DRIVE ROTATE SPEED LIMIT SWITCH 1 lt 8 8 THEN 55 ee P134PWR RD RD 4 6 0 354268 a BLAD 983 lt lt BLRD 5 4 4 DEN 3 228282 15 2 88 m lt 86 LIMIT SWITCH 5 556558 656 C6TRF WH RD 9 5 8 15111718 9 lt 5 WH BK m C34 C4TRL WH Sen 9 C64 TURNTABLE ROTATE cw C4TRL WH A 1 9 5 le Ccw C6 5 8 TURNTABLE ROTATE 5 s CSTAR WH BK 7 TURN 85 F 2 6 TURNTABLE ROTATE H1 RD BK Su x OTHE WED H FLOW CONTROL wee rg Hi EX c39 C9PER BK RD ac oe C8PBR BK WH C37 C29MS Rdn 2 BK oc LED BL RD a o o MONET 226 06 7 H PRIMARY BOOM EXTEND 5 DEM C7PBE BK gt 5 C144DER BUWH Pe 7 F 8 RETRACT ces T 5 PRIMARY BOOM 19 27 ty LEFT sc 3 5 RETRACT C143DEL BUBK 8 16 DES PRIMARY BOOM 1 I C9PERF BK RD JJ EXTEND RETRAC
276. RD EXTEND RETRACT 258 2 FLOW CONTROL 2 8 SESUP 8 m EX om 2 C30EDC WH EDC DRIVE FORWARD z 081800 WH BK EDC DRIVE REVERSE 20 11 8 GND BR 21 C130TA WH RD I 4 TRAVEL ALARM OPTION P24FS 22 o g 4 s 8 T 24 WH 224 Tax Cis 6523 C32BRK WH RD BRAKE RELEASE P26ESTP BK 83 c1 3 5 24 Sp 2 SPEED 1 MOTOR STROKE m z ou P134PWR RD bones foes Zl 5 S6 c6 11 9 15825 C59CNK BL BK Sus LOOSE CABLE TAS LIMIT SWITCH 55 ed 8 l C3 11 el 146 147 N We LOOSE CABLE LED SN C4 2 3 C14PLU OR 3 PLATFORM DOWN LEVEL C15PLD OR BK 8 8 2 ui I se PLAT LEVEL DOWN RIS 55 C4 8 8 DOWN t C44JD GR BK 475 tup C43JU GR X m 8 A5 DOWN JB BOOM 5 85 OPTION 9 PE ur GROUND C4 6 55 B22 t C18PRR GR BK 045 C17PRL GR S PLAT ROTATE m tw 4 PLATFORM LEVEL UP 322311 241 7 5 26 J22 12 PLATFORM LEVEL DOWN 7 222 8 g
277. Remove the muffler and bracket assembly from the engine 8 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing engine fasteners 9 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 10 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Part No 122985 September 2015 Section 4 Repair Procedures Perkins model 11 Tag and disconnect the wiring from the bell housing 12 Remove the exhaust pipe clamp at the muffler Burn hazard Hot engine parts can ACAUTION cause severe burns 13 Remove the muffler mounting bracket fasteners Remove the muffler and bracket assembly from the engine 14 Remove the hose clamps from the air cleaner elbow and the engine intake manifold 15 Remove the air cleaner mounting bracket fasteners Remove the air cleaner and bracket assembly from the engine 16 Support the drive pump with an appropriate lifting device Remove all of the remaining bell housing to engine fasteners Continental model 17 Tag and disconnect the wire harness from the oxygen sensor 18 Remove the exhaust pipe heat shield fasteners from the top of the muffler ACAUTION Burn Hazard Hot engine parts can cause severe burns 19 Remove the muffler retainer bracket fasteners 20 Remove the
278. S 80X Loosen the retract cable nut at the platform end of the boom Pull the cable rod from the support and let it hang down Remove the cable guard fasteners and remove the cable guard Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube Remove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the way Remove the fasteners from the retaining blocks from the extension cylinder saddle Remove the blocks Note Access the fasteners through the access hole in the outer boom tube at the pivot end 10 Disconnect the wire connector to the extend cable break limit switch 11 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube Part No 122985 September 2015 Section 4 Repair Procedures extend cable lock nuts extend cable mounting plate extend cable mounting plate fastener extend cable bracket 12 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube Part No 122985 Genie S 80 S 85 0 BOOM COMPONENTS 13 Lift up the extend cable mounting plate and push the extend cables towards the platform to create slack in the cables Rest the cable and bracket assembly on top of the extend cylinder 14 Locate the lower extend cable bracket on the bottom o
279. T FLOW CONTROL 8 g Ti 21 thr RD E LST3S BOOM ANGLE BR io 4 STOWED a Se 45 45 GROUND BOX ZONE A WH 7 SAFETY LIMIT SWITCH 1 8 RWH zem co WH BKWH P109LS GR WH C616 63 12 lt lt 1 ie E NE LSB1ES BOOM EXTEND 1 79 C6 38 BR 8 al zJ LIMIT SWITCH 2 i 1 lt lt 821290 GRBK gt gt OR BR 5 g al 2 5 5 0630 BK amp 9 LSB1EO BOOM EXTEND Qe CAPACITY OPERATIONAL 9 re LIMIT SWITCH 5 17715 BURD BURD ER 8 9 1 RD RD al LST3O BOOM UP DOWN lt BR toto GROUND BOX ZONE A 424 OPERATION AND SPEED E I P210PWR 906 12 1 CN REDUCTION LIMIT SWITCH ig ig ig os m y C61 AD g d 5 hr 9 2 01080 RD 7 PRIMARY BOOM UP a a m 8 e a sz 062 C2PBD RD BK ni 9 PRIMARY BOOM DOWN 88 23 Bro a 21 PES 8 5 C6 3 5 PRIMARY BOOM H FLOW CONTROL zu t 12 og 15 eee za i S a 6 8 5 5 ET CR34 PRI
280. TTON AUXILIARY TOGGLE SWITCH TILT ALARM H1 JC3 JC7 L1 L47 L48 P2 P3 TS1 TS2 TS4 TS6 TS7 September 2015 Section 6 Schematics _ Platform Control Box Switch Panel Wiring Diagram 5 80 and 5 85 ANSI CSA AS Deutz 2011 041 Models 20 21 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Deutz TD201 1L04i Models before serial number 81 11 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Deutz TD201 1L04i Models before serial number 81 11 C132PLI BK
281. URNTABLE ROTATE TS2 ENGINE START TOGGLE SWITCH 085 TIME DELAY RELAY 2 SECONDS 30A L1 LED DRIVE ENABLE TS4 RPM SELECT TOGGLE SWITCH L4 LED PLATFORM OVERLOAD TS6 GLOW PLUG TOGGLE SWITCH NOTE DASHED LINES INDICATE OPTIONS 8 L47 LED CABLE TENSION TS7 PLATFORM ROTATE TOGGLE SWITCH 1 ROCKER STEER OPTION 148 LED ALARM TS8 JIBBOOM UP DOWN TOGGLE SWITCH S 85 OPTION Genie Part No 122985 S 80 5 85 0 6 31 September 2015 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Deutz TD2011L04l Models before serial number 8111 Section 6 Schematics September 2015 ES Electrical Schematic 5 80 S 85 Deutz 020111041 Models after serial number 8110 33 6 34 September 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 CE Deutz TD201 1L 041 Models after serial number 8110
282. VBAT MIL GROUND DBW STEP DBW STEP FPUMP AUX PWM3 AUX PWM3 AUX PWMI AUX PWM2 AUX AUX PWM4 0 September 2015 n K Genie 6 4 A WG S 80 S 85 S 80X PartNo 122985 INJECTOR 4 INJECTOR 3
283. WOOd 2 90 1L 8 0 2 L 9S 1 lovulau WOOS Idd 8 90 HME 8 860 8 9 0991 134 1X3 IHd 6 90 08 6 860 auma 6 9 2951 61 90 1 13A31 2 8 1 6981 NMOG T3A31 WHOSLV1d SL 9 699 4g HO MO 0 9 8 1 9 2991 MOO 31VLOH ld 9 8 2 1 2991 81 AlddNS 61 08 6 2 280 AlddNS NOLLINSI AZL 11 90 HM 999 HM 1 14 OL HMd 22 690 15 WHOSLW 1d OL 2 849 ZLHM 6 2 NSI HM za l LSA HM aa aasnwn ve 5 9 99 8 22 e9d vi NSI 7 1951 HOSN3S 13437 82 90 8 0 2810 8 Qu 6 0 6 810 6 16 90 HM r 819 HM 0 5 06 90 8 810 ME HM 8 56 90 QU HM 9 15 Qu HM 66 WHV IV T3AVHL QH HM 1 15 9 90 1 810 66 NSI 2851 9 81 9 9991 HW l8 6 39 6 919 6 10 1 551 MO 8 95 99 18 01 910 18 9 MOO 83215 48 90 11 81 qasn
284. YD OIL COOLER C2 6 Pod 8 d 4 C116HYD Wi 46955 P134PWRRD e 5 OPTION 5 9 8 2 HYD OIL COOLER 5 5 21 R116HYD OR OPTION 5 51 a 8 amp 9 5 a 8 um 9 i g 4 5 5 leq 13 88 a 8 es a Ix 5 ALTERNATOR 2 e EC 6 9 BATTERY SEPERATOR ele lt 58 a C J RD 4 START BATTERY a gt a 82 8 o 8 RD CONTROL BATTERY a a a amp N LO PartNo 122985 5 80 5 85 S 80X 6 106 Section 6 Schematics September 2015 Continental TME27 Models Electrical Schematic S 80 and S 85 ANSI CSA AS
285. ad crane 10 Remove the suction strainers from the tank and clean them using a mild solvent 11 Rinse out the inside of the tank using a mild solvent 12 Install the suction strainers using pipe thread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill installing the drain plug and strainers Genie Part No 122985 S 80 S 85 0 Section 4 Repair Procedures September 2015 Turntable Rotation Components 10 1 Turntable Rotation Drive Hub Assembly How to Remove the Turntable Rotation Drive Hub Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin backlash pivot plate adjustment bolt with lock nut backlash pivot plate mounting bolts om 5 Remove the backlash pivot plate mounting bolts Carefully remove the drive hub assembly from the machine AWARNING Crushing hazard The turntable rotation drive h
286. all rings watches and other jewelry 1 Test the coil for resistance Refer to How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA Genie S 80 S 85 0 co 4 JW 201 109 9V RESISTOR BATTERY pon Ww s s 1 R MEE ON PEL LS b Lo Poren 448 4 i i multimeter 9V DC battery 100 resistor coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good
287. and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Genie Serial Number Information Genie offers the following Service Manuals for these models Title Part No Genie S 80 and S 85 Service Manual from serial number 101 to 785 34032 Genie S 80 and S 85 Service Manual from serial number 786 to 965 52270 Genie S 80 and S 85 Service Manual from serial number 966 to 3081 72062 Genie S 80 and S 85 Service Manual from serial number 3082 to 3737 77832 Genie S 80 and S 85 Service Manual from serial number 3738 to 5380 111165 Genie S 80 and S 85 Service Manual from serial number 5381 to 7999 122149 Copyright O 2011 Terex Corporation 122985 Rev D February 2012 Seventh Edition Fourth Printing Genie and S are registered trademarks of Terex South Dakota Inc in the USA and many other countries 4 Printed on recycled paper Printed in U S A S 80 5 85 S 80X Part No 122985 September 2015 Revision History Revision Date Section Procedure Schematic Page Description 22012 3 1 3 51 4 3 to 4 6 4 18 92015 2 1 Section 2 Specifications Page Electronic Version 3 3 Section3 Maintenance Procedure Page 4 48 Section4 Repair Procedure Pag
288. and S 85 ANSI CSA AS Deutz TD2011L04 Models A SNOILOANNOO 1 1 aNnou9 OL q8racog uo a 6sal Ma 1d anas AND UI WH H8 1 1 9 260 5 1951 L ESX HM 4 1951 01 08 assral qu uo LH QH HM 1 2951 qiqi qu 9 00 7 G 8 qza8l g 6 AR 9 0 0881 asaL Au Nd Qavva oig H9 qviar Ho astaLl 49 40 01 WSI HM 22 9 duY 06901 2861 L 1 21 L cdo du 6281 2 1551 S8 tv HO HH 9 1 81 2281 1 08 dOLS 3 ON ON RA 91 90 08 v c9S L QH HM q98 L QH HM c 9S1 dH 914 91 08 1 q8rral Ho 961 CwH ug Joc 98 S8 8 18 ES0504D
289. ard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks Part No 122985 Genie S 80 S 85 0 PLATFORM COMPONENTS 2 4 Platform Overload System How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Section 4 Repair Procedures September 2015 PLATFORM COMPONENTS 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and t
290. are closed remove the key from the key switch and tag the machine to inform personnel of the condition 1 open closed Genie Part No 122985 S 80 S 85 0 4 39 Section 4 Repair Procedures September 2015 HYDRAULIC PUMPS 7 2 2 Close the two hydraulic tank valves located at the hydraulic tank Drive Pump 0 The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wire harness at the electronic displacement controller EDC located on the drive pump Component damage hazard Th
291. art No 122985 S 80 S 85 8 September 2015 Section 4 Repair Procedures MANIFOLDS L 7 Genie S 80 S 85 0 Part No 122985 56 September 2015 Section 4 Repair Procedures eee LL LL LLL MANIFOLDS 8 11 Drive Oil Diverter Manifold Components welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Directional Valve Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice disc 0 031 inch 0 8 Delays shift to drive 3 Solenoid valve CW uis Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Pressure switch Oy Power to relay 16 ft lbs 22 Nm 6 CONNECTOR u eng EURER EEE For pressure switch 11 ft Ibs 15 Nm 7 Check OY auus Prevents oil to generator 35 40 ft lbs 47 54 Nm Genie Part No 122985 S 80 S 85 0 4 57 Section 4 Repair Procedures September 2015 MANIFOLDS
292. ations Manifold Component Specifications Platform rotator 1 8 center bolt GR 5 lubricated 480 ft lbs Plugtorque 651 No 2 50 in Ibs 6 Nm 3 8 16 bolts GR 8 35 ft Ibs use blue thread locking compound 47 SAE No 4 14 ft Ibs 18 9 Nm Turntable rotate assembly SAE No 6 23 Rare en Rotate bearing mounting bolts lubricated 180 ft Ibts No 8 poe SENM 244NM SAE No 10 62 ft lbs 84 1 Nm Rotate drive hub mounting bolts lubricated 80 ft lbs SAE No 12 84 ft lbs 113 9 Nm 108 Nm Backlash plate mounting bolts lubricated 280 ft lbs 379 Nm Drive motor and hubs Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft Ibs use blue thread locking compound 217 Nm Drive motor mounting bolts dry 110 ft Ibs 149 Nm Drive motor mounting bolts lubricated 80 ft Ibs use blue thread locking compound 108 Nm Drive hub oil plug O ring seal 13 ft Ibs 18 Nm Genie S 80 S 85 S 80X Part No 122985 September 2015 Section 2 Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SA
293. bearing is worn and needs to be replaced 8 Fully retract the boom and raise the boom to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine 3 52 S 80 S 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures D 5 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING
294. ble break limit switch Component damage hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the boom Note During removal of the extension cylinder the overhead crane strap will need to be carefully adjusted for proper balancing Genie S 80 S 85 0 4 5 Boom Extend Retract Cables How to Adjust the Boom Extend Retract Cables The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Proper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise Note Perform this procedure with the boom ina horizontal position 1 Start the engine from the Ground Controls 2 Raise the boom to a horizontal position 3 Fully retract the boom 4 Stopthe engine 5 Remove the boom end cover retaining fasteners and remove the cover 6 Inspect the threaded ends of the boom extend cables The threads must be clean and in good condition with no damaged threads Part No 122985 September 2015 Section 4 Repair Procedures 7 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom Loosen the nut but do not remove the nut 8 L
295. c No Description Item Function Torque 1 Relief valve 280 psi 19 3 bar DE Charge pressure circuit 35 40 ft lbs 48 54 Nm 2 Flow divider combiner valve DB Controls flow to non steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 3 Check DF Steer end drive motor circuit 35 40 ft lbs 48 54 Nm 4 Check valve DO Non steer end drive motor circuit 35 40 ft lbs 48 54 Nm 5 Flow divider combiner valve uu Controls flow to flow divider combiner valves 19 80 90 ft lbs 108 122 Nm 6 CHECK scenic DD Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm DE us Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm DA Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm Equalizes pressure on both sides of flow divider combiner valve 13 10 Check DG Steer end drive motor circuit 60 70 ft lbs 81 95 Nm 11 Check valve rit DH Steer end drive motor circuit 35 40 ft Ibs 48 54 Nm 12 Shuttle valve
296. c 99 90 99 vrele SNOOV3 amp HM 9 HO 61 59 290 7 820 GH HO 991 890 9 6951 GH HO 0 gt 2 260 a o N A 2 2 T 5 a 6 6 E z og 508181 8 Ol Ma 6 gt cla 2 68461 41 D ole 9 1951 9 rae 8 1 820 8 4 E 2 og Oeealog r a oj 9 976181 qu 1 HARNESS TO SWITCH PANEL PartNo 122985 CABLE RESTRAINT wo S 80 S 85 S 80X G ES503D 6 62 Section 6 Schematics September 2015 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins 804D 33 Models C SNOILOANNOO OL 081981 9 006981 ANLS 080 0 08 9 260 1951 I LSY HM raw 1951 1 1 4 assral dqu do 8904 v m 2951 LH QH HM 0881 89 Gral HM 191 9 VLU HNVQH 9 17 Gqeg g ad azaLNd 9 0881 2951
297. ce 8 If TURNTABLE ROTATE 6 1 54 rp TURNTABLE ROTATE mE 4 19 5518 git cow i 3 AQ K TURNTABLE ROTATE 0 g eis 2 5 ES 5 n 5 TURNTABLE ROTATE C6TRF WH RD A 05 PETS FLOW CONTROL ig z f 7 88885 C61 Sinus HD gt fl PRIMARY BOOM 55 8 00 UP PRIMARY BOOM 8 amp 838 M B 8E DOWN lt C2PBD RD BK gt m V EM BOUM 38 5 e a i E PRIMARY BOOM 5 28 RD WH 4 UP DOWN 5 FLOW CONTROL oz Ay C3 1 x CIPBU RD 129 RD BK DESCENT ALARM lt 6 I 3 C32 C2PBD RD BK 5 7 C3 3 8 5 222 TIE 8 RD WH LONE 5 GROUND 5 gt C3 9 C9PER BK RD 88542 cs C8PBR BKIWH m 2 C37 mac C7PBE BK b 5 da 987 RD BR gt PRIMARY BOOM 84 ET 4 T EXTEND um E L PRIMARY BOOM m lt RETRACT 1 C6 8 BRA gt PRIMARY BOOM 5 23 3 54 0 ae 5 gru 7 7 C6 0 z PRIMARY BOOM BK RD EXTEND RETRACT gt 2358 FLOW CONTROL 8 5825 8 5 ncs H5 lt z mE C30E
298. ced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a models with o ring plugs Part No 122985 Genie S 80 S 85 0 CHECKLIST A PROCEDURES 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Install the plugs 5 Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications 6 Repeat steps 1 through 4 for the other drive hub 7 Checkthe torque of the drive hub mounting bolts Refer to Section 2 Specifications Turntable rotate drive hub Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor 3 Attach a suitable lifting device to the lifting eyes located near the drive motor Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES 4 Remove the drive hub mounting
299. ced and fall when removed from the machine 19 Attach a lifting strap from an overhead crane to the cable track 20 Remove the mounting fasteners that attach the lower cable track to the boom 21 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Component damage hazard The cable track can be damaged if it is twisted Section 4 Repair Procedures September 2015 BOOM COMPONENTS How to Repair the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Industries Service Parts Department part no 77896 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 4 20 5
300. ch 059 FILTER ENABLE VALVE d woa L P 1 7 Lg BB BD 2 J 108 ge SR PR2 PRI d HIGH PRESSURE Pod I I i I FILTER i Pa ly N DRIVE PUMP 0 030 inch RC RI 4 gt lt 6 4 es BG 1 2 GaS me MASTER BRAKE 2SPEED Ta e V2 CYLINDER SEE MEE EE NAE B 5 M2 iX 102 psi i eee 1 7 250 psi B PLM1 PLS1 PLS2 PLM2 PR2 PRI 1 J2 loss 17 i la pe L 4 F3 1 LM ED ri x P2 s Al PN PRESS E 11 ol 5 Th ate 3 2900 psi 221 HEX t t gt lt 200 bar 01 1790m oS 9 4 n oe r 2400 ps E E EE ER x AUXILIARY PT ST PIE gg br T lee amp WATS TIDE T PUMP 3200 psil i pou e IK SB 4 4 221 torum 17 80 EA Eg Wu 1 ss X E ADT SN 5200 pel 0 3
301. cylinder rod end pivot pin and the rotator pivot pin Section 4 Repair Procedures September 2015 PLATFORM COMPONENTS 8 Use a soft metal drift to remove both pivot pins Remove the platform rotator from the machine Crushing hazard The platform ACAUTION rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications Refer to Section 2 Specifications S 85 9 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 10 Support the jib boom leveling arms 11 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Bodily injury hazard The jib boom ACAUTION leveling arms may fall if not properly supported 12 Lower the jib boom leveling arms Crushing hazard The platform ACAUTION rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications Refer to Section 2 Specifications Genie S 80 S 85 0 How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle Switch to the right then the left through two
302. d Note When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated See 1 2 How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Pushin the Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted to the inside of the platform control box AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 Attach a grounded wrist strap to the ground screw inside the platform control box Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5 Carefully disconnect the wire connectors from the circuit board 6 Remove the ALC 500 circuit board mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box Part No 122985 September 2015 Section 4 Repair Procedures 1 2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control If a joystick is disconnected or replaced it must be calibrated
303. d may cause component damage AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Open the turntable cover at the engine side of the machine 2 Remove the engine tray retaining fastener Swing the engine tray out away from the machine a engine tray anchor hole b engine tray retaining fastener Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES 3 Locate the engine tray anchor hole on the turntable 4 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 5 Inspect the following areas for burnt chafed corroded pinched and loose wires Engine wiring harness 6 Open the turntable cover at the ground controls side of the machine 7 Inspect the following areas for burnt chafed corroded pinched and loose wires Battery area wiring Inside the ground control box Hydraulic manifold wiring Hydraulic oil cooler wiring 8 Inspect for a liberal coating of dielectric grease in the following locations All wire harness connectors to ground control box 9 Startthe engine from the ground controls and raise the boom above the turntable covers
304. d of the boom visually inspect the boom extend cables for even cable droop or sag Note If the boom extend cables are uneven tighten the boom extend cable adjustment nut at the pivot end of the boom for the appropriate cable 6 375 inches 16 2 cm N Illustration 1 Section 4 Repair Procedures September 2015 BOOM COMPONENTS 17 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm is centered in the notch of the pivot plate Note If the boom extend cables are adjusted evenly the wheel of the limit switch arm should be centered in the notch of the pivot plate Illustration 2 a cable break limit switch b extend cable adjustment nut extend cable pivot plate 18 Install the boom end cover at the pivot end of the boom 19 Fully retract and lower the boom to the stowed position Genie S 80 S 85 0 How to Replace the Boom Extend Retract Cables Note The cable pulleys must also be replaced when replacing the cables 1 Remove the boom extension cylinder See Section 4 4 How to Remove the Boom Extension Cylinder Boom extend cables 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pi
305. e Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 5 Section 6 Schematic Page Genie PartNo 122985 S 80 S 85 S 80X September 2015 REVISION HISTORY CONTINUED r Procedure Schematic Page Description 2 1_Section 2_Specifications Page Electronic Version 3 3_Section 3_Maintenance Procedure Page 4 48_Section4_Repair Procedure Page Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 5 Section 6 Schematic Page Genie S 80 S 85 5 80 PartNo 122985 September 2015 Serial Number Legend Genie A TEREX BRAND Model S 80 Serial number 58008 12345 Model year 2006 Manufacture date 01 05 06 Electrical schematic number ES503 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 16 670 Maximum allowable inclination of the chassis 0 deg S80 08 12345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 80 ft 24 4 m Maximum platform reach 71 ft 6 in 21 8m Gradeability N A Country of manufacture USA This machine complies with Model Sequence number Model year Terex South Dakota 500 Oak Wood road PO Box 1150 Watertown SD 57201 USA Serial label Sequence number located under cover
306. e Boom 1 Start the engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad if itis less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes Boom wear pad specifications Minimum Boom number one Bottom wear pads 1 2 inch extension end of boom 12 7 mm Top and side wear pads 5 8 inch extension end of boom 15 9 mm Boom number two Top bottom and side wear pads 1 e inch extension end of boom 12 7 mm Bottom wear pads 1 e inch pivot end of boom 12 7 mm Top and side wear pads 5 8 inch pivot end of boom 15 9 mm Boom number three Top bottom and side wear pads 1 e inch pivot end of boom 12 7 mm boom 1 boom 2 boom 3 Genie S 80 5 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures D 2 Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to saf
307. e engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed Genie 4 40 S 80 S 85 0 Part No 122985 September 2015 Section 4 Repair Procedures 3 Tag disconnect and plug the hydraulic hoses from the drive and function pumps Cap the fittings on the pumps AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump assembly from the machine Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Note Before installing the pump verify proper pump coupler spacing See 5 2 Flex Plate HYDRAULIC PUMPS How to Prime the Pump Component damage hazard Be sure that the hydraulic tank shutoff valves if equipped are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damag
308. e procedure See 12 2 How to Remove a Drive Motor 13 2 Drive Hub How to Remove a Drive Hub This procedure is the same as the steer axle procedure See 12 3 How to Remove a Drive Hub Genie 4 72 5 80 S 85 S 80X Part No 122985 September 2015 Section 4 Repair Procedures Oscillating Axle Components 14 1 Tag disconnect and plug the oscillating axle Oscillate Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain a level chassis while driving over uneven terrain The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillate Axle Cylinder Note Perform this procedure on firm level surface with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires 2 Remove the fasteners from the drive chassis cover at the steer end Remove the cover Part No 122985 Genie S 80 S 85 0 cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connecti
309. e 4 PLATFORM ROTATE CCW 5 80 5 85 S 80X Part No 122985 September 2015 Section 6 Schematics m m 7 m Y oo z nr Electrical Schematic S 80X Deutz TD2011L04I Models 6 47 6 48 September 2015 Section 6 Schematics ER Ground Control Box Terminal Strip Wiring Diagram S 80X Deutz TD2011L04I Models 49 GROUND STUD ENGINE C5 FUNCTIONS C6 18 22 CABLE C2B 16 22 CABLE C7B 2 3 12V TO PLAT CABLE RESTRAINT September 2015 C PartNo 122985 m lt iz Ba 36 a 8 5 15 gt ul 5 JRE B 5 58 a lt x 55 E 210 10 lt lt 5 lt lt 916 lt 2 zu Elo ulg 5 5 86 e
310. e first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second Note When the red LED is flashing the code the yellow LED will be on solid 4 Determine the error type The yellow LED indidates the error type and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second Note When the yellow LED is flashing the code the red LED will be on solid 5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected PartNo 122985 Section 5 Fault Codes September 2015 FAULT CODES Value at 5V Value too high Value too low Value at OV Value too high Value too low Not calibrated Value at 5V Value too high Value too low Value at OV Not calibrated Invalid setup Angle sensor Function is inoperative Alarm sounds indicating a fault Valve is operating outside of limits Alarm sounds indicating a fault Valve is operating outside of limits Alarm sounds Normalfunction exceptthreshold for one or both directions is zero Reduced speed function Alarm sounds indicating a fault Cycle power off then on after problem has been corrected problem has been correted Cycle power off th
311. e indicator light should turn on and remain on while the boom is anywhere in the range shown 4 Slowly move the drive control handle off center Result The drive function should not operate 5 Rotate the turntable until the boom moves past the other non steer wheel Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 6 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center Result The drive function should operate AWARNING Collision hazard Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel Note When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved Blue 4 Yellow B 18 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 7 Confirm the Pro
312. e inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of four years or in compliance with employer jobsite and governmental regulations and requirements Part No 122985 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2011 Terex Corporation Genie is a registered trademark of Terex South Dakota Inc 133192 RevD Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882
313. e machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge could result in death or serious injury and property damage Collision hazard Select a work site AWARNING that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Non steer wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer wheels 3 Lift the wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub I disengaged position md engaged position Part No 122985 Genie S 80 S 85 0 CHECKLIST D PROCEDURES 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks llision h es AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Steer wheels 4WD models 7 Chockthe non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capaci
314. e platform O Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Part No 122985 Genie S 80 S 85 S 80X CHECKLIST C PROCEDURES 14 Start the engine and test all machine functions from the ground controls O Result All ground control functions should operate normally 15 Turn the key switch to platform control 16 Test all machine functions from the platform controls O Result All platform control functions should operate Note If the platform overload system is not operating properly Referto Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped 17 Push in the red Emergency stop button at the platform to shut off engine 18 Using a suitable lifting device remove all test weights from the platform 19 Pull out the red Emergency stop button to the on position at the platform controls 20 Remove the fasteners securing the lid to the platform controls Using Illustration 2 as a guide locate the timer relay inside the platform control box Tag and disconnect the red wire from terminal 5 on the timer relay Terminal 5 NN Illustration 2 Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 21 Using Illustration 3 as a guide locate D31 Valve Power LED on the ALC500 printed circuit board _ Valve Power LED ALC 500 Board s Sl
315. e will occur Connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump Continental models If equipped close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select toggle switch to the LPG position Deutz and Perkins models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 300 psi 20 7 bar Continental models If equipped connect the LPG hose to the LPG tank and open the valve on the tank Deutz and Perkins models Connect the engine wiring harness to the fuel solenoid Start the engine from the ground controls and check for hydraulic leaks Genie PartNo 122985 S 80 S 85 S 80X 4 41 Section 4 Repair Procedures September 2015 Manifolds 8 1 Function Manifold Components The function manifold assembly is located on the tank side tray behind the ground control box Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way SJ BOOM UP 50 55 ft lbs 68 75 Nm 2 Solenoid valve 2 position 3 way 6 Boom 30 35 ft lbs 41 47 Nm 3 Solenoid valve NO Poppet Extend niente nettes 33 37 ft Ibs 45 50 Nm 4 Solenoid valve NO Poppet SQ Renac a 33 37 ft lb
316. e with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 122985 Genie S 80 S 85 0 4 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a Suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend 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 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate
317. ecure the engine tray from moving could result in death or serious injury Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES 3 Remove the fasteners from the engine side cover then remove the cover 4 Inspect the oil cooler for leaks and physical damage a oilcooler b cylinder head cooling fins 0 fan blower fins 5 Clean the oil cooler of debris and foreign material Cooling and fan blower fins 6 Inspect the fan blower fins for physical damage 7 Cleanthe fan blower fins of debris and foreign material 8 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 9 Clean the cylinder head cooling passages of debris and foreign material 10 Install the engine side cover 11 Swing the engine back to its original position and install the engine pivot plate retaining fastener Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B 7 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect to be sure itis in the enga
318. eduled Maintenance Procedures Checklist C Procedures C 1 C 2 Perform Engine Maintenance Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner s Manual Genie part number 111901 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification To access the engine 1 Remove the engine tray retaining fastener
319. efer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Genie 3 40 S 80 5 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures 7 Using a suitable lifting device remove the test weights restart the engine and carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should sound the engine should shut off and the platform overload indicator lights should be flashing at both the ground and platform controls W Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash the alarm sounds and the engine shuts off 8 Test all machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls O Result All ground control functions should not operate 11 Activate the auxiliary power toggle switch 12 Using auxiliary power test all machine functions from the ground controls O Result All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from th
320. en 0 9999 EEE CL BM lt 35 and RPM between 0 9999 p and MAP between 0 99 psi Catalyst Gasoline Cat Monitor EGO2 RMS gt 0 005 phi and EGO2 Monitor RMS gt EGO1 RMS 50 and EGO2 RMS gt CL waveform RMS 50 LPG Cat Monitor EGO2 RMS gt 0 005 phi and EGO2 RMS gt EGO1 RMS 50 and EGO2 RMS gt CL waveform RMS 50 FAULT CODES Fault Conditions c 5 3 Slo 5 Bla Sis clo 6 lt x 0 o 5 o gt Adaptive Learn Key Cycle Continued on next page Genie Part No 122985 S 80 S 85 S 80X 5 9 Section 5 Fault Codes September 2015 FAULT CODES System Fault Name EGO EGO Open Lazy Pre cat 1 Sensors EGO Open Lazy Post cat 1 Injectors Injector Loop Open or Injector off state low side 4 vdc Low Side Short to Ground and battery voltage 9 vdc Injector Coil Shorted Y Injector on state low side 4 vdc and battery voltage 16 vdc Power Relay Control Ground Shot Relay 685 ReayColShot 2 Control 687 RelayColShottoPw Fault Conditions EGO cold persistently gt 120 seconds EGO cold persistently gt 120 seconds lt lt Adaptive Learn KC Shutdown lt MEM Lx LL coil 11111 Tach 2618 Output Ground Shot jDoesnottumonMILL Output 2619 Tach Output ShorttoPpwr
321. en on after problem has been Cycle power off then on after problem has been corrected Calibrate angle sensor as Continued on next page Genie PartNo 122985 S 80 5 85 S 80X 5 3 Section 5 Fault Codes September 2015 FAULT CODES inoperative Value too low Alarm sounds Value at 0V indicating a fault Valve is operating outside of limits Alarm sounds indicating a fault Value too high Valve is operating outside of limits Alarm sounds Not calibrated Normalfunction exceptthreshold for one or both directions is zero Invalid setup Value at 5V Limited speed Value too high and direction Value too low frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after problem has been corrected Cycle power off then on after problem has been correted Cycle power off then on after problem has been Cycle power off then on after problem has been corrected Calibrate joystick Genie 5 4 S 80 S 85 0 PartNo 122985 September 2015 Section 5 Fault Codes Limited direction Frozen at zero and neutral Alarm sounds indicating a fault Value too high Limited speed Value too low and direction Frozen at zero Not calibrated Normalfunction exceptthreshold for one or both directions is zero Drive enable override direction Value at 5V Limited speed and direction Frozen at zero and neutral Alarm
322. en the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Open the engine side turntable cover 2 Start the engine from the ground controls 3 Change the engine idle to high rpm rabbit symbol 4 Visually inspect the filter condition indicator Result The filter condition indicator should be operating with the plunger in the green area Result If the indicator displays the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See D 6 Heplace the Hyaraulic Filters Genie S 80 S 85 S 80X A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage whichever comes first After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures e A 10 Grease the Turntable Rotation Bearing and Rotate Gear B 8 Inspectthe Tires Wheels and Lug Nut Torque e B 9 Check the Drive Hub Oil Level and Fastener Torque B 24 Inspect the Boom Extend Retract Cables 0 4 Checkthe Turnable Rotation Bearing Bolts D 7 Replace the Hydraulic Filter Elements PartNo 122985 September 2015 Section 3 Scheduled Maintenance Procedures A 8 Perfo
323. enie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a models with o ring plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Install the plugs 5 Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures 6 Repeat steps 1 through 4 for the other drive hub 7 Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications Turntable rotate drive hub Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin Note
324. eplacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank Refer to Repair Procedure 9 1 How to Hemove the Fuel Tank Part No 122985 Genie S 80 S 85 0 2 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications Models with hydraulic tank shutoff valves Close the two hydraulic tank valves located at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 3 Remove the drain plug from the hydraulic tank open closed and completely drain the tank into a suitable container Refer t
325. eptember 2015 E C3 DT06 12SC COLOR CIRCUIT RD RD BK RD WH WH WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL WH C1PBU C2PBD C3PBF C4TRL C5TRR C6TRF C7PBE C8PBR C9PERF C132PLI2 C59CNK C133PLA P109LS C4 DT06 12SD COLOR CIRCUIT PIN BL RD OR OR BK OR RD GR GR BK GR WH RD OR OR GR LT BR C13DRE C14PLU C15PLD V155PCE C17PRL C18PRR C43JU C44JD C49DLITE SPARE PLUG PLUG C3 GREEN CE MODEL CE MODEL S 80X MODEL C4 BROWN S 80 S 85 S 80X PartNo 122985 C6 FUNCTION MANIFOLD PIN CIRCUIT COLOR 1 C1PBU RD 2 C2PBD RD BK 3 C3PBF RD WH 4 C4TRL WH 5 5 WH BK 6 C6TRF WH RD 7 BK 8 C8PBR BK WH 9 BK RD 10 11 C59CNK BL BK 12 P210PWR BK 13 C13DRE BL RD 14 15 16 C109LS GR WH 17 18 19 20 21 17715 BL RD 22 C42LS OR RD 23 P134PWR A RD 24 P134PWR B RD 25 P134PWR C RD 26 27 28 C28TTA RD BK 29 so C211LO BL BK 31 C118LSR OR 32 33 C123PBS RD BK 94 SNSRGND 35 P109ANG GR WH 36 C36STC BL 37 0 BL BK 38 C212LO GR BK 39 C45GEN GR WH 40 C40LS OR S 80X MODEL S 80X MODEL S 80X MODEL S 80X MODEL S 80X MODEL
326. er 8 6 Oil cooler and fins Machine owner 5 axle Deutz models Inspected by print A 6 Filter condition indicator B 7 Brake configuration Perform after 40 hours B 8 Tires wheels and Inspector signature A 7 30 day service lug nut torque Perform after 50 hours B 9 Drive hub maintenance Inspector title A 8 Engine maintenance B 10 Engine RPM Inspector company and Continental B 11 Engine maintenance MOHS B 12 Oscillate directional Instructions Perform every 100 hours Control Make copies of this report to use for 9 Inspect filter separator B 13 Ground control each inspection Diesel models override Select the appropriate checklist s for A 10 Grease rotation B 14 Platform self leveling the type of inspection to be bearing B 15 Engine idle select performed A 11 Engine maintenance B 16 Fuel select operation Daily or 8 hour Perform after 150 hours B 17 Drive enable system ion A 12 Repl Dri Hub Inspection A eplace oi B 18 Drive brakes Quarterly or 250 hour error every 19 Drive speed stowed Inspection A B A 13 Engine maintenance B 20 Drive speed raised Six Month or 500 hour Perkins models Grextendad Inspection A B C B 21 Alarm package and Annual or 1000 hour descent alarm inspection B 22 Fuel and hydraulic tank 2 Year or 2000 hour venting systems Inspection A B4C D E B 23 Hydraulic oil analysis e Place a check in the appropriate box B 24 I
327. er 102 psi bypass pressure 7 bar Medium pressure filter Beta 3 200 Medium pressure filter 51 psi bypass pressure 3 5 bar 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Genie S 80 S 85 S 80X Valve Coil Resistance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 8 that your air temperature increases or decreases from 68 F 20 C Valve coil resistance specifications Proportional solenoid valve 3 7 Q schematic items SE Proportional solenoid valve 480 schematic items SR SF 2 position 3 way solenoid valve 410 schematic items SJ 2 position 3 way solenoid valve 9Q schematic items SK 3 position 4 way solenoid valve 720 schematic items SI and SL Solenoid valve NO Poppet 5 6 Q schematic items SP and SQ Part No 122985 September 2015 Section 2 Specifications vm SPECIFICATIONS Continental TME27 Engine Fuel Requirement For fuel requirements refer to the engine Operator s Displacement 164 cu in 2 68 liters Manual on your machine Number of cylinders 4 Electronic fuel pump Bore and stroke 3 58 4 06 inches Fuel pressure static 55 psi 91 x 103 2 mm 3 8 bar Horsepower
328. er serial number 8110 6 138 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models after serial number 8110 6 139 Electrical Schematic S 80X Continental TME27 Models 6 142 Ground Control Box Terminal Strip Wiring Diagram S 80X Continental TME27 Models seen 6 146 Ground Control Box Switch Panel Wiring Diagram S 80X Continental TME27 Models sse 6 147 Platform Control Box Wiring Diagram S 80X Continental TME27 Models sese 6 150 Platform Control Box Switch Panel Wiring Diagram S 80X Continental TME27 Models 6 151 Continental TME27 Engine 6 154 Platform Level Cutout CTE Option 01000000111 enne 6 155 Continental Options Schematic 6 158 Deutz and Perkins Options Schematic 6 159 12 kW Hydraulic Generator Wiring Diagram sese 6 162 12 kW Hydraulic Generator Electrical Schematic 6 163 Belt Driven Generator Option eene nnne nnn 6 166 Relay and Fuse Panel Legend 0 6 167 Hydraulic Schematic 2WD 6 170 Hydraulic Schematic 4WD
329. ess 1961 mamm 8 38475 2951 6 87 M8 HM 269 eeu ZL 01 18 38 8 Oza 6098100 2 7 80961140 9 7 a razoa 8 3 NOILdO LHON SAG 2 i 4 00018 _ Ovelal du 1 N e LO nio G S 80 S 85 S 80X PartNo 122985 6 146 Section 6 Schematics September 2015 Continental TME27 Models Ground Control Box Switch Panel Wiring Diagram S 80X SNOLLO3NNOO 1 OL 6881 8 18 ANLS 9 260 1 91 08 L LSM HM vay 88181 0 89da 5 Wr L4 aU HM N 881 8 Qval HM 2181 914 4 1 1651 06 00 88 v 06 68 3 asaL au Nd 21 90 v5 ro vd ON Qe DE 1 1 asraloug Ho OLFIASI HM 1 060 4 9 6 18861
330. ession pressure Pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Oil temperature switch point 284 F 140 C Oil pressure switch Oil pressure switch point 22 psi 1 5 bar Fuel injection system Injection pump make Bosch Injection pump pressure maximum15 000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel Requirement For fuel requirements refer to the engine Operator s Manual on your machine Batteries Governor centrifugal mechanical Type 12V DC Valve clearance cold 3 Group 31 Intake 0 012 in 0 3mm Quantity 1 Exhaust 0 020 in Cold cranking ampere 1000A 0 5 mm Lubrication system Reserve capacity 25A rate 200 minutes Minimum oil pressure hot 21 8 psi Alternator output PORT ARD at 1300 rpm 1 5 Fan belt deflection 3 8 to 1 2 inch Oil capacity 12 8 quarts including filter 12 1 liters Genie S 80 5 85 S 80X Part No 122985 September 2015 Section 2 Specifications Perkins 804D 33 Engine Displacement 201 cu in 3 3 liters Number of cylinders 4 Bore and stroke 3 70 x 4 72 inches 94 x 120 mm Horsepower 63 Q 2600 rpm
331. esult There should be a pause and the alarm should sound 12 times indicating that the machine is in Angle Sensor calibration mode 6 Startthe engine from the platform controls and press down the foot switch 7 Momentarily activate the drive enable toggle Switch to the right 1 time to set the stowed position Note The alarm will not sound indicating the setting 8 Raise the primary boom to the fully elevated position Part No 122985 Genie S 80 S 85 0 4 7 PLATFORM CONTROLS Note Manually reduce the boom speed as it reaches the fully elevated position 9 Momentarily activate the drive enable toggle switch to the right 1 time to set the elevated position Result The alarm will sound indicating that the angle sensor has been calibrated 10 Release the joystick and the foot switch and wait for 10 seconds Result The alarm will sound indicating that the settings have been saved and is leaving calibration mode 11 Cycle the red Emergency Stop button off then back on Start the machine and return to the stowed position Section 4 Repair Procedures September 2015 By This page intentionally left blank Genie 4 8 S 80 S 85 S 80X Part No 122985 September 2015 Section 4 Repair Procedures Platform Components 2 1 7 Support and secure the platform to an Platform appropriate lifting device 8 Remove the platform mounting fasteners and How to Remove the Plat
332. f the number 3 boom tube 15 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 16 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 17 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder 18 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom 19 Use a soft metal drift to remove the pin 20 Tag disconnect and plug the boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures September 2015 BOOM COMPONENTS 21 Attach a lifting strap from a 5 ton 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder 22 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube 23 Carefully support and slide the extension cylinder out of the boom AWARNING Crushing hazard The extension cylinder could fall when removed from the boom if not properly supported Component damage hazard Be careful not to damage the ca
333. fer to Repair Procedure 1 2 How to Calibrate the Boom angle Sensor Genie CHECKLIST C PROCEDURES Move the primary boom down joystick off center and retract the primary boom until the unrestricted platform capacity light stops flashing Result Primary boom down should return to normal operation Lower the primary boom 5 feet 1 5 m and activate primary boom extend Result Primary boom extend will stop and the unrestricated platform capacity light will start flashing Activate primary boom extend and raise the primary boom until the unrestricated platform capacity light stops flashing Result Primary boom extend should return to normal operation Return the machine to the fully stowed position Part No 122985 S 80 S 85 S 80X 3 47 Section 3 Scheduled Maintenance Procedures September 2015 Checklist D Procedures D 1 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions Note If the wear pads are still within specification refer to Repair Procedure 4 2 How to Shim th
334. form remove the platform from the machine 1 Remove the cable clamp from the top of the AWARNING platform mounting weldment 2 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side Do not disconnect the wiring Remove the foot switch mounting fasteners 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals 5 Tag and disconnect the foot switch wiring from the foot switch Remove the cable from the back of the platform Electrocution burn hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the platform control box mounting fasteners Lower the control box and set it aside Component damage hazard Cables can be damaged if they are kinked or pinched Note If your machine is equipped with an airline to platform option the airline must be disconnected from the platform before removal Crushing hazard The platform could become unstable and fall when it is removed from the machine if not properly supported Genie Part No 122985 S 80 S 85 0 Section 4 Repair Procedures September 2015 PLATFORM COMPONENTS 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform
335. g 5 4988 o F 8600 ceo r oxe 5 u cmm Ne 2 5 otsal 8 le 5 0998206 Z 5 anis u 518 91951 9 a 15 razoa 6 5 5 LN D 088818 vezal 7 6 1 80 80 HW Ground Control Box Terminal Strip Wiring Diagram S 80X Deutz TD2011L04I Models Section 6 Schematics wo S 80 S 85 S 80X G 6 50 Section 6 Schematics September 2015 Deutz TD201 1LO4l Models Ground Control Box Switch Panel Wiring Diagram S 80X SNOILO3NNOO OL 08181 1 anas 1 9 65 1 3 1951 L LSX HM 1488 4 088 81 0 QS8 L518 HM 2951 78 06 28 8 8 06 68 38 9 0 0 881 2L 90 r Yd ON ON Qe 26 97194 90 1861 290 6951
336. g bolts in sequence to 46 7 ft lbs 63 3 Nm 2 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 3 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm 4 Install the pump onto the pump mounting plate 4 36 5 80 S 85 S 80X Genie Apply Loctite removable thread sealant to the pump retaining fasteners Torque the pump retaining fasteners to 57 ft lbs 77 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine Install the pump and pump mounting plate assembly onto the engine Apply Loctite removable thread sealant to the mounting screws Perkins model Torque the pump mounting plate fasteners in sequence to 28 ft lbs 38 Nm Deutz model Torque the pump mounting plate fasteners in sequence to 46 7 ft lbs 63 3 Nm Continental model Torque the pump mounting plate fasteners in sequence to 23 ft Ibs 31 2 Nm Component damage hazard When installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Component damage hazard Do not force the drive pump during
337. ged position o disengaged position ar f 2 1 engaged position Genie S 80 S 85 S 80X B 8 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result 8 machine tip over Component damage may also result if problems are not discovered and repairedina timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could result in death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the pressure in each air filled tire Add air as necessary Refer to Section 2 Specifications Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 9 Check Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours Failure to maintain proper d
338. get into machine components and cause damage other lifting 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 45 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 any forklift overhead crane or Be sure fasteners intended for one Be sure properly dispose of old oil or 2 other fluids Use approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Part No 122985 September 2015 Table of Contents Introduction Important Information 0 nnns entren enn li SerialNumberLegend nennen nnne nennen ennt nennen enirn enn iii Section 1 Safety Rules General Safety RUES u u una a W aka SR i aeai Section2 Rev Specifications 00 2 1 Performance Specifications 2 2 Hydraulic Oil Specifications 2 2 Hydraulic Component Specifications 2 3 Valve Coil Resistance 1 2 4 Continental TME27 Engine Specifications
339. go 2 o 6 GRIEK RA6HRN GR SERVICE HORN C7 1 1 fo V e B T K 5 52 OIL COOLER TEMP SWITCH 1 12 C BUWH ossi 0 Ml WH at C2 6 8 a a K RD gt 52 1 MD OIL COLLER FAN en s OR OPTION 1 1001 E PD 134 RD 4 I FLASHING BEACONS 4 lt OPTION 8 ale I 4 P134FB RD gy 1f E Q 5 M d C52 H Ba CA1RPM 52 4 Qe BE a 42 Je aM erus jezi N a 8 i 55 e 188 E 15 ALTERNATOR 95 AUX MAIN T 1 6 15 zef H BATTERY BP lt 2 2 SEPERATOR ns 5 ia 8 1 4 9 1 RD START BATTERY 5 9 x og 8 RD 3 CONTROL BATTERY 5 PartNo 122985 S 80 S 85 S 80X 6 10 Section 6 Schematics Deutz TD201 1LO4l Models Electrical Schematic S 80 and S 85 ANSI CSA AS September 2015
340. h 7 l 1 8 I Ic gl dmm 5 E 1 77 u NE t de 4 ole cs E N E la 4 Leet 8 M1 1 ot A i m LEFT bg OUT T lB i HS0166C TS UE og OSCILLATE CYLINDERS TRACTION MANIFOLD E gt lt E gt j OSCILLATE VALVE Genie Part No 122985 S 80 S 85 S 80X 6 171 September 2015 Section 6 Schematics mM n Hydraulic Schematic 4WD Models 6 171 6 172 September 2015 Section 6 Schematics sO 12 kW Hydraulic Generator Hydraulic Schematic H G F E D C B A 277 5212 1 is CNET 1 B OILCOOLER 3 5 GPM 13 25Umin DRIVE PUMP CASE fl te 1 2 PMP CLR PMP A E WELDER MANIFOLD 3 cw N W 0 031 inch Gv 079mm 4 PRESSURE SWITCH gt 12 1777 MEE EE 1 200 PSI 13 8 BAR 4 N O CU 2 1210 12 81 7 CX 0 p 21 CZ 270 PSI 18 6 BAR MM 3 5 13 25 L min 5 G2 MTR
341. h Panel Wiring Diagram S 80X Perkins 804D 33 Models 6 99 6 100 Section 6 Schematics September 2015 III m Platform Control Box Wiring Diagram S 80X Perkins804D 33 Models 6 101 6 102 September 2015 Section 6 Schematics Platform Control Box Wiring Diagram S 80X Perkins 804D 33 Models CONTROL HARNESS TO PLATFORM SWITCH PANEL TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 MEE TS48 C49DLITE WH BK C4P 9 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 J8 P109LS GR WH C3P 12 L47 C59CNK BL BK C3P 11 J1 SNSR GND BR C1P 10 J1 P109ANG GR WH C2P 9 P3 C46HRN GR C2P 5 TS47 C45GEN C2P 7 1 C40LS OR C2P 2 WH RD C3P 6 C123PBS RD BK C2P 8 C7PBE BK C3P 7 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2
342. h or serious injury Genie S 80 S 85 S 80X B 12 Check the Oscillate Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper axle oscillation is essential to safe machine operation If the oscillate directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover from the non steer end of the machine 2 Locate the oscillate directional valve inside of the non steer axle and inspect the linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed e Cotter pins are installed through clevis pins e Linkage is properly attached to directional valve PartNo 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 13 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button at the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed positio
343. h to platform control Start the engine and level the platform Procedure 2 4 How to Calibrate the Platform Overload System if equipped 2 Determine the maximum platform capacity Using a suitable lifting device place an Refer to the machine serial plate additional 50 16 23 kg of weight onto the platform 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test Result The alarm should sound and the engine should shut off The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound the engine 4 Using a suitable lifting device place a test does not shut off and the platform overload weight equal to that of the available capacity at indicator lights are not flashing Calibrate the one of the locations shown platform overload system Refer to Repair Refer to Illustration 1 Procedure 2 4 How to Calibrate the Platform O Result The platform overload indicator lights OQUIRREN should be off at both the ground and platform Note There may be a2 second delay before the controls and the alarm should not sound overload indicator lights flash the alarm sounds Result The platform overload indicator lights are and the engine on and the alarm is sounding Calibrate the platform overload system R
344. he turntable counterweight Failure to remove the counterweight before removing the boom assembly will result in the machine tipping over Do not remove the boom without first removing the counterweight ADANGER Tlp over hazard When installing the boom onto the machine the boom assembly must be first installed prior to the installation of the counterweight If the counterweight is installed before the boom assembly the machine will tip over resulting in death or serious injury IN 71153 Tlp over hazard The turntable 1 counterweight is essential for machine stability Failure to install the counterweight after installing the boom assembly will compromise machine stability resulting in the machine tipping over Death or serious injury will result AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Remove the cable track See 4 1 How to Genie S 80 S 85 0 Remove the Cable Track Section 4 Repair Procedures September 2015 BOOM COMPONENTS 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers 4 Place a block of wood measuring 4 x 4 x 60 inches
345. he alarm does not sound Proceed to step 6 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle O Result The overload indicator lights are off at the platform and ground controls and the alarm does not sound Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds Genie S 80 S 85 0 7 Move the platform up and down by ha
346. he boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed Crushing hazard The long and ACAUTION short link arms may fall if not properly supported when the boom pivot pins are removed Genie S 80 S 85 0 4 3 Boom Lift Cylinder The boom lift cylinder raises and lowers the boom The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Lift Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position 2 Attach a 5 ton 5000 kg overhead crane to the boom at the platform end for support Do not lift the boom 3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device 4 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove
347. ications If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B 11 Perform Engine Maintenance Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in deat
348. if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the master cylinder rod end pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie 4 32 S 80 S 85 S 80X 4 Remove the pin retaining fastener from the master cylinder barrel end pivot pin 5 Place a rod through the barel end pivot pin and twist to remove the pin 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 7 Remove the pin retaining fastener from the rod end pivot pin 8 Place a rod through the rod end pivot pin and twist to remove the pin 9 Remove the master cylinder from the machine AWARNING Crushing hazard The master cylinder could become unbalanced and fall if it is not properly supported by the lifting device when removed from the machine Part No 122985 September 2015 Section 4 Repair Procedures Engines 5 1 5 2 RPM Adjustment Flex Plate Refer to Maintena
349. if not properly supported by the overhead crane resulting in death or serious injury Keep personnel away from the area when removing the counterweight 11 Attach lifting straps from a 5 ton 5000 kg overhead crane to each end of the boom Support the boom Do not apply any lifting pressure 12 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device 13 Remove the lift cylinder rod end pivot pin retaining fasteners Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom could fall if not properly supported when the lift cylinder rod end pivot pin is removed Part No 122985 September 2015 Section 4 Repair Procedures 14 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off AWARNING Crushing hazard The boom lift cylinder could fall if not properly supported and secured to the lifting device 15 Using the overhead crane carefully lower the boom lift cylinder and allow it to rest on the boom rest pad Protect the cylinder rod from damage 16 Remove the boom end cover retaining fasteners and remove the cover Part No 122985 Genie S 80 S 85 0 4 23 BOOM COMPONENTS 17 Tag disconnect and plug the boom extension cylinder hydraulic hoses Cap the fittings o
350. il 20 E RD gt g 4 P134FB RD Al y B BR FLASHING BEACONS 4 8 lt OPTION mi O 3 a 4 P134FB RD B i 5 2 9 i C41RPM ORBK 1 ag e Oy oo e 5 m gt e x2 8 5 182 5 ALTERNATOR 5 8 AUX MAIN LI E ache ne SEPERATOR ale ns Ts ERC GER e BIBAT RD START BATTERY as gt 6 E RD e CONTROL BATTERY N LO co N PartNo 122985 S 80 S 85 S 80X 6 70 Section 6 Schematics September 2015 80 and S 85 CE Perkins 804D 33 Models before serial number 81 11 Electrical Schematic S A
351. ine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on 8 firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate fault code thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil
352. injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures September 2015 Platform Controls The platform control box contains one printed circuit board The ALC 500 circuit board inside the platform control box controls all proportional machine functions from the platform The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls If a joystick error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 2 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion e a X ALC 500 circuit board b drive steer joystick controller primary boom up down extend retract and turntable rotate right left joystick controller Genie 4 2 S 80 5 85 S 80X 1 1 ALC 500 Circuit Boar
353. is not operating correctly the stability of the machine is compromised and it may tip over ADANGER Tip over hazard Failure to perform this procedure on a firm level surface will compromise the stability of the machine and could result in the machine tipping over 1 Start the engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb O Result The non steer tires should stay in firm contact with the ground Note If the chassis does not remain level during the test refer to Repair Procedure 14 2 How to Set Up the Directional Valve Linkage Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES A 6 Check the High Pressure Hydraulic Filter Condition Indicator Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show wh
354. isconnect the wire connectors from the bottom of the platform control box Note When installing the wire connectors to the bottom of the platform control box match the color of the connectors to those on the control box to be sure they are installed in the correct location 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side Genie S 80 S 85 S 80X 6 5 80 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag disconnect and plug the hydraulic hoses from the platform leveling slave cylinder at the platform manifold and cap the fittings Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Remove the timing link timing link cam pin and gently rest the timing link against the counterweight 9 S 85 Remove the hose and cable cover from the side of the jib boom 10 Tag disconnect and plug the hydraulic hoses from the jib boom platform rotate select manifold Cap
355. ive hub mounting fasteners Genie specifications require the use of new fasteners Part No 122985 Genie S 80 S 85 0 4WD STEER AXLE COMPONENTS 12 4 Steer Cylinders How to Remove a Steer Cylinder There are two identical steer cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod cylinder maintains equal movement of the tires Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the hose bracket mounting fastener on the steer cylinder barrel end pivot pin 3 Remove the pin retaining fasteners from the steer cylinder pivot pins Remove the pivot pin from each end of the steer cylinder 4 Remove the steer cylinder from the machine Section 4 Repair Procedures September 2015 Non steer Axle Components 13 1 Drive Motor How to Remove a Drive Motor This procedure is the same as the steer axl
356. l 4 Press down the foot switch and raise the boom 10 above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Genie S 80 S 85 S 80X 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Performance Specifications Note To adjust the speed refer to Repair procedure 1 2 How to Adjust the Joystick Max out Setting 8 Press down the foot switch and lower the boom to the stowed position 9 Extend the boom 3 feet 90 cm 10 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 11 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 12 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Performance Specifications Note To adjust the speed refer to Repair procedure 1 2 How to Adjust the Joystick Max out Setting Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 21 Test the Alarm Package if equipped and the Descent Alar
357. l Box Terminal Strip Wiring Diagram 5 80 and S 85 ANSI CSA AS Continental TME27 Models 6 109 6 110 GROUND STUD ENGINE FUNCTIONS 16 22 CABLE 18 22 CABLE HARNESS TO SWITCH PANEL 12V TO PLAT September 2015 PartNo 122985 C Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models Section 6 Schematics I 6 x al 5 ul 2 2 5 gt Z oz di lt zu 5 m Ore 2 21518 e 5 lt z S Es u blu 6 F 265 E ZO GSE 8 5 I 5 900 68 58 z 5828 85052088 o x 6 5 w S gt a a 23 0 00 5 S o 8 8 m O u 2 Ex 28181212 2 5 35 lt ol9loa2mnrot 6 6 lt s 21 2 25 o WIFIPIS 0 1 rk O m 5 5 5 6 5 2 lt 5 5 210 u
358. leaner canister 2 Remove the filter element 3 Usea damp cloth to wipe the filter sealing surface and the inside of the outlet tube Make sure that all contaminant is removed before the filter is inserted 4 Check new filter element gasket for damage before installing 5 Install the new filter element 6 Install the end cap on the canister and secure Note Be sure the discharge slot is pointing down Part No 122985 Genie S 80 S 85 0 CHECKLIST C PROCEDURES C 5 Replace the Fuel Filter Water Separator Element Diesel Models Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Regular replacement of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off Perkins Models 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover and locate the fuel filter water separator next to the hydrau
359. lic cylinder drive motor or hydraulic pump is replaced the max out setting should be adjusted to maintain optimum performance The max out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 Do press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch Section 4 Repair Procedures September 2015 PLATFORM CONTROLS 7 Momentarily activate the drive enable toggle switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the machine functi
360. lic return filter on the bulkhead 3 Inspectthe filter bowl for water buildup O Result If water is present in the filter bowl continue with steps 4 through 8 Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 4 Loosen the vent plug located on the fuel filter water separator head J ITS vent plug drain plug filter bowl separator head 5 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 6 Tighten the vent plug Note If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine See C 6 Replace The Fuel Filter Water Separator Element Perkins Models for instructions on how to prime the fuel filter water separator 7 Clean up any fuel that may have spilled Genie S 80 S 85 S 80X 8 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Deutz Models 1 Puton protective clothing and eye wear 2 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine
361. located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 Genie S 80 S 85 0 Chevron Ultra duty grease EP 2 lithium based or equivalent Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Illustration 1 Testing the platform overload system regularly is essential to safe machine operation Continued use 5 of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound W Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Note Perform this procedure with the machine on a firm level surface 1 Turn the key switc
362. lter water separator 7 Clean up any fuel that may have spilled Genie S 80 S 85 S 80X 8 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Deutz Models 1 Puton protective clothing and eye wear 2 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 4 Locate the fuel filter water separator next to the oil filter Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures 5 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Note Do not completely drain the filter a fuel filter water separator b drain valve 6 Clean up any fuel that may have spilled 7 Startthe engine from the ground controls and check the fuel filter water separator for leak
363. ly attached to the overhead crane Part No 122985 September 2015 Section 4 Repair Procedures 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks Part No 122985 JIB BOOM COMPONENTS S 85 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 2odily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite le
364. ly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Open the ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position Result The check engine light should turn on The check engine light should begin to blink Part No 122985 FAULT CODES 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1654 three times After the fault codes the check engine light will blink a code 1654 three times again indicating the end of the sto
365. m Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travelalarm Flashing beacons Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable rear cover Beacons are installed on both turntable covers Note The alarms and beacons will operate with the engine running or not running 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result Both flashing beacons should be on and flashing 2 Move and hold the function enable button to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down Part No 122985 CHECKLIST B PROCEDURES Turn the key switch to platform controls Result The flashing beacons should be on andflashing Press down the foot switch Move the boom controller to the down position hold for a moment and then release it Result The descent alarm should sound when the controller is held down Press down the foot switch Move the drive controller off center hold for a moment and then release it Move the drive controller off center in the opposite direction hold for a mome
366. maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Part No 122985 Genie 5 80 S 85 S 80X 3 7 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition W Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the
367. manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed daily Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 3 8 S 80 S 85 S 80X A 3 Perform Engine Maintenance Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz T
368. mum platform capacity Gr Measure between the centers of these ivot pins 4 Extend the primary boom until it is fully extended 5 Lower the primary boom until it stops Result The boom will automatically stop after 10 degrees Result The primary boom does not stop after 10 degrees Check limit switches LST30 and LST3S 6 Turn the key switch to the off position and push in the red Emergency Stop button Note The follwing step can be done using a measuring tape or a digital protractor Genie part number 58377 Genie 3 46 S 80 5 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures Platform controls 6 Note Start this procedure with the boom fully retracted and in the stowed position 1 Pull out the red Emergency Stop button to the on position and start the engine 2 Select the restricted maximum platform capacity 7 with the toggle switch 1 1000 Ibs 500 Ibs 1 454 kg 221 kg a restricted maximum platform capacity b unrestricted maximum platform capacity Raise the primary boom until it is fully elevated Extend the primary boom until it is fully extended 5 Lowerthe primary boom until it stops O Result The boom will automatically stop after 10 degrees and the unrestricted platform capacity light will flash W Result The primary boom does not stop after 10 degrees Calibrate the boom angle sensor Re
369. n 1 Pushin the red Emergency Stop button at the platform controls to the off position 2 Start the engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES B 14 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B 15 Test the Engine Idle Select Operation Genie specifications require that this procedure be performed every 250 hours or quar
370. n Use a soft metal drift to remove the pin Note When driving the pivot pin out be sure to drive it from the shaped end of the pin 5 Remove the pulley and boom extend cables from the extension cylinder assembly Discard the old cables and pulleys 6 Route the new boom extend cables through the boom extend pulley bracket 7 Install the new boom extend cable pulley pivot pin and snap rings Note Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder Part No 122985 September 2015 Section 4 Repair Procedures 8 Install the boom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube Boom retract cables 10 Remove the rue rings and clevis pins from the boom retract cables at the platform end of the boom 11 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom Note A cable pulling tool is available through Genie Service Parts Department Genie part no 94510 12 At the platform end of the boom pull on the boom retract cable that has the rope attached to it 13 Pull the old cable completely out of the boom tube Remove the rope Discard the old boom retract cable 14 Securely attach the rope to the same end of the new boom retract cable
371. n the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 18 Tag and disconnect the electrical connector for the cable break limit switch 19 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom 20 Support the platform leveling master cylinder Remove the master cylinder rod end pivot pin retaining fasteners Place a rod through the pin and twist to remove Carefully lower the master cylinder down 21 Tag disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom Cap the bulkhead fittings AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 22 Remove the external snap rings from both boom pivot pins at the short and long link arms Do not remove the pins Section 4 Repair Procedures September 2015 BOOM COMPONENTS 23 Using the overhead crane adjust the boom as necessary to relieve pressure from the pivot pins 24 Use a soft metal drift to remove each boom pivot pin Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard T
372. n the rotation motor pinion gear and the turntable bearing ring gear Note Perform this procedure with the boom between the non steer end tires and with the machine on a firm and level surface 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Loosen the backlash pivot plate mounting fasteners c gt backlash pivot plate b adjustment bolt with lock nut backlash pivot plate mounting bolts September 2015 zz Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear Loosen the lock nut on the adjustment bolt Turn the adjustment bolt clockwise until it contacts the backlash pivot plate Turn the adjustment bolt one half turn counterclockwise Tighten the lock nut on the adjustment bolt Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt Then torque the mounting fasteners on the backlash pivot plate Refer to Section 2 Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Genie 4 66 S 80 S 85 S 80X Part No 122985 September 2015 Section 4 Repair Procedures 2WD Steer Axle Components 11 1 How to Remove the Hub Yoke and Hub How to Remove the Yoke and Hub 1
373. n to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time Note Each time the drive enable toggle switch is momentarily moved the time will change in 5 increments Part No 122985 Genie S 80 S 85 0 Section 4 Repair Procedures PLATFORM CONTROLS 13 Repeat steps 9 through 11 for each joystick controlled machine function 14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time 15 Cycle the red Emergency Stop button off then back on Ramp rate factory settings Turntable rotate accelerate 3 seconds decelerate 2 second Boom up down accelerate 3 seconds decelerate 1 second Boom extend retract accelerate 2 5 seconds decelerate 1 second Drive accelerate 4 seconds decelerate to neutral 0 5 second decelerate change of direction 0 75 second decelerate coasting 1 second decelerate braking 1 second decelerate shift from low to high speed 1 second decelerate shift from high to low speed 4 seconds 4 5 Section 4 Repair Procedures September 2015 PLATFORM CONTROLS How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which
374. nce sese 3 28 B 12 Check the Oscillate Directional Valve Linkage 3 28 B 13 Testthe Ground Control Override 2 2 400 00 3 29 B 14 Test the Platform Self leveling 0 04 4 0 1000 3 29 B 15 Test the Engine Idle Select Operation 3 30 B 16 Test the Fuel Select Operation Gasoline LPG 100618 3 31 B 17 Test the Drive Enable System 3 32 B 18 Test the Drive Brakes 0 0 3 33 B 19 Test the Drive Speed Stowed Position 3 33 B 20 Testthe Drive Speed Raised or Extended Position 3 34 B 21 Testthe Alarm Package if equipped and the Descent Alarm 3 35 B 22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 36 B 23 Perform Hydraulic Oil 20 4444440 3 37 B 24 Inspect the Boom Extend Retract 3 37 Checklist C Procedures C 1 Perform Engine Maintenance Deutz and Perkins Models 3 39 C 2 Grease the Platform Overload Mechanism if equipped 3 39 C 3 Test the Platform Overload System if equipped 3 40 C 4 Replace the Engine Air Filter Element Deutz and Perkins
375. nce Procedure B 10 The flex plate acts as a coupler between the Check and Adjust the Engine RPM engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump Type B flex plates combines the pump coupler as part of the flex plate which is installed onto the engine flywheel Type B flexplate with coupler combined Genie Part No 122985 S 80 S 85 0 4 33 Section 4 Repair Procedures September 2015 ENGINES How to Remove the Flex Plate Note Perform this procedure with the engine off and cool to the touch 1 Open the engine side turntable cover 2 Tag and disconnect the battery cables from the battery s AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Remove the engine tray retaining fastener Swing the engine tray out away from the machine a engine tray anchor hole b engine tray retaining fastener 4 Tag and disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 4 34 Genie S 80 S 85 0 Deutz model 5 Tag and disconnect the wiring from the bell housing 6 Remove the U bolt from the exhaust flex pipe at the muffler ACAUTION Burn hazard Hot engine parts can cause severe burns 7 Remove the muffler bracket retaining fasteners from bell housing
376. nd so it bounces approximately 2 5 to 5 cm 1 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 8 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Add an additional 10 Ib 4 5 kg test weight to the platform O Result The overload indicator light is flashing at both the ground and platform controls and the alarm is sounding Proceed to step 9 Wi Result The overload indicator light is off at both the ground and platform controls and the alarm does not sound Remove the additional 10 Ib 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Testall machine functions from the platform controls Result All platform control functions should not operate Part No 122985 September 2015 Section 4 Repair Procedures EE e LLL LL LL LLL LLL PLATFORM COMPONENTS 10 Turn the key switch to ground control 11 Test all machine functions from the ground controls O Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform
377. nd component damage 1 Start the engine from the platform controls and extend the axles 2 Turn the key switch to ground controls 3 Raise the boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock AWARNING C ushinghazard Keep hands away from cylinder and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie Service Parts 4 Remove the center turntable cover retaining fasteners Remove the cover PartNo 122985 September 2015 Section 3 Scheduled Maintenance Procedures 5 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications 2 if gue e 21 18 13 Bolt torque sequence 6 Install the center turntable cover and tighten the retaining fasteners 7 Raise the boom and remove the safety chock 8 Lowerthe boom to the stowed position 9 Confirmthat each bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Section 2 Specifications Part No 122985 Genie S 80 S 85 0 CHECKLIST D PROCEDURES D 4 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service
378. ne Maintenance Deutz Models Engine specifications require that this procedure be performed every 1500 hours of operation Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Note Before r
379. ns 8040 33 Models 6 67 Electrical Schematic S 80 and S 85 CE Perkins 8040 33 Models before serial number 8111 6 70 Genio PartNo 122985 S 80 S 85 S 80X XV September 2015 n TABLE OF CONTENTS Section 6 Rev Schematics continued Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models before serialnumber8111 6 74 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models before serial number 8111 6 75 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models before serial number 8111 6 78 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models before serial number 8111 6 79 Electrical Schematic S 80 and S 85 CE Perkins 8040 33 Models after serial 8110 6 82 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models after serial number 8110 6 86 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 8040 33 Models after serial number 8110 6 87 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 8040 33
380. nspect the Boom after each inspection procedure is Extend Retract Cables completed e Use the step by step procedures in Comments this section to learn how to perform these inspections e If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Genie Part No 122985 S 80 S 85 5 80 3 5 Section 3 Scheduled Maintenance Procedures MAINTENANCE INSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections f any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist C Y
381. nt and then release it Result The travel alarm should sound when the drive controller is moved off center in either direction Genie S 80 S 85 S 80X 3 35 Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES B 22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off Note This procedure applies to diesel equipped machines only 1 Remove the cap from the fuel tank 2 Checkfor proper venting O Result Air passes through the fuel tank cap Procced to step 4 Result If air does not pass through the cap clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely
382. ntamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES B 24 Inspect the Boom Extend Retract Cables Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Raise the boom to horizontal and fully extend the boom 2 After the boom is fully extended lower the boom until the platform is at chest height Turn the machine off 3 Remove the boom end cover retaining fasteners and remove the cover 4 Remove the retaining fasteners from the access covers located on the side of the boom at the platform end of the machine Remove the covers Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES 5 Visually inspect the cables and components through both inspection holes for the following e Frayed or broken
383. o Section 2 Specifications 4 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 5 Disconnect and plug the T fitting located at the return filter with the two hoses connected to it Cap the fitting on the return filter housing 6 Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST E PROCEDURES 7 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 8 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device 9 Remove the hydraulic tank from the machine AWARNING C shinghazard The hydraulic tank may become unbalanced and fall if it is not properly supported and secured to the lifting device 10 Remove the suction strainers from the tank and clean them using a mild solvent 11 Rinse out the inside of the tank using a mild solvent 12 Install the suction strainers using pipe thread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until the level is wi
384. ocate the extend cable adjustment nuts on the counterweight end of boom tube 1 Refer to Illustration 2 Loosen the nylock nuts and jam nuts on the cable tension equalizer bracket Do not remove the nuts 9 Adjust the extend cable adjustment nut to obtain 6 3 8 inches 16 2 cm to 6 1 2 inches 16 5 cm between the platform end of boom tube 2 and boom tube 3 Refer to illustration 1 There should be approximately 1 2 inch of exposed threads on the adjustment bolts Refer to Illustration 2 Note If the cables have been replaced be sure the adjustment nuts have been replaced Do not re use the existing nuts 10 Extend the boom until there is approximately 3 feet 1 m of travel left Do not fully extend the boom 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom 12 Using a dial type torque wrench torque the retract cable adjustment nut to 32 36 ft Ibs 43 49 Nm using gentle and steady torque Part No 122985 Genie S 80 S 85 0 BOOM COMPONENTS 13 Retract and extend the boom approximately 3 feet 1 m two times and stop during the extension cycle This will create slack in the retract cables Note Be sure to not fully extend the boom Stop when there is approximately feet 1 m of travel left 14 Repeat steps 12 and 13 two to three times 15 Fully extend the boom then retract the boom approximately 12 inches 30 cm 16 At the pivot en
385. olds 8 1 Function Manifold Components 4 42 82 Valve Adjustments Function Manifold a 4 44 8 3 Brake Two speed Manifold Components 4 46 8 4 Turntable Rotation Manifold Components 4 47 8 5 Platform Rotate Manifold Components 4 48 8 6 Platform Manifold Components S 80 4 49 8 7 Platform Manifold Components 5 85 4 50 8 8 2WD Traction Manifold Components 4 51 8 9 4WDTraction Manifold Components before serial number 8581 4 53 8 10 4WD Traction Manifold Components after serial number 8580 4 55 8 11 Drive Oil Diverter Manifold Components welder option 4 57 8 12 Valve Adjustments Traction 4 58 8 19 Valve ect ea en ee eat ce ees eee c ete 4 59 Fuel and Hydraulic Tanks 921 Tank s iE nine dui 4 61 9 2 Hydraulic Tank 4 4 62 Turntable Rotation Components 10 1 Turntable Rotation Drive Hub 4 64 2WD Steer Axle Components 11 1 Yokeand Hub 4 Tu uu ae en 4 67 11 2 nein 4 68 Genie xii 5 80 S 85 S 80X Part No 122985 September 2015 mn TABLE OF CONTENTS Section4 Rev RepairProcedures continued 4WD Steer Axle Components 12 1 Yokeand Drive
386. on 6 Schematics September 2015 Platform Control Box Wiring Diagram S 80 and S 85 CE Deutz 20111041 Models before serial number 81 11 29 6 30 September 2015 RD E STOP Zeil BAS RD LS18 CABLE P134PWR RD P134PWR RD o R20 RD H1 CONTROL HARNESS TO PLATFORM SWITCH PANEL COM NO U35 C3 10 C4 10 P26ESTP BK E STOP R26ESTP BK C9P 1 BR GND e e TS7 C18PRR GR BK J22 3 TS7 C17PRL GR J22 4 TS8 C43JU GR J22 5 TS8 C44JD GR BK J22 6 TS9 C14PLU OR J22 7 TS9 C15PLD OR BK J22 8 P2 P26ESTP BK C9P 1 TS2 P25FS RD C9P 3 J3 P24FS WH C9P 2 P2 P23PWR WH C7P 2 P2 P22PWR BK C7P 1 TS1 V155PCE OR RD C4P 4 TS7 C18PRR GR BK C4P 6 TS7 C17PRL GR C4P 5 TS8 C43JU GR C4P 7 TS8 C44JD GR BK C4P 8 TS9 C14PLU OR C4P 2 TS9 C15PLD OR BK C4P 3 LS18 C132PLI2 BK C3P 10 H1 C133PLA GR BK C3P 12 L47 C59CNK BL BK C3P 11 a T 0 m a e o J1 SNSR GND BR C2P 10 J1 P109ANG GR WH C2P 9 P3 C46HRN GR 2 5 iacao TS47 C45GEN GRANH C2P 7 yal E x C40LS OR C2P 2 E s C6TRF WH RD C3P 6 8 E 123 RD BK 2 8
387. on time with the function times listed in Section 2 Specifications Determine whether the function time needs to increase or decrease 11 While the joystick is activated adjust the max out setting to achieve the proper function cycle time Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed Note Each time the drive enable toggle switch is momentarily moved the function speed will change in 2 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function Genie 4 4 S 80 S 85 S 80X 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Result The alarm does not sound The minimum or maximum adjustment has been obtained No changes can be saved Note Do not operate any machine function during the 10 second waiting time 14 Cycle the red Emergency Stop button off then back on How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain
388. onnector on the orange wire and securely connect the other multimeter lead to a ground point in the control box Result The readout on the multimeter should indicate zero resistance W Result The readout on the multimeter shows resistance Remove the machine from service and contact the Genie Service Department 29 Using a suitable lifting device remove all weight from the platform Note the result on the multimeter Result The readout on the multimeter should indicate infinite resistance W Result The readout on the multimeter shows zero resistance Remove the machine from service and contact the Genie Service Department 31 Turn off the multimeter and remove the leads from the machine Securely connect the wires disconnected in step 27 32 Close the platform control box Install and securely tighten the fasteners Do not overtighten Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures C 4 Replace the Engine Air Filter Element Engine specifications require that this procedure be performed every 500 hours or six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the air cleaner cap Remove the end cap from the air c
389. ons very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 5 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 6 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin 7 Remove the cylinder from the machine Crushing hazard The oscillate AWARNING cylinder could become unbalanced and fall if not properly attached to the overhead crane when removed from the machine Section 4 Repair Procedures September 2015 OSCILLATING AXLE COMPONENTS 14 2 Oscillate Directional Valve How to Adjust the Oscillate Relief Valve Pressure 1 Connecta 0 to 2000 psi 0 to 150 bar pressure gauge to the diagnostic nipple located on the function manifold 2 Remove the drive chassis cover from the non steer end of the machine 3 Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis Refer to illustration 1 4 Startthe engine from the ground control 5 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 6 Turnthe engine off 7 Locate the relief valve on the function manifold item SC 8 Loosen the jam nut on the relief val
390. out This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Note Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures September 2015 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the
391. ove the pin retaining fasteners from both the steer cylinder and the tie rod cylinder pivot pins Remove the pins 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Loosen the wheel lug nuts Do not remove them 4 Block the non steer wheels and center a lifting jack of ample capacity under the steer axle 5 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Part No 122985 Genie S 80 S 85 0 4 69 6 Remove the lug nuts Remove the tire and wheel assembly 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support and secure the yoke and drive hub assembly to a lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin Use a soft metal drift to drive the lower yoke pivot pin down and out AWARNING Crushing hazard The yoke and drive hub assembly could become unbalanced and fall when the yoke pivot pins are removed if no
392. oving a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform Part No 122985 Genie S 80 S 85 0 PLATFORM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 85 Support the jib boom leveling arms and the platform mounting weldment with an appropriate lifting device Do not apply any lifting pressure 4 Remove the mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator AWARNING Crushing hazard The platform mounting weldment could become unbalanced and fall if not properly supported when removed from the machine 5 Support the platform rotator with an appropriate lifting device Do not apply any lifting pressure S 80 6 Support the rod end of the platform leveling slave cylinder Protect the cylinder rod from damage 7 Remove the pivot pin retaining fasteners from both the slave
393. p gt gt z 6 Slol lt 65 ao 2 5 2 2 u Ou lt Z lt S 5 998 55 2 9 5 2 5 2 83488 915 2554 HH al2la 5 521959 as aagal olega olg legs 5555 8129 PIP E IPP PE 55 515 0 CH Oz NO 13h NOI 6 On SSVdAd A34 8 O A3 2 IO4 281 AdaLiva 9 C 2 8 O NO XV r INdNI LHVLS H313WOHOVL 2 21 16 AY THU IHVIS 11 C Soya SEcHL HM M90 18 NOILYNINY 3L ASVE er 1 99 aed 7 1951 anis 2 90 yg Qu 28 08 2 Orval 620 9 1951 4g QH WOO 6 92 HW AH 068 MO 1 1 90 1 HM 850 2951 HM MOO 31VLOH 9 90 8 9 820 8 1 6951 8 1 1 1 1 9 90 GH HM 9 860 QU HM 9 vr GH HM 1X3 W008 IHd 2 99 1 8 0 Ma 1 6981 LOVYLAY WOOd 8 90 HME 9 60 HMA 8 9SL HWE 134 1X3 WOOd Idd 6 99 6 860 6 9 951 0 8 199 5 1 8 00 78 dn 13A31 8 91 1 6951 13437 WHOSLW 1d 9 xg uO SL 9 6991 4g HO
394. peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position Part No 122985 September 2015 4 Donot press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 6 times Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and simultaneously move the joystick in either direction full stroke Note how long it takes the function to reach maximum speed This is the ramp rate 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease 11 Release the foot switch 12 While the joystick is activated set the ramp rate Momentarily move the drive enable toggle switch in the right directio
395. per Brake Configuration Note Select a test area that is firm level and free of obstructions Note Perform this procedure with the boom in the stowed position 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 4 Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test line 5 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb CHECKLIST B PROCEDURES B 19 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions Note Perform this procedure with the boom in the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart
396. raulic Schematic 2WD Models A September 2015 G K L PLATFORM LEVEL 6 170 Genie
397. red codes Note If any fault codes are present the ECM will blink a three or four digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause blink the third digit then pause and possibly a fourth digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connect the negative battery cable to the battery Genie S 80 S 85 S 80X 5 7 Section 5 Fault Codes September 2015 FAULT CODES Power Derate 1 Power Derate 2 Low Rev Limit Fault Conditions MAP pressure gt 16 psi and TPS lt 10 and RPM gt 1800 To Unlatch MAP pressure must be lt 10 psi MAP voltage gt 0 05 vdc and TPS gt 2 and RPM lt 7000
398. res and additional engine information are available in the Perkins 804D 33 Operation and Maintenance Manual Genie part number To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury CHECKLIST A PROCEDURES Genie Part No 122985 S 80 S 85 S 80X Section 3 Scheduled Maintenance Procedures September 2015 Checklist B Procedures B 1 Inspect the Battery s Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions A single battery configuraton is standard A dual battery option is available where one battery is used to start the engine and the other is used to power the control system and auxiliary power unit The two batteries are charged by the alternator through a battery separator AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily
399. rive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive hubs 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees a models with o ring plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Part No 122985 Genie S 80 S 85 0 CHECKLIST B PROCEDURES 4 Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications 5 Checkthe torque of the drive hub mounting fasteners Refer to Section 2 Specifications 6 Repeat steps 1 through 5 for the other drive hubs Turntable rotate drive hub Single fill port rotator 1 Remove the plug located on the top of the hub and check the oil level Result The oil level should be visible below the bottom of the fill port Single fill port rotator a motor b fillport C drive hub mounting bolts d drive hub Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST B PROCEDURES Dual fill port rotator 2 Remove one of the plugs located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole
400. rm Engine Maintenance Deutz and Continental Models Engine specifications require that this one time procedure be performed after the first 50 hours of operation Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures for commissioning new and overhauled engines and additional engine information are available in the Deutz TD2011 Operation Manual Genie part number 139320 Continental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 122985 Genie S 80 S 85 0 CHECKLIST A PROCEDURES A 9 Inspect the Fuel Filter Water Separator Diesel Models Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard star
401. rnia to cause cancer birth defects or other reproductive harm
402. rs i GLOW PLUG 8 2 1 a R34SA BKWH ae 3 2 883 2E P dg GLOW PLUG 925 C33STR BK 229 WATER TEMPERATURE SWITCH 1 1 985 C5 15 oases WI 2 OIL PRESSURE gt gt swrcH 1 7 SS c 5 M 222 E 8 C5 3 81718 5 p fo 2 8 0 8 IGNITION POWER amp RELAY C27AUX RD m 2 E R21IGN WH 1 6 0 4 FUEL SOLENOID e 4 8 9 5 a 8 7 ga 5 5 46 AUXLARY PUMP ur i 6 AUXILIARY PUMP x RELAY m 5 a 5 8 mi 7 o o AUXILIARY PUMP 5 5 5 ROTALDE RD POWER RELAY a aa a 2 C72 AUXILIARY PUMP P23PWR WH E E 5 81518 IGNITION START 1 9 RELAY 3 C1 2 C28TTA RD BK t 87175 POWER RELAY 6 O g gt a 5 STARTER MOTOR P 5 8 8 5 5 TILT ALARM 9 5 8 D a a lt a a e pr C6 28 C28TTA RD BK lt lt WH 4 COH P134PWR RD p BK 4 LEVEL SENSOR 2 Ecl EI m ES 5 7 88 4 5 8718 4 SERVICE HORN 8 9 o zi GR BK L R4GHRN GR g SERVICE HORN 7 1 m 80 P22PWR BK 1 9 e Res eor tubi guests bote pen gone eee a 2 5 je 59 OIL COOLER E SI WH 0 lt lt TEMPERATURE SWITCH 8058 OPTION i 1 C2 6
403. s ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener Part No 122985 Genie S 80 S 85 0 CHECKLIST A PROCEDURES A 10 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the platform end of the tank side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 18 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES A 11 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1
404. s Genie specifications require that this procedure be performed every 10 years The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Replacement of the boom extend retract cables is essential to good machine performance and safe machine operation The boom extend retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Replace the boom extend retract cables See Repair Procedure 4 5 How to Replace the Boom Extend Retract Cables 3 60 S 80 5 85 S 80X Genie PartNo 122985 September 2015 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure Be sure that all necessary tools and parts available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedur
405. s 45 50 Nm 5 Proportional valve SR ius Extend proportional 20 25 ft lbs 27 34 Nm 6 Differential sensing valve SS Boom extend a enne 30 35 ft lbs 41 47 Nm 7 Proportional valve SE 2 Boom up down proportional 33 37 ft Ibs 45 50 Nm 8 Solenoid valve 3 position 4 way Suns Steering directional 20 25 ft lbs 27 34 Nm 9 Proportional valve SE Swing proportional 20 25 ft lbs 27 34 Nm 10 Solenoid valve 3 position 4 way Sl ase Swing directional 26 30 ft lbs 35 41 Nm 11 Flow regulator valve SD Oscillate flow control 20 25 ft lbs 27 34 Nm 12 Relief valve 2400 psi 165 bar Boom down relief 20 25 ft lbs 27 34 Nm 13 Relief valve 2400 psi 165 bar SO sus Boom extend relief 20 25 ft lbs 27 34 Nm 14 Check valve 30 psi 2 1 bar ST Return check valve 30 35 ft lbs 41 47 Nm 15 Differential sensing valve Primary it 30 35 ft Ibs 41 47 Nm 16 Check valve SA Back flow check function pump 30 35 ft lbs 41 47 Nm 17 Relief
406. s and warming the engine to normal operating temperature 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 2 the engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Genie Part No 122985 5 80 5 85 0 3 31 CHECKLIST B PROCEDURES B 17 Test the Drive Enable System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive enable system operation is essential to safe machine operation When the boom is past the non steering wheels drive movement is stopped and the indicator light turns on The drive enable switch must be held to either side to reactivate the drive function and should alert the operator that the machine may move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position Note Perform this procedure with the boom in the stowed position 1 Start the engine from the platform controls Press down the foot switch 3 Rotate the turntable until the boom moves past one of the the non steer wheels Result The drive enabl
407. s could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 6 Schematics September 2015 Electrical Symbols Legend BLK Quick disconnect terminal 21 WHT 21 T circuits connect at terminal T circuits connect Connection no terminal Circuits crossing no connection Battery separator 15 Circuit breaker with amperage Coil solenoid or relay H1 Horn or alarm i Flashing beacon Hour meter L3 LED Fi 25A Fuse with amperage Starting aid glow plug or flame ignitor LS3 N O H C Limit switch PLATFORM GROUND Power relay m RB 6 Toggle switch SPDT o m m m Toggle switch DPDT CR4 NO 77777 Control relay contact normally open Genie HR Horn button normally open uo OTS2 0 Oil temperature switch normally open Coolant temperature switch normally open OPS1 N C Oil pressure switch normally closed Al Gauge sending unit HOLD PULL IN Fg 5
408. susu z 2 2 riu 24 S suls e 8 55 5 5 8 518 2850 52 5 5 86 gt SIPIOIEIOIE 2 5 LO aE um g o 2 65589 D ui 5 5 2 2 lt lt lt 0 2 5 5 35 gt 8 6 x 2 s uw gt x o 215 0 5 Qiz z zz gt 25 6 526065650 5 Ok zr xu 6 5 lt 6 5 50 0 2 gt 2 Q 552 5 2 a gt gt 55 lolaga 2 5 lt 00 6 555 2 lt 5 0 gt gt 5 gt x 5 lt 5 2 5 gt gt 2 5 i 3 lt LL m 358833 9 5158555656515 82 4 000000 5 m al 5 040 lt NO 6 CH m SSVdA8 A34 8 O Ss gt Yee 2 31108 9 CH en S G4 8 NO Xv Y Ozz8l au 5 1ndNI 1815 CH Seed Ia OF 8
409. symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure Genie 3 2 S 80 5 85 0 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year To account for repeated procedures the Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six month or every 500 hours Annual every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenanc
410. t 7 Carefully pull the cylinder out of the primary boom to access the hydraulic hoses 8 Tag disconnect and plug the hydraulic hoses from the slave cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray How to Bleed the Slave Cylinder Note Do not start the engine Use auxiliary power for this procedure 1 Raise the primary boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 122985 September 2015 Section 4 Repair Procedures 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position Note When rem
411. t 1 5 4 eje EEE p d 2 pr sn 5 le P 5 m 5 4 8 ta bt 141 a 8 xz a 1182 JE 95 l 1 AUX MAIN 1 EP q Qr a BIBAT RD 5 3 55 B g 8 m E RD N LO CHECK ENGINE LED 505040 HOURMETER PRESSURE COMP VALVE FUNCTION ENABLE RPM CONTROL RELAY RPM SOLENOID RPM MODULE GLOW PLUG TIME DELAY 30 SECONDS GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID CONTROL RELAY FUEL SOLENOID AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP POWER RELAY AUXILIARY PUMP IGNITION STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION FLASHING BEACONS OPTION G S 80 S 85 S 80X ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY PartNo 122985 6 34 Section 6 Schematics September 2015 Electrical Schematic S 80 and S 85 CE Deutz 2011 041 Models after serial number 81 10
412. t If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed 6 Install the filter element 7 Install the air filter canister end cap and secure the end cap latches Note Be sure the discharge valve is pointing down when the cap is instaled Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 6 Check the Oil Cooler and Cooling Fins Deutz Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may result in severe burns Oil cooler 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to s
413. t properly supported and secured to the lifting jack 13 Place the yoke and drive hub assembly on a flat surface with the drive hub facing down 14 Remove the drive hub mounting fasteners that attach the drive hub to the yoke Remove the yoke from the drive hub Refer to Section 2 Specifications Note Replace the thrust washer when installing the yoke and drive hub assembly onto the axle Section 4 Repair Procedures September 2015 4WD STEER AXLE COMPONENTS 12 2 Drive Motor How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized Sauer dealer Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the axles 2 Remove the drive motor access covers from both sides of the inner axle Genie S 80 S 85 0 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin
414. tained Part No 122985 September 2015 Section 4 Repair Procedures 8 13 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Part No 122985 Genie S 80 S 85 0 MANIFOLDS Valve Coil Resis
415. tance Specifications Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 8 C that your air temperature increases or decreases from 68 F 20 C Proportional solenoid valve 480 schematic items K and W 2 position 3 way solenoid valve 6 30 schematic items D R X TT and UU 2 position 3 way solenoid valve 3 30 schematic items G 3 position 4 way solenoid valve 6 30 schematic items A E N and S 2 position 3 way solenoid valve 6 30 schematic items AK AM VV and WW 2 position 3 way solenoid valve 3 30 schematic item G Section 4 Repair Procedures September 2015 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove
416. tate bearing plate at the non steer end Confirm whether the drive chassis is completely level 7 Ifthe drive chassis is not level start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level Part No 122985 Genie S 80 S 85 0 OSCILLATING AXLE COMPONENTS 8 Verify that the ground and drive chassis are completely level 9 Loosen the jamb nuts and adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the axle 10 Install the cotter pin and tighten the jamb nuts 11 Measure the gap between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Result The measurements should be equal Note The gap on both sides should be between 0 150 inch 0 381 cm and 0 170 inch 0 432 cm 12 Add or remove shims between the oscillation stop bar and the drive chassis to achieve the proper gap Section 4 Repair Procedures September 2015 This page intentionally left blank Genie 4 76 S 80 S 85 0 Part No 122985 September 2015 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the mach
417. tch Result The engine rpm should change to high idle high idle 10 Press down the foot switch O Result The engine rpm should change to high idle 3 30 S 80 5 85 S 80X Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B 16 4 Release the foot switch and shut the engine off hing th E 1 tton Test the Fuel Select Operation ep UBRO 1 the off position Gasoline LPG Models 5 Move the fuel select toggle switch to LPG 6 Start the engine and allow it to run at low idle Press down the foot switch to allow the engine Genie specifications require that this procedure be to run at high idle performed every 250 hours or quarterly whichever firet Result The engine should start promptly and operate smoothly in low and high idle The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made whether the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Note Perform this test after checking the gasoline and LPG fuel level
418. tember 2015 Section 6 Schematics Electrical Schematic S 80 and S 85 ANSI CSA AS Continental TME27 Models 8 2 Dd 2 5 Ehe 2223 es 1 8 P INN yt BK 12GA 3 9 2000 1 5 CONTINENTAL TME27 ENGINE E VEHICLE INTERFACE 1 Ti US 8 8 x m T 9 5 amp 1 79228 115 0 gt Im 5 EE a 5 5 8 5 amp e e N e e 6 o 4 DADA SAGAS Ly 715 PU 8 LP C2 1 G E t 7 C39LP BL RD 8 GAS 2 o 9 x c
419. teps 9 through 11 for each boom joystick controlled machine function boom up down boom extend retract and turntable rotate 13 Return the joystick to the neutral position and wait for approximately 10 seconds Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time 14 Cycle the red Emergency Stop button off then back on Function speeds factory settings Boom up 89 to 93 seconds Boom down 90 to 94 seconds Boom extend 73 to 79 seconds Boom retract 79 to 84 seconds Turntable rotate 360 boom fully stowed 95 to 103 seconds Drive speeds factory settings Stowed high speed 7 9 to 8 5 seconds Non stowed 40 to 45 seconds Part No 122985 September 2015 Section 4 Repair Procedures How to Calibrate the Boom Angle Sensor The boom angle sensor controls the maximum angle that the boom can attain Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Turn the key switch to platform controls 3 Move and hold the drive enable toggle switch to the right and pull out the red Emergency Stop button to the on position 4 Whenthe alarm sounds release the drive enable toggle switch 5 Momentarily activate the drive enable toggle switch to the right 12 times R
420. terly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions only Functon enable button high idle rabbit symbol allows the operator to control multiple boom functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This setting activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Start the engine from the ground controls 4 Move and hold the function button in and move the idle switch to the high idle rabbit symbol position Result The engine rom should change to high idle Genie 5 Release the function enable button Result The engine rpm should change to low idle 6 Turn the key switch to platform controls 7 Move the engine idle select toggle switch to low idle turtle symbol Result The engine rom should remain at low idle 8 Move the engine idle select toggle switch to foot switch activated high idle rabbit and foot switch symbol Result The engine rpm should not change to high idle 9 Press down the foot swi
421. the fittings on the manifold Part No 122985 September 2015 Section 4 Repair Procedures 11 Tag disconnect and plug the wiring from the jib boom platform rotate select manifold 12 Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray All models 13 From the ground controls raise the boom to a horizontal position 14 Remove the fasteners from the drive speed limit switch bracket LS1RS mounted on the side of the boom at the platform end of the boom Do not remove the limit switch from the bracket 15 Remove the cotter pin from the upper cable track at the platform end of the boom Note Always replace the cotter pin with a new one 16 Remove the cable track guide fasteners from the cable track guides at the platform end of the boom Remove the cable track guides from the boom 17 Remove the cable clamp from the pivot end of the boom Part No 122985 Genie S 80 S 85 0 BOOM COMPONENTS 18 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalan
422. the pin AWARNING Crushing hazard The boom will fall if not properly supported when the primary boom rod end pivot pin is removed Part No 122985 September 2015 Section 4 Repair Procedures 5 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off 6 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the pin retaining fasteners from the boom lift cylinder barrel end pivot pins Do not remove the pins 8 Use a slide hammer to remove the barrel end pivot pins AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 9 Move the boom lift cylinder towards the counterweight end of the machine Rotate the boom lift cylinder until the barrel end pivot pin bores will clear the boom linkage 10 Carefully remove the boom lift cylinder from the machine AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device Part
423. the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 3 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications 4 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank 5 Tag and disconnect and plug the hose from the return filter Cap the fitting on the return filter housing 6 Tag and disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank Part No 122985 September 2015 Section 4 Repair Procedures FUEL AND HYDRAULIC TANKS 7 Remove the retaining fasteners from the 17 Clean up any oil that may have spilled hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 8 Supportthe hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 9 Remove the hydraulic tank from the machine 18 Open the hydraulic tank shutoff valves if equipped Component damage hazard Be sure to open the two hydraulic tank shutoff valves if equipped and prime the pump after installing the hydraulic tank AWARNING C rushing hazard The hydraulic Note Always use pipe thread sealant when tank could become unbalanced and fall if not properly supported and secured to the overhe
424. thin the top 2 inches 5 cm of the sight gauge Do not overfill 17 Clean up any oil that may have spilled Genie S 80 S 85 S 80X 18 Open the hydraulic tank shutoff valves if equipped Component damage hazard Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Refer to Repair Procedure 7 2 How to Prime the Pump Note Always use pipe thread sealant when installing the drain plug and strainers 19 Operate all machine functions through a full cycle and check for leaks Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use PartNo 122985 September 2015 Section 3 Scheduled Maintenance Procedures E 2 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 2000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 804D 33 Operation and Maintenance Manual Genie part number 111332 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Deutz and Perkins
425. through the cap Genie S 80 S 85 S 80X 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air passes through the hydraulic tank cap Procced to step 8 Result If air does not pass through the cap clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeatthis procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Part No 122985 September 2015 Section 3 Scheduled Maintenance Procedures B 23 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of co
426. tinental Models 3 11 9 Inspect the Fuel Filter Water Separator Diesel Models 3 11 A 10 Grease the Turntable Rotation Bearing and Rotate Gear 3 13 11 Perform Engine 3 14 12 Replace the Drive Hub 0 0 0 1 0 000 3 15 A 13 Perform Engine Maintenance Perkins Models 3 17 Checklist B Procedures B 1 Inspect the 5 nennen 3 18 B 2 Inspect the Electrical 3 19 B 3 Test the Key 2 4024 0 000000 enn nnne nennen 3 21 B 4 Check the Exhaust System 0 7 3 21 Genie Viii 5 80 S 85 S 80X Part No 122985 September 2015 mn TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 5 Inspect the Engine Air 3 22 B 6 Check the Oil Cooler and Cooling Fins Deutz Models 3 23 B 7 Confirmthe Proper Brake Configuration 3 24 B 8 Inspect the Tires Wheels and Lug Nut 3 24 B 9 Check the Drive Hub Oil Level and Fastener Torque 3 25 B 10 Check and Adjust the Engine RPM 3 26 B 11 Perform Engine Maintena
427. ting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off Perkins Models 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover and locate the fuel filter water separator next to the hydraulic return filter on the bulkhead 3 Inspectthe filter bowl for water buildup O Result If water is present in the filter bowl continue with steps 4 through 8 Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST A PROCEDURES 4 Loosen the vent plug located on the fuel filter water separator head J ITS vent plug drain plug filter bowl separator head 5 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 6 Tighten the vent plug Note If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine See C 6 Replace The Fuel Filter Water Separator Element Perkins Models for instructions on how to prime the fuel fi
428. tion 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly six months annually and every two years as specified on the Maintenance Inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than three months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No 122985 Genie 5 80 S 85 S 80X 3 1 Ab
429. ty 20 000 Ibs 10 000 kg under the drive chassis between the steer wheels 9 Liftthe wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub disengaged position Et FA 1 S engaged position Section 3 Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage All models 13 Turn the valve in a clockwise direction to be sure it is fully closed Note The free wheel valve is located on the bottom of the drive pump and should always remain closed a drive pump b screwdriver liftpump d free wheel valve Genie S 80 S 85 S 80X D 3 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition a
430. ub assembly could become unbalanced and fall when unlocked locked itis removed from the machine if not properly supported 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor 6 Install the drive hub Apply removable thread Bodily injury hazard Spraying locking compound to fastener threads Torque AWARNING hydraulic oil can penetrate and the backlash pivot plate mounting fasteners to burn skin Loosen hydraulic specification Refer to Section 2 Machine When installing the drive hub assembly connections very slowly to allow Torque Specifications the oil pressure to dissipate 7 Install the brake and then the motor onto the gradually Do not allow oil to drive hub Apply removable thread locking squirt or spray compound to fastener threads Torque the 3 Loosen the backlash pivot plate and adjustment motor brake mounting fasteners to bolts specification Refer to Section 2 Machine Torque Specifications 4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly 8 Adjust turntable rotation gear backlash See 10 1 How to Adjust the Turntable Rotation Gear Backlash Genie 4 64 S 80 S 85 S 80X Part No 122985 September 2015 Section 4 Repair Procedures TURNTABLE ROTATION COMPONENTS How to Remove the Turntable Rotation Hydraulic Motor Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or
431. uit Board a 4 2 1 2 2JOYSUCKS abemus teet 4 3 Platform Components 2 1 ia este edet t dp t 4 9 2 2 Platform Leveling Slave 4 10 Genie S 80 5 85 S 80X Part No 122985 September 2015 eee TABLE OF CONTENTS Section4 Rev RepairProcedures continued 2 3 Platform Rotator s idee uk ein 4 11 2 4 Calibrate the Platform Overload System 4 13 Jib Boom Components S 85 31 Jib BOOM Hr rco E o Ca ih i eni eR 4 16 3 3 Jib Boom Lift Cylinder sise essien 4 17 Boom Components 4 Cable a aia ied dme RE as 4 18 4 2 BOOIn ut ER e nu ae aan RH 4 21 4 3 Boom Lift Cylinder enne nnne 4 24 4 4 Extension 4 25 4 5 Extend Retract Cables 4 28 4 6 Platform Leveling Master 4 32 Engines 5 1 o tee ick 4 33 5 2 Flex IRRE 4 33 Ground Controls 6 1 Control Relays tied tbc len 4 38 Hydraulic Pumps 7 1 uu aa S Susu nennen a a nnne 4 39 7 2 eden nen RE 4 40 Genie Part No 122985 S 80 S 85 S 80X Xi September 2015 TABLE OF CONTENTS Section4 Rev Repair Procedures continued Manif
432. valve 3200 psi 221 bar System relief 20 25 ft lbs 27 34 Nm 18 Pressure reducing valve SC ue Oscillate pressure control 30 35 ft lbs 41 47 Nm 19 Differential sensing valve SG Differential sensing turntable rotate 30 35 ft lbs 41 47 Nm 20 Flow regulator valve SM Steering flow control 20 25 ft lbs 27 34 Nm Genie 4 42 S 80 S 85 S 80X Part No 122985 Section 4 Repair Procedures September 2015 MANIFOLDS G S 80 S 85 S 80X 43 Part No 122985 Section 4 Repair Procedures September 2015 MANIFOLDS 8 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the boom in the stowed position Note Auxiliary power will be used to perform this procedure Do not start the engine 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the diagnostic nipple PrEsT located next to the auxiliary pump 2 Simultaneously activate and hold the auxiliary power toggle switch and the primary boom retract toggle switch with the primary boom fully retracted Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 3 Locate the system relief valve on
433. ve 9 Turn the valve clockwise to increase the pressure or counterclockwise to decrease the pressure AWARNING Tip over hazard Do not adjust the relief valve higher than specified 10 Tighten the jam nut 11 Repeat steps 4 through 10 to confirm the oscillate relief valve pressure Note The oscillate pressure required is while the oscillate cylinders motion Do not dead head the cylinders to either side gt y 12 Turn the engine off remove the pressure gauge 4 assemble the directional valve linkage 13 Install the cover on the non steer end of the drive chassis zi L 8 oscillate valve b clevis yoke C drive chassis Genie 4 74 5 80 S 85 0 Part No 122985 September 2015 Section 4 Repair Procedures How to Set Up the Directional Valve Linkage Note Perform this procedure on a firm level surface 1 Lower the boom to the stowed position 2 Use bubble type level to be sure the surface the machine is on is completely level ADANGER Tip over hazard Failure to perform this procedure on a firm level surface will compromise the stability of the machine and could result in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover from the non steer end of the machine 5 Disconnect the linkage clevis yoke from the axle 6 Place a bubble type level on the turntable ro
434. veling arm Do not remove the pin Attach a lifting strap from an overhead crane to the lug at the rod end of the jib boom lift cylinder Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine Genie S 80 S 85 0 4 17 Section 4 Repair Procedures September 2015 Boom Components 4 1 Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom How to Remove the Cable Track Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Open the platform control box 2 and disconnect the foot switch wiring from the terminal strip inside the platform control box 3 Loosen the squeeze connector and remove the foot switch cable from the control box 4 D

Download Pdf Manuals

Related Search

Related Contents

Corel VideoStudio Ultimate X6, WIN, x32, CD, mini-Box, DUT/ITA/FRE  ISO-OXY-2 Instruction Manual - World Precision Instruments  SW Two - AudioSource  Samsung MM-Z100 User Manual  同意する - メルセデス・ベンツ    Solar Power Clamp Manual  ML-1000  Kompernass KH 1128 Operating Instructions  American Audio TTD-2500 Turntable User Manual  

Copyright © All rights reserved. Failed to retrieve file