Genie S-80 User manual

Service Manual
S-80
from S80/85/80X13-11876
to S80/85/80X15-
12263
S-85
S-80X
Part No. 1259369GT
Rev C
February 2017

Service Manual February 2017
Introduction
ii S-80 • S-85 • S-80X Part No. 1259369GT
Intr od ucti on Intr od ucti on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2014 by Terex Corporation
1259369GT Rev C, February 2017
Eigth Edition, Third Printing
"Genie" and "S" are registered trademarks of Terex South
Dakota, Inc. in the USA and many other countries.

February 2017 Service Manual
Introduction
Part No. 1259369GT S-80 • S-85 • S-80X iii
Revision History
Revision Date Section Procedure / Page / Description
A 3/2014 Initial Release
A1 6/2015 Maintenance D-4 Turntable bearing wear
B 9/2015 Added ending serial break to front cover.
C 2/2017 Maintenance B-21, D-10, E-6 Cable inspections
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service Manual February 2017
Introduction
iv S-80 • S-85 • S-80X Part No. 1259369GT
Revision History (continued)
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

February 2017 Service Manual
Introduction
Part No. 1259369GT S-80 • S-85 • S-80X v
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

Service Manual February 2017
Safety Rules
vi S-80 • S-85 • S-80X Part No. 1259369GT
Section 1 Safet y R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

February 2017 Service Manual
Safety Rules
Part No. 1259369GT S-80 • S-85 • S-80X vii
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—used to
alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indica
tes a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation
which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components w
hen lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are
properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and sta
bilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they ar
e used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

February 2017
Table of Contents
viii S-80 • S-85 • S-80X Part No. 1259369GT
Introduction Introduction .......................................................................................................... ii
Important Information ..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History .....................................................................................................iii
Serial Number Legend ........................................................................................... v
Section 1 Safety Rules......................................................................................................... vi
General Safety Rules .............................................................................................vi
Section 2 Specifications....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 2
Hydraulic Oil Specifications ................................................................................... 2
Hydraulic Component Specifications ..................................................................... 5
Manifold Component Specifications....................................................................... 6
Continental TME27 Engine Specifications............................................................. 7
Deutz TD2011L04i Engine Specifications ............................................................. 8
Deutz TD 2.9 Engine Specifications ...................................................................... 9
Perkins 804D-33 Engine Specifications............................................................... 10
Perkins 404F-22T Engine Specifications ............................................................. 11
Machine Torque Specifications............................................................................ 12
Hydraulic Hose and Fitting Torque Specifications ............................................... 13
Torque Procedure ................................................................................................ 14

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X ix
Section 3 Scheduled Maintenance Procedures ...............................................................16
Introduction...........................................................................................................16
Pre-Delivery Preparation Report ..........................................................................19
Maintenance Inspection Report............................................................................20
Checklist A Procedures .....................................................................................22
A-1 Inspect the Manuals and Decals....................................................................22
A-2 Perform Pre-operation Inspection..................................................................23
A-3 Perform Function Tests .................................................................................23
A-4 Perform Engine Maintenance – Perkins Models ...........................................24
A-5 Perform Engine Maintenance – Deutz Models ..............................................24
A-6 Perform Engine Maintenance – Continental Models .....................................25
A-7 Test the Oscillate Axle ...................................................................................25
A-8 Check the High Pressure Hydraulic Filter Condition Indicator ......................26
A-9 Perform 30-Day Service ...............................................................................26
A-10 Perform Engine Maintenance – Continental Models ...................................27
A-11 Perform Engine Maintenance – Continental Models ...................................27
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ...........................28
A-13 Replace the Drive Hub Oil ...........................................................................28
Checklist B Procedures .....................................................................................29
B-1 Inspect the Batteries ......................................................................................29
B-2 Inspect the Electrical Wiring ..........................................................................30
B-3 Check the Exhaust System............................................................................32
B-4 Inspect the Engine Air Filter...........................................................................33
B-5 Perform Engine Maintenance – Continental Models .....................................34
B-6 Perform Engine Maintenance – Perkins Models ...........................................34
B-7 Confirm the Proper Brake Configuration .......................................................35
B-8 Inspect the Tires, Wheels and Lug Nut Torque .............................................35
B-9 Check the Drive Hub Oil Level and Fastener Torque....................................36
B-10 Check the Oscillate Directional Valve Linkage ............................................37

February 2017
Table of Contents
x S-80 • S-85 • S-80X Part No. 1259369GT
B-11 Test the Ground Control Override ............................................................... 37
B-12 Test the Platform Self-leveling .................................................................... 38
B-13 Test the Engine Idle Select ......................................................................... 38
B-14 Test the Fuel Select Operation - Ford Models ............................................ 39
B-15 Test the Drive Brakes.................................................................................. 40
B-16 Test the Drive Speed - Stowed Position ..................................................... 41
B-17 Test the Drive Speed - Raised or Extended Position.................................. 41
B-18 Test the Alarm Package (if equipped) and the Descent Alarm ................... 42
B-19 Inspect the Fuel and Hydraulic Tank Cap Venting Systems....................... 43
B-20 Perform Hydraulic Oil Analysis.................................................................... 44
B-21 Inspect the Boom Extend/Retract Cables ................................................... 45
B-22 Test the Emergency Power System ............................................................ 46
Checklist C Procedures..................................................................................... 48
C-1 Perform Engine Maintenance - Continental Models ..................................... 48
C-2 Perform Engine Maintenance - Deutz Models .............................................. 48
C-3 Perform Engine Maintenance - Perkins Models............................................ 49
C-4 Replace the Engine Air Filter Element .......................................................... 49
C-5 Check and Adjust the Engine RPM............................................................... 50
C-6 Grease the Platform Overload Mechanism (if equipped).............................. 52
C-7 Test the Platform Overload System (If equipped)......................................... 52
C-8 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X......... 54

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X xi
Checklist D Procedures .....................................................................................57
D-1 Check the Boom Wear Pads .........................................................................57
D-2 Check the Free-wheel Configuration.............................................................58
D-3 Check the Turntable Rotation Bearing Bolts .................................................60
D-4 Inspect for Turntable Bearing Wear ..............................................................61
D-5 Replace the Hydraulic Filters.........................................................................62
D-6 Replace the Drive Hub Oil .............................................................................63
D-7 Perform Engine Maintenance - Continental Models......................................65
D-8 Perform Engine Maintenance - Deutz Models...............................................65
D-9 Perform Engine Maintenance - Perkins Models ............................................66
D-10 Inspect the Boom Extend/Retract Cables ...................................................66
Checklist E Procedures .....................................................................................68
E-1 Test or Replace the Hydraulic Oil ..................................................................68
E-2 Perform Engine Maintenance - Perkins Models ............................................70
E-3 Perform Engine Maintenance - Deutz Models...............................................70
E-4 Perform Engine Maintenance - Perkins Models ............................................71
E-5 Perform Cooling System Maintenance - Perkins 404F Models.....................71
E-6 Remove and Inspect the Boom Extend/Retract Cables ................................72
Cable Replacement Criteria ............................................................................74

February 2017
Table of Contents
xii S-80 • S-85 • S-80X Part No. 1259369GT
Section 4 Repair Procedures ............................................................................................. 75
Introduction .......................................................................................................... 75
Platform Controls............................................................................................... 77
1-1 ALC-500 Circuit Board................................................................................... 77
How to Remove the ALC-500 Circuit Board ................................................... 77
1-2 Joysticks ........................................................................................................ 78
How to Adjust the Joystick Max-out Setting ................................................... 79
How to Adjust the Joystick Ramp Rate Setting .............................................. 80
How to Adjust the Joystick Threshold Setting ................................................ 81
How to Calibrate the Boom Angle Sensor ...................................................... 82
Platform Components ....................................................................................... 84
2-1 Platform.......................................................................................................... 84
2-2 Platform Leveling Slave Cylinder................................................................... 85
How to Remove the Platform Leveling Slave Cylinder ................................... 85
How to Bleed the Slave Cylinder .................................................................... 85
2-3 Platform Rotator............................................................................................. 86
How to Remove the Platform Rotator ............................................................. 86
How to Bleed the Platform Rotator ................................................................. 87
2-4 Platform Overload System............................................................................. 88
Jib Boom Components...................................................................................... 91
3-1 Jib Boom ........................................................................................................ 91
3-2 Jib Boom Lift Cylinder .................................................................................... 92

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X xiii
Boom Components ............................................................................................93
4-1 Cable Track ....................................................................................................93
How to Remove the Cable Track, S-80 ..........................................................93
How to Repair the Cable Track .......................................................................95
4-2 Boom ..............................................................................................................95
How to Shim the Boom ...................................................................................95
How to Remove the Boom ..............................................................................96
4-3 Boom Lift Cylinder..........................................................................................98
4-4 Boom Extension Cylinder.............................................................................100
4-5 Boom Extend/Retract Cables.......................................................................102
How to Adjust the Extend/Retract Cables .....................................................102
How to Replace the Boom Extend/Retract Cables .......................................104
4-6 Platform Leveling Master Cylinder ...............................................................106
Engines..............................................................................................................107
5-1 RPM Adjustment ..........................................................................................107
5-2 Flex Plate .....................................................................................................107
How to Remove the Flex Plate......................................................................107
How to Install the Flex Plate..........................................................................110
How to install the Pump and Bell Housing Assembly ...................................111
Ground Controls...............................................................................................112
6-1 Control Relays..............................................................................................112
Hydraulic Pumps ..............................................................................................113
7-1 Function Pump .............................................................................................113
7-2 Drive Pump...................................................................................................114
How to Prime the Pump ................................................................................115

February 2017
Table of Contents
xiv S-80 • S-85 • S-80X Part No. 1259369GT
Manifolds .......................................................................................................... 116
8-1 Function Manifold ........................................................................................ 116
8-2 Valve Adjustments - Function Manifold ....................................................... 118
How to Adjust the System Relief Valve ........................................................ 118
How to Adjust the Boom Down Relief Valve................................................. 118
How to Adjust the Boom Extend Relief Valve............................................... 119
8-3 Brake/Two-Speed Manifold Components .................................................... 120
8-4 Turntable Rotation Manifold Components ................................................... 121
8-5 Platform Rotate Manifold Components........................................................ 122
8-6 Platform Manifold Components, S-80.......................................................... 123
8-7 Platform Manifold Components, S-85.......................................................... 124
8-8 2WD Traction Manifold Components........................................................... 125
8-9 4WD Traction Manifold Components........................................................... 126
8-10 Drive Oil Diverter Manifold Components (welder option) .......................... 128
8-11 Valve Adjustments - Traction Manifold ...................................................... 129
8-12 Valve Coils ................................................................................................. 130
Valve Coil Resistance Specifications............................................................ 130
Fuel and Hydraulic Tanks ............................................................................... 132
9-1 Fuel Tank ..................................................................................................... 132
9-2 Hydraulic Tank ............................................................................................. 133
Turntable Rotation Components .................................................................... 135
10-1 Turntable Rotation Drive Hub Assembly ................................................... 135
How to Remove the Turntable Rotation Drive Hub Assembly...................... 135
How to Remove the Turntable Rotation Hydraulic Motor ............................. 136
How to Adjust the Turntable Rotation Gear Backlash .................................. 137

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X xv
Steer Axle Components...................................................................................139
11-1 Yoke and Drive Hub ...................................................................................139
11-2 Drive Motors ...............................................................................................140
11-3 Drive Hubs..................................................................................................140
11-4 Steer Cylinders...........................................................................................141
Non-steer Axle Components ...........................................................................142
12-1 Drive Motor.................................................................................................142
12-2 Drive Hub ...................................................................................................142
Oscillating Axle Components .........................................................................143
13-1 Oscillate Axle Cylinders .............................................................................143
13-2 Oscillate Directional Valve .........................................................................144
How to Adjust the Oscillate Relief Valve.......................................................144
How to Set Up the Directional Valve Linkage ...............................................145

February 2017
Table of Contents
xvi S-80 • S-85 • S-80X Part No. 1259369GT
Section 5 Fault Codes....................................................................................................... 147
Introduction ........................................................................................................ 147
Control System Fault Codes........................................................................... 148
How to Retrieve Control System Fault Codes .............................................. 148
Control System Fault Codes......................................................................... 149
Fault Code Display - Deutz and Perkins Models........................................... 153
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins
404F-22 Models .................................................................................... 153
Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins
404F-22 Models .................................................................................... 154
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
.............................................................................................................. 155
Main Menu Structure - Deutz D 2.9 L4 Models ............................................ 156
Main Menu Structure - Perkins 404F-22 Models .......................................... 157
Deutz D 2.9 L4 Engine Fault Codes................................................................ 158
Perkins 404F-22 Engine Fault Codes............................................................. 169
Continental TME27 Engine Fault Codes........................................................ 171
How to Retrieve Continental Engine Fault Codes ........................................ 171
How to Clear Engine Fault Codes from the ECM ......................................... 171
Continental TME27 Engine Fault Codes ...................................................... 172

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X xvii
Section 6 Schematics........................................................................................................178
Introduction.........................................................................................................178
Electrical Symbol Legend...................................................................................179
Hydraulic Symbols Legend.................................................................................180
Relay and Fuse Panel Legend - Deutz TD2011L04i..........................................181
Relay and Fuse Panel Legend - Deutz TD2.9 L4 ..............................................181
Relay and Fuse Panel Legend - Perkins 404F-22T ...........................................181
Relay and Fuse Panel Legend - Perkins 804D-33.............................................182
Relay and Fuse Panel Legend - Continental TME27.........................................182
Connector Pin Legends......................................................................................183
Continental TME27 Engine Harness ..................................................................188
S-80X Ground Control Box Wiring Diagram.......................................................189
Deutz TD2.9 L4 Engine Harness........................................................................192
Perkins 404F-22T Engine Harness ....................................................................193
Electrical Schematics, S-80X – ANSI and CSA Models ................................195
Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ..........196
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)...........200
Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) .........201
Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA) .....204
Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ......208
Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ....209
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA).......212
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) .......216
Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ......217
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA).........220
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) .........224
Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)........225
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA) ....228
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA) .....232
Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)....233

February 2017
Table of Contents
xviii S-80 • S-85 • S-80X Part No. 1259369GT
Electrical Schematics, S-80, S-85 – ANSI and CSA Models ........................ 235
Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA) . 236
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA).. 240
Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA) 241
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA)
.............................................................................................................. 244
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA)
.............................................................................................................. 248
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (ANSI / CSA)
.............................................................................................................. 249
Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)
.............................................................................................................. 252
Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)
.............................................................................................................. 256
Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models (ANSI / CSA)
.............................................................................................................. 257
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA) 260
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA) 264
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)265
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
.............................................................................................................. 268
Ground Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
.............................................................................................................. 272
Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)
.............................................................................................................. 273
Electrical Schematics, S-80, S-85 – CE Models ............................................ 275
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE) .......... 276
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 280
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).......... 281
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE) ............. 284
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 288
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)............. 289
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE) ......... 292
Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE) .......... 296
Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)......... 297

February 2017
Table of Contents
Part No. 1259369GT S-80 • S-85 • S-80X xix
Electrical Schematics, S-80, S-85 – AS Models.............................................299
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS) ...........300
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)............304
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS) ..........305
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS) ..............308
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)...............312
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) .............313
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS) ..........316
Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)...........320
Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS) .........321
Schematics - Options.......................................................................................323
Continental Options Schematic.....................................................................324
Deutz and Perkins Options Schematic .........................................................325
Platform Level Cutout, CTE Option...............................................................328
12 kW Hydraulic Generator Wiring Diagram.................................................329
12 kW Hydraulic Generator Electrical Schematic .........................................332
Belt Driven Generator Option........................................................................333
Hydraulic Schematics ......................................................................................335
Hydraulic Schematic, 2WD Models...............................................................336
Hydraulic Schematic, 4WD Models...............................................................337