Genie S-80, S-85 Workshop Service Repair Manual 11165

February 2012 S-80 • S-85 • S-80X Part No. 122985 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 and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. 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 Introduction Copyright © 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. Printed on recycled paper Printed in U.S.A. ii

February 2012 Part No. 122985 S-80 • S-85 • S-80X Revision Date Section Procedure / Schematic Page / Description D 2/2012 2 - Spec. 2-1 3 - Maint. 3-1, 3-51 4 - Repair 4-3 to 4-6, 4-18 6 - Schem. REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. Revision History

February 2012 S-80 • S-85 • S-80X Part No. 122985 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

February 2012 Part No. 122985 S-80 • S-85 • S-80X iii Serial Number Legend S80 08 - 12345 Model Model year Sequence number PN - 77055 Country of manufacture: USA This machine complies with: Model: S-80 Serial number: S8008-12345 Electrical schematic number: ES503 Machine unladen weight: Rated work load (including occupants): 500 lb / 227 kg Maximum allowable inclination of the chassis: 0 deg Gradeability: N/A Maximum allowable side force : 150 lb / 670 N Maximum number of platfrm occupants: 2 Model year: Manufacture date: 01/05/06 2006 Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 80 ft/ 24.4 m Maximum platform reach : 71 ft 6 in/ 21.8 m Sequence number (stamped on chassis) Serial label (located under cover) Terex South Dakota 500 Oak Wood road PO Box 1150 Watertown, SD 57201 USA

February 2012 S-80 • S-85 • S-80X Part No. 122985 This page intentionally left blank. iv

February 2012 Part No. 122985 S-80 • S-85 • S-80X 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 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. Safety Rules Section 1 • Safety Rules v

February 2012 S-80 • S-85 • S-80X Part No. 122985 SAFETY RULES Section 1 - Safety Rules vi 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. 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 potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbol—used to 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 such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety 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 stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.

February 2012 Part No. 122985 S-80 • S-85 • S-80X Table of Contents Introduction Important Information ................................................................................................... ii Serial Number Information ............................................................................................ ii Serial Number Legend ................................................................................................. iii Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 2 Hydraulic Oil Specifications ................................................................................... 2 - 2 Hydraulic Component Specifications ...................................................................... 2 - 3 Valve Coil Resistance Specifications ..................................................................... 2 - 4 Continental TME27 Engine Specifications ............................................................. 2 - 5 Deutz TD2011L04i Engine Specifications ............................................................... 2 - 6 Perkins 804D-33 Engine Specifications ................................................................. 2 - 7 Machine Torque Specifications .............................................................................. 2 - 8 Manifold Component Specifications ....................................................................... 2 - 8 Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 9 SAE and Metric Torque Specifications ................................................................. 2 - 10 vii

February 2012 S-80 • S-85 • S-80X Part No. 122985 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 Checklist A Procedures A-1 Inspect the Manuals and Decals .................................................................. 3 - 7 A-2 Perform Pre-operation Inspection ................................................................. 3 - 8 A-3 Perform Engine Maintenance ....................................................................... 3 - 8 A-4 Perform Function Tests ................................................................................ 3 - 9 A-5 Test the Oscillate Axle ................................................................................. 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 Continental Models .................... 3 - 11 A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11 A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13 A-11 Perform Engine Maintenance ..................................................................... 3 - 14 A-12 Replace the Drive Hub Oil .......................................................................... 3 - 15 A-13 Perform Engine Maintenance - Perkins Models .......................................... 3 - 17 Checklist B Procedures B-1 Inspect the Battery(s) ................................................................................. 3 - 18 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19 B-3 Test the Key Switch ................................................................................... 3 - 21 B-4 Check the Exhaust System ....................................................................... 3 - 21 viii

Genie S-80, S-85 Workshop Service Repair Manual 11165

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