Contents - safety rules
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- specifications
- performance specifications
- Hydraulic Component Specifications
- Manifold Component Specifications
- machine torque specifications
- Hydraulic Hose and Fitting Torque Specifications
- Torque Procedure
- February
- Section 3 Scheduled Maintenance Procedures
- Pre-Delivery Preparation Report
- maintenance inspection report
- Checklist A Procedures
- A-2 Perform Pre-operation Inspection
- A-5 Perform Engine Maintenance – Deutz Models
- A-7 Test the Oscillate Axle
- A-8 Check the High Pressure Hydraulic Filter Condition Indicator
- A-10 Perform Engine Maintenance – Continental Models
- A-12 Grease the Turntable Rotation Bearing and Rotate Gear
- Checklist B Procedures
- B-2 Inspect the Electrical Wiring
- B-3 Check the Exhaust System
- B-4 Inspect the Engine Air Filter
- B-5 Perform Engine Maintenance – Continental Models
- B-7 Confirm the Proper Brake Configuration
- B-9 Check the Drive Hub Oil Level and Fastener Torque
- B-10 Check the Oscillate Directional Valve Linkage
- B-15 Test the Drive Brakes
- B-16 Test the Drive Speed - Stowed Position
- B-19 Inspect the Fuel and Hydraulic Tank Cap Venting Systems
- B-20 Perform Hydraulic Oil Analysis
- B-21 Inspect the Boom Extend/Retract Cables
- B-22 Test the Emergency Power System
- Checklist C Procedures
- C-3 Perform Engine Maintenance - Perkins Models
- C-5 Check and Adjust the Engine RPM
- C-6 Grease the Platform Overload Mechanism (if equipped)
- C-8 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X
- Checklist D Procedures
- D-2 Check the Free-wheel Configuration
- D-3 Check the Turntable Rotation Bearing Bolts
- D-4 Inspect for Turntable Bearing Wear
- D-5 Replace the Hydraulic Filters
- D-6 Replace the Drive Hub Oil
- D-7 Perform Engine Maintenance - Continental Models
- D-9 Perform Engine Maintenance - Perkins Models
- Checklist E Procedures
- E-2 Perform Engine Maintenance - Perkins Models
- E-4 Perform Engine Maintenance - Perkins Models
- E-6 Remove and Inspect the Boom Extend/Retract Cables
- Cable Replacement Criteria
- repair procedures
- Platform Controls
- Joysticks
- How to Adjust the Joystick Max-out Setting
- How to Adjust the Joystick Ramp Rate Setting
- How to Adjust the Joystick Threshold Setting
- How to Calibrate the Boom Angle Sensor
- platform components
- Platform Leveling Slave Cylinder
- platform rotator
- How to Bleed the Platform Rotator
- Platform Overload System
- jib boom
- jib boom lift cylinder
- Boom Components
- How to Repair the Cable Track
- How to Remove the Boom
- boom lift cylinder
- Boom Extension Cylinder
- Boom Extend/Retract Cables
- How to Replace the Boom Extend/Retract Cables
- Platform Leveling Master Cylinder
- Engines
- How to Install the Flex Plate
- How to install the Pump and Bell Housing Assembly
- control relays
- hydraulic pumps
- drive pump
- How to Prime the Pump
- function manifold components
- Valve Adjustments - Function Manifold
- How to Adjust the Boom Extend Relief Valve
- Brake/Two-Speed Manifold Components
- turntable rotation manifold components
- Platform Rotate Manifold Components
- Platform Manifold Components, S-80
- Platform Manifold Components, S-85
- WD Traction Manifold Components
- Drive Oil Diverter Manifold Components (welder option)
- Valve Adjustments - Traction Manifold
- Valve Coils
- fuel and hydraulic tanks
- hydraulic tank
- turntable rotation components
- rotation hydraulic motor
- How to Adjust the Turntable Rotation Gear Backlash
- Steer Axle Components
- Drive Motors
- Steer Cylinders
- drive hub
- oscillating axle components
- Oscillate Directional Valve
- How to Set Up the Directional Valve Linkage
- fault codes
- Control System Fault Codes
- Fault Code Display - Deutz and Perkins Models
- F-22 Models
- Main Menu Structure - Deutz D 2.9 L4 Models
- Main Menu Structure - Perkins 404F-22 Models
- Deutz D 2.9 L4 Engine Fault Codes
- Perkins 404F-22 Engine Fault Codes
- Continental TME27 Engine Fault Codes
- Section 6 Schematics
- Electrical Symbol Legend
- hydraulic symbols legend
- Relay and Fuse Panel Legend - Deutz TD2011L04i
- Relay and Fuse Panel Legend - Perkins 804D-33
- Connector Pin Legends
- Continental TME27 Engine Harness
- S-80X Ground Control Box Wiring Diagram
- Deutz TD2.9 L4 Engine Harness
- Perkins 404F-22T Engine Harness
- Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)
- Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
- Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
- Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
- Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
- Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (ANSI / CSA)
- Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)
- Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)
- Continental Options Schematic
- Deutz and Perkins Options Schematic
- Platform Level Cutout, CTE Option
- kW Hydraulic Generator Wiring Diagram
- kW Hydraulic Generator Electrical Schematic
- Belt Driven Generator Option
- Hydraulic Schematics
- Hydraulic Schematic, 2WD Models
- Hydraulic Schematic, 4WD Models
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Service Manual February 2017Checklist D Procedures66 S-80 • S-85 • S-80X Part No. 1259369GTD-9Perform Engine Maintenance –Perkins ModelsEngine specifications require that this procedure beperformed every 1000 hours.804D Models• Alternator- check• Engine valve lash- inspect/adjust• Starter- check• Turbocharger- check404F Models• Alternator and fan belts- replace• Crankcase breather (canister)- replace• Engine valve lash- check• Turbocharger- inspectRequired maintenance procedures and additionalengine information are available in the: Perkins800D Series Operation Manual (Perkins partnumber SEBU8324)OR the Perkins 404F SeriesOperation Manual (Perkins part numberSEBU8609).Perkins 800 Series Operation and MaintenanceManualGenie part number 111332Perkins 404F Series Operation ManualGenie part number 1251562D-10Inspect the Boom Extend/RetractCablesGenie specifications require that this procedure beperformed annually.Manufacturers specifications require that thisprocedure be performed by personnel that arecompetent in cable / wire rope inspection.Note: Additional or more frequentinspections may be required due to thefollowing:• exposed to hostile or corrosiveenvironmental conditions.• boom is overloaded• sustains a shock load• electrical arcing• unused for extended periodsThe boom extend/retract cables are responsible forthe extension and retraction of the boom tubes.Inspecting for foreign objects, damage and/orimproper adjustment of the boom extend/retractcables and related components on a regular basisis essential to good machine performance and safemachine operation. The boom extend and retractfunctions should operate smoothly and be free ofhesitation, jerking and unusual noise.1 Raise the boom to the horizontal position andfully extend the boom.2 After the boom is fully extended, lower theboom until the platform is at chest height. Turnthe machine off.3 Remove the boom end cover retainingfasteners and remove the cover.4 Remove the retaining fasteners from theaccess covers located on the side of the boomat the platform end of the machine. Removethe covers.
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