S-80 XC Telescopic Boom Lift

Service and Repair Manual
Serial Number Range

S®-80 XCTM S®-80 HF S®-85 XCTM S®-85 HF

from S80XCH-101 to S80XCH-3100
from S85XCH-101 to S85XCH-3090
from S85XCD-101 to S85XCD-2001

This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics
For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

Original Instructions Part No. 1280490GT Rev E April 2022

Service and Repair Manual
Introduction

April 2022

Intro ductio n

Intro ductio n

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: awp.techpub@terex.com
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 © 2017 by Terex Corporation 1280490GT Rev E, April 2022 First Edition, Fifth Printing Genie and “S” are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. “XC” is a trademark of Terex South Dakota, Inc.

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Revision History

Revision A B C

Date 11/2017 12/2017 1/2018

C1

4/2018

C2

7/2018

C3

10/2018

C4

5/2019

C5

6/2019

C6

7/2019

C7

10/2019

D

5/2020

E

4/2022

Section
Schematics Specifications Schematics Repair Repair Schematics Specifications Specifications Repair Fault Codes Schematics Fault Codes Repair Schematics All Sections Repair Front cover

Service and Repair Manual
Introduction
Procedure / Page / Description New Release Electrical schematics Hydraulic Component Specifications Electrical schematics 6-1 Move Ground Controls to Control System Electrical schematics Machine Specifications Machine Torque Specifications Display Menu Control System Fault Codes Electrical schematics Control System Fault Codes Display Menu Limit Switch Legend Add Deutz TCD 2.2 L3 Engine 2-4 Add ending serial break

Reference Examples: Section ­ Repair Procedure, 4-2 Section ­ Fault Codes, All charts Section ­ Schematics, Legends and schematics

Electronic Version
Click on any content or procedure in the Table of Contents to view the update.

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Service and Repair Manual
Introduction
Serial Number Legend
1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis)

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Safety Rul es

Service and Repair Manual
Safety Rules
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 modify or alter a MEWP without prior written permission from the manufacturer.
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.

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Safety Rules

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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.
Indicates 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 when 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 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 selflocking 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.

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Table of Contents

Introduction
Section 1 Section 2

Introduction …………………………………………………………………………………………ii Important Information …………………………………………………………………………….. ii Find a Manual for this Model……………………………………………………………………. ii Revision History …………………………………………………………………………………… iii Serial Number Legend…………………………………………………………………………… iv
Safety Rules…………………………………………………………………………………………v General Safety Rules …………………………………………………………………………….. v
Specifications ………………………………………………………………………………………1 Machine Specifications ……………………………………………………………………………1 Performance Specifications ……………………………………………………………………..2 Hydraulic Oil Specifications ……………………………………………………………………..2 Hydraulic Component Specifications………………………………………………………….5 Manifold Component Specifications …………………………………………………………..6 Deutz TD2011 L04i Engine Specifications ………………………………………………….7 Deutz TCD 2.2 L3 Engine Specifications…………………………………………………….8 Deutz TD 2.9 Engine Specifications…………………………………………………………..9 Perkins 404D-22T Engine Specifications ………………………………………………….10 Perkins 404F-E22TA Engine Specifications ………………………………………………11 Machine Torque Specifications ……………………………………………………………….12 Machine Component Weights…………………………………………………………………12 Hydraulic Hose and Fitting Torque Specifications ………………………………………13 Torque Procedure ………………………………………………………………………………..14

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Table of Contents

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Section 3

Repair Procedures …………………………………………………………………………….. 16 Introduction ………………………………………………………………………………………… 16
Control System …………………………………………………………………………………. 18 1-1 ALC-600 Platform Control Module …………………………………………………….. 18 1-2 ALC-600 Service Mode …………………………………………………………………… 18 1-3 Full Machine Calibration ………………………………………………………………….. 19 1-4 Machine Functions …………………………………………………………………………. 20
How to Adjust the Machine Maximum Speed Setting …………………………….. 20 How to Adjust the Joystick Ramp Rate Setting …………………………………….. 21 How to Adjust the Joystick Threshold Setting ………………………………………. 22 1-5 How to Enter ALC600 Software Update Mode …………………………………….. 22 1-6 Display Module Menus ……………………………………………………………………. 23 1-7 How to Replace the Display Controller (DISCON) Module …………………….. 28 1-8 How to Replace the Ground Control Overlay ………………………………………. 29
Platform Components………………………………………………………………………… 32 2-1 Platform ……………………………………………………………………………………….. 32 2-2 Platform Leveling Slave Cylinder ………………………………………………………. 33
How to Remove the Platform Leveling Slave Cylinder …………………………… 33 How to Bleed the Slave Cylinder ……………………………………………………….. 33 2-3 Platform Rotator…………………………………………………………………………….. 34 How to Remove the Platform Rotator …………………………………………………. 34 How to Bleed the Platform Rotator …………………………………………………….. 35 2-4 Platform Overload System……………………………………………………………….. 36 How to Perform a Zero Load Platform Calibration…………………………………. 36 How to Perform a Full Load Platform Calibration ………………………………….. 37 How to Replace the Platform Overload Load Cell …………………………………. 39

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Table of Contents
Jib Boom Components ……………………………………………………………………….40 3-1 Jib Boom ……………………………………………………………………………………….40 3-2 Jib Boom Lift Cylinder………………………………………………………………………41
Boom Components …………………………………………………………………………….42 4-1 Cable Track……………………………………………………………………………………42
How to Remove the Cable Track, S-80 ………………………………………………..42 How to Repair the Cable Track…………………………………………………………..44 4-2 Boom ……………………………………………………………………………………………44 How to Shim the Boom……………………………………………………………………..44 How to Remove the Boom…………………………………………………………………45 4-3 Boom Lift Cylinder …………………………………………………………………………..48 4-4 Boom Extension Cylinder………………………………………………………………….49 4-5 Boom Extend/Retract Cables…………………………………………………………….51 How to Adjust the Extend/Retract Cables……………………………………………..51 How to Replace the Boom Extend/Retract Cables …………………………………53 4-6 Platform Leveling Master Cylinder ……………………………………………………..55 4-7 Primary Boom Angle Sensor Calibration ……………………………………………..56 4-8 Boom Length Sensor……………………………………………………………………….57
Engines …………………………………………………………………………………………….. 58 5-1 RPM Adjustment …………………………………………………………………………….58 5-2 Flex Plate ………………………………………………………………………………………58
How to Remove the Flex Plate……………………………………………………………58 How to Install the Flex Plate ………………………………………………………………61 How to install the Pump and Bell Housing Assembly………………………………62 _5-3 Diesel Particle Filter Regeneration – Deutz TCD 2.2 L3 ………………………..63
Hydraulic Pump ………………………………………………………………………………….64 6-1 Function Pump ……………………………………………………………………………….64 6-2 Drive Pump ……………………………………………………………………………………65
How to Prime the Drive Pump…………………………………………………………….66

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Manifolds………………………………………………………………………………………….. 67 7-1 Function Manifold…………………………………………………………………………… 67 7-2 Valve Adjustments – Function Manifold………………………………………………. 69
How to Adjust the System Relief Valve……………………………………………….. 69 How to Adjust the Boom Down Relief Valve ………………………………………… 69 How to Adjust the Boom Extend Relief Valve……………………………………….. 70 7-3 Brake/Two-Speed Manifold Components……………………………………………. 71 7-4 Turntable Rotation Manifold Components…………………………………………… 72 7-5 Platform Rotate Manifold Components ………………………………………………. 73 7-6 Platform Manifold Components, S-80 XC …………………………………………… 74 7-7 Platform Manifold Components, S-85 XC …………………………………………… 75 7-8 4WD Traction Manifold Components …………………………………………………. 77 7-9 Valve Adjustments – Traction Manifold……………………………………………….. 79 7-10 Generator Manifold Components…………………………………………………….. 80 7-11 Valve Coils………………………………………………………………………………….. 81 Valve Coil Resistance Specifications ………………………………………………….. 81
Fuel and Hydraulic Tanks …………………………………………………………………… 83 8-1 Fuel Tank……………………………………………………………………………………… 83 8-2 Hydraulic Tank ………………………………………………………………………………. 84
Turntable Rotation Components …………………………………………………………. 86 9-1 Turntable Rotation Drive Hub Assembly …………………………………………….. 86
How to Remove the Turntable Rotation Drive Hub Assembly………………….. 86 How to Remove the Turntable Rotation Hydraulic Motor………………………… 87 How to Adjust the Turntable Rotation Gear Backlash…………………………….. 88 How to Calibrate the Turntable Tilt Sensor ………………………………………….. 89
Steer Axle Components……………………………………………………………………… 91 10-1 Yoke and Drive Hub ……………………………………………………………………… 91 10-2 Drive Motors ……………………………………………………………………………….. 92 10-3 Drive Hubs ………………………………………………………………………………….. 92
Generators………………………………………………………………………………………… 93 11-1 Hydraulic Generator ……………………………………………………………………… 93

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Table of Contents
Fault Codes………………………………………………………………………………………..94 Introduction …………………………………………………………………………………………94 Control System Fault Codes………………………………………………………………..95
How to Retrieve Control System Fault Codes ……………………………………….95 Control System Fault Codes – Models with Revision G Software or Lower….96 Control System Fault Codes – Models with Revision H Software or Higher . 113 Engine Fault Codes …………………………………………………………………………..130 Deutz TD 2.9 L4 Engine Fault Codes …………………………………………………..131 Deutz TCD 2.2 L3 Engine Fault Codes…………………………………………………142 Perkins 404-22 Engine Fault Codes…………………………………………………….152 GM 3.0L Engine Fault Codes………………………………………………………………154

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Section 5

Schematics……………………………………………………………………………………… 159 Introduction ………………………………………………………………………………………. 159 Electrical Symbol Legend ……………………………………………………………………. 160 Hydraulic Symbols Legend………………………………………………………………….. 161 Limit Switch Location Legend ………………………………………………………………. 162 Engine Relay Layout – Deutz TD2.9 ……………………………………………………… 163 Engine Relay Layout – Deutz TD2011L04i ……………………………………………… 164 Engine Relay Layout – Perkins 404D-22T ………………………………………………. 165 Engine Relay Layout – GM 3.0L……………………………………………………………. 166 Connector Pin Legend………………………………………………………………………… 167
Electrical Schematics ………………………………………………………………………. 169 Electrical Schematic, TCON
(to Serial number S80XCH-513, S85XCH- 518) ……………………………….. 170 Electrical Schematic, Platform Controller
(to Serial number S80XCH-513, S85XCH- 518) ……………………………….. 171 Electrical Schematic, Turntable Controller
(from S80XCH-514 to S80XCH-1393, S85XCH-519 to 1399)……………… 174 Electrical Schematic, Platform Controller
(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) … 175 Electrical Schematic, Turntable Controller
(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ……… 178 Electrical Schematic, Platform Controller
(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ……… 179 Electrical Schematic, Deutz TCD 2.2 L3 Engine ……………………………………… 182 Electrical Schematic, Deutz TD 2.9 L4 Engine………………………………………… 186 Electrical Schematic, Deutz TD2011 L04i Engine ……………………………………. 187 Electrical Schematic, Perkins 404D-22T Engine ……………………………………… 190 Electrical Schematic, Perkins 404F-E22TA Engine ………………………………….. 191 Electrical Schematic, GM 3.0L Engine…………………………………………………… 194 Electrical Schematic, 12 kW Welder Generator and 3 kW Generator ………….. 195
Hydraulic Schematics ………………………………………………………………………. 197 Hydraulic Schematic, S-80 XC Models ………………………………………………….. 198 Hydraulic Schematic, S-85 XC Models………………………………………………… 199

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Specifications

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Specificatio ns

Machine Specifications

Tires and wheels Rough Terrain and Non Marking Tire size Tire ply rating
Overall tire diameter

Tire pressure Wheel diameter

Wheel width

Tire weight, new foam filled (minimum) High Flotation Tire size Tire ply rating Overall tire diameter

Tire pressure

Wheel diameter

Wheel width

Tire weight

18-625 FF 16 ply 40.7 in
103,3 cm foam filled
24.5 in 62,2 cm
15 in 38,1 cm 622 lbs
282 kg
41/18LL 20 ply 41.2 in
104,6 cm 100 psi 6,89 bar 22.5 in 57,2 cm 14 in 35,6 cm 250 lbs
113,4 kg

Fluid capacities

Fuel tank, Diesel models

35 gallons 132,5 liters

Fuel tank, Gas models

30 gallons 113,5 liters

LPG tank

33.5 lbs 15,2 kg

Hydraulic tank

40 gallons 151 liters

Hydraulic system (including tank)

64 gallons 242 liters

Turntable rotation drive hub (single fill port)

40 fl oz 1183 cc

Turntable rotation drive hub (dual fill port)

43 fl oz 1262 cc

Drive hubs four wheel drive

48 fl oz 1420 cc

Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5

Lugs and Lug Nut Torque Wheel lugs Lug nut torque, dry
Lug nut torque, lubricated

11 @ 3/4 – 16
420 ft-lbs 569 Nm
320 ft-lbs 434 Nm

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Specifications

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Performance Specifications

Drive speed, maximum

Stowed position, RT tires

40 ft / 9 – 11 sec 12,2 m / 9 – 11 sec

Raised or extended

40 ft / 55 – 65 sec 12,2 m / 55 – 65 sec

Braking distance, maximum

High range on paved surface

3 – 6 ft / 0,91 – 1,8 m

Gradeability

Refer to Operator’s Manual

Boom function speeds, maximum from platform controls

Jib boom up (S-85 XC)

25 – 35 sec

Jib boom down (S-85 XC)

15 – 25 sec

Primary boom up

75 – 83 sec

Primary boom down

110 – 115 sec

Primary boom extend

59 – 67 sec

Primary boom retract

57 – 65 sec

Turntable rotate stowed, (360°)

95 – 103 sec

Turntable rotate raised or extended, (360°)

210 – 250 sec

Platform rotate, 160°

40 – 50 sec

Platform level (10° range of motion)

20 – 22 sec

For operational specifications, refer to the Operator’s Manual.

Hydraulic Oil Specifications

Hydraulic Fluid Specifications
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 prevention, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Cleanliness level, minimum

ISO 15/13

Water content, maximum

250 ppm

Recommended Hydraulic Fluid

Hydraulic oil type

Chevron Rando HD Premium

Viscosity grade

32

Viscosity index

200

Optional Hydraulic Fluids

Mineral based

Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Donax TG (Dexron III)
Chevron 5606A

Biodegradable

Petro Canada Environ MV 46

Fire resistant

UCON Hydrolube HP-5046

Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult Genie Product Support before use.

Optional fluids may not have the same hydraulic lifespan and may result in component damage.

Note: Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range. If the hydraulic fluid temperature consistently exceeds 200°F / 90°C an optional oil cooler may be required.

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Service and Repair Manual
Specifications

Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filters, control valves and may result in component damage.
Note: Do not operate the machine when the ambient air temperature is consistently above 120°F / 49°C.
Hydraulic Fluid Temperature Range

Chevron Rando HD Premium Oil MV Fluid Properties

ISO Grade
Viscosity index
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C
Brookfield Viscosity cP @ -4°F / -20°C cP @ -22°F / -30°C
Flash point
Pour point
Maximum continuous operating temperature

32 200
7.5 33.5
1040 3310 375°F / 190°C -58°F / -50°C 171°F / 77°C

Note: A hydraulic oil heating system is recommended when the ambient temperature is consistently below 0°F / -18°C.
Note: Do not operate the machine when the ambient temperature is below -20°F / -29°C with Rando HD Premium MV.

Ambient air temperature
1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV

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Specifications

April 2022

Chevron 5606A Hydraulic Oil Fluid Properties

ISO Grade
Viscosity index
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ -40°F / -40°C
Flash point
Pour point
Maximum continuous operating temperature

15 300
5.5 15.0 510 180°F / 82°C -81°F / -63°C 124°F / 51°C

Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used.
Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage

Petro-Canada Environ MV 46 Fluid Properties

ISO Grade
Viscosity index
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C
Flash point
Pour point
Maximum continuous operating temperature

46 154
8.0 44.4 482°F / 250°C -49°F / -45°C 180°F / 82°C

Shell Tellus S4 VX Fluid Properties

ISO Grade
Viscosity index
Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C
Brookfield Viscosity cSt @ -4°F / -20°C cSt @ -13°F / -25°C cSt @ -40°F / -40°C
Flash point
Pour point
Maximum continuous operating temperature

32 300
9 33.8
481 702.4 2624 >100 -76°F / -60°C 103°F / 75°C

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Service and Repair Manual
Specifications

UCON Hydrolube HP-5046 Fluid Properties

ISO Grade
Viscosity index
Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C
Flash point
Pour point
Maximum continuous operating temperature

46 192
22 46 1300 None -81°F / -63°C 189°F / 87°C

Hydraulic Component Specifications

Drive Pump

Type: bi-directional variable displacement piston pump

Displacement per revolution

0 to 2.8 cu in 0 to 46 cc

Flow rate @ 2300 rpm

30.3 gpm 114,7 L/min

Drive pressure, maximum

3750 psi 259 bar

Charge Pump

Type

gerotor

Displacement per revolution

0.85 cu in 13,9 cc

Flow rate @ 2300 rpm

9 gpm 34 L/min

Charge pressure @ 2300 rpm Neutral position

310 psi 21,4 bar

Function Pump

Type: variable displacement piston pump

Displacement per revolution

0 to 2.3 cu in 0 to 38 cc

Flow rate @ 2300 rpm

0 to 23 gpm 0 to 87 L/min

Pressure, maximum

2900 psi 200 bar

Pressure compensator

2900 psi 200 bar

Standby pressure

250 psi 17,3 bar

Auxiliary Pump

Type: fixed displacement gear pump

Displacement per revolution

0.15 cu in 2,47 cc

Generator Pump

Displacement per revolution

1.4 cu in 23 cc

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Specifications

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Function manifold System relief valve pressure, maximum Primary boom extend relief pressure (measured at PTEST port) Platform Manifold and Oscillate Valve Platform level flow regulator
Platform rotate flow regulator
Oscillate relief valve pressure
Traction Manifold Hot oil relief pressure
Brakes Brake release pressure, Wheel drive hubs Drive Motors Displacement per revolution high speed: Displacement per revolution low speed Hydraulic Filters High pressure filter: High pressure filter bypass pressure
Medium pressure filter Medium pressure filter bypass pressure Hydraulic tank return filter
Drive motor case drain return filter Accumulator Relief pressure Note: This component is not serviceable.

3200 psi 221 bar 2400 psi 165 bar
0.6 gpm 2,3 L/min
0.3 gpm 1,1 L/min
950 psi 65,5 bar
280 psi 19,3 bar
240 psi 16,5 bar
0.9 cu in 14.7 cc
2.7 cu in 45 cc
Beta 3 200 102 psi 7 bar
Beta 3 200 51 psi 3,5 bar
15 micron hydraulic 10 micron air breather Beta 10 2
1100 psi 75,8 bar

Manifold Component Specifications
Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12

36 in-lbs / 4 Nm 10 ft-lbs / 13 Nm 14 ft-lbs / 19 Nm 38 ft-lbs / 51 Nm 41 ft- lbs / 55 Nm 56 ft-lbs / 76 Nm

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Specifications

Deutz TD2011 L04i Engine

Displacement

220.9 cu. in 3,62 liters

Number of cylinders

4

Bore and Stroke

3.78 x 4.92 inches 96 x 125 mm

Horsepower net intermittent @ 2400 rpm

74 hp 55 kW

Induction system

turbocharged

Firing order

1 – 3 – 4 – 2

Low idle

1500 rpm

High idle

2350 rpm

Compression ratio

17.5:1

Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

centrifugal mechanical

Valve clearance, cold

Intake

0.012 in 0,3 mm

Exhaust

0.020 in 0,5 mm

Lubrication system

Oil pressure, hot (@ 2000 rpm)

40 to 60 psi 2.8 to 4.1 bar

Oil capacity (including filter)

12.8 quarts 12,1 liters

Oil viscosity requirements

-22°F to 86°F / -30°C to 30°C

5W-30 (synthetic)

-4°F to 104°F / -20°C to 40°C

10W-40

Above 5°F / -15°C

15W-40

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil Temperature sender

Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Oil Pressure sender

Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Fuel injection system

Motorpal

Injection pump pressure, maximum

15,000 psi 1034 bar

Injector opening pressure

3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load

140 – 200A

Cranking speed

250 – 350 rpm

Battery ­ Engine starting and control system

Type

12V DC, Group 31

Quantity

2

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator output

80A @ 14V DC

Fan belt deflection

3/8 to 1/2 inch 9 to 12 mm

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Service and Repair Manual
Specifications

April 2022

Deutz TCD 2.2 L3 Engine

Displacement

134 cu. in 2,2 liters

Number of cylinders

3

Bore and Stroke

3.6 x 4.3 inches 92 x 110 mm

Horsepower net intermittent @ 2600 rpm

74 hp 55 kW

Induction system

turbocharged

Firing order

1 – 2 – 3

Low idle, standby

1000 rpm

Low idle, function enable

1500 rpm

High idle

2400 rpm

Governor

electronic

Lubrication system

Low ash oil required

Oil pressure, hot (@ 2000 rpm)

40 to 60 psi 2,8 to 4,1 bar

Oil capacity (including filter)

8 quarts 7,6 liters

Oil viscosity requirements

-22°F to 86°F / -30°C to 30°C

5W-30 (synthetic)

-4°F to 104°F / -20°C to 40°C

10W-40

Above 5°F / -15°C

15W-40

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Installation torque Temperature switch point

8 – 18 ft-lbs 11 – 24 Nm
257°F 125°C

Oil Pressure switch Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Pressure switch point

17.4 psi 1,2 bar

Fuel requirement
For fuel requirements, refer to the engine Operator Manual for your engine.

Engine coolant capacity

2.5 gallons 9,5 liters

Unit ships with Ethylene Glycol engine coolant. Consult your local supplier for compatibility before mixing alternative engine coolants.

Starter motor Current draw, normal load Cranking speed

140 – 200A 250 – 350 rpm

Battery ­ Engine starting and control system

Type

12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator output

95A @ 14V DC

8

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Specifications

Deutz TD 2.9 L4 Engine

Displacement

177 cu. in 2,9 liters

Number of cylinders

4

Bore and Stroke

3.6 x 4.3 inches 92 x 110 mm

Horsepower net intermittent @ 2600 rpm

74.2 hp 55 kW

Induction system

turbocharged

Firing order

1 – 3 – 4 – 2

Low idle, standby

1000 rpm

Low idle, function enable

1500 rpm

High idle

2500 rpm

Compression ratio

17.4:1

Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

electronic

Valve clearance, cold

Intake

0.012 in 0,3 mm

Exhaust

0.020 in 0,5 mm

Lubrication system

Oil pressure, hot (@ 2000 rpm)

40 to 60 psi 2,8 to 4,1 bar

Oil capacity (including filter)

12.8 quarts 12,1 liters

Oil viscosity requirements

Low ash oil required

-22°F to 86°F / -30°C to 30°C

5W-30 (synthetic)

-4°F to 104°F / -20°C to 40°C

10W-40

Above 5°F / -15°C

15W-40

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil Temperature sender

Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Oil Pressure sender

Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Fuel injection system

Motorpal

Injection pump pressure, maximum

15,000 psi 1034 bar

Injector opening pressure

3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load

140 – 200A

Cranking speed

250 – 350 rpm

Battery ­ Engine starting and control system

Type

12V DC, Group 31

Quantity

2

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator output

95A @ 14V DC

Fan belt deflection

3/8 to 1/2 inch 9 to 12 mm

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

9

Service and Repair Manual
Specifications

April 2022

Perkins 404D-22T Engine

Displacement

134 cu in 2,2 liters

Number of cylinders

4

Bore and Stroke

3.31 x 3.94 inches 84 x 100 mm

Horsepower

58 @ 2500 rpm 44 kW @ 2500 rpm

Firing order

1 – 3 – 4 – 2

Low idle, standby

1000 rpm

Low idle, function enable

1500 rpm

High idle

2500 rpm

Compression ratio

23.3:1

Compression pressure

426 psi 29,4 bar

Pressure (psi) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder

Governor

centrifugal mechanical

Valve clearance, cold

Intake

0.008 in 0,2 mm

Exhaust

0.008 in 0,2 mm

Lubrication system

Oil pressure, cold (at 2500 rpm)

60 psi 4,1 bar

Oil capacity (including filter)

9.3 quarts 8,8 liters

Oil viscosity requirements

Below 86°F / 30°C

5W-20

-4°F to 104°F / -20°C to 40°C

10W-30

Above 14°F / -10°C

15W-40

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Fuel injection system

Injection pump make Injection pressure

Zexel
2133 psi 147 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Alternator output

55A @ 12V DC

Fan belt deflection

3/8 in 10 mm

Starter motor Current draw, no load Brush length, new
Brush length, minimum

140-200A
0.7480 in 19 mm
0.5 in 12,7 mm

Battery Type Quantity Cold cranking ampere Reserve capacity @ 25A rate

12V DC, Group 31 2
1000A 200 minutes

Engine coolant Capacity

7.7 quarts 7,3 liters

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Specifications

Perkins 404F-E22TA Engine

Displacement

134 cu. in 2,2 liters

Number of cylinders

4

Bore and Stroke

3.31 x 3.94 inches 84 x 100 mm

Horsepower net intermittent @ 2800 rpm Horsepower continuous @ 2800 rpm

55 hp / 41,1 kW 52 hp / 38,8 kW

Induction system

turbocharged

Firing order

1 – 3 – 4 – 2

Low idle, standby

1100 rpm

Low idle, function enable

1500 rpm

High idle

2500 rpm

Compression ratio

23.3:1

Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

electronic

Valve clearance, cold

Intake

0.008 in 0,2 mm

Exhaust

0.018 in 0,45 mm

Lubrication system

Oil pressure, hot (@ 2000 rpm)

40 to 60 psi 2,8 to 4,1 bar

Oil capacity (including filter)

9.4 – 11.2 quarts 8,9 – 10,6 liters

Oil viscosity requirements

-22°F to 86°F / -30°C to 30°C

5W-20 CJ4

-4°F to 104°F / -20°C to 40°C

10W-40 CJ4

Above 5°F / -15°C

15W-40 CJ4

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil Pressure switch

Installation torque

8 – 18 ft-lbs 11 – 24 Nm

Pressure switch point

14.2 psi 1 bar

Fuel injection system

Injection pump make

Zexel

Injection pressure

2133 psi 147 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load

140A – 200A

Cranking speed

200 – 250 rpm

Battery ­ Engine starting and control system

Type

12V DC, Group 31

Quantity

2

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Engine coolant

Capacity

13.3 quarts 12,6 liters

Coolant temperature switch

Installation torque Temperature switch point

8 – 18 ft-lbs 11 – 24 Nm
221°F 105°C

Alternator output

85A @ 12V DC

Fan belt deflection

3/8 to 1/2 inch 9 to 12 mm

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

11

Service and Repair Manual
Specifications

April 2022

Machine Torque Specifications

Platform Rotator 1-8 center bolt, GR 5, dull gray, lubricated 1/2-13 bolts, GR 8, dull gray, LOCTITE® 243TM threadlocker
Turntable rotate assembly Rotate bearing mounting bolts, lubricated Rotate drive hub mounting bolts, lubricated Backlash plate mounting bolts, lubricated
Drive motors and hubs Drive hub mounting bolts, lubricated
Drive motor mounting bolts, dry
Drive motor mounting bolts, lubricated LOCTITE® 243TM threadlocker
Function Pump Pump mounting bolts, LOCTITE® 243TM threadlocker
Engine vibration isolators Compressed height

500 ft-lbs 678 Nm 80 ft-lbs 108 Nm
180 ft-lbs 244 Nm 80 ft-lbs 108 Nm
280 ft-lbs 379 Nm
180 ft-lbs 217 Nm
110 ft-lbs 149 Nm 85 ft-lbs 115 Nm
57 ft lbs 77 Nm
0.44 in – 0.56 in 11 mm – 14 mm

Machine Component Weights

Primary boom assembly (does not include jib assembly) Turntable assembly (does not include boom, jib or engine) Counterweight, S-80 XC/HF
Counterweight, S-85 XC/HF
Drive chassis assembly (does not include tire options) Tire and wheel assembly RT foam filled, max. Tire and wheel assembly High flotation, max. Drive motor and hub
Engine assembly, max.
Primary boom lift cylinder
Primary boom extend cylinder (includes cables and sheaves) Jib boom assembly (does not include platform) Jib boom cylinder
Oscillate cylinder
Platform, 6 ft / 1,8 m
Platform, 8 ft / 2,4 m
Battery

4808 lbs 2181 kg
4441 lbs 2015 kg
12300 lbs 5580 kg
14200 lbs 6441 kg
8505 lbs 3858 kg
646 lbs 293 kg
258 lbs 117 kg
282 lbs 128 kg
1300 lbs 590 kg
884 lbs 401 kg
1000 lbs 454 kg
363 lbs 165 kg
62 lbs 28 kg
99 lbs 45 kg
275 lbs 125 kg
315 lbs 143 kg
63 lbs 29 kg

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Specifications

Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with Parker Seal-LokTM ORFS or 37° JIC 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.

Seal-LokTM Fittings

(hose end – ORFS)

SAE Dash Size

Torque

-4

18 ft-lbs / 25 Nm

-6

30 ft-lbs / 41 Nm

-8

40 ft-lbs / 55 Nm

-10

60 ft-lbs / 81 Nm

-12

85 ft-lbs / 115 Nm

-16

110 ft-lbs / 150 Nm

-20

150 ft-lbs / 205 Nm

-24

230 ft-lbs / 315 Nm

JIC 37° Fittings

(swivel nut or hose connection)

SAE Dash Size

Thread Size

-4

7/16-20

-6

9/16-18

-8

3/4-16

-10

7/8-14

-12

1 1/16-12

-16

1 5/16-12

-20

1 5/8-12

-24

1 7/8-12

Flats 2
1 1/2 1 1/2 1 1/2 1 1/4
1 1 1

SAE O-ring Boss Port

(tube fitting – installed into Aluminum) (all types)

SAE Dash Size

Torque

-4

14 ft-lbs / 19 Nm

-6

23 ft-lbs / 31,2 Nm

-8

36 ft-lbs / 49 Nm

-10

62 ft-lbs / 84 Nm

-12

84 ft-lbs / 114 Nm

-16

125 ft-lbs / 169,5 Nm

-20

151 ft-lbs / 204,7 Nm

-24

184 ft-lbs / 249,5 Nm

Adjustable Fitting 1 jam nut

Non-adjustable fitting

SAE O-ring Boss Port

(tube fitting – installed into Steel)

SAE Dash Size

Torque

-4 ORFS / 37° (Adj) ORFS (Non-adj) 37° (Non-adj)

15 ft-lbs / 20,3 Nm 26 ft-lbs / 35,3 Nm
22 ft-lbs / 30 Nm

-6 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

35 ft-lbs / 47,5 Nm 29 ft-lbs / 39,3 Nm

-8 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

60 ft-lbs / 81,3 Nm 52 ft-lbs / 70,5 Nm

-10 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

100 ft-lbs / 135,6 Nm 85 ft-lbs / 115,3 Nm

-12 (All types)

135 ft-lbs / 183 Nm

-16 (All types)

200 ft-lbs / 271,2 Nm

-20 (All types)

250 ft-lbs / 339 Nm

-24 (All types)

305 ft-lbs / 413,5 Nm

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

13

Service and Repair Manual
Specifications

April 2022

Torque Procedure
Seal-LokTM 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-ring in Parker Seal LokTM fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the Oring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal 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. Refer to the appropriate torque chart in this section.
6 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks.

JIC 37° fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4 Nm. 2 Using a permanent ink marker, make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to Illustration 1.
Illustration 1 1 hex nut 2 reference mark 3 body hex fitting

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022
3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position. Note: The marks indicate the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.
Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. 5 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks.

Service and Repair Manual
Specifications

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

15

Service and Repair Manual
Repair Procedures

April 2022

Secti on 3

Repair P roce dur es

Observe and Obey:
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 Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate operator’s manual on your machine.
Be sure that all necessary tools and parts are
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.

Machine Configuration:
Unless otherwise specified, perform each
repair procedure with the machine in the following configuration:
· Machine parked on a firm, level surface
· Key switch in the off position with the key removed
· The red Emergency Stop button in the off position at both the ground and platform controls
· Wheels chocked
· All external AC power supply disconnected from the machine
· Boom in the stowed position
· Turntable secured with the turntable rotation lock

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Part No. 1280490GT

April 2022
About This Section
Most of the procedures in this section should only be performed by 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 reassemble, 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.
Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates 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.
Indicates that a specific result is expected after performing a series of steps.
Indicates that an incorrect result has occurred after performing a series of steps.

Service and Repair Manual
Repair Procedures

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

17

Service and Repair Manual
Control System

April 2022

1-1 ALC-600 Control Module
Platform Controls
The platform control box contains the ALC600 platform Control Module. The platform Control Module receives all signals from the platform switches, joysticks and foot switch, and provides operator feedback through an Indicator Module. The joystick controllers at the platform controls utilize Hall Effect technology and require no calibration. Automatic calibration of center voltage occurs on power up if the signal value is in the valid range. Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. The remaining boom functions operate by on/off toggle switches.

1-2 How to Enter ALC-600 Service Mode

1 ALC-600 platform control module 2 primary boom up/down and turntable
rotate left/right joystick controller 3 LED indicator module 4 drive/steer joystick controller

ALC-600 Control System Display
1 Number 1 or Escape 2 Number 2 or UP arrow 3 Number 3 or DOWN arrow 4 Number 4 or OK 5 Settings menu 6 (not implemented) 7 Faults menu 8 Fault LED Indicator 9 Engine hours 10Maintenance LED indicator 11Maintenance menu 12Home menu

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Control System

The Control System on this machine allows access to calibrations through the Service Mode. The procedures that follow will require the operator to be in Service Mode. Service Mode can only be entered at machine start up and requires a special code.
1 At the ground controls, select the ground control mode using the key switch.
2 Push and hold buttons numbered 2 and 3 underneath the display screen.
3 Pull out the red Emergency Stop button.
4 You will be prompted for a password. Enter 3 – 3 – 2 – 4.
5 Press the Gear button to access the settings menu.
Note: There will be a delay while the menu is being loaded on the display screen.
6 The machine will now operate normally and allow the viewing and modification of calibrations and parameters.
Note: When a parameter is changed in Service Mode, the change is effective immediately when button 4 (OK) is pushed. Machine restart is not required. A confirmation beep accompanies every save (button 4).
Note: Pushing in the red Emergency Stop button will exit Service Mode.
Note: If there has been no input for 10 minutes while in Service Mode, the ALC-600 will power down and Service Mode will be exited, unless the engine is running.

1-3 Full Machine Calibration
Full machine calibration must be completed in the proper sequence when the ALC-600 controller (TCON) in the ground control box has been replaced.
How to Fully Calibrate the Machine
Calibration procedures shall only be completed by qualified technicians that have Genie factory service training.
Tip-over hazard. Failure to calibrate the machine in the proper sequence could cause the machine to tip over resulting in death or serious injury.
Note: A digital level will be required to perform this procedure.
Note: Start this procedure with the boom in the stowed position.
Full machine calibration must be completed in the following sequence:
· Select model, engine, tires, and region, then cycle power. Refer to Repair Section Display Module.
· Turntable level sensor. Refer to Repair Procedure, How to Calibrate the Turntable Level Sensor.
· Load cell sensor. Refer to Repair Procedure, How to Calibrate the Load Cell Sensor.
· Primary boom angle sensor. Refer to Repair Procedure, How to Calibrate the Primary Boom Angle Sensor.
· Primary boom length sensor. Refer to Repair Procedure, How to Calibrate the Primary Boom Length Sensor.
· Select option configuration. Refer to Repair Section, Display Module, Options.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

19

Service and Repair Manual
Control System

April 2022

1-4 Machine Functions
How to Adju st th e M achin e Ma ximu m Spe ed Set ting
How to Adjust the Joystick Maximum Speed Setting
The maximum speed of a joystick controlled machine function can be modified from the ground controls display. Whenever a hydraulic cylinder, drive motor or hydraulic pump is replaced, the maximum speed setting should be adjusted to maintain optimum performance. The maximum speed 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 Enter the Service Mode. See Repair Procedure, How to Enter the Service Mode.
2 Press the SETTINGS button above the display screen.
3 Select SPEEDS from the display screen.
4 Navigate to the desired function’s Maximum Speed setting.
5 Select the desired setting to change and press OK.
6 In the parameter adjustment screen, use the display buttons to change the parameter. Note that the factory default speed is considered 100% for maximum speeds.
7 Scroll and press OK. The change is effective immediately.
8 Start the engine from the ground controls.
9 Start a timer and activate the machine function that needs to be adjusted. Using the ground control functions is the same as asking for full joystick deflection at the platform.

10 Record the time it takes for that function to complete a full cycle (ie; boom up).
11 Compare the machine function time with the function times listed in Refer to Specifications, Performance Specifications. Determine whether the function time needs to increase or decrease.
12 Adjust the parameter in the ground display to achieve the proper function cycle time.

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Part No. 1280490GT

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Service and Repair Manual
Control System

How to Adju st th e Joys tick Ra mp Ra te Setti ng
How to Adjust the Joystick Ramp Rate Setting
The ramp rate setting is an adjustment that controls the way boom functions start and stop. There are two types of ramp rates to adjust on separate menus:
Ramp Up Time — the amount of time it takes to accelerate to speed.
Ramp Down Time — the amount of time it takes to decelerate to a stop
The ramp rate settings of a 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 Enter the Service Mode. See Repair Procedure, How to Enter the Service Mode.
2 Press the SETTINGS button above the display screen.
3 Select SPEEDS from the display screen.
4 Navigate to the desired function’s Ramp setting.
5 Select the desired setting to change and press OK.
6 In the parameter adjustment screen, use the display buttons to change the parameter. Note that the ramp rate is expressed in seconds to complete the ramp.
7 Scroll and press OK. The change is effective immediately.

8 Start the engine from the ground controls.
9 Start a timer and activate the machine function that needs to be adjusted. Using the ground control functions is the same as asking for full joystick deflection at the platform.
10 Record the time it takes for that function to complete the ramp.
11 Compare the machine function time with the function times listed in Specifications, Performance Specifications. Determine whether the ramp time needs to increase or decrease.
12 Adjust the parameter in the ground display to achieve the proper ramp time.
Note: Refer to Repair Procedure, Display Module Menus for ramp rates.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

21

Service and Repair Manual
Control System

April 2022

How to Adju st th e Joys tick T hres hold S etting
How to Adjust the Joystick Threshold Setting
The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate.
The boom function threshold current should be operating at near zero speed, smoothly with no vibrations.
Note: Perform this procedure with the boom in the stowed position.
1 Enter the Service Mode.
2 Press the SETTINGS button above the display screen.
3 Select SPEEDS from the display screen.
4 Navigate to the desired function’s Threshold setting.
5 Select the desired setting to change and press OK.
6 In the parameter adjustment screen, use the display buttons to change the parameter. Note that the factory default speed is considered 100% for threshold values.
7 Scroll and press OK. The change is effective immediately.
8 Switch the machine control to platform control and start the engine from the platform controls..
9 Using the joystick, verify that the function engages smoothly and without sudden movement or excessive joystick dead spots.
10 Adjust the parameter in the ground display to achieve a smooth function threshold.

1-5 How to Enter ALC600 Software Update Mode
1 Go to the Genie website http://firmware.ghttps://www.genielift.com/en/s upport/firmwareenielift.com/, select your Machine Model and select Search.
2 Download the software to a USB flash drive. If zipped, extract the files to the USB flash drive.
3 With the machine off, open the GBOX (ground box) lid and then remove the four Torx head screws securing the Display Controller (DISCON) door and remove the door to expose the USB port.
4 Insert the flash drive into the USB port.
5 Set key switch to ground and pull out the red ground ESTOP while holding buttons 1 and 4.
6 The Display Controller will go into the bootloader mode.
7 Browse and select the desired software. Follow the on-screen guidance to start the update procedure.
8 When complete, turn off machine.
9 Remove USB flash drive, re-install the Display Controller door and close the GBOX (ground box).
10 Power up normally.
11 As the display controller starts, operator shall verify on the start-up screen that the proper software and revision are displayed.
12 Perform a function check.

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Part No. 1280490GT

April 2022

1-6 Display Module Menus

Screen or Menu Display Settings
Screen or Menu Model Configuration

Backlight Contrast

Item

Display Inversion

Model

Item

Tires
(These are locked Engine unless factory defaults are restored)

(Platform configuration is not locked)
Screen or Menu Options Note: Some options may not be visible with earlier software revisions.

Region: Platform Width
Platform Level Item
Footswitch Timeout Drive Priority Drive Cutout
Platform Level Generator Contact Alarm Platform Recirculation Units Aircraft Proximity Fuel Level Sensor Low Fuel Threshold Alarm Setting Standby RPM Power Save Timeout Plat Level Threshold Cal

Service and Repair Manual
Control System

Selection

Default

0 – 100% 0 – 100%

On · Off

Off

Selection

Default

S-40 · S-45 · S-60 · S-65 · S-80 · S85 · S-60 J · S-80 J
Rough Terrain · High Float · Trax

Select Model Select Tires

Deutz D 2.9L T4 · Deutz TD 2.9L T4 · Deutz TCD 2.2L S5 · Deutz TCD 2.2L T4 · Deutz TD 2.2L S5 · Deutz 2011 L03i · Deutz TD2011 L04i · Ford MSG425 EFI · GM 3.0L · Kubota D1105 · Kubota D1803 · Perkins 404D 22 · Perkins 404D 22T · Perkins 404F E22T · Perkins 404F E22TA

Select Engine

ANSI/CSA · AUS · CE

Select Region

Standard Platform 4m Platform

Standard Platform

Hydraulic · eLevel Selection
10 sec · 2 min · 30 min On · Off On · Off

Select Platform Level Default
2 min Off Off

Priority · Cutout

Priority

No Generator · Generator Installed No Generator

Gen 2 · Gen 1 · Off

Gen 2

On · Off

Off

US Customary · Metric

US Customary

On · Off

Off

Installed · Not Installed

Installed

10% – 100%

10%

Off · Travel · Motion

Travel

Default · High RPM

Default

10 min · 30 min · 60 min · 4 hrs · Off Off

On · Off

On

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Control System

Screen or Menu Sensor Calibration

Item Chassis Tilt Load Sense Boom Angle Boom Length

Select OK to calibrate Select OK to calibrate Select OK to calibrate Select OK to calibrate

Default

Platform Angle

Select OK to calibrate

Screen or Menu Drive Speeds

Item Forward Threshold Reverse Threshold

Default 1% – 128%, 100% = 800mA 1% – 134%, 100% = 720mA

Forward Max

75% – 150%, 100% = 1665mA

Reverse Max

73% – 150%, 100% = 1575mA

Forward Out of Stowed High Max 82% – 150%, 100% = 1259mA

Reverse Out of Stowed High Max 80% – 150%, 100% = 1211mA

Screen or Menu Drive Ramps

Item Standard Acceleration Standard Deceleration

0.1 – 10 sec, 4 sec 0.1 – 5 sec, 1 sec

Default

Torque Switching Deceleration 0.5 – 5 sec, 4 sec

Screen or Menu Deutz TD2011 L04i Anti-Stall

Item Threshold Drive Minimum Range

2100 rpm 50% 100 rpm

Default

Hysteresis

125 rpm

Screen or Menu Deutz TD 2.9 T4 Anti-Stall

Item Threshold Drive Minimum Range

2375 rpm 50% 125 rpm

Default

Hysteresis

100 rpm

April 2022

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Part No. 1280490GT

April 2022

Screen or Menu Deutz TCD 2.2L T4 Anti-Stall

Item Threshold Drive Minimum Range

Hysteresis

Screen or Menu Deutz TCD 2.2L S5 Anti-Stall

Item Threshold Drive Minimum Range

Hysteresis

Screen or Menu Perkins 404D 22T Anti-Stall

Item Threshold Drive Minimum Range

Hysteresis

Screen or Menu Perkins 404F E22T Anti-Stall

Item Threshold Drive Minimum Range

Hysteresis

Screen or Menu GM 3.0L Anti-Stall

Item Threshold Drive Minimum Range

Hysteresis

Screen or Menu Primary Lift Speeds

Item Extend Threshold Retract Threshold

Up Threshold

Down Threshold

Extend Max

Retract Max

Retracted Up Max

Retracted Down Max

Service and Repair Manual
Control System

2375 rpm 50% 125 rpm

Default

100 rpm

2275 rpm 50% 125 rpm

Default

100 rpm

2375 rpm 50% 125 rpm

Default

100 rpm

2400 rpm 30% 130 rpm

Default

100 rpm

2250 rpm 50% 400 rpm

Default

375 rpm

Default 1% – 212%, 100% = 460mA 1% – 169%, 100% = 460mA

1% – 186%, 100% = 560mA

1% – 292%, 100% = 400mA

66% – 150%, 100% = 1499mA

71% – 150%, 100% = 1096mA

32% – 150%, 100% = 1530mA

32% – 150%, 100% = 1937mA

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Control System

Screen or Menu Primary Lift Ramps

Item Extend Accelerating Rate Extend Decelerating Rate Retract Accelerating Rate Retract Decelerating Rate

Up Accelerating Rate

Up Decelerating Rate Down Accelerating Rate Down Decelerating Rate

Screen or Menu Turntable Speeds

Item Rotate CW Threshold Rotate CCW Threshold

Rotate CW Max Rotate CCW Max CW Out of Stow Max

CCW Out of Stow Max

Screen or Menu Turntable Ramps

Item CW Accelerating CW Decelerating

CCW Accelerating

CCW Decelerating

Screen or Menu
Jib Boom and Platform Speeds

Item Jib Up Threshold Jib Down Threshold Platform Level Up Threshold

Platform Level Down Threshold

Jib Up Max Jib Down Max Platform Level Up Max

Platform Level Down Max

Default 5000 ms max, 1000 ms min, 2500 ms 5000 ms max, 250 ms min, 1000 ms 5000 ms max, 1000 ms min, 2500 ms 5000 ms max, 500 ms min, 1000 ms

5000 ms max, 1000 ms min, 3000 ms

5000 ms max, 500 ms min, 3000 ms 5000 ms max, 1000 ms min, 3000 ms 5000 ms max, 1000 ms min, 1000 ms

Default 1% – 105%, 100% = 800mA 1% – 105%, 100% = 800mA

84% – 150%, 100% = 1210mA 84% – 150%, 100% = 1210mA 96% – 150%, 100% = 881mA

96% – 150%, 100% = 881mA

1 – 10 sec, 3 sec 0.5 – 2 sec, 2 sec

Default

1 – 10 sec, 3 sec

0.5 – 2 sec, 2 sec

Default 1% – 177%, 100% = 500mA 1% – 173%, 100% = 500mA 1% – 144%, 100% = 690mA

1% – 146%, 100% = 680mA

62% – 150%. 100% = 1014mA 63% – 150%. 100% = 990mA 73% – 150%, 100% = 1100mA

72% – 150%, 100% = 1100mA

April 2022

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Screen or Menu Jib and Platform Ramps
Screen or Menu Machine Disable Options

Item Jib Up/Down Ramp Platform Level Ramp
Item Drive Disable Machine Disable Remote Disable

Reset Defaults Software Update

Service and Repair Manual
Control System

0.2 – 2 sec. 0.75 sec 0.2 – 2 sec. 0.5 sec

Default

Default On / Off On / Off Disable Engine Start · Drive Speed Cripple · Lift Speed Cripple OK to reset Model Configuration and Options

OK to enter Software Update Mode

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Control System

April 2022

1-7 How to Replace the Display Controller (DISCON) Module
1 Push in the red Emergency Stop button to the off position at both the ground and platform controls.
2 Disconnect the negative terminal from the start battery and auxiliary battery, if equipped.
Illustration 1 1 ground box lid 2 DISCON gasket 3 DISCON 4 8/32 nylock nuts 5

8 flat washers 6 ribbon cable 7 DISCON door 8 Torx head screws

3 Open the ground box lid (1) and disconnect the wire harness going to the display controller (DISCON).
4 Remove the DISCON door from the back by loosening the four Torx head screws (8) and remove the two ribbon cables (6) connecting the ground box overlay to the DISCON.
Note the orientation of the cables for reassembly.
5 Remove the DISCON from the ground control box lid by removing the five hex nuts and washers (4, 5). Discard the nuts and washers.
Note the lanyard attachment point for reassembly.
6 Remove the old DISCON gasket (2) from the ground box lid and clean the lid surface from any dirt, oil or old adhesive residue. Use a 99% solution of isopropyl alcohol to clean the surface. Allow the surface to completely dry.
Note: Both the ground box lid and new gasket must be 70° F / 21° C or higher at the time of application. Application of the new gasket at lower temperatures is not recommended.
7 Peel the adhesive protective film from the back of the new gasket. Carefully line up the new gasket over the ground box lid, making sure the cutouts for the LCD screen, ribbon cables and mounting studs are centered and lining up with the gasket. Apply the new gasket to the ground box lid and work from the center out to eliminate air bubbles and make sure all the gasket edges are securely fixed.
Note: Once applied it is not recommended to lift the gasket and attempt to reposition it.

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Service and Repair Manual
Control System

8 Install the new DISCON onto the ground box lid and fasten it using the new hex nuts and washers. All five fastening points must be used. Attach the DISCON door’s lanyard to the DISCON’s mounting stud.
9 Evenly tighten the nuts, beginning with the lower center nut, working out and then up.
10 Install the new ribbon cables, connecting the ground box overlay to the DISCON and reinstall the DISCON door, using the Torx head screws removed in step 4. Be sure to fully lock the tabs after the ribbon cables have been fully inserted.
11 Reconnect the wire harness going to the DISCON, then close and fasten the ground box lid.
12 Reconnect the negative terminal to the start battery and auxiliary batteries, if equipped.

1-8 How to Replace the Ground Box Control Overlay
1 Push in the red Emergency Stop button to the off position at both the ground and platform controls.
2 Disconnect the negative terminal from the start battery and auxiliary battery, if equipped.
3 Open the ground control box and remove the switch contacts from the function enable switch, key switch and the red emergency stop button. Do not disconnect the wires. Insert a small screwdriver into the loop at the base of the contacts and engage the release mechanism.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

29

Service and Repair Manual
Control System

April 2022

4 Unscrew the nut holding the buttons and key switch and remove the key switch and buttons.
Note the orientation of the key switch so it can be reassembled in the same position. 5 Disconnect the wire harness connected to the
DISCON and cut the zip ties securing the harness to the ground box lid. Do not remove the wire harness from the ground box. 6 Remove the DISCON door (4) and disconnect the ribbon cables (3) from the Display Controller (DISCON) (2). Note the orientation of the cables for reassembling.
1 ground box lid 2 DISCON 3 ribbon cables 4 DISCON door 5 Torx head screws

7 Remove the ground box lid (1) from the ground box.
8 Remove the old overlay and clean the ground box lid surface from any dirt, oils or old adhesive residue. Clean the lid with 99% isopropyl alcohol. Allow the surface to completely dry.
9 Before placing the new overlay, make sure the temperature of the lid and overlay is between 80-100° F / 26-38° C. Application below 80° F / 26° C is not recommended.
10 Peel the adhesive protective film from the back of the overlay. Carefully align the overlay, making sure the LCD screen cutout, push buttons and key switch are centered. Apply the overlay to the ground box, applying pressure evenly to eliminate any air bubbles.
Note: Pay particular attention to the outside edges, the LCD cutout edges and the area around the ribbon cables, making sure there is complete contact between the overlay and the ground box.
Note: It is not recommended peeling and reapplying the overlay, so take time to align the overlay before making contact with the ground box.
11 Maintain the temperature of 80-100° F / 2638° C for a minimum of 20 minutes to allow the adhesive to cure.
12 Install the provided ribbon cables, first to the overlay and then the DISCON. Be sure the connectors are applied evenly in the sockets and the tabs are fully locked.
13 Reinstall the DISCON door using the Torx head screws (5). Tighten, but do not overtighten.
14 Reinstall the ground box door to the ground box, using the fasteners removed in step 7. Tighten the fasteners securely.

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Part No. 1280490GT

April 2022
15 Reinstall the E-Stop button, function enable button and key switch and the contact assemblies.
16 Reinstall the wire harness from the ground box to the DISCON. Secure the harness to the ground box lid using zip ties.
17 Close and fasten the ground box lid. 18 Reconnect the negative terminal to the start
battery and auxiliary batteries, if equipped.

Service and Repair Manual
Control System

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

31

Service and Repair Manual
Platform Components
2-1 Platform
How to Remove the Platform
1 Remove the cable clamp from the top of the 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.
3 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 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.
7 Support and secure the platform to an appropriate lifting device.
8 Remove the platform mounting fasteners and remove the platform from the machine.
Crushing hazard. The platform could become unstable and fall when it is removed from the machine if not properly supported.

April 2022

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Part No. 1280490GT

April 2022

Service and Repair Manual
Platform Components

2-2 Platform Leveling Cylinder
The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closedcircuit 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 Cylinder
Note: Before cylinder removal is considered, bleed the leveling 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 hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
How to Re mov e th e Platfo rm Leveli ng Slave Cylind er
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.

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.
Crushing 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 out.
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.
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 Blee d th e Slave C ylinde r
How to Bleed the Slave Cylinder
Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure.
1 Raise the 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. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

33

Service and Repair Manual
Platform Components

April 2022

2-3 Platform Rotator
The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees.
How to Re mov e th e Platfo rm R otat or
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 removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the platform. Refer to Repair Procedure, How to Remove the Platform.

2 Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the fittings on the rotator.
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 S-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.
Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported.
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 cylinder rod- end pivot pin and the rotator pivot pin.

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Service and Repair Manual
Platform Components

8 Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the machine.
Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported.
Note: When installing the platform rotator fasteners, torque the fasteners to 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 leveling arms may fall if not properly supported.
12 Lower the jib boom leveling arms.
Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported.
Note: When installing the platform rotator fasteners, torque the fasteners to specifications.

How to Blee d th e Platf orm Rota tor
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 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.
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 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.
Crushing hazard. Keep clear of the platform during rotation.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

35

Service and Repair Manual
Platform Components

April 2022

5 Open the bottom bleed screw on the rotator, but do not remove it.
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.
Crushing hazard. 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.

2-4 Platform Overload System
Proper 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.
How to Pe rfor m a Ze ro Loa d Platfo rm C alibr ation
How to Perform a Zero Load Platform Calibration
Perform this procedure when platform overload is not operating within the calibration parameters. This procedure will re-calibrate the zero load point without affecting a previous full load calibration. In most cases the machine will maintain full load capacity, however, in some situations the platform load capacity may be reduced until a full load calibration has been performed.
Note: Perform this procedure with the machine on a firm, level surface.
1 Fully retract and lower the boom. Level the platform.
2 Remove all weight, tools, accessories and equipment from the platform.
Note: Remove the welder (if equipped).
Tip-over hazard. Failure to remove all non-integrated factory and non-factory options and accessories could result in the machine tipping over, causing death or serious injury.

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S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Platform Components

3 Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode.
4 Press the settings button above the display and select the Calibrations menu.
5 Navigate to the Sensor calibration screen.
6 Navigate to the Load Sense calibration screen.
7 Select and start the calibration procedure.
8 Follow the on-screen prompts to set the zero load.
9 Follow the prompts to accept the weight.
10 Calibration is now complete.
Exit Service Mode.

How to Pe rfor m a Full Loa d Platf orm Calibr ation
How to Perform a Full Load Platform Calibration
Perform this procedure if the platform support or load cell sensor has been replaced, or if a zero load platform calibration does not return the machine to full load capacity.
Note: Perform this procedure with the machine on a firm, level surface.
1 Fully retract and lower the boom. Level the platform.
2 Remove all weight, tools, accessories and equipment from the platform.
Note: Remove the welder (if equipped).
Tip-over hazard. Failure to remove all non-integrated factory and non-factory options and accessories could result in the machine tipping over, causing death or serious injury.
3 Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode.
4 Press the settings button above the display and select the Calibrations menu.
5 Navigate to the Sensor calibration screen.
6 Navigate to the Load Sense calibration screen.
7 Select and start the calibration procedure.
8 Follow the on-screen prompts to set the zero load.
9 Continue with the on screen prompts to set the maximum load.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

37

Service and Repair Manual
Platform Components

April 2022

10 Place a test weight on the platform floor using a suitable lifting device. Place the weight near the center entry point of the platform, as far away from the operator controls as possible. Weight = 1,000 lbs / 454 kg
Note: If test weights are not available, you may use an industrial scale to weigh available objects until it equals the platform’s maximum capacity.
Note: Alternate method for achieving rated load in the platform is to attach a hanging scale to the bottom of the platform and apply load using a winch or chain hoist until the readout displays the appropriate weight.

11 Follow the prompts to accept the weight.
12 Calibration is now complete.
13 Exit Service Mode.
14 Push in the red Emergency Stop button to the off position.
Confirm calibration:
15 Start the engine from the ground controls.
16 Add an additional 50 lbs / 23 kg of weight or load to the platform.
Result: The alarm sounds. The engine turns off. The platform overload indicator light flashes at the platform controls and Platform Overload is displayed on the LCD screen at the ground controls.
Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds.
17 Test all machine functions from the ground controls.
Result: Engine does not start. Limited APU functionality. Elevate and extend functions do not operate.
18 Remove the weight or rated load from the platform.

Platform hidden from illustration for clarity
1 platform support 2 sling 3 hanging scale 4 winch or chain hoist 5 anchoring device

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Part No. 1280490GT

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Service and Repair Manual
Platform Components

How to Re place the Platfo rm O verlo ad Load Cell
How to Replace the Load Cell Sensor
Note: The preload adjustment should only be performed after the load cell sensor has been replaced.
1 Remove all equipment or tools from the platform. Remove the welder if equipped.
2 At the platform, remove the plastic instruction holder from the document mount plate.
3 Tag and disconnect the load cell sensor harness.
4 Loosen the jam nut securing the load cell sensor foot and rotate the foot screw clockwise to remove the preload.

Install the new Load Cell Sensor
6 Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out of the bottom of the sensor.The foot should not contact the flex plate when assembling onto the platform support.
7 Assemble the load cell and foot assembly to the platform and securely tighten the two mounting screws. Torque the bolts to 101 ftlbs / 137 Nm.
Set the Load Cell Sensor Preload
8 Rotate the foot screw counter clockwise until the foot just contacts the flex plate (finger tight).
9 Using an open end wrench, continue to rotate the foot counter clockwise an additional 1/2 turn (180°). Then, while holding the foot bolt, securely tighten the jam nut. Torque the jam nut to 55 ft-lbs / 75 Nm.
10 Attach the load cell sensor harness.
11 Install the plastic instruction holder.
12 Calibrate the platform overload system. Refer to, How to Perform a Full Load Platform Calibration.

1 flex plate 2 load cell sensor foot 3 jam nut 4 load cell sensor
5 Remove the fasteners securing the load cell sensor and remove the sensor.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

39

Service and Repair Manual
Jib Boom Components

April 2022

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 hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the platform. Refer to Repair Procedure, How to Remove the Platform.
Note: If the platform overload components are disassembled and/or removed from the platform support, the platform overload system will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System.
2 Tag and disconnect the electrical connector from the platform load sense cell.
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. Cables and hoses can be damaged if they are kinked or pinched.

5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.
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.
Crushing 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.
Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead lifting device.

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Part No. 1280490GT

April 2022

Service and Repair Manual
Jib Boom Components

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 hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, 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.
2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.
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 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

4 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 leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a lifting device.
6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.
Crushing hazard. The platform and jib boom could become unbalanced and fall when the jib boom barrel-end pivot pin is removed if not properly supported.
7 Attach a lifting strap from an overhead lifting device to the lug on the rod end of the jib boom lift cylinder.
8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the cylinder from the machine.
Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the suitable lifting device.

Part No. 1280490GT

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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 Re mov e th e Cabl e T rack, S-80
How to Remove the Cable Track
Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
1 Open the platform control box.
2 Tag 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 Disconnect 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.

6 S-80XC: 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 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 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-85XC: 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 the fittings on the manifold.
11 Tag, disconnect and plug the wiring from the jib boom/platform rotate select manifold.

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Service and Repair Manual
Boom Components

12 Tag, disconnect and plug the hydraulic hoses from the jib boom lift cylinder. Cap the fittings on the cylinder.
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 cotter pin from the upper cable track at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
15 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.
16 Remove the cable clamp from the pivot end of the boom.

17 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together.
Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.
18 Attach a lifting strap from an overhead crane to the cable track.
19 Remove the mounting fasteners that attach the lower cable track to the boom.
20 Remove the cable track from the machine and place it on a structure capable of supporting it.
Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the lifting device.
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.

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Service and Repair Manual
Boom Components

April 2022

How to Re pair the Cable Tr ack
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 Genie Service Parts, 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 Lift up 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.
5 Remove the upper rollers from the replacement section of cable track.
6 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.
7 Connect the ends of the replacement cable track section to the existing cable track using the snap rings.
8 Install the rollers onto the new section of cable track.
9 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track.

4-2 Boom

How to Shi m th e Boo m
How to Shim the Boom
1 Measure each wear pad.

Boom wear pad specifications

Boom number one

Minimum

Bottom wear pads (extension end of boom)

0.50 inch 12.7 mm

Top and side wear pads (extension end of boom)

0.625 inch 15.9 mm

Boom number two

Top, bottom and side wear pads (extension end of boom)

0.50 inch 12.7 mm

Bottom wear pads (pivot end of boom)

0.50 inch 12.7 mm

Top and side wear pads (pivot end of boom)

0.625 inch 15.9 mm

Boom number three

Top, bottom and side wear pads (pivot end of boom)

0.50 inch 12.7 mm

Note: Replace the pad if thickness is less than minimum specification. If thickness is more than minimum specification, perform the following procedure.

2 Extend the boom until the wear pads are accessible.
3 Loosen the wear pad mounting fasteners.
4 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.

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Service and Repair Manual
Boom Components

How to Re mov e th e Boo m
How to Remove the Boom
Tip-over hazard. This procedure requires the removal of the 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.
Tip-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.
Tip-over hazard. The turntable 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.
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.

1 Remove the jib boom. Refer to Repair Procedure, How to Remove the Jib Boom.
2 Remove the cable track. Refer to Repair Procedure, How to Remove the Cable Track.
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 / 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 Securely attach shackles and lifting straps or chains with a minimum rating of 7.5 tons / 7000 kg to the lifting points on the top of the turntable counterweight. Attach the lifting straps or chains to a 7.5 ton / 7000 kg overhead crane.
Note: A spreader bar and other hardware may be needed to safely remove the counterweight.
8 Slowly operate the overhead crane to apply tension to the lifting straps. Do not attempt to lift the machine with the overhead crane.

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Service and Repair Manual
Boom Components

April 2022

9 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 if not properly supported by the overhead crane resulting in death or serious injury. Keep personnel away from the area when removing the counterweight.
10 Remove the end cover from the pivot end of the primary boom.
11 Remove the limit switch mounting fasteners from the limit switch on the ground controls side of the primary boom. Do not disconnect the wiring. Remove the limit switch.
12 Disconnect the electrical connector from the string potentiometer.
13 Disconnect the electrical connector from the primary boom angle sensor.
Note: The primary boom angle sensor is located on the pivot pin on the engine side of the boom.
14 Remove the primary boom angle sensor bracket mounting fasteners and remove the primary boom angle sensor from the primary boom. Do not remove the angle sensor from the bracket.
Note: When the primary boom is installed, the primary boom angle sensor will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Primary Boom Angle Sensor.

15 Remove the hose and cable guide fasteners at the primary boom pivot pin. Remove the hose and cable guide.
16 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.
17 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device.
18 Remove the lift cylinder rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin.
Crushing hazard. The boom could fall if not properly supported when the lift cylinder rod-end pivot pin is removed.
19 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.
Crushing hazard. The boom lift cylinder could fall if not properly supported and secured to the lifting device.
20 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.
21 Remove the boom end cover retaining fasteners and remove the cover.

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Service and Repair Manual
Boom Components

22 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder.
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.
23 Tag and disconnect the electrical connector for the cable break limit switch.
24 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom.
25 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.
26 Tag, disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom. Cap the bulkhead fittings.
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.
27 Remove the external snap rings from both boom pivot pins at the short and long link arms. Do not remove the pins.

28 Using the overhead crane, adjust the boom as necessary to relieve pressure from the pivot pins.
29 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.
Crushing hazard. The boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed.
Crushing hazard. The long and short link arms may fall if not properly supported when the boom pivot pins are removed.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Boom Components

April 2022

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
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.
Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, 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 the pin.
Crushing hazard. The boom will fall if not properly supported when the primary boom rodend pivot pin is removed.

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.
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.
Crushing hazard. The 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.
Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device.

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Service and Repair Manual
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
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.
Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
Note: Perform this procedure with the boom fully retracted.
1 Raise the boom to a horizontal position.
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 Remove the mounting plates and the string potentiometer.

5 Fully loosen the lock nuts on the extend cables. Do not remove the nuts.
1 boom angle sensor 2 string potentiometer 3 cable guard 4 cable guard retaining plate 6 Loosen the retract cable nut at the platform end of the boom. Pull the cable rod from the support and let it hang down. 7 Remove the cable guard fasteners and remove the cable guard. 8 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube. 9 Remove the cable retaining plates and pull the retract cables off of the pulleys. Lay the cables flat and out of the way.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

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Service and Repair Manual
Boom Components

April 2022

10 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. 11 Disconnect the wire connector to the extend
cable break limit switch. 12 Remove the retaining fasteners that secure
the extend cable mounting plates to the inside of the number 1 boom tube.
1 extend cable lock nuts 2 extend cable mounting plate 3 extend cable mounting plate fastener 4 extend cable bracket 13 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube.

14 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.
15 Locate the lower extend cable bracket on the bottom of the number 3 boom tube.
16 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube.
17 While pushing the lower extend cable bracket towards the platform, pull the extend cable mounting plate towards the pivot end of the boom.
18 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder.
19 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom.
20 Use a soft metal drift to remove the pin.
21 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder.
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 Attach a lifting strap from a 5 ton / 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder.

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Service and Repair Manual
Boom Components

23 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube.
24 Carefully support and slide the extension cylinder out of the boom.
Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported.
Component damage hazard. Be careful not to damage the cable 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 primary boom.
Note: During removal of the extension cylinder, the overhead crane strap will need to be carefully adjusted for proper balancing.

4-5 Boom Extend and Retract Cables
How to Adju st th e Exten d/Ret ract 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 in a horizontal position.
1 Start the engine from the ground controls.
2 Raise the boom to a horizontal position.
3 Fully retract the boom.
4 Stop the 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.
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.

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Service and Repair Manual
Boom Components

April 2022

8 Locate the extend cable adjustment nuts on the counterweight end of boom tube #1. Refer to Illustration 1. 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 2. There should be approximately 1/2 inch of exposed threads on the adjustment bolts. Refer to Illustration 1.
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 lbs / 43-49 Nm using gentle and steady torque.
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 3 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 end 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.

Illustration 1
1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate

Illustration 2 1 6.375 inches / 16.2 cm

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Service and Repair Manual
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.
18 Install the boom end cover at the pivot end of the boom.
19 Fully retract and lower the boom to the stowed position.

How to Re place the Boom Exten d/Ret ract C ables
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. Refer to Repair Procedure, 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 pin. 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. 1280490GT

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Service and Repair Manual
Boom Components

April 2022

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.
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.
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. Refer to Repair Procedure, How to Adjust the Boom Extend/Retract Cables.

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Part No. 1280490GT

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Service and Repair Manual
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 (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.
1 Raise the boom until the master cylinder rodend pivot pin is accessible.
2 Remove the turntable end cover to access the master cylinder.
3 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder.
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 pin retaining fastener from the master cylinder barrel-end pivot pin.

5 Place a rod through the barrel-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. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the lifting device.

Part No. 1280490GT

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Service and Repair Manual
Boom Components

April 2022

4-7 Primary Boom Angle Sensor
The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the turntable and gravity.
How to Calibrate the Primary Boom Angle Sensor
Note: Perform this procedure with the machine on a firm, level surface with the boom in the stowed position.
Note: The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor.
Note: This procedure will establish the cross-check angle with the boom limit switch LST3S. If LST3S does not switch its state properly during the calibration, the calibration will be invalidated.
1 Fully retract and lower the boom. Ensure the boom is in contact with the boom rest pad.
2 Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode.
3 Press the settings button above the display and navigate to the Sensor Calibrations menu.
4 Navigate to the Boom Angle Sensor calibration screen.
5 Select and start the calibration procedure.
6 Start the engine.
7 When the display prompts the operator to lower the boom, press and hold the function enable button and the boom down buttons until the display indicates that the lower calibration point has been obtained. This may require holding the buttons for several seconds after the boom has touched the rest pad.

8 Press OK on the display to continue with the procedure to capture the maximum angle point.
9 Operate the boom up function until the boom reaches its maximum angle. Continue holding the function enable and boom up buttons for several seconds until the display indicates that the upper calibration point has been obtained. This may require holding the buttons for several seconds after the boom reaches its maximum angle.
10 Follow the on-screen prompts to lower the boom until the display indicates the calibration is complete. If this step isn’t done, the boom will be in the safety envelope when the calibration procedure ends
11 The calibration is now complete.
12 Exit the Service Mode.

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Service and Repair Manual
Boom Components

4-8 Boom Length Sensor
How to Calibrate the Primary Boom Length Sensor
Note: The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor.
Note: The turntable level sensor, platform load sensor and primary boom angle sensor must be calibrated before calibrating the boom length sensor.
Note: This procedure will establish the cross-check angle with the boom limit switch LSB1RS. If LSB1RS does not switch its state properly during calibration, the calibration will be invalidated.
1 Fully retract the boom. Ensure the boom angle is above 65°.
2 Enter Service Mode. See Repair Procedure, How to Enter Service Mode.
3 Press the settings button above the display and navigate to Sensor Calibrations.
4 Navigate to the Boom Length Sensor calibration screen.
5 Select and start the calibration procedure.
6 Start the engine.
7 When the display prompts the operator to retract the boom, press and hold the function enable and boom retract buttons until the display indicates the retracted calibration point has been obtained. This may require holding the buttons for several seconds after the boom has fully retracted.

8 Press the OK button to continue to capture the maximum extension point.
9 Press the function enable and boom extend buttons until the boom reaches its maximum extension. Continue holding the buttons for several seconds after the boom reaches its maximum extension until the display indicates the calibration point has been captured.
10 The calibration is complete.
11 Exit the Service Mode.

Part No. 1280490GT

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Service and Repair Manual
Engines

April 2022

5-1 RPM Adjustment
Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine, Check and Adjust the Engine RPM.

5-2 Flex Plate
The flex plate acts as a coupler between the 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)
How to Re mov e th e Fl ex Plate
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).
Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
3 Tag and disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump.

58

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Engines

Deutz TD2011L04i models:
1 Tag and disconnect the wiring from the bell housing.
2 Remove the U-bolt from the exhaust flex pipe at the muffler.
Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns.
3 Remove the muffler bracket retaining fasteners from bell housing. Remove the muffler and bracket assembly from the engine.
4 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners.
5 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.
6 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel.

Deutz TD 2.9, TCD 2.2 models:
1 Tag and disconnect the wiring from the bell housing.
2 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners.
3 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.
4 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel.

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

59

Service and Repair Manual
Engines

April 2022

Perkins models:
1 Tag and disconnect the wiring from the bell housing.
2 Remove the fasteners supporting the muffler assembly from the bell housing.
Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns.
3 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners.
4 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.
5 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel.

GM model:
1 Tag and disconnect the wire harness from the oxygen sensor.
2 Remove the exhaust pipe heat shield fasteners from the top of the muffler.
Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns.
3 Remove the muffler retainer bracket fasteners.
4 Remove the muffler fasteners securing the muffler to the exhaust manifold. Remove the muffler from the bracket.
5 Remove the relay housing from the muffler mount. Do not disconnect the relays.
6 Disconnect and remove the ECM from the muffler mount.
7 Close the shutoff valve on the Liquid Petroleum Gas (LPG) tank by turning it clockwise (if equipped).
8 Unbolt the EPR valve from the muffler mount. Leave the hoses attached to the EPR valve.
9 Remove the muffler mount.
10 Support the drive pump with an appropriate lifting device. Remove all of pump plate mounting fasteners.
11 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.
12 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel.

60

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

Part No. 1280490GT

April 2022

Service and Repair Manual
Engines

How to I nstall t he Flex Plat e
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 locker to the mounting fasteners.
Note: Torque the flex plate mounting fasteners in two stages.
2 Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm.

3 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.
4 Apply Loctite® removable thread locker to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm.
5 Install the pump onto the pump mounting plate. 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.
6 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.
7 Install the pump and pump mounting plate assembly onto the engine. Apply Loctite® removable thread locker to the mounting screws.

Deutz, Perkins

GM

Part No. 1280490GT

S®-80 XCTM · S®-80 HF · S®-85 XCTM · S®-85 HF

61

Service and Repair Manual
Engines
How to ins tall th e Pum p a nd Bell Ho using Assem bly
How to Install the Pump and Bell Housing Assembly
1 Install the pump and bell housing assembly.
Deutz models: Torque the bell housing mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the bell housing mounting bolts in sequence to 40 ft-lbs / 54 Nm.
Perkins 404D models: Torque the bell housing mounting bolts labeled “B” in sequence to 28 ft-lbs / 38 Nm and the mounting bolts labeled “A” to 49 ft-lbs / 66 Nm. Then torque the bell housing mounting bolts labeled “B” in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled “A” to 70 ft-lbs / 95 Nm.
GM 3.0L model: Torque the bell housing mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the bell housing mounting in sequence to 40 ft-lbs / 54 Nm bolts.
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 no

References

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