Genie S-80X Service and Repair Manual

Service and Repair Manual

Serial Number Range

S-80

from S8015-12264 to

S8016H-

13999

from S8515-12264

to

S8516H-13999

This manual

includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S-85

from S80X15-12264 to

S80X16H-

13999

from S8015D-

101 to

S8016D-339

S-80X

from S80X15D-101 to

S80X16D-

339

from S80H-14000

from S85H-

14000

from S80XH-

14000

from S80D-340

from S85D-

340

from S80XD-

340

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1269074

Rev A3

October 2016

Service and Repair Manual October 2016

Introduction

ii S-80 • S-85 • S-80X Part No. 1269074

Intr oducti o n Intr oducti o n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual 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.

1269074 Rev A, September 2015

First Edition, First Printing

"Genie" and "S" are registered trademarks of Terex South

Dakota, Inc. in the USA and many other countries.

October 2016 Service and Repair Manual

Introduction

Part No. 1269074 S-80 • S-85 • S-80X iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 9/2015

Initial Release

A1 7/2016 Repair Procedures Added 4-7, Primary Boom Angle Sensor, S80X

A2 9/2016 Introduction Serial Number Legend

A3 10/2016 Repair; Schematics Hydraulic Drive Manifolds, Hydraulic Schematics

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual October 2016

Introduction

iv S-80 • S-85 • S-80X Part No. 1269074

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (located under cover)

6 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

October 2016 Service and Repair Manual

Safety Rules

Part No. 1269074 S-80 • S-85 • S-80X v

Section 1 Safet y R ules

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

 You are trained and qualified to perform

maintenance on this machine.

 You read, understand and obey:

• manufacturer's instructions and safety rules

• employer's safety rules and worksite

regulations

• applicable governmental regulations

 You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual October 2016

Safety Rules

vi S-80 • S-85 • S-80X Part No. 1269074

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 hazar

ds

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 with

in 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 lift

ing or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is

properly ventilated and well lit.

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X vii

Introduction Introduction ........................................................................................................... ii

Important Information ............................................................................................. ii

Find a Manual for this Model .................................................................................. ii

Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v

Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1

Performance Specifications .................................................................................... 2

Hydraulic Specification ........................................................................................... 2

Hydraulic Component Specifications...................................................................... 5

Manifold Component Specifications ....................................................................... 6

Continental TME27 Engine Specifications ............................................................. 7

Deutz TD2011L04i Engine Specifications .............................................................. 8

Deutz TD 2.9 Engine Specifications ....................................................................... 9

Perkins 804D-33 Engine Specifications ............................................................... 10

Perkins 404F-22T Engine Specifications ............................................................. 11

Machine Torque Specifications ............................................................................ 12

Hydraulic Hose and Fitting Torque Specifications ............................................... 13

Torque Procedure ................................................................................................ 14

October 2016

Table of Contents

viii S-80 • S-85 • S-80X Part No. 1269074

Section 3 Repair Procedures ............................................................................................. 16

Introduction .......................................................................................................... 16

Platform Controls ............................................................................................... 18

1-1 ALC-500 Circuit Board ................................................................................... 18

How to Remove the ALC-500 Circuit Board ................................................... 18

1-2 Joysticks ........................................................................................................ 19

How to Adjust the Joystick Max-out Setting ................................................... 20

How to Adjust the Joystick Ramp Rate Setting .............................................. 21

How to Adjust the Joystick Threshold Setting ................................................ 22

How to Calibrate the Boom Angle Sensor ...................................................... 23

Platform Components ....................................................................................... 25

2-1 Platform .......................................................................................................... 25

2-2 Platform Leveling Slave Cylinder ................................................................... 26

How to Remove the Platform Leveling Slave Cylinder ................................... 26

How to Bleed the Slave Cylinder .................................................................... 26

2-3 Platform Rotator ............................................................................................. 27

How to Remove the Platform Rotator ............................................................. 27

How to Bleed the Platform Rotator ................................................................. 28

2-4 Platform Overload System ............................................................................. 29

Jib Boom Components ...................................................................................... 32

3-1 Jib Boom ........................................................................................................ 32

3-2 Jib Boom Lift Cylinder .................................................................................... 33

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X ix

Boom Components ............................................................................................ 34

4-1 Cable Track .................................................................................................... 34

How to Remove the Cable Track, S-80 .......................................................... 34

How to Repair the Cable Track ....................................................................... 36

4-2 Boom .............................................................................................................. 36

How to Shim the Boom ................................................................................... 36

How to Remove the Boom .............................................................................. 37

4-3 Boom Lift Cylinder .......................................................................................... 39

4-4 Boom Extension Cylinder ............................................................................... 41

4-5 Boom Extend/Retract Cables ......................................................................... 43

How to Adjust the Extend/Retract Cables ....................................................... 43

How to Replace the Boom Extend/Retract Cables ......................................... 45

4-6 Platform Leveling Master Cylinder ................................................................. 47

4-7 Primary Boom Angle Sensor, S-80X .............................................................. 48

Engines ................................................................................................................ 50

5-1 RPM Adjustment ............................................................................................ 50

5-2 Flex Plate ....................................................................................................... 50

How to Remove the Flex Plate........................................................................ 50

How to Install the Flex Plate ............................................................................ 53

How to install the Pump and Bell Housing Assembly ..................................... 54

Ground Controls ................................................................................................. 55

6-1 Control Relays ................................................................................................ 55

Hydraulic Pumps ................................................................................................ 56

7-1 Function Pump ............................................................................................... 56

7-2 Drive Pump..................................................................................................... 57

How to Prime the Pump .................................................................................. 58

October 2016

Table of Contents

x S-80 • S-85 • S-80X Part No. 1269074

Manifolds ............................................................................................................ 59

8-1 Function Manifold .......................................................................................... 59

8-2 Valve Adjustments - Function Manifold ......................................................... 61

How to Adjust the System Relief Valve .......................................................... 61

How to Adjust the Boom Down Relief Valve ................................................... 61

How to Adjust the Boom Extend Relief Valve ................................................. 62

8-3 Brake/Two-Speed Manifold Components ...................................................... 63

8-4 Turntable Rotation Manifold Components ..................................................... 64

8-5 Platform Rotate Manifold Components .......................................................... 65

8-6 Platform Manifold Components, S-80 ............................................................ 66

8-7 Platform Manifold Components, S-85 ............................................................ 67

8-8 2WD Traction Manifold Components ............................................................. 68

8-9 4WD Traction Manifold Components ............................................................. 69

8-10 Drive Oil Diverter Manifold Components (welder option) ............................ 71

8-11 Valve Adjustments - Traction Manifold ........................................................ 72

8-12 Valve Coils ................................................................................................... 73

Valve Coil Resistance Specifications ............................................................. 73

Fuel and Hydraulic Tanks ................................................................................. 75

9-1 Fuel Tank ....................................................................................................... 75

9-2 Hydraulic Tank ............................................................................................... 76

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X xi

Turntable Rotation Components ...................................................................... 78

10-1 Turntable Rotation Drive Hub Assembly ...................................................... 78

How to Remove the Turntable Rotation Drive Hub Assembly ........................ 78

How to Remove the Turntable Rotation Hydraulic Motor ............................... 79

How to Adjust the Turntable Rotation Gear Backlash .................................... 80

Steer Axle Components ..................................................................................... 82

11-1 Yoke and Drive Hub ..................................................................................... 82

11-2 Drive Motors ................................................................................................. 83

11-3 Drive Hubs.................................................................................................... 83

11-4 Steer Cylinders ............................................................................................. 84

Non-steer Axle Components ............................................................................. 85

12-1 Drive Motor ................................................................................................... 85

12-2 Drive Hub ..................................................................................................... 85

Oscillating Axle Components ........................................................................... 86

13-1 Oscillate Axle Cylinders ............................................................................... 86

13-2 Oscillate Directional Valve ........................................................................... 87

How to Adjust the Oscillate Relief Valve ......................................................... 87

How to Set Up the Directional Valve Linkage ................................................. 88

October 2016

Table of Contents

xii S-80 • S-85 • S-80X Part No. 1269074

Section 4 Fault Codes ......................................................................................................... 89

Introduction .......................................................................................................... 89

Control System Fault Codes ............................................................................. 90

How to Retrieve Control System Fault Codes ................................................ 90

Control System Fault Codes ........................................................................... 91

Fault Code Display - Deutz and Perkins Models ............................................. 95

How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins

404F-22 Models ...................................................................................... 95

Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins

404F-22 Models ...................................................................................... 96

Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models

................................................................................................................ 97

Main Menu Structure - Deutz D 2.9 L4 Models .............................................. 98

Main Menu Structure - Perkins 404F-22 Models ............................................ 99

Deutz D 2.9 L4 Engine Fault Codes ................................................................ 100

Perkins 404F-22 Engine Fault Codes ............................................................. 111

Continental TME27 Engine Fault Codes ........................................................ 113

How to Retrieve Continental Engine Fault Codes ........................................ 113

How to Clear Engine Fault Codes from the ECM ......................................... 113

Continental TME27 Engine Fault Codes ...................................................... 114

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X xiii

Section 5 Schematics ........................................................................................................ 119

Introduction ......................................................................................................... 119

Electrical Symbol Legend ................................................................................... 120

Hydraulic Symbols Legend ................................................................................. 121

Relay and Fuse Panel Legend - Deutz TD2011L04i.......................................... 122

Relay and Fuse Panel Legend - Deutz TD2.9 L4 .............................................. 122

Relay and Fuse Panel Legend - Perkins 404F-22T ........................................... 122

Relay and Fuse Panel Legend - Perkins 804D-33 ............................................. 123

Relay and Fuse Panel Legend - Continental TME27 ......................................... 123

Connector Pin Legends ...................................................................................... 124

Continental TME27 Engine Harness .................................................................. 129

S-80X Ground Control Box Wiring Diagram ....................................................... 130

Deutz TD2.9 L4 Engine Harness........................................................................ 133

Perkins 404F-22T Engine Harness .................................................................... 134

Electrical Schematics, S-80X – ANSI and CSA Models ................................ 136

Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) .......... 137

Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ........... 141

Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ......... 143

Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ..... 146

Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ...... 150

Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) .... 151

Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA) ....... 154

Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ....... 158

Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ...... 159

Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA) ........ 162

Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) ......... 166

Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) ........ 167

Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA) .... 170

Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA) ..... 174

Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA) .... 175

October 2016

Table of Contents

xiv S-80 • S-85 • S-80X Part No. 1269074

Electrical Schematics, S-80, S-85 – ANSI and CSA Models ........................ 177

Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models

(ANSI / CSA) ......................................................................................... 178

Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models

(ANSI / CSA) ......................................................................................... 182

Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models

(ANSI / CSA) ......................................................................................... 183

Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models

(ANSI / CSA) ......................................................................................... 186

Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models

(ANSI / CSA) ......................................................................................... 190

Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models

(ANSI / CSA) ......................................................................................... 191

Electrical Schematic, S-80 • S-85 - Perkins 404F-22T Models

(ANSI / CSA) ......................................................................................... 194

Ground Control Box, S-80 • S-85 - Perkins 404F-22T Models

(ANSI / CSA) ......................................................................................... 198

Platform Control Box, S-80 • S-85 - Perkins 404F-22T Models

(ANSI / CSA) ......................................................................................... 199

Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models

(ANSI / CSA) ......................................................................................... 202

Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models

(ANSI / CSA) ......................................................................................... 206

Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models

(ANSI / CSA) ......................................................................................... 207

Electrical Schematic, S-80 • S-85 - Continental TME27 Models

(ANSI / CSA) ......................................................................................... 210

Ground Control Box, S-80 • S-85 - Continental TME27 Models

(ANSI / CSA) ......................................................................................... 214

Platform Control Box, S-80 • S-85 - Continental TME27 Models (ANSI / CSA)

.............................................................................................................. 215

October 2016

Table of Contents

Part No. 1269074 S-80 • S-85 • S-80X xv

Electrical Schematics, S-80, S-85 – CE Models............................................. 217

Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ............... 218

Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ................ 222

Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ............... 223

Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 226

Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 230

Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) .......... 231

Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 234

Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 238

Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) ............. 239

Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE) .......... 242

Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE) .......... 246

Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE) ......... 247

Electrical Schematics, S-80, S-85 – AS Models............................................. 249

Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS) ........... 250

Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)............ 254

Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS) .......... 255

Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS) .............. 258

Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) ............... 262

Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) ............. 263

Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS) .......... 266

Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS) ........... 270

Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS) ......... 271

Schematics - Options ....................................................................................... 273

Continental Options Schematic ..................................................................... 274

Deutz and Perkins Options Schematic ......................................................... 275

Platform Level Cutout, CTE Option ............................................................... 278

12 kW Hydraulic Generator Wiring Diagram ................................................. 279

12 kW Hydraulic Generator Electrical Schematic ......................................... 282

Belt Driven Generator Option ........................................................................ 283

Hydraulic Schematics ...................................................................................... 285

Hydraulic Schematic, 2WD Models ............................................................... 286

Hydraulic Schematic, 4WD Models ............................................................... 287

October 2016 Service and Repair Manual

Specifications

Part No. 1269074 S-80 • S-85 • S-80X 1

Section 2 Speci fic ations

Machine Specifications

Tires and wheels

Rough Terrain and Non Marking

Tire size

18-

625 FF

Tire ply rating

16 p

ly

Overall tire diameter

40.7 i

n

103.3 c

m

Tire pressure

Foam filled

Wheel diameter

24.5 i

n

62.2 c

m

Wheel width

15 i

n

38.1 c

m

Tire weight, new foam filled

(minimum)

622 l

bs

282 k

g

Tires and wheels High Flotation

Tire size

41/18LLx22.5

Tire ply rating

14 p

ly

Tire pressure

70 p

si

4.8 b

ar

Wheel diameter

22.5 i

n

57 c

m

Wheel width

14 i

n

35.6 c

m

Lugs

and Lug Nut Torque

Wheel lugs

11 @ 3/4 -

16

Lug nut torque, dry

420 ft-

lbs

569 Nm

Lug nut torque, lubricated

320 ft-

lbs

434 Nm

Fluid capacities

Fuel tank,

Deutz and Perkins models

35 g

allons

132.5 l

iters

Fuel tank,

Continental model

30 g

allons

113.5 l

iters

LPG tank

33.5 l

bs

15.2 k

g

Hydraulic tank

40 g

allons

151.4 l

iters

Hydraulic system (including tank)

50 g

allons

189.3 l

iters

Turntable rotation drive hub

(single fill port)

40 f

l oz

1183 c

c

Turntable rotation drive hub

(dual fill port)

43 f

l oz

1262 c

c

Drive hubs

four wheel drive

30.5 f

l oz

902 c

c

Drive hubs

two wheel drive

23 f

l oz

680 c

c

Drive hub oil type: SAE 9

0 multipurpose hypoid

gear oil API service classification GL5

Service and Repair Manual October 2016

Specifications

2 S-80 • S-85 • S-80X Part No. 1269074

Performance Specifications

Drive speed, maximum

Stowed position,

RT tires

40 ft / 7.9 - 8.5 s

ec

12.2 m / 7.9 - 8.5 s

ec

Stowed position,

High Flotation tires

40 ft / 11 - 13 s

ec

12.2 m / 11 - 13 s

ec

Raised or Extended

40 ft / 40 - 45 s

ec

12.2 m / 40 - 45 s

ec

Braking distance,

maximum

High range on paved surface

6 ft / 1.8

m

Gradeability

Refer to Operator's Manual

Boom function speeds, maximum from platform

controls

Jib Boom up (S

-85) 25 - 35 s

ec

Jib Boom down (S

-85) 15 - 25 s

ec

Boom up (ANSI, CSA, models)

57 - 65 s

ec

Boom up (CE, AS models)

75 - 83 s

ec

Boom down (ANSI, CSA, models)

61 - 69 s

ec

Boom down (CE, AS models)

75 - 83 s

ec

Boom extend

59 - 67 s

ec

Boom retract

57 - 65 s

ec

Turntable rotate, (360°) fully stowed

95 - 103 s

ec

Turntable rotate, (360°) boom

raised

or extended

210 - 250 s

ec

Platform rotate, 160°

8 - 12 s

ec

Platform level (10° range of motion)

ANSI, CSA

3 - 5 s

ec

Platform level (10° range of motion)

CE, AS

20 - 22 s

ec

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 p

pm

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

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 it's

maximum allowable range. If the hydraulic fluid

temperature consistently exceeds 200°F / 90°C an

optional oil cooler may be required.

October 2016 Service and Repair Manual

Specifications

Part No. 1269074 S-80 • S-85 • S-80X 3

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

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

Chevron Rando HD Premium Oil

MV Fluid Properties

ISO Grade

32

Viscosity index

200

Kinematic Viscosity

cSt @ 200°F / 100°C

cSt @ 104°F / 40°C

7.5

33.5

Brookfield Viscosity

cP @

-4°F / -20°C

cP @

-22°F / -30°C

1040

3310

Flash point

375°F / 190°C

Pour point

-58°F / -

50°C

Maximum continuous operating

temperature

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.

Service and Repair Manual October 2016

Specifications

4 S-80 • S-85 • S-80X Part No. 1269074

Chevron 5606A Hydraulic Oil

Fluid Properties

ISO Grade

15

Viscosity index

300

Kinematic Viscosity

cSt @ 200°F / 100°C

cSt @ 104°F / 40°C

cSt @

-40°F / -40°C

5.5

15.0

510

Flash point

180°F / 82°C

Pour point

-81°F / -

63°C

Maximum continuous operating

temperature

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

46

Viscosity index

154

Kinematic Viscosity

cSt @ 200°F / 100°C

cSt @ 104°F / 40°C

8.0

44.4

Flash point

482°F

/ 250°C

Pour point

-49°F / -

45°C

Maximum continuous operating

temperature

180°F / 82°C

Shell Tellus S4 VX Fluid

Properties

ISO Grade

32

Viscosity index

300

Kinematic Viscosity

cSt @ 200°F / 100°C

cSt @ 104°F / 40°C

9

33.8

Brookfield Viscosity

cSt

@ -4°F / -20°C

cSt @

-13°F / -25°C

cSt @

-40°F / -40°C

481

702.4

2624

Flash point

>100

Pour point

-76°F / -

60°C

Maximum continuous operating

temperature

103°F / 75°C

UCON Hydrolube HP-5046 Fluid

Properties

ISO Grade

46

Viscosity index

192

Kinematic Viscosity

cSt @ 149°F / 65°C

cSt @ 104°F / 40°C

cSt @ 0°F /

-18°C

22

46

1300

Flash point

None

Pour point

-81°F / -

63°C

Maximum continuous operating

temperature

189°F / 87°C

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