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Genie S-85, S-80, S-80X Service and Repair Manual

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Service and Repair Manual
Serial Number Range
from S8015-12264 to
S8016H-
13999
from S8515-12264
to
S8516H-13999
This manual
includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
from S80X15-12264 to
S80X16H-
13999
from S8015D-
101 to
S8016D-339
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.
Copyright © 2015 by Terex Corporation
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
/