Terex Genie S-80 XC Series User Manual

Terex Genie S-80 XC Series

197 pages

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Service and Repair Manual

Serial Number Range

S

®

-80 XC

™

from S80XCH-101

from S80XCD-

101

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S

®

-80 HF

S

®

-85 XC

™

from S85XCH-101

from S85XCD-

101

S

®

-85 HF

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part

No. 1280490GT

Rev C7

October 2019

Table of Contents

Introduction2
- Find a Manual for this Model2
- Serial Number Legend4
Safety Rules5
- Table of Contents7
Specifications13
- Machine Specifications13
- Performance Specifications14
- Hydraulic Oil Specifications14
- Hydraulic Component Specifications17
- Manifold Component Specifications18
- Deutz TD2011 L04I Engine Specifications19
- Deutz TD 2.9 Engine Specifications20
- Perkins 404D-22T Engine Specifications21
- Perkins 404F-E22TA Engine Specifications22
- GM 3.0L Engine Specifications23
- Machine Torque Specifications24
- Hydraulic Hose and Fitting Torque Specifications25
- Torque Procedure26
Repair Procedures28
- Introduction28
- About this Section29
Control System30
- 1 ALC-600 Platform Control Module30
- Service Mode30
- Full Machine Calibration31
- Machine Functions32
- How to Enter ALC600 Software Update Mode34
- Display Module Menus35
- How to Replace the Display Controller (DISCON) Module39
- How to Replace the Ground Control Overlay40
Platform Components43
- Platform43
- Platform Leveling Slave Cylinder43
  - How to Remove the Platform Leveling Slave Cylinder43
  - How to Bleed the Slave Cylinder44
- Platform Rotator44
  - How to Remove the Platform Rotator44
  - How to Bleed the Platform Rotator46
- Platform Overload System47
Jib Boom Components50
- Jib Boom50
- Jib Boom Lift Cylinder51
Boom Components52
- Cable Track52
  - How to Remove the Cable Track, S-8052
  - How to Repair the Cable Track54
- Boom54
  - How to Shim the Boom54
  - How to Remove the Boom55
- Boom Lift Cylinder58
- Boom Extension Cylinder59
- Boom Extend/Retract Cables61
  - How to Adjust the Extend/Retract Cables61
  - How to Replace the Boom Extend/Retract Cables63
- Platform Leveling Master Cylinder65
- Primary Boom Angle Sensor Calibration66
- Boom Length Sensor67
Engines68
- RPM Adjustment68
- Flex Plate68
Hydraulic Pumps73
- Function Pump73
- Drive Pump74
  - How to Prime the Drive Pump75
Manifolds76
- Function Manifold76
- Valve Adjustments - Function Manifold78
- Brake/Two-Speed Manifold Components80
- Turntable Rotation Manifold Components81
- Platform Rotate Manifold Components82
- Platform Manifold Components, S-80 XC83
- Platform Manifold Components, S-85 XC84
- 4WD Traction Manifold Components86
- Valve Adjustments - Traction Manifold88
- Generator Manifold Components89
- Valve Coils90
  - Valve Coil Resistance Specifications90
Fuel and Hydraulic Tanks92
- Fuel Tank92
- Hydraulic Tank93
Turntable Rotation Components95
- Turntable Rotation Drive Hub Assembly95
Steer Axle Components100
- Yoke and Drive Hub100
- Drive Motors101
- Drive Hubs101
Generators102
- Hydraulic Generator102
Fault Codes104
- Introduction104
Control System Fault Codes105
- How to Retrieve Control System Fault Codes105
- Control System Fault Codes106
  - Models with Revision G Software or Lower106
- Control System Fault Codes107
Engine Fault Codes140
Deutz D 2.9 L4 Engine Fault Codes141
Perkins 404-22 Engine Fault Codes152
GM 3.0L Engine Fault Codes154
Schematics159
- Introduction159
- Electrical Symbol Legend160
- Hydraulic Symbols Legend161
- Limit Switch Location Legend162
- Engine Relay Layout - Deutz TD2.9163
- Engine Relay Layout - Deutz Td2011L04I164
- Engine Relay Layout - Perkins 404D-22T165
- Engine Relay Layout - GM 3.0L166
- Connector Pin Legend167
Electrical Schematics169
- (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)176
- 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 TD2.9 L4 Engine182
- Electrical Schematic, Deutz TD2011 L04I Engine183
- Electrical Schematic, Perkins 404D-22T Engine186
- Electrical Schematic, Perkins 404F-E22TA Engine187
- Electrical Schematic. GM 3.0L Engine190
- Electrical Schematic, 12 Kw Welder Generator and 3 Kw Generator191
Hydraulic Schematics193
- Hydraulic Schematic, S80XC 4WD Model194
- Hydraulic Schematic, S85 XC 4WD Models195

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Terex Genie S-80 XC Series Specifications

General

Brand	Terex
Model	Genie S-80 XC Series
Category	Boom Lifts
Language	English

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