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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
from S80XCH-101
from S80XCD-
101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
from S85XCH-101
from S85XCD-
101
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part
No. 1280490GT
Rev C7
October 2019

Table of Contents

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Terex Genie S-80 XC Series Specifications

General IconGeneral
BrandTerex
ModelGenie S-80 XC Series
CategoryBoom Lifts
LanguageEnglish

Summary

Introduction

Important Information

Read and understand safety rules and operating instructions before maintenance.

Technical Publications

Information on product accuracy and continuous improvement policies.

Revision History

Details changes and updates made to the manual over time.

Serial Number Legend

Explains the structure and meaning of machine serial numbers.

Safety Rules

General Safety Rules

Covers essential safety guidelines for operation and maintenance.

Specifications

Machine Specifications

Details on tires, wheels, lug nuts, and fluid capacities.

Performance Specifications

Information on drive speed, braking distance, and boom function speeds.

Hydraulic Specifications

Covers hydraulic fluid requirements and component specifications.

Engine Specifications

Details for Deutz, Perkins, and GM engine models.

Torque Specifications

Provides torque values for machine components and hydraulic fittings.

Repair Procedures

General Repair Practices

Guidelines for performing repairs, including safety and preparation.

Control System Repair

Procedures for control module, calibration, settings, and software updates.

Platform Component Repair

Covers platform, leveling, rotator, and overload procedures.

Boom Component Repair

Procedures for jib boom, cable track, boom lift, extension, cables, sensors.

Engine Service

Covers RPM adjustment, flex plate, and pump installation.

Hydraulic Pump Service

Procedures for removing and priming function and drive pumps.

Manifold Service

Details on manifold components, valve adjustments, and coils.

Tank Service

Procedures for removing and installing fuel and hydraulic tanks.

Turntable Rotation Service

Covers drive hub, motor, backlash, and tilt sensor procedures.

Steer Axle Service

Procedures for yoke, drive motors, and drive hubs.

Generator Service

Procedure for adjusting hydraulic generator frequency.

Fault Codes

Control System Fault Codes

Lists and explains fault codes for the machine's control system.

Engine Fault Codes

Details fault codes specific to Deutz, Perkins, and GM engines.

Schematics

Electrical Schematics

Includes symbols, legends, relay layouts, and wiring diagrams.

Hydraulic Schematics

Includes hydraulic symbols and system diagrams.

Electrical Symbol Legend

Defines symbols used in electrical schematics.

Hydraulic Symbols Legend

Defines symbols used in hydraulic schematics.

Limit Switch Location Legend

Identifies the location of various limit switches and sensors.

Engine Relay Layouts

Diagrams for Deutz, Perkins, and GM engine relay configurations.

Connector Pin Legend

Lists and describes connector pin assignments for various components.

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