Terex Genie S-80 J Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-80 J

from S80JH-101

from S80JD-

101

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic

Schematics

S®-80 J TraX™

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1285307GT

Rev A

June 2021

Service and Repair Manual June 2021

Introduction

ii S®-80 J, S®-80 J TraX™Part No. 1285307GT

Introducti on Introduction

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.

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.

1285307GT Rev A, June 2021

First Edition, First Printing

Genie and "S" are registered trademarks of Terex South

Dakota, Inc. in the U.S.A. and many other countries.

June 2021 Service and Repair Manual

Introduction

Part No. 1285307GT S®-80 J, S®-80 J TraX™iii

Revision History

Revision Date Section Procedure / Page / Description

A 05/2021

Initial Release

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 June 2021

Introduction

iv S®-80 J, S®-80 J TraX™Part No. 1285307GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

June 2021 Service and Repair Manual

Safety Rules

Part No. 1285307GT S®-80 J, S®-80 J TraX™v

Section 1 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.

Service and Repair Manual June 2021

Safety Rules

vi S®-80 J, S®-80 J TraX™Part No. 1285307GT

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 dec

als 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

t avoided, may cause minor

or moderate injury.

Indicates a potentially

hazardous situation which,

not avoided, may result in

property damage.

Be sure to wear protective eye wear

and other protective clothing if the

situation warrants it.

Be awa

re 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

approved fire extinguisher within

easy reach.

Be sure that all tools and workin

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 self-

locking nuts) are not reused. These

components m

ay 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 w

orkshop or work

area is properly ventilated and well lit.

June 2021

Table of Contents

Part No. 1285307GT S®-80 J, S®-80 J TraX™vii

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

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

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

Revision History..................................................................................................... iii

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

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

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

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

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

Performance Specifications....................................................................................1

Hydraulic Oil Specifications....................................................................................2

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

Kubota D1803-CR-TIE4 Engine Specifications......................................................6

Deutz D2011 L03i Engine Specifications ...............................................................7

Machine Torque Specifications ..............................................................................8

Machine Component Weights ................................................................................8

Hydraulic Hose and Fitting Torque Specifications .................................................9

Torque Procedure ................................................................................................10

June 2021

Table of Contents

viii S®-80 J, S®-80 J TraX™Part No. 1285307GT

Section 3 Repair Procedures ............................................................................................. 12

Introduction .......................................................................................................... 12

Control System................................................................................................... 14

1-1 ALC-600 Platform Control Module................................................................. 14

1-2 ALC-600 Service Mode.................................................................................. 14

1-3 Full Machine Calibration ................................................................................ 15

1-4 Machine Functions......................................................................................... 16

How to Adjust the Machine Maximum Speed Setting..................................... 16

How to Adjust the Joystick Ramp Rate Setting .............................................. 17

How to Adjust the Joystick Threshold Setting ................................................ 18

1-5 How to Enter ALC600 Software Update Mode.............................................. 18

1-6 Display Module Menus .................................................................................. 19

1-7 How to Replace the Display Controller (DISCON) Module ........................... 23

1-8 How to Replace the Ground Control Overlay ................................................ 24

Platform Components ....................................................................................... 26

2-1 Platform Leveling Slave Cylinder................................................................... 26

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

2-3 Platform Overload System............................................................................. 28

How to Perform a Zero Load Platform Calibration.......................................... 28

How to Perform a Full Load Platform Calibration ........................................... 29

How to Replace the Platform Overload Load Cell.......................................... 31

2-4 Platform.......................................................................................................... 32

2-5 Platform Function Manifold............................................................................ 33

June 2021

Table of Contents

Part No. 1285307GT S®-80 J, S®-80 J TraX™ix

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

3-1 Jib Boom ........................................................................................................34

3-2 Jib Boom Lift Cylinder ....................................................................................35

Boom Components ............................................................................................36

Boom Components .........................................................................................36

Boom Components ............................................................................................37

4-1 Cable Track....................................................................................................37

How to Remove the Cable Track ....................................................................37

How to Repair the Cable Track.......................................................................39

4-2 Primary Boom ................................................................................................40

4-3 Boom Lift Cylinder..........................................................................................41

4-4 Primary Boom Extension Cylinder .................................................................42

4-5 Platform Leveling Master Cylinder .................................................................43

4-6 Primary Boom Angle Sensor..........................................................................45

How to Repalce the Primary Boom Angle Sensor ..........................................45

4-5 Boom Extend/Retract Cables.........................................................................46

Engines................................................................................................................48

5-1 RPM Adjustment - Kubota D1105 and Deutz D2011 Models ........................48

5-2 Flex Plate .......................................................................................................48

How to Install the Flex Plate............................................................................49

How to install the Pump and Bell Housing Assembly .....................................50

5-3 Engine Fault Codes - Kubota D1803 Models.................................................51

Hydraulic Pump ..................................................................................................52

6-1 Function Pump ...............................................................................................52

6-2 Drive Pump.....................................................................................................52

How to Install the Drive Pump Coupler ...........................................................53

6-3 How to Prime the Drive and Function Pumps ................................................53

6-4 Generator Pump.............................................................................................54

June 2021

Table of Contents

x S®-80 J, S®-80 J TraX™Part No. 1285307GT

Manifolds ............................................................................................................ 56

7-1 Function Manifold Components..................................................................... 56

7-2 Valve Adjustments - Function Manifold ......................................................... 60

How to Adjust the Boom Extend Relief Valve................................................. 60

7-3 Platform Function Manifold Components ...................................................... 61

7-4 Turntable Rotation Manifold Components ..................................................... 62

7-5 Valve Adjustments - Oscillate Relief Valve.................................................... 63

How to Set Up the Oscillate Directional Valve................................................ 63

7-6 Traction Manifold Components, 4WD............................................................ 65

7-7 Valve Adjustments, 4WD Traction Manifold .................................................. 67

7-8 Brake/Two-Speed Manifold Components...................................................... 68

7-9 Generator Manifold Components .................................................................. 69

7-10 Turntable Rotation Manifold Components................................................... 70

7-11 Valve Coils................................................................................................... 71

Turntable Rotation Components...................................................................... 72

8-1 Turntable Rotation Assembly......................................................................... 72

How to Adjust the Turntable Rotation Gear Backlash .................................... 73

8-2 Turntable Angle Sensor Replacement........................................................... 74

How to Calibrate the Turntable Tilt Sensor..................................................... 75

Axle Components............................................................................................... 77

9-1 Oscillating Axle Cylinders .............................................................................. 77

Track Components ............................................................................................ 78

10-1 Track Assembly ........................................................................................... 78

How to Replace the Track .............................................................................. 78

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