Terex Genie S-80 XC Series Installations- und Betriebsanleitung

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

Service and Repair Manual October 2019

Introduction

ii S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT

Intr od ucti o n Intr od ucti o n

Impor ta nt In for m at i on

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also 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.

1280490GT Rev C, January 2018

First Edition, Third Printing

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

Inc. in the USA and many other countries.

"XC" is the trademark of Terex South Dakota, Inc.

October 2019 Service and Repair Manual

Introduction

Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF iii

RevisionHistory

Revision History

Revision Date Section Procedure / Page / Description

A 11/2017

New Release

B 12/2017 Schematics Electrical schematics

C 1/2018 Specifications Hydraulic Component Specifications

Schematics Electrical schematics

C1 4/2018 Repair 6-1

C2 7/2018 Repair Move Ground Controls to Control System

Schematics Electrical schematics

C3 10/2018 Specifications Machine Specifications

C4 5/2019 Specifications Machine Torque Specifications

Repair Display Menu

Fault Codes Control System Fault Codes

Schematics Electrical schematics

C5 6/2019 Fault Codes Control System Fault Codes

C6 7/2019 Repair Display Menu

C7 10/2019 Schematics Limit Switch Legend

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 2019

Introduction

iv S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

1 Serial label (located under cover)

2 Serial number (stamped on drive chassis)

October 2019 Service and Repair Manual

Safety Rules

Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF v

Section 1 Safet y R ul es Gener al Saf et 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 2019

Safety Rules

vi S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT

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

manua

l 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

tuation 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 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 an

approved fire extinguisher within 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 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

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 2019

Table of Contents

Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF 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....................................................................................2

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

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

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

Deutz TD2011 L04i Engine Specifications.............................................................7

Deutz TD 2.9 Engine Specifications.......................................................................8

Perkins 404D-22T Engine Specifications ...............................................................9

Perkins 404F-E22TA Engine Specifications ........................................................10

GM 3.0L Engine Specifications ............................................................................11

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

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

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

October 2019

Table of Contents

viii S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT

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

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

Control System ...................................................................................................18

1-1 ALC-600 Platform Control Module .................................................................18

1-2 ALC-600 Service Mode ..................................................................................18

1-3 Full Machine Calibration.................................................................................19

1-4 Machine Functions .........................................................................................20

How to Adjust the Machine Maximum Speed Setting .....................................20

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

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

1-5 How to Enter ALC600 Software Update Mode...............................................22

1-6 Display Module Menus ...................................................................................23

1-7 How to Replace the Display Controller (DISCON) Module ............................27

1-8 How to Replace the Ground Control Overlay.................................................28

Platform Components ........................................................................................31

2-1 Platform ..........................................................................................................31

2-2 Platform Leveling Slave Cylinder ...................................................................31

How to Remove the Platform Leveling Slave Cylinder ...................................31

How to Bleed the Slave Cylinder.....................................................................32

2-3 Platform Rotator .............................................................................................32

How to Remove the Platform Rotator .............................................................32

How to Bleed the Platform Rotator..................................................................34

2-4 Platform Overload System .............................................................................35

How to Calibrate the Platform Overload System.............................................35

How to Perform a Zero Load Platform Overload Calibration ..........................36

How to Replace the Platform Overload Load Cell...........................................36

October 2019

Table of Contents

Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF ix

Jib Boom Components ......................................................................................38

3-1 Jib Boom ........................................................................................................38

3-2 Jib Boom Lift Cylinder ....................................................................................39

Boom Components ............................................................................................40

4-1 Cable Track ....................................................................................................40

How to Remove the Cable Track, S-80 ..........................................................40

How to Repair the Cable Track .......................................................................42

4-2 Boom ..............................................................................................................42

How to Shim the Boom ...................................................................................42

How to Remove the Boom ..............................................................................43

4-3 Boom Lift Cylinder..........................................................................................46

4-4 Boom Extension Cylinder...............................................................................47

4-5 Boom Extend/Retract Cables.........................................................................49

How to Adjust the Extend/Retract Cables .......................................................49

How to Replace the Boom Extend/Retract Cables .........................................51

4-6 Platform Leveling Master Cylinder .................................................................53

4-7 Primary Boom Angle Sensor Calibration .......................................................54

4-8 Boom Length Sensor .....................................................................................55

Engines................................................................................................................56

5-1 RPM Adjustment ............................................................................................56

5-2 Flex Plate .......................................................................................................56

How to Remove the Flex Plate........................................................................56

How to Install the Flex Plate............................................................................59

How to install the Pump and Bell Housing Assembly .....................................60

Hydraulic Pumps ................................................................................................61

7-1 Function Pump ...............................................................................................61

7-2 Drive Pump.....................................................................................................62

How to Prime the Drive Pump.........................................................................63

October 2019

Table of Contents

x S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT

Manifolds .............................................................................................................64

8-1 Function Manifold ...........................................................................................64

8-2 Valve Adjustments - Function Manifold..........................................................66

How to Adjust the System Relief Valve...........................................................66

How to Adjust the Boom Down Relief Valve ...................................................66

How to Adjust the Boom Extend Relief Valve .................................................67

8-3 Brake/Two-Speed Manifold Components ......................................................68

8-4 Turntable Rotation Manifold Components......................................................69

8-5 Platform Rotate Manifold Components ..........................................................70

8-6 Platform Manifold Components, S-80 XC ......................................................71

8-7 Platform Manifold Components, S-85 XC ......................................................72

8-8 4WD Traction Manifold Components .............................................................74

8-9 Valve Adjustments - Traction Manifold...........................................................76

8-10 Generator Manifold Components .................................................................77

8-11 Valve Coils ...................................................................................................78

Valve Coil Resistance Specifications ..............................................................78

Fuel and Hydraulic Tanks ..................................................................................80

9-1 Fuel Tank........................................................................................................80

9-2 Hydraulic Tank ...............................................................................................81

Turntable Rotation Components.......................................................................83

10-1 Turntable Rotation Drive Hub Assembly ......................................................83

How to Remove the Turntable Rotation Drive Hub Assembly ........................83

How to Remove the Turntable Rotation Hydraulic Motor................................84

How to Adjust the Turntable Rotation Gear Backlash.....................................85

How to Calibrate the Turntable Tilt Sensor .....................................................86

Steer Axle Components .....................................................................................88

11-1 Yoke and Drive Hub .....................................................................................88

11-2 Drive Motors .................................................................................................89

11-3 Drive Hubs....................................................................................................89

Generators...........................................................................................................90

12-1 Hydraulic Generator .....................................................................................90

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