Terex S8015-12264 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-80

from S8015-12264

to S8016H-

13642

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S®-85

from S8515-12264

to S8516H-

13642

S®-80X

from S80X15-12264

to S80X16H-

13642

includes S8516H-13685

and S8516H-

13711

from S8015D-101

to S8016D-

339

from S80X15D-

101

to S80X16D-339

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

from S80D-340

from S85D-

340

from S80XD-

340

Part No. 126907

4GT

Rev A4

March 2018

Service and Repair Manual March 2018

Introduction

ii S®-80 • S®-85 • S®-80X Part No. 1269074GT

Intr od ucti o n Intr od ucti 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.

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.

1269074GT Rev A4, March 2018

First Edition, First Printing

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

Dakota, Inc. in the USA and many other countries.

March 2018 Service and Repair Manual

Introduction

Part No. 1269074GT 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, Valve Coil resistance, Hydraulic

Schematics

3/2018

Schematics

Update Electrical Schematics

AddSerial Breaks

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 March 2018

Introduction

iv S®-80 • S®-85 • S®-80X Part No. 1269074GT

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

1 Sequence number

2 Serial label (located under cover)

3 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

1 Serial label (located under cover)

2 Serial number (stamped on chassis)

March 2018 Service and Repair Manual

Safety Rules

Part No. 1269074GT S®-80 • S®-85 • S®-80X v

Section 1 Safet y R ul es

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 March 2018

Safety Rules

vi S®-80 • S®-85 • S®-80X Part No. 1269074GT

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,

uld 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 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

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

March 2018

Table of Contents

Part No. 1269074GT 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 2Specifications .......................................................................................................1

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

Performance Specifications....................................................................................2

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

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....................................................19

How to Adjust the Joystick Ramp Rate Setting...............................................20

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

How to Calibrate the Boom Angle Sensor ......................................................23

March 2018

Table of Contents

viii S®-80 • S®-85 • S®-80X Part No. 1269074GT

Platform Components ....................................................................................... 24

2-1 Platform.......................................................................................................... 24

2-2 Platform Leveling Slave Cylinder................................................................... 25

How to Remove the Platform Leveling Slave Cylinder ................................... 25

How to Bleed the Slave Cylinder .................................................................... 25

2-3 Platform Rotator............................................................................................. 26

How to Remove the Platform Rotator ............................................................. 26

How to Bleed the Platform Rotator ................................................................. 27

2-4 Platform Overload System............................................................................. 28

Jib Boom Components...................................................................................... 31

3-1 Jib Boom ........................................................................................................ 31

3-2 Jib Boom Lift Cylinder .................................................................................... 32

Boom Components............................................................................................ 33

4-1 Cable Track.................................................................................................... 33

How to Remove the Cable Track, S-80 .......................................................... 33

How to Repair the Cable Track....................................................................... 35

4-2 Boom.............................................................................................................. 35

How to Shim the Boom ................................................................................... 35

How to Remove the Boom.............................................................................. 36

4-3 Boom Lift Cylinder ......................................................................................... 38

4-4 Boom Extension Cylinder .............................................................................. 40

4-5 Boom Extend/Retract Cables ........................................................................ 42

How to Adjust the Extend/Retract Cables ...................................................... 42

How to Replace the Boom Extend/Retract Cables......................................... 44

4-6 Platform Leveling Master Cylinder................................................................. 46

4-7 Primary Boom Angle Sensor, S-80X ............................................................. 47

Engines ............................................................................................................... 49

5-1 RPM Adjustment............................................................................................ 49

5-2 Flex Plate ....................................................................................................... 49

How to Remove the Flex Plate ....................................................................... 49

How to Install the Flex Plate ........................................................................... 52

How to install the Pump and Bell Housing Assembly ..................................... 53

March 2018

Table of Contents

Part No. 1269074GT S®-80 • S®-85 • S®-80X ix

Ground Controls.................................................................................................54

6-1 Control Relays................................................................................................54

Hydraulic Pumps ................................................................................................55

7-1 Function Pump ...............................................................................................55

7-2 Drive Pump.....................................................................................................56

How to Prime the Drive Pump.........................................................................57

Manifolds.............................................................................................................58

8-1 Function Manifold...........................................................................................58

8-2 Valve Adjustments - Function Manifold..........................................................60

How to Adjust the System Relief Valve...........................................................60

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

How to Adjust the Boom Extend Relief Valve .................................................61

8-3 Brake/Two-Speed Manifold Components ......................................................62

8-4 Turntable Rotation Manifold Components .....................................................63

8-5 Platform Rotate Manifold Components ..........................................................64

8-6 Platform Manifold Components, S-80 ............................................................65

8-7 Platform Manifold Components, S-85 ............................................................66

8-8 2WD Traction Manifold Components .............................................................67

8-9 4WD Traction Manifold Components .............................................................68

8-10 Drive Oil Diverter Manifold Components (welder option).............................70

8-11 Valve Adjustments - Traction Manifold ........................................................71

8-12 Valve Coils ...................................................................................................72

Valve Coil Resistance Specifications ..............................................................72

Fuel and Hydraulic Tanks..................................................................................74

9-1 Fuel Tank .......................................................................................................74

9-2 Hydraulic Tank ...............................................................................................75

Turntable Rotation Components ......................................................................77

10-1 Turntable Rotation Drive Hub Assembly......................................................77

How to Remove the Turntable Rotation Drive Hub Assembly ........................77

How to Remove the Turntable Rotation Hydraulic Motor ...............................78

How to Adjust the Turntable Rotation Gear Backlash ....................................79

March 2018

Table of Contents

x S®-80 • S®-85 • S®-80X Part No. 1269074GT

Steer Axle Components .................................................................................... 81

11-1 Yoke and Drive Hub..................................................................................... 81

11-2 Drive Motors................................................................................................. 82

11-3 Drive Hubs ................................................................................................... 82

11-4 Steer Cylinders ............................................................................................ 83

Non-steer Axle Components............................................................................. 84

12-1 Drive Motor .................................................................................................. 84

12-2 Drive Hub ..................................................................................................... 84

Oscillating Axle Components ........................................................................... 85

13-1 Oscillate Axle Cylinders ............................................................................... 85

13-2 Oscillate Directional Valve ........................................................................... 86

How to Adjust the Oscillate Relief Valve ........................................................ 86

How to Set Up the Directional Valve Linkage................................................. 87

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............................................. 94

How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins

404F-22 Models ...................................................................................... 94

Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins

404F-22 Models ...................................................................................... 95

Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models

................................................................................................................ 96

Main Menu Structure - Deutz D 2.9 L4 Models .............................................. 97

Main Menu Structure - Perkins 404F-22 Models ............................................ 98

Deutz D 2.9 L4 Engine Fault Codes.................................................................. 99

Perkins 404F-22 Engine Fault Codes............................................................. 110

Continental TME27 Engine Fault Codes........................................................ 112

How to Retrieve Continental Engine Fault Codes ........................................ 112

How to Clear Engine Fault Codes from the ECM ......................................... 112

Continental TME27 Engine Fault Codes ...................................................... 113

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