Genie S-80 Installation and operating manual

Service and Repair Manual
S-80
from S80/85/80X15-12264
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
S-85
S-80X
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1269074
Rev A
September 2015

Service and Repair Manual September 2015
Introduction
ii S-80 • S-85 • S-80X Part No. 1269074
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
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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Operator's, Parts,
Maintenance, and Service and Repair manuals.
Copyright © 2015 by Terex Corporation
1269074 Rev A, September 2015
First Edition, First Printing
"Genie" and "S" are registered trademarks of Terex South
Dakota, Inc. in the USA and many other countries.

September 2015 Service and Repair Manual
Introduction
Part No. 1269074 S-80 • S-85 • S-80X iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 9/2015 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 September 2015
Introduction
iv S-80 • S-85 • S-80X Part No. 1269074
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

September 2015Service and Repair Manual
Safety Rules
Part No. 1269074 S-80 • S-85 • S-80X 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 September 2015
Safety Rules
vi S-80 • S-85 • S-80X Part No. 1269074
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
a
lert 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 not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situa
tion 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 workin
g 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 suppor
ting 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 fai
l 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.

September 2015
Table of Contents
Part No. 1269074 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 Specification ...........................................................................................2
Hydraulic Component Specifications......................................................................4
Manifold Component Specifications .......................................................................5
Continental TME27 Engine Specifications .............................................................6
Deutz TD2011L04i Engine Specifications..............................................................7
Deutz TD 2.9 Engine Specifications.......................................................................8
Perkins 804D-33 Engine Specifications .................................................................9
Perkins 404F-22T Engine Specifications .............................................................10
Machine Torque Specifications ............................................................................11
Hydraulic Hose and Fitting Torque Specifications ...............................................12
Torque Procedure ................................................................................................13

September 2015
Table of Contents
viii S-80 • S-85 • S-80X Part No. 1269074
Section 3 Repair Procedures ............................................................................................. 15
Introduction .......................................................................................................... 15
Platform Controls............................................................................................... 17
1-1 ALC-500 Circuit Board ................................................................................... 17
How to Remove the ALC-500 Circuit Board ................................................... 17
1-2 Joysticks ........................................................................................................ 18
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 ................................................ 21
How to Calibrate the Boom Angle Sensor ...................................................... 22
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

September 2015
Table of Contents
Part No. 1269074 S-80 • S-85 • S-80X ix
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
Engines................................................................................................................47
5-1 RPM Adjustment ............................................................................................47
5-2 Flex Plate .......................................................................................................47
How to Remove the Flex Plate........................................................................47
How to Install the Flex Plate............................................................................50
How to install the Pump and Bell Housing Assembly .....................................51
Ground Controls.................................................................................................52
6-1 Control Relays................................................................................................52
Hydraulic Pumps ................................................................................................53
7-1 Function Pump ...............................................................................................53
7-2 Drive Pump.....................................................................................................54
How to Prime the Pump ..................................................................................55

September 2015
Table of Contents
x S-80 • S-85 • S-80X Part No. 1269074
Manifolds ............................................................................................................ 56
8-1 Function Manifold .......................................................................................... 56
8-2 Valve Adjustments - Function Manifold ......................................................... 58
How to Adjust the System Relief Valve .......................................................... 58
How to Adjust the Boom Down Relief Valve................................................... 58
How to Adjust the Boom Extend Relief Valve................................................. 59
8-3 Brake/Two-Speed Manifold Components ...................................................... 60
8-4 Turntable Rotation Manifold Components ..................................................... 61
8-5 Platform Rotate Manifold Components.......................................................... 62
8-6 Platform Manifold Components, S-80............................................................ 63
8-7 Platform Manifold Components, S-85............................................................ 64
8-8 2WD Traction Manifold Components............................................................. 65
8-9 4WD Traction Manifold Components............................................................. 66
8-10 Drive Oil Diverter Manifold Components (welder option) ............................ 68
8-11 Valve Adjustments - Traction Manifold ........................................................ 69
8-12 Valve Coils ................................................................................................... 70
Valve Coil Resistance Specifications ............................................................. 70
How to Test a Coil Diode ................................................................................ 71
Fuel and Hydraulic Tanks ................................................................................. 72
9-1 Fuel Tank ....................................................................................................... 72
9-2 Hydraulic Tank ............................................................................................... 73
Turntable Rotation Components ...................................................................... 75
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 75
How to Remove the Turntable Rotation Drive Hub Assembly........................ 75
How to Remove the Turntable Rotation Hydraulic Motor ............................... 76
How to Adjust the Turntable Rotation Gear Backlash .................................... 77

September 2015
Table of Contents
Part No. 1269074 S-80 • S-85 • S-80X xi
Steer Axle Components.....................................................................................79
11-1 Yoke and Drive Hub .....................................................................................79
11-2 Drive Motors .................................................................................................80
11-3 Drive Hubs....................................................................................................80
11-4 Steer Cylinders.............................................................................................81
Non-steer Axle Components .............................................................................82
12-1 Drive Motor...................................................................................................82
12-2 Drive Hub .....................................................................................................82
Oscillating Axle Components ...........................................................................83
13-1 Oscillate Axle Cylinders ...............................................................................83
13-2 Oscillate Directional Valve ...........................................................................84
How to Adjust the Oscillate Relief Valve.........................................................84
How to Set Up the Directional Valve Linkage .................................................85
Section 4 Fault Codes .........................................................................................................87
Introduction...........................................................................................................87
Control System Fault Codes .............................................................................88
How to Retrieve Control System Fault Codes ................................................88
Control System Fault Codes ...........................................................................89
Fault Code Display - Deutz and Perkins Models .............................................93
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................93
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................94
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................95
Main Menu Structure - Deutz D 2.9 L4 Models...............................................96
Main Menu Structure - Perkins 404F-22 Models ............................................97
Deutz D 2.9 L4 Engine Fault Codes ..................................................................98
Perkins 404F-22 Engine Fault Codes .............................................................109
Continental TME27 Engine Fault Codes ........................................................111
How to Retrieve Continental Engine Fault Codes.........................................111
How to Clear Engine Fault Codes from the ECM .........................................111
Continental TME27 Engine Fault Codes.......................................................112

September 2015
Table of Contents
xii S-80 • S-85 • S-80X Part No. 1269074
Section 5 Schematics ....................................................................................................... 117
Introduction ........................................................................................................ 117
Electrical Symbol Legend .................................................................................. 118
Hydraulic Symbols Legend ................................................................................ 119
Relay and Fuse Panel Legend - Deutz TD2011L04i ......................................... 120
Relay and Fuse Panel Legend - Deutz TD2.9 L4 .............................................. 120
Relay and Fuse Panel Legend - Perkins 404F-22T........................................... 120
Relay and Fuse Panel Legend - Perkins 804D-33 ............................................ 121
Relay and Fuse Panel Legend - Continental TME27 ........................................ 121
Connector Pin Legends ..................................................................................... 122
Continental TME27 Engine Harness.................................................................. 128
S-80X Ground Control Box Wiring Diagram ...................................................... 129
Deutz TD2.9 L4 Engine Harness ....................................................................... 132
Perkins 404F-22T Engine Harness.................................................................... 133
Electrical Schematics, S-80X – ANSI and CSA Models................................ 135
Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA).......... 136
Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) .......... 140
Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA) ......... 141
Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA) ..... 144
Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)...... 148
Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA) .... 149
Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA) ...... 152
Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA) ....... 156
Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)...... 157
Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA) ........ 160
Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)......... 164
Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA) ....... 165
Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA) .... 168
Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)..... 172
Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA) ... 173

September 2015
Table of Contents
Part No. 1269074 S-80 • S-85 • S-80X xiii
Electrical Schematics, S-80, S-85 – ANSI and CSA Models.........................175
Electrical Schematic, S-80 • S-85 -
Deutz TD2.9 L4 Models (ANSI / CSA) ..................................................176
Ground Control Box, S-80 • S-85 -
Deutz TD2.9 L4 Models (ANSI / CSA) ..................................................180
Platform Control Box, S-80 • S-85 -
Deutz TD2.9 L4 Models (ANSI / CSA) ..................................................181
Electrical Schematic, S-80 • S-85 -
Deutz TD2011L04i Models (ANSI / CSA) .............................................184
Ground Control Box, S-80 • S-85 -
Deutz TD2011L04i Models (ANSI / CSA) .............................................188
Platform Control Box, S-80 • S-85 -
Deutz TD2011L04i Models (ANSI / CSA) .............................................189
Electrical Schematic, S-80 • S-85 -
Perkins 404F-22T Models (ANSI / CSA)...............................................192
Ground Control Box, S-80 • S-85 -
Perkins 404F-22T Models (ANSI / CSA)...............................................196
Platform Control Box, S-80 • S-85 -
Perkins 404F-22T Models (ANSI / CSA)...............................................197
Electrical Schematic, S-80 • S-85 -
Perkins 804D-33 Models (ANSI / CSA).................................................200
Ground Control Box, S-80 • S-85 -
Perkins 804D-33 Models (ANSI / CSA).................................................204
Platform Control Box, S-80 • S-85 -
Perkins 804D-33 Models (ANSI / CSA).................................................205
Electrical Schematic, S-80 • S-85 -
Continental TME27 Models (ANSI / CSA).............................................208
Ground Control Box, S-80 • S-85 -
Continental TME27 Models (ANSI / CSA).............................................212
Platform Control Box, S-80 • S-85 -
Continental TME27 Models (ANSI / CSA).............................................213

September 2015
Table of Contents
xiv S-80 • S-85 • S-80X Part No. 1269074
Electrical Schematics, S-80, S-85 – CE Models ............................................ 215
Electrical Schematic, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) ............... 216
Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE)................ 220
Platform Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (CE) .............. 221
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE) .......... 224
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE) ........... 228
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE).......... 229
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE) ............. 232
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE) .............. 236
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)............. 237
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE) ......... 240
Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE) .......... 244
Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)......... 245
Electrical Schematics, S-80, S-85 – AS Models ............................................ 247
Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS)........... 248
Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS) ........... 252
Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS).......... 253
Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS).............. 256
Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) .............. 260
Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS) ............. 261
Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS).......... 264
Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS) .......... 268
Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS) ......... 269
Schematics - Options ...................................................................................... 271
Continental Options Schematic .................................................................... 272
Deutz and Perkins Options Schematic ......................................................... 273
Platform Level Cutout, CTE Option .............................................................. 276
12 kW Hydraulic Generator Wiring Diagram ................................................ 277
12 kW Hydraulic Generator Electrical Schematic......................................... 280
Belt Driven Generator Option ....................................................................... 281
Hydraulic Schematics...................................................................................... 283
Hydraulic Schematic, 2WD Models .............................................................. 284
Hydraulic Schematic, 4WD Models .............................................................. 285

September 2015 Service and Repair Manual
Specifications
Part No. 1269074 S-80 • S-85 • S-80X 1
Section 2 Speci ficati ons
Machine Specifications
Tires and wheels
Rough Terrain and Non Marking
Tire size
18-
625 FF
Tire ply rating
16 p
ly
Overall tire diameter
40.7 i
n
103.3 c
m
Tire pressure
Foam filled
Wheel diameter
24.5 i
n
62.2 c
m
Wheel width
15 i
n
38.1 c
m
Tire weight, new foam filled
(minimum)
622 l
bs
282 k
g
Tires and wheels High Flotation
Tire size
41/18LLx22.5
Tire ply rating
14 p
ly
Tire pressure
70 p
si
4.8 b
ar
Wheel diameter
22.5 i
n
57 c
m
Wheel width
14 i
n
35.6 c
m
Lugs
and Lug Nut Torque
Wheel lugs
11 @ 3/4 -
16
Lug nut torque, dry
420 ft-
lbs
569 Nm
Lug nut torque, lubricated
320 ft-
lbs
434 Nm
Fluid capacities
Fuel tank,
Deutz and Perkins models
35 g
allons
132.5 l
iters
Fuel tank,
Continental model
30 g
allons
113.5 l
iters
LPG tank
33.5 l
bs
15.2 k
g
Hydraulic tank
40 g
allons
151.4 l
iters
Hydraulic system (including tank)
50 g
allons
189.3 l
iters
Turntable rotation drive hub
(single fill port)
40 f
l oz
1183 c
c
Turntable rotation drive hub
(dual fill port)
43 f
l oz
1262 c
c
Drive hubs
four wheel drive
30.5 f
l oz
902 c
c
Drive hubs
two wheel drive
23 f
l oz
680 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid
gear oil API service classification GL5

Service and Repair Manual September 2015
Specifications
2 S-80 • S-85 • S-80X Part No. 1269074
Performance Specifications
Drive speed, maximum
Stowed position,
RT tires
40 ft / 7.9 - 8.5 s
ec
12.2 m / 7.9 - 8.5 s
ec
Stowed position,
High Flotation tires
40 ft / 11 - 13 s
ec
12.2 m / 11 - 13 s
ec
Raised or Extended
40 ft / 40 - 45 s
ec
12.2 m / 40 - 45 s
ec
Braking distance,
maximum
High range on paved surface
6 ft / 183 c
m
Gradeability
Refer to Operator's Manual
Boom function speeds, maximum from platform
controls
Jib Boom up (S
-85) 25 - 35 s
ec
Jib Boom down (S
-85) 15 - 25 s
ec
Boom up (ANSI, CSA, models)
57 - 65 s
ec
Boom up (CE, AS models)
75 - 83 s
ec
Boom down (ANSI, CSA, models)
61 - 69 s
ec
Boom down (CE, AS models)
75 - 83 s
ec
Boom extend
59 - 67 s
ec
Boom retract
57 - 65 s
ec
Turntable rotate, (360°) fully stowed
95 - 103 s
ec
Turntable rotate, (360°) boom
raised
or extended
210 - 250 s
ec
Platform rotate, 160°
8 - 12 s
ec
Platform level (10° range of motion)
ANSI, CSA
3 - 5 s
ec
Platform level (10° range of motion)
CE, AS
20 - 22 s
ec
For operational specifications, refer to the
Operator's Manual.
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range,
and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron
III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
Support before use.
Optional fluids may not have the
same hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

September 2015 Service and Repair Manual
Specifications
Part No. 1269074 S-80 • S-85 • S-80X 3
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: An hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.

Service and Repair Manual September 2015
Specifications
4 S-80 • S-85 • S-80X Part No. 1269074
Continued use of Chevron
5606A hydraulic fluid, or
equivalent,
when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C
Hydraulic Component Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Displacement per revolution
0 to 2.8 c
u in
0 to 46 c
c
Flow rate @ 230
0 rpm 30.3 g
pm
114.7 L/min
Drive pressure, maximum
3750 p
si
259 b
ar
Charge Pump
Type
gerotor
Displacement per revolution
0.85 c
u in
13.9 c
c
Flow rate @ 230
0 rpm 9 g
pm
34 L/min
Charge pressure @ 230
0 rpm
Neutral position
310 p
si
21.4 b
ar
Function pump
Type: variable displacement piston pump
Displacement per revolution
0 to 2.3 c
u in
0 to 38 c
c
Flow rate @ 230
0 rpm 0 to 23 g
pm
0 t
o 87 L/min
Pressure, maximum
2900 p
si
200 b
ar
Pressure compensator
2900 p
si
200 b
ar
Standby pressure
250 p
si
17.3 b
ar
Auxiliary Pump
Type: fixed displacement gear pump
Displacement per revolution
0.15 c
u in
2.47 c
c

September 2015 Service and Repair Manual
Specifications
Part No. 1269074 S-80 • S-85 • S-80X 5
Function manifold
System relief valve pressure,
maximum
3200 p
si
221 b
ar
Primary boom extend relief pressure
(measured at
PTEST port) 2400 p
si
165 b
ar
Platform Manifold and Oscillate Valve
Platform level flow regulator
Platform rotate flow regulator
0.6 g
pm
2.3 L/min
0.3 g
pm
1.1 L/min
Oscillate relief pressure
950 p
si
65.5 b
ar
Traction Manifold
Hot oil relief pressure
280 p
si
19.3 b
ar
Brakes
Brake release
pressure,
Wheel drive hubs
240 p
si
16.5 b
ar
Drive Motors
Displacement per revolution
high speed:
0.9 c
u in
14.7 c
c
Displacement per revolution
low speed
2.7 c
u in
45 c
c
Hydraulic Filters
High pressure filter:
Beta 3 ≥
200
High pressure filter bypass pressure
102 p
si
7 b
ar
Medium pressure filter
Beta 3 ≥
200
Medium pressure filter bypass
pressure
51 p
si
3.5 b
ar
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 b
ar
bypass
Drive motor case drain return filter
Beta 10 ≥
2
Manifold Component
Specifications
Plug torque
SAE No. 2
36 in-
lbs / 4 Nm
SAE No. 4
10 ft-
lbs / 13 Nm
SAE No. 6
14 ft-
lbs / 19 Nm
SAE No. 8
38 ft-lbs /
51 Nm
SAE No. 10
41 ft-
lbs / 55 Nm
SAE No. 12
56 ft-
lbs / 76 Nm

Service and Repair Manual September 2015
Specifications
6 S-80 • S-85 • S-80X Part No. 1269074
Continental TME27 Engine
Displacement
164 c
u. in
2.68 l
iters
Number of cylinders
4
Bore and Stroke
3.58 x 4.06 i
nches
91 x 103.2 m
m
Horsepower,
continuous
@ 250
0 rpm 59 hp / 43.9 k
W
Firing order
1 - 3 - 4 -
2
Standby idle
-computer
controlled Frequency
1000 r
pm
Low function idle-computer
controlled Frequency
1500 r
pm
53.33
Hz
High function idle-computer
controlled Frequency
2500 r
pm
83.33 Hz
Compression ratio
8.2:1
Compression pressure pressure (psi or bar) of the
lowest cylinder must be at least 75% of the highest
cylinder
Governor
electronic
Valve clearance, warm
Intake
0.014 i
n
0.36 m
m
Exhaust
0.018 i
n
0.45 m
m
Lubrication system
Oil pressure, hot
40 to 60 p
si
2.8 to 4.1 b
ar
Oil capacity (including filter)
7 q
uarts
6.6 l
iters
Oil viscosity requirements
-
22°F to 86°F / -30°C to 30°C 5W-
20
-
4°F to 104°F / -20°C to 40°C 10W-
40
Above 5°F /
-15°C 15W-
40
Unit ships with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
Oil Pressure switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point
7 p
si
0.55 b
ar
Fuel pump
Fuel pressure
39-40 p
si
2.7 b
ar
Fuel flow rate
0.42 g
pm
1.59 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, normal load
150-
345A
Cranking speed
200 - 250 r
pm
Battery – Engine starting and control system
Type
12V DC, Group 31
Quantity
2
Battery capacity, maximum
1000A
Reserve capacity @ 25A rate
200 Minutes
Engine coolant
Capacity
(engine only)
10.7 q
uarts
10.1 liters
Coolant temperature
switch
Installation torque
8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point
230°F
110°C
Alternator output
65A @ 13.8V DC
Fan belt deflection
1/2 i
nch
12 m
m