Terex Genie S-80 J Installation and operating manual

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.
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 Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2021 by Terex Corporation
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
no
t 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 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
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
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

June 2021
Table of Contents
Part No. 1285307GT S®-80 J, S®-80 J TraX™xi
Section 4 Fault Codes.........................................................................................................82
Introduction...........................................................................................................82
Control System Fault Codes .............................................................................83
How to Retrieve Control System Fault Codes ................................................83
Control System Fault Codes ...........................................................................84
Engine Fault Codes..........................................................................................101
Kubota D1803-CR-TIE4 Engine Fault Codes .................................................102

June 2021
Table of Contents
xii S®-80 J, S®-80 J TraX™Part No. 1285307GT
Section 5 Schematics ....................................................................................................... 105
Introduction ........................................................................................................ 105
Important Information......................................................................................... 105
Electrical Symbol Legend .................................................................................. 106
Hydraulic Symbols Legend ................................................................................ 107
Limit Switch Location Legend ............................................................................ 108
Electrical Schematics – Options .................................................................... 109
Electrical Schematic, Generator Options........................................................... 110
Electrical Schematic, Positive Air Shutdown ..................................................... 111
Electrical Schematics ...................................................................................... 113
Electrical Schematic, Turntable Controller......................................................... 114
Electrical Schematic, Platform Controller .......................................................... 115
Electrical Schematic, Kubota D1803.................................................................. 118
Electrical Schematic, Deutz D2011.................................................................... 119
Hydraulic Schematics...................................................................................... 121
Hydraulic Schematic .......................................................................................... 122

June 2021 Service and Repair Manual
Specifications
Part No. 1285307GT S®-80 J, S®-80 J TraX™1
Section 2 Specificati ons
Machine Specifications
Tires and Wheels
Tire size (Rough terrain)
355/55D625
Tire
weight (foam filled) 426 l
bs
193 k
g
Tire ply rating
14
Overall tire diameter
36.8 i
n
93,6 c
m
Wheel diameter
24.5 in x 11.75 i
n
62,2 cm x 29,8 c
m
Wheel lugs
9 @ 5/8 -
18
Lug nut torque
, dry 240 ft-
lbs
325 Nm
Lug nut torque, lubricated
180 ft-
lbs
244
Nm
Fuel capacities
Fuel tank
30 g
allons
114 l
iters
Hydraulic tank
23 g
allons
87 l
iters
Hydraulic system (including tank)
27 g
allons
102 l
iters
Drive hubs
24.5 f
l oz
724 c
c
Turntable
rotation drive hub 8 f
l oz
237 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
Performance Specifications
Boom function
speeds, maximum from platform
controls
Jib boom up
30 to 35 s
econds
Jib boom down
30 to 35 s
econds
Primary boom up extended
80 to 85 s
econds
Primary boom up retracted
65 to 70 s
econds
Primary boom down extended
80 to 85 s
econds
Primary boom down ret
racted 65 to 70 s
econds
Primary boom extend
45 to 50 s
econds
Primary boom retract
45 to 50 s
econds
Turntable rotate, 355°
Boom stowed
80 to 90 s
econds
Turntable rotate, 355°
Boom extended
160 to 180 s
econds
Platform rotate, 160°
18 to 22 s
econds
Br
aking distance, maximum
High range on paved
surface 3 to 6 f
t
0.9 to 1.8
m
Drive speed, maximum stowed position
40 ft / 9.1 s
ec
12.2 m / 9.1 s
ec
Drive speed, maximum raised or extended position
40 ft / 40 s
ec
12.2 m / 40 s
ec
Gradeability
See Oper
ator's Manual
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual June 2021
Specifications
2 S®-80 J, S®-80 J TraX™Part No. 1285307GT
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protect
ion 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 sup
pression
properti
es.
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 Te
llus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32
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 its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
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

June 2021 Service and Repair Manual
Specifications
Part No. 1285307GT S®-80 J, S®-80 J TraX™3
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: A 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.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage

Service and Repair Manual June 2021
Specifications
4 S®-80 J, S®-80 J TraX™Part No. 1285307GT
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
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @
200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour
point -76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°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

June 2021 Service and Repair Manual
Specifications
Part No. 1285307GT S®-80 J, S®-80 J TraX™5
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Flow rate @ 250
0 rpm 29.7 g
pm
112,4 L/min
Drive pressure, maximum
3625 p
si
250 b
ar
Charge Pump
Type: gerotor
Displace
ment 0.73 c
u in
12 c
c
Flow rate @ 250
0 rpm 9.2 g
pm
34,8 L/min
Charge pressure @ 250
0 rpm 310 p
si
21,4 b
ar
Function Pump
Type: fixed
displacement gear pump
Displacement
1.52 c
u in
25 c
c
Flow rate @ 250
0 rpm 16.5 g
pm
62,5 L/min
Auxiliary Pump
Type:
fixed displacement gear pump
Displacement
1.75 g
pm
2,8 L/min
Function manifold
System relief valve pressure,
maximum
3200 p
si
220 b
ar
Primary boom extend relief
pressure
2000 p
si
138 b
ar
Platform level relief valve
pressure
3000 p
si
207 b
ar
Steer
flow regulator 2 g
pm
7,6 L/min
Oscillate relief valve pressure
@ 250
0 rpm
750 p
si
52 b
ar
Drive manifold
Hot oil relief
valve pressure 280 p
si
19,3 b
ar
Drive motor
Displacement per revolution,
high speed
1.53 c
u in
25 c
c
Displacement per revolut
ion,
low speed
.54 c
u in
8,77 c
c
Hydraulic Filters
High pressure filter:
Beta 5
High pressure filter bypass
pressure
102 p
si
7 b
ar
Medium pressure filter
Beta 6
Medium pressure filter bypass
pressure
51 p
si
3,5 b
ar
Hydraulic tank return filter
10 micron with 25 p
si /
1,7 b
ar bypass
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 N
m

Service and Repair Manual June 2021
Specifications
6 S®-80 J, S®-80 J TraX™Part No. 1285307GT
Kubota D1803-CR-TIE4, D1803-
CR-TE5B Engines
Displacement
111.4 c
u in
1,825 l
iters
Number of cylinders
3
Bore and Stroke
3.43 x 4.031 i
nches
87 x 102,4 m
m
Horsepower, gross
intermittent
49.6 @ 2700 r
pm
37 kW @ 2700 r
pm
Firing order
1 - 2 -
3
Low idle, standby
cold engine
1500 r
pm
250 Hz
Low idl
e, standby
warm engine
1200 r
pm
200 Hz
Low idle, function enable
1500 r
pm
250 Hz
High idle
2700 r
pm
450 Hz
Compression ratio
D1803
-CR-TiE4
16:0
D1803
-CR-TE5B
18:1
Compression pressure
428 to 468 p
si
29,5 to 32,3 b
ar
Governor
centrifugal
mechanical
Valve clearance, cold
0.0071 to 0.0086 i
n
0,18 to 0,22 m
m
Lubrication system
Oil pressure
35 to 64 p
si
2,4 to 4,4 b
ar
Oil capacity (including filter)
8.6 quar
ts
8,1 l
iters
Oil viscosity requirements
-
22° F to 86° F/ -30° C to 30° C 5W-
30 (synthetic)
-
4° F to 90° F / -20° C to 32° C 10W-
40
Above 23° F /
-5° C 20W-
50
Unit ships with 15W
-40. Extreme operating
temperatures may require the use of alternative e
ngine
oils. For oil requirements, refer to the Engine Operator
Manual for
your engine.
Engine coolant
Capacity
10 q
uarts
9,5 l
iters
Fuel injection system
Injection pump make
Bosch MD
Injection pump pressure, maximum
Low idle
3700 - 4300 p
si
255 - 296 b
ar
High idle
14500 - 15900 p
si
1000 - 1096 b
ar
Injection
timing
18° BTDC
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Cranking speed
200 -
300 RPM
Current draw, normal load
155A
Battery
Type
12V DC
Group
31
Quantity
1
Ampere hour
120AH
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
175 m
inutes
Alternator output
40A @ 12V DC
Fan belt deflection
1/4 to 3/8 i
nch
7 to 9 m
m

June 2021 Service and Repair Manual
Specifications
Part No. 1285307GT S®-80 J, S®-80 J TraX™7
Deutz D2011 L03i Engine
Displacement
142 c
u in
2.33 l
iters
Number of cylinders
3
Bore and Stroke
3.7 x 4.4 i
nches
94 x 112 m
m
Horsepower
48 @ 2800 r
pm
36 kW @ 2800 r
pm
Firing order
1 - 2 -
3
Low idle
1500 r
pm
313 Hz
High idle
2500 r
pm
521.7 Hz
Compression ratio
19:01
Compression pressure
362 to 435 p
si
25 to 30 b
ar
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.012 i
n
0.3 m
m
Exhaust
0.020 i
n
0.5 m
m
Lubrication system
Oil pressure
40 to 60 p
si
1.4 to 3 b
ar
Oil capacity
(includ
ing filter)
9.5 q
uarts
9 l
iters
Oil
viscosity requirements
-
22° F to 86° F/ -30° C to 30° C 5W-
30 (synthetic)
-
4° F to 90° F / -20° C to 32° C 10W-
40
Above 23° F /
-5° C 20W-
50
Unit ships with 15W
-40. Extreme operating
temperatures may require the us
e of alternative engine
oils. For
oil requirements, refer to the Engine Operator
Manual for your engine.
Oil temperature switch
Temperature switch point
220°F
104°C
Oil Pressure switch
Oil pressure switch point
22 p
si
1.5 b
ar
Fuel injection system
Injection pump make
Bosch
Injection pump pressure,
maximum
15000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
Current draw, no
rmal load
140A to 200A
Brush length, new
0.72 i
n
18.5 m
m
Brush length, minimum
0.27 i
n
7 m
m
Battery
Type
12V DC, Group 34/78
Quantity
1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 m
inutes
Alternator output
60A @ 14V DC
Fan belt def
lection 3/8 to 1/2 i
nch
9 to 12 m
m

Service and Repair Manual June 2021
Specifications
8 S®-80 J, S®-80 J TraX™Part No. 1285307GT
Machine Torque Specifications
Note: All torque values are shown lubricated
unless otherwise noted.
Platform Rotator
1
-8 center bolt, GR 5 483 ft-
lbs
655 Nm
1/2
-13 bolts, GR 8 80 ft-
lbs
108 Nm
Drive motor and hub
Drive hub mounting bolts
159 ft-
lbs
216 Nm
Drive motor mounting bolts
52 ft-
lbs
70.5 Nm
Turntable bearing
Rotate bearing mounting bolts
171 ft-
lbs
232 Nm
Turntable rotate assembly
Turntable rotate motor mounting bolts
Removable threadlocker
99 ft-
lbs
134 Nm
Backlash plate mounting bolts
282 ft-
lbs
382 Nm
Machine Component Weights
Lift structure
5300 l
bs
2404 k
g
Turntable assembly without lift structure,
includes
counterweights
6700 l
bs
3040 k
g
Counterweight, (x2)
1100 l
bs
500 k
g
Drive chassis assembly
4800 l
bs
2177 k
g
Tire and wheel assembly
290 l
bs
132 k
g
Drive motor and hub
140 l
bs
64 k
g
Engine assembly
475 l
bs
215 k
g
Primary boom
1920 l
bs
871 k
g
Primary boom lift cylinder
330 l
bs
150 k
g
Primary boom extend cylinder
330 l
bs
150 k
g
Jib boom assembly, with
6 ft / 1,8 m
platform
800 l
bs
363 k
g
Jib boom cylinder
106 l
bs
48 k
g
Oscillate cylinder
97 l
bs
44 k
g
Platform,
6 ft / 1,8 m 275 l
bs
125 k
g
Platform,
8 ft / 2,4 m 315 l
bs
143 k
g
Battery
63 l
bs
29 k
g