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