Terex Genie S-80 XC Series Installation and operating manual

Service and Repair Manual
Serial Number Range
S®-80 XC™
from S80XCH-101
from S80XCD-
101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
S®-80 HF
S®-85 XC™
from S85XCH-101
from S85XCD-
101
S®-85 HF
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part
No. 1280490GT
Rev C7
October 2019

Service and Repair Manual October 2019
Introduction
ii S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT
Intr od ucti o n Intr od ucti o n
Impor ta nt In for m at i on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
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 © 2017 by Terex Corporation
1280490GT Rev C, January 2018
First Edition, Third Printing
Genie and "S" are registered trademarks of Terex South Dakota,
Inc. in the USA and many other countries.
"XC" is the trademark of Terex South Dakota, Inc.

October 2019 Service and Repair Manual
Introduction
Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF iii
RevisionHistory
Revision History
Revision Date Section Procedure / Page / Description
A 11/2017 New Release
B 12/2017 Schematics Electrical schematics
C 1/2018 Specifications Hydraulic Component Specifications
Schematics Electrical schematics
C1 4/2018 Repair 6-1
C2 7/2018 Repair Move Ground Controls to Control System
Schematics Electrical schematics
C3 10/2018 Specifications Machine Specifications
C4 5/2019 Specifications Machine Torque Specifications
Repair Display Menu
Fault Codes Control System Fault Codes
Schematics Electrical schematics
C5 6/2019 Fault Codes Control System Fault Codes
C6 7/2019 Repair Display Menu
C7 10/2019 Schematics Limit Switch Legend
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual October 2019
Introduction
iv S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
1 Serial label (located under cover)
2 Serial number (stamped on drive chassis)

October 2019 Service and Repair Manual
Safety Rules
Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF v
Section 1 Safet y R ul es Gener al Saf et y R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual October 2019
Safety Rules
vi S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manua
l and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
si
tuation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine
fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners
intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally
safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

October 2019
Table of Contents
Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2 Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................5
Manifold Component Specifications .......................................................................6
Deutz TD2011 L04i Engine Specifications.............................................................7
Deutz TD 2.9 Engine Specifications.......................................................................8
Perkins 404D-22T Engine Specifications ...............................................................9
Perkins 404F-E22TA Engine Specifications ........................................................10
GM 3.0L Engine Specifications ............................................................................11
Machine Torque Specifications ............................................................................12
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14

October 2019
Table of Contents
viii S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT
Section 3 Repair Procedures..............................................................................................16
Introduction ...........................................................................................................16
Control System ...................................................................................................18
1-1 ALC-600 Platform Control Module .................................................................18
1-2 ALC-600 Service Mode ..................................................................................18
1-3 Full Machine Calibration.................................................................................19
1-4 Machine Functions .........................................................................................20
How to Adjust the Machine Maximum Speed Setting .....................................20
How to Adjust the Joystick Ramp Rate Setting...............................................21
How to Adjust the Joystick Threshold Setting .................................................22
1-5 How to Enter ALC600 Software Update Mode...............................................22
1-6 Display Module Menus ...................................................................................23
1-7 How to Replace the Display Controller (DISCON) Module ............................27
1-8 How to Replace the Ground Control Overlay.................................................28
Platform Components ........................................................................................31
2-1 Platform ..........................................................................................................31
2-2 Platform Leveling Slave Cylinder ...................................................................31
How to Remove the Platform Leveling Slave Cylinder ...................................31
How to Bleed the Slave Cylinder.....................................................................32
2-3 Platform Rotator .............................................................................................32
How to Remove the Platform Rotator .............................................................32
How to Bleed the Platform Rotator..................................................................34
2-4 Platform Overload System .............................................................................35
How to Calibrate the Platform Overload System.............................................35
How to Perform a Zero Load Platform Overload Calibration ..........................36
How to Replace the Platform Overload Load Cell...........................................36

October 2019
Table of Contents
Part No. 1280490GT S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF ix
Jib Boom Components ......................................................................................38
3-1 Jib Boom ........................................................................................................38
3-2 Jib Boom Lift Cylinder ....................................................................................39
Boom Components ............................................................................................40
4-1 Cable Track ....................................................................................................40
How to Remove the Cable Track, S-80 ..........................................................40
How to Repair the Cable Track .......................................................................42
4-2 Boom ..............................................................................................................42
How to Shim the Boom ...................................................................................42
How to Remove the Boom ..............................................................................43
4-3 Boom Lift Cylinder..........................................................................................46
4-4 Boom Extension Cylinder...............................................................................47
4-5 Boom Extend/Retract Cables.........................................................................49
How to Adjust the Extend/Retract Cables .......................................................49
How to Replace the Boom Extend/Retract Cables .........................................51
4-6 Platform Leveling Master Cylinder .................................................................53
4-7 Primary Boom Angle Sensor Calibration .......................................................54
4-8 Boom Length Sensor .....................................................................................55
Engines................................................................................................................56
5-1 RPM Adjustment ............................................................................................56
5-2 Flex Plate .......................................................................................................56
How to Remove the Flex Plate........................................................................56
How to Install the Flex Plate............................................................................59
How to install the Pump and Bell Housing Assembly .....................................60
Hydraulic Pumps ................................................................................................61
7-1 Function Pump ...............................................................................................61
7-2 Drive Pump.....................................................................................................62
How to Prime the Drive Pump.........................................................................63

October 2019
Table of Contents
x S®-80 XC™• S®-85 XC™•S®-80 HF • S®-85 HF Part No. 1280490GT
Manifolds .............................................................................................................64
8-1 Function Manifold ...........................................................................................64
8-2 Valve Adjustments - Function Manifold..........................................................66
How to Adjust the System Relief Valve...........................................................66
How to Adjust the Boom Down Relief Valve ...................................................66
How to Adjust the Boom Extend Relief Valve .................................................67
8-3 Brake/Two-Speed Manifold Components ......................................................68
8-4 Turntable Rotation Manifold Components......................................................69
8-5 Platform Rotate Manifold Components ..........................................................70
8-6 Platform Manifold Components, S-80 XC ......................................................71
8-7 Platform Manifold Components, S-85 XC ......................................................72
8-8 4WD Traction Manifold Components .............................................................74
8-9 Valve Adjustments - Traction Manifold...........................................................76
8-10 Generator Manifold Components .................................................................77
8-11 Valve Coils ...................................................................................................78
Valve Coil Resistance Specifications ..............................................................78
Fuel and Hydraulic Tanks ..................................................................................80
9-1 Fuel Tank........................................................................................................80
9-2 Hydraulic Tank ...............................................................................................81
Turntable Rotation Components.......................................................................83
10-1 Turntable Rotation Drive Hub Assembly ......................................................83
How to Remove the Turntable Rotation Drive Hub Assembly ........................83
How to Remove the Turntable Rotation Hydraulic Motor................................84
How to Adjust the Turntable Rotation Gear Backlash.....................................85
How to Calibrate the Turntable Tilt Sensor .....................................................86
Steer Axle Components .....................................................................................88
11-1 Yoke and Drive Hub .....................................................................................88
11-2 Drive Motors .................................................................................................89
11-3 Drive Hubs....................................................................................................89
Generators...........................................................................................................90
12-1 Hydraulic Generator .....................................................................................90