Terex S8015-12264 Installation and operating manual

Service and Repair Manual
Serial Number Range
S®-80
from S8015-12264
to S8016H-
13642
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
S®-85
from S8515-12264
to S8516H-
13642
S®-80X
from S80X15-12264
to S80X16H-
13642
includes S8516H-13685
and S8516H-
13711
from S8015D-101
to S8016D-
339
from S80X15D-
101
to S80X16D-339
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
from S80D-340
from S85D-
340
from S80XD-
340
Part No. 126907
4GT
Rev A4
March 2018

Service and Repair Manual March 2018
Introduction
ii S®-80 • S®-85 • S®-80X Part No. 1269074GT
Intr od ucti o n Intr od ucti o n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
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 © 2015 by Terex Corporation
1269074GT Rev A4, March 2018
First Edition, First Printing
"Genie" and "S" are registered trademarks of Terex South
Dakota, Inc. in the USA and many other countries.

March 2018 Service and Repair Manual
Introduction
Part No. 1269074GT S®-80 • S®-85 • S®-80X iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 7/2016 Repair Procedures Added 4-7, Primary Boom Angle Sensor, S80X
A2 9/2016 Introduction Serial Number Legend
A3 10/2016 Repair; Schematics Hydraulic Drive Manifolds, Valve Coil resistance, Hydraulic
Schematics
A4
3/2018
Schematics
Update Electrical Schematics
AddSerial Breaks
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual March 2018
Introduction
iv S®-80 • S®-85 • S®-80X Part No. 1269074GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
1 Sequence number
2 Serial label (located under cover)
3 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
1 Serial label (located under cover)
2 Serial number (stamped on chassis)

March 2018 Service and Repair Manual
Safety Rules
Part No. 1269074GT S®-80 • S®-85 • S®-80X v
Section 1 Safet y R ul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual March 2018
Safety Rules
vi S®-80 • S®-85 • S®-80X Part No. 1269074GT
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all
safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
co
uld result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure
to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that
are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil
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.

March 2018
Table of Contents
Part No. 1269074GT S®-80 • S®-85 • S®-80X vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................5
Manifold Component Specifications .......................................................................6
Continental TME27 Engine Specifications .............................................................7
Deutz TD2011L04i Engine Specifications ..............................................................8
Deutz TD 2.9 Engine Specifications.......................................................................9
Perkins 804D-33 Engine Specifications ...............................................................10
Perkins 404F-22T Engine Specifications .............................................................11
Machine Torque Specifications ............................................................................12
Hydraulic Hose and Fitting Torque Specifications ...............................................13
Torque Procedure ................................................................................................14
Section 3 Repair Procedures .............................................................................................16
Introduction...........................................................................................................16
Platform Controls ...............................................................................................18
1-1 ALC-500 Circuit Board ...................................................................................18
How to Remove the ALC-500 Circuit Board ...................................................18
1-2 Joysticks.........................................................................................................19
How to Adjust the Joystick Max-out Setting....................................................19
How to Adjust the Joystick Ramp Rate Setting...............................................20
How to Adjust the Joystick Threshold Setting.................................................22
How to Calibrate the Boom Angle Sensor ......................................................23

March 2018
Table of Contents
viii S®-80 • S®-85 • S®-80X Part No. 1269074GT
Platform Components ....................................................................................... 24
2-1 Platform.......................................................................................................... 24
2-2 Platform Leveling Slave Cylinder................................................................... 25
How to Remove the Platform Leveling Slave Cylinder ................................... 25
How to Bleed the Slave Cylinder .................................................................... 25
2-3 Platform Rotator............................................................................................. 26
How to Remove the Platform Rotator ............................................................. 26
How to Bleed the Platform Rotator ................................................................. 27
2-4 Platform Overload System............................................................................. 28
Jib Boom Components...................................................................................... 31
3-1 Jib Boom ........................................................................................................ 31
3-2 Jib Boom Lift Cylinder .................................................................................... 32
Boom Components............................................................................................ 33
4-1 Cable Track.................................................................................................... 33
How to Remove the Cable Track, S-80 .......................................................... 33
How to Repair the Cable Track....................................................................... 35
4-2 Boom.............................................................................................................. 35
How to Shim the Boom ................................................................................... 35
How to Remove the Boom.............................................................................. 36
4-3 Boom Lift Cylinder ......................................................................................... 38
4-4 Boom Extension Cylinder .............................................................................. 40
4-5 Boom Extend/Retract Cables ........................................................................ 42
How to Adjust the Extend/Retract Cables ...................................................... 42
How to Replace the Boom Extend/Retract Cables......................................... 44
4-6 Platform Leveling Master Cylinder................................................................. 46
4-7 Primary Boom Angle Sensor, S-80X ............................................................. 47
Engines ............................................................................................................... 49
5-1 RPM Adjustment............................................................................................ 49
5-2 Flex Plate ....................................................................................................... 49
How to Remove the Flex Plate ....................................................................... 49
How to Install the Flex Plate ........................................................................... 52
How to install the Pump and Bell Housing Assembly ..................................... 53

March 2018
Table of Contents
Part No. 1269074GT S®-80 • S®-85 • S®-80X ix
Ground Controls.................................................................................................54
6-1 Control Relays................................................................................................54
Hydraulic Pumps ................................................................................................55
7-1 Function Pump ...............................................................................................55
7-2 Drive Pump.....................................................................................................56
How to Prime the Drive Pump.........................................................................57
Manifolds.............................................................................................................58
8-1 Function Manifold...........................................................................................58
8-2 Valve Adjustments - Function Manifold..........................................................60
How to Adjust the System Relief Valve...........................................................60
How to Adjust the Boom Down Relief Valve ...................................................60
How to Adjust the Boom Extend Relief Valve .................................................61
8-3 Brake/Two-Speed Manifold Components ......................................................62
8-4 Turntable Rotation Manifold Components .....................................................63
8-5 Platform Rotate Manifold Components ..........................................................64
8-6 Platform Manifold Components, S-80 ............................................................65
8-7 Platform Manifold Components, S-85 ............................................................66
8-8 2WD Traction Manifold Components .............................................................67
8-9 4WD Traction Manifold Components .............................................................68
8-10 Drive Oil Diverter Manifold Components (welder option).............................70
8-11 Valve Adjustments - Traction Manifold ........................................................71
8-12 Valve Coils ...................................................................................................72
Valve Coil Resistance Specifications ..............................................................72
Fuel and Hydraulic Tanks..................................................................................74
9-1 Fuel Tank .......................................................................................................74
9-2 Hydraulic Tank ...............................................................................................75
Turntable Rotation Components ......................................................................77
10-1 Turntable Rotation Drive Hub Assembly......................................................77
How to Remove the Turntable Rotation Drive Hub Assembly ........................77
How to Remove the Turntable Rotation Hydraulic Motor ...............................78
How to Adjust the Turntable Rotation Gear Backlash ....................................79

March 2018
Table of Contents
x S®-80 • S®-85 • S®-80X Part No. 1269074GT
Steer Axle Components .................................................................................... 81
11-1 Yoke and Drive Hub..................................................................................... 81
11-2 Drive Motors................................................................................................. 82
11-3 Drive Hubs ................................................................................................... 82
11-4 Steer Cylinders ............................................................................................ 83
Non-steer Axle Components............................................................................. 84
12-1 Drive Motor .................................................................................................. 84
12-2 Drive Hub ..................................................................................................... 84
Oscillating Axle Components ........................................................................... 85
13-1 Oscillate Axle Cylinders ............................................................................... 85
13-2 Oscillate Directional Valve ........................................................................... 86
How to Adjust the Oscillate Relief Valve ........................................................ 86
How to Set Up the Directional Valve Linkage................................................. 87
Section 4 Fault Codes......................................................................................................... 89
Introduction .......................................................................................................... 89
Control System Fault Codes............................................................................. 90
How to Retrieve Control System Fault Codes ................................................ 90
Control System Fault Codes........................................................................... 91
Fault Code Display - Deutz and Perkins Models............................................. 94
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins
404F-22 Models ...................................................................................... 94
Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins
404F-22 Models ...................................................................................... 95
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models
................................................................................................................ 96
Main Menu Structure - Deutz D 2.9 L4 Models .............................................. 97
Main Menu Structure - Perkins 404F-22 Models ............................................ 98
Deutz D 2.9 L4 Engine Fault Codes.................................................................. 99
Perkins 404F-22 Engine Fault Codes............................................................. 110
Continental TME27 Engine Fault Codes........................................................ 112
How to Retrieve Continental Engine Fault Codes ........................................ 112
How to Clear Engine Fault Codes from the ECM ......................................... 112
Continental TME27 Engine Fault Codes ...................................................... 113