Terex Genie S80, S85, S85X Telescopic Boom Lift Service Manual
359 pages · Publication 1259369
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What's inside
From the manual's own table of contents: 158 sections, 237 entries. See sample pages (PDF, 604 KB)
Introduction Introduction
Important Information
Find a Manual for this Model
Revision History
Serial Number Legend
Section 1 Safety Rules
General Safety Rules
Section 2 Specifications
Machine Specifications
Performance Specifications
Hydraulic Oil Specifications
Hydraulic Component Specifications
Manifold Component Specifications
Continental TME27 Engine Specifications
Deutz TD2011L04i Engine Specifications
Deutz TD 2.9 Engine Specifications
Perkins 804D-33 Engine Specifications
Perkins 404F-22T Engine Specifications
Machine Torque Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
Section 3 Scheduled Maintenance Procedures
Introduction
Pre-Delivery Preparation Report
Show all 158 sections
Maintenance Inspection Report
Checklist A Procedures
Inspect the Manuals and Decals
Perform Pre-operation Inspection
Perform Function Tests
Perform Engine Maintenance – Perkins Models
Perform Engine Maintenance – Deutz Models
Perform Engine Maintenance – Continental Models
Test the Oscillate Axle
Check the High Pressure Hydraulic Filter Condition Indicator
Perform 30-Day Service
Grease the Turntable Rotation Bearing and Rotate Gear
Replace the Drive Hub Oil
Checklist B Procedures
Inspect the Batteries
Inspect the Electrical Wiring
Check the Exhaust System
Inspect the Engine Air Filter
Confirm the Proper Brake Configuration
Inspect the Tires, Wheels and Lug Nut Torque
Check the Drive Hub Oil Level and Fastener Torque
Check the Oscillate Directional Valve Linkage
Test the Ground Control Override
Test the Platform Self-leveling
Test the Engine Idle Select
Test the Fuel Select Operation - Ford Models
Test the Drive Brakes
Test the Drive Speed - Stowed Position
Test the Drive Speed - Raised or Extended Position
Test the Alarm Package (if equipped) and the Descent Alarm
Inspect the Fuel and Hydraulic Tank Cap Venting Systems
Perform Hydraulic Oil Analysis
Inspect the Boom Extend/Retract Cables
Test the Emergency Power System
Checklist C Procedures
Perform Engine Maintenance - Continental Models
Perform Engine Maintenance - Deutz Models
Perform Engine Maintenance - Perkins Models
Replace the Engine Air Filter Element
Check and Adjust the Engine RPM
Grease the Platform Overload Mechanism (if equipped)
Test the Platform Overload System (If equipped)
Check the Safety Envelope Limit Switches and Angle Sensor, S-80X
Checklist D Procedures
Check the Boom Wear Pads
Check the Free-wheel Configuration
Check the Turntable Rotation Bearing Bolts
Inspect for Turntable Bearing Wear
Replace the Hydraulic Filters
Checklist E Procedures
Test or Replace the Hydraulic Oil
Perform Cooling System Maintenance - Perkins 404F Models
Remove and Inspect the Boom Extend/Retract Cables1 topic
- Cable Replacement Criteria
Section 4 Repair Procedures
Platform Controls
ALC-500 Circuit Board1 topic
- How to Remove the ALC-500 Circuit Board
Joysticks4 topics
- How to Adjust the Joystick Max-out Setting
- How to Adjust the Joystick Ramp Rate Setting
- How to Adjust the Joystick Threshold Setting
- How to Calibrate the Boom Angle Sensor
Platform Components
Platform
Platform Leveling Slave Cylinder2 topics
- How to Remove the Platform Leveling Slave Cylinder
- How to Bleed the Slave Cylinder
Platform Rotator2 topics
- How to Remove the Platform Rotator
- How to Bleed the Platform Rotator
Platform Overload System
Jib Boom Components
Jib Boom
Jib Boom Lift Cylinder
Boom Components
Cable Track2 topics
- How to Remove the Cable Track, S-80
- How to Repair the Cable Track
Boom2 topics
- How to Shim the Boom
- How to Remove the Boom
Boom Lift Cylinder
Boom Extension Cylinder
Boom Extend/Retract Cables2 topics
- How to Adjust the Extend/Retract Cables
- How to Replace the Boom Extend/Retract Cables
Platform Leveling Master Cylinder
Engines
RPM Adjustment
Flex Plate3 topics
- How to Remove the Flex Plate
- How to Install the Flex Plate
- How to install the Pump and Bell Housing Assembly
Ground Controls
Control Relays
Hydraulic Pumps
Function Pump
Drive Pump1 topic
- How to Prime the Pump
Manifolds
Function Manifold
Valve Adjustments - Function Manifold3 topics
- How to Adjust the System Relief Valve
- How to Adjust the Boom Down Relief Valve
- How to Adjust the Boom Extend Relief Valve
Brake/Two-Speed Manifold Components
Turntable Rotation Manifold Components
Platform Rotate Manifold Components
Platform Manifold Components, S-80
Platform Manifold Components, S-85
2WD Traction Manifold Components
4WD Traction Manifold Components
Drive Oil Diverter Manifold Components (welder option)
Valve Adjustments - Traction Manifold
Valve Coils1 topic
- Valve Coil Resistance Specifications
Fuel and Hydraulic Tanks
Fuel Tank
Hydraulic Tank
Turntable Rotation Components
Turntable Rotation Drive Hub Assembly3 topics
- How to Remove the Turntable Rotation Drive Hub Assembly
- How to Remove the Turntable Rotation Hydraulic Motor
- How to Adjust the Turntable Rotation Gear Backlash
Steer Axle Components
Yoke and Drive Hub
Drive Motors
Drive Hubs
Steer Cylinders
Non-steer Axle Components
Drive Motor
Drive Hub
Oscillating Axle Components
Oscillate Axle Cylinders
Oscillate Directional Valve2 topics
- How to Adjust the Oscillate Relief Valve
- How to Set Up the Directional Valve Linkage
Section 5 Fault Codes
Control System Fault Codes2 topics
- How to Retrieve Control System Fault Codes
- Control System Fault Codes
Fault Code Display - Deutz and Perkins Models3 topics
- Models
- Main Menu Structure - Deutz D 2.9 L4 Models
- Main Menu Structure - Perkins 404F-22 Models
Deutz D 2.9 L4 Engine Fault Codes
Perkins 404F-22 Engine Fault Codes
Continental TME27 Engine Fault Codes3 topics
- How to Retrieve Continental Engine Fault Codes
- How to Clear Engine Fault Codes from the ECM
- Continental TME27 Engine Fault Codes
Section 6 Schematics
Electrical Symbol Legend
Hydraulic Symbols Legend
Relay and Fuse Panel Legend - Deutz TD2011L04i
Relay and Fuse Panel Legend - Deutz TD2.9 L4
Relay and Fuse Panel Legend - Perkins 404F-22T
Relay and Fuse Panel Legend - Perkins 804D-33
Relay and Fuse Panel Legend - Continental TME27
Connector Pin Legends
Continental TME27 Engine Harness
Ground Control Box Wiring Diagram
Deutz TD2.9 L4 Engine Harness
Perkins 404F-22T Engine Harness
Electrical Schematics, S-80X – ANSI and CSA Models15 topics
- Electrical Schematic, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
- Electrical Schematic, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
- Electrical Schematic, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Ground Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Platform Control Box, S-80X - Perkins 404F-22T Models (ANSI / CSA)
- Electrical Schematic, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Ground Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Platform Control Box, S-80X - Perkins 804D-33 Models (ANSI / CSA)
- Electrical Schematic, S-80X - Continental TME27 Models (ANSI / CSA)
- Ground Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
- Platform Control Box, S-80X - Continental TME27 Models (ANSI / CSA)
Electrical Schematics, S-80, S-85 – ANSI and CSA Models1 topic
- Ground Control Box, S-80 • S-85 - Deutz TD2.9 L4 Models (ANSI / CSA)
Electrical Schematics, S-80, S-85 – CE Models9 topics
- Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (CE)
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (CE)
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (CE)
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (CE)
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (CE)
Electrical Schematics, S-80, S-85 – AS Models9 topics
- Electrical Schematic, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Ground Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Platform Control Box, S-80 • S-85 - Deutz TD2011L04i Models (AS)
- Electrical Schematic, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Ground Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Platform Control Box, S-80 • S-85 - Perkins 804D-33 Models (AS)
- Electrical Schematic, S-80 • S-85 - Continental TME27 Models (AS)
- Ground Control Box, S-80 • S-85 - Continental TME27 Models (AS)
- Platform Control Box, S-80 • S-85 - Continental TME27 Models (AS)
Schematics - Options6 topics
- Continental Options Schematic
- Deutz and Perkins Options Schematic
- Platform Level Cutout, CTE Option
- kW Hydraulic Generator Wiring Diagram
- kW Hydraulic Generator Electrical Schematic
- Belt Driven Generator Option
Hydraulic Schematics2 topics
- Hydraulic Schematic, 2WD Models
- Hydraulic Schematic, 4WD Models
Inside this manual
Real pages from this service manual (359 pages). Open the sample pages (PDF, 603 KB)
- Specifications, page 27: Specifications
- Troubleshooting, page 167: Fault Codes
- Diagram, page 337: Electrical Schematic, S-80 • S-85
- Foldout diagram, page 261: February 2017
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the Genie S80, S85 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 1259369$69.73
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 359 pages
Quantity one is the manual described above.
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Other editions and similar models
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