Page 1 Service and Repair Manual Serial Number Range -80 XC ® ™ from S80XCH-101 This manual includes: from S80XCD-101 Repair procedures -80 HF ® Fault Codes Electrical and -85 XC ® ™ from S85XCH-101 Hydraulic Schematics from S85XCD-101 -85 HF ® For detailed maintenance procedures, refer to the appropriate Maintenance...
Page 2: Introduction
Unrestricted with proper operation, inspection and 1280490GT Rev C, January 2018 scheduled maintenance. 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. ®...
Page 3 October 2019 Service and Repair Manual Introduction Revision His tory Revision History Revision Date Section Procedure / Page / Description 11/2017 New Release 12/2017 Schematics Electrical schematics 1/2018 Specifications Hydraulic Component Specifications Schematics Electrical schematics 4/2018 Repair 7/2018 Repair Move Ground Controls to Control System Schematics Electrical schematics 10/2018...
Page 4: Serial Number Legend
Service and Repair Manual October 2019 Introduction Serial Number Legend 1 Model 1 Serial label (located under cover) 2 Facility code 2 Serial number (stamped on drive chassis) 3 Sequence number ® -80 XC ™ • S ® -85 XC ™...
Page 5: Safety Rules
October 2019 Service and Repair Manual Safety Rules Gener al Safety R ules Section 1 Safety 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.
Page 6 Service and Repair Manual October 2019 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 7: Table Of Contents
October 2019 Table of Contents 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 .......................
Page 8 October 2019 Table of Contents 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 ........
Page 9 October 2019 Table of Contents 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 ...............
Page 10 October 2019 Table of Contents 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 ..........
Page 11 October 2019 Table of Contents Section 4 Fault Codes ......................92 Introduction ......................92 Control System Fault Codes ................93 How to Retrieve Control System Fault Codes ..........93 Control System Fault Codes - Models with Revision G Software or Lower ..........94 Control System Fault Codes - Models with Revision H Software or Higher ..........
Page 12 October 2019 Table of Contents Section 5 Schematics ......................147 Introduction ......................147 Electrical Symbol Legend ................... 148 Hydraulic Symbols Legend ................. 149 Limit Switch Location Legend ................150 Engine Relay Layout - Deutz TD2.9 ..............151 Engine Relay Layout - Deutz TD2011L04i ............152 Engine Relay Layout - Perkins 404D-22T ............
Page 13: Specifications
October 2019 Service and Repair Manual Specifications Section 2 Specific ati ons Machi ne Specific ations Machine Specifications Fluid capacities Fuel tank, 35 gallons Tires and wheels Diesel models 132.5 liters Rough Terrain and Non Marking Fuel tank, 30 gallons Tire size 18-625 FF Gas models...
Page 14: Performance Specifications
Service and Repair Manual October 2019 Specifications Performanc e Specific ati ons Hydraulic Oil Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position, 40 ft / 9 - 11 sec Genie specifications require hydraulic oils which are RT tires 12.2 m / 9 - 11 sec designed to give maximum protection to hydraulic...
Page 15 October 2019 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
Page 16 Service and Repair Manual October 2019 Specifications Shell Tellus S4 VX Fluid Chevron 5606A Hydraulic Oil Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.8 cSt @ 104°F / 40°C...
Page 17: Hydraulic Component Specifications
October 2019 Service and Repair Manual Specifications Hydraulic C omponent Speci fications Hydraulic Component Function manifold Specifications System relief valve pressure, 3200 psi maximum 221 bar Drive Pump Primary boom extend relief pressure 2400 psi (measured at port) 165 bar PTEST Type: bi-directional variable displacement piston pump Platform Manifold and Oscillate Valve...
Page 18: Manifold Component Specifications
Service and Repair Manual October 2019 Specifications Manifold Com ponent Specific ati ons 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.
Page 19: Deutz Td2011 L04I Engine Specifications
October 2019 Service and Repair Manual Specifications Deutz TD 2011 L04i Engine Speci ficati ons Deutz TD2011 L04i Engine Oil Temperature sender Installation torque 8 - 18 ft-lbs 220.9 cu. in Displacement 11 - 24 Nm 3.62 liters Oil Pressure sender Number of cylinders Installation torque 8 - 18 ft-lbs...
Page 20: Deutz Td 2.9 Engine Specifications
Service and Repair Manual October 2019 Specifications Deutz TD 2.9 Engi ne Specifications Deutz TD 2.9 L4 Engine Oil Temperature sender Installation torque 8 - 18 ft-lbs 177 cu. in Displacement 11 - 24 Nm 2.9 liters Oil Pressure sender Number of cylinders Installation torque 8 - 18 ft-lbs...
Page 21: Perkins 404D-22T Engine Specifications
October 2019 Service and Repair Manual Specifications Perki ns 404D-22T Engi ne Specific ations Perkins 404D-22T Engine Fuel injection system Injection pump make Zexel 134 cu in Displacement Injection pressure 2133 psi 2.2 liters 147 bar Number of cylinders Fuel requirement 3.31 x 3.94 inches Bore and stroke For fuel requirements, refer to the engine Operator's...
Page 22: Perkins 404F-E22Ta Engine Specifications
Service and Repair Manual October 2019 Specifications Perki ns 404F-E22TA Engi ne Specific ati ons Perkins 404F-E22TA Oil Pressure switch Installation torque 8 - 18 ft-lbs 134 cu. in Displacement 11 - 24 Nm 2.2 liters Pressure switch point 14.2 psi Number of cylinders 1 bar 3.31 x 3.94 inches...
Page 23: Gm 3.0L Engine Specifications
October 2019 Service and Repair Manual Specifications GM 3.0L Engi ne Specifications GM 3.0L Engine Fuel requirement For fuel requirements, refer to the engine Operator 183 cu. in Displacement Manual for your engine. 3.0 liters Battery – Engine starting and control system Number of cylinders Type 12V DC, Group 31...
Page 24: Machine Torque Specifications
Service and Repair Manual October 2019 Specifications Machi ne T orque Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5, dull gray, 500 ft-lbs lubricated 678 Nm 1/2-13 bolts, GR 8, dull gray, 80 ft-lbs LOCTITE ® ™ threadlocker 108 Nm Turntable rotate assembly...
Page 25: Hydraulic Hose And Fitting Torque Specifications
October 2019 Service and Repair Manual Specifications Hydraulic H ose and Fitting T orque Specific ations Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37°...
Page 26: Torque Procedure
Service and Repair Manual October 2019 Specifications Torque Pr ocedure Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
Page 27 October 2019 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 28: Repair Procedures
Service and Repair Manual October 2019 Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures Intr oducti on  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
Page 29: About This Section
October 2019 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
Page 30: Control System
Service and Repair Manual October 2019 Control System Control System 1-2 ALC-600 Service Mode 1-1 ALC-600 Pl atform C ontrol M odule How to Enter ALC-600 Service ALC-600 Control Module Mode Platform Controls The platform control box contains the ALC-600 platform Control Module.
Page 31: Full Machine Calibration
October 2019 Service and Repair Manual Control System 1-3 F ull M achi ne C alibration The Control System on this machine allows access to calibrations through the Service Mode. The Full Machine Calibration procedures that follow may require the operator to already be in the Service Mode.
Page 32: Machine Functions
Service and Repair Manual October 2019 Control System 1-4 M ac hine F unctions 10 Record the time it takes for that function to complete a full cycle (ie; boom up). Machine Functions 11 Compare the machine function time with the How to Adj ust the Mac hine M axim um Speed Setti ng How to Adjust the Joystick function times listed in Refer to Specifications,...
Page 33: How To Adjust The Joystick Ramp Rate Setting
October 2019 Service and Repair Manual Control System How to Adj ust the Joystick Ram p R ate Setting How to Adjust the Joystick Ramp Start the engine from the ground controls. Rate Setting Start a timer and activate the machine function that needs to be adjusted.
Page 34: How To Adjust The Joystick Threshold Setting
Service and Repair Manual October 2019 Control System How to Adj ust the Joystick Thr es hol d Setting 1-5 H ow to Enter ALC 600 Softw are U pdate Mode How to Adjust the Joystick Threshold Setting How to Enter ALC600 Software Update Mode The threshold setting of a joystick is the minimum output at which a function proportional valve can...
Page 35: Display Module Menus
October 2019 Service and Repair Manual Control System 1-6 Dis pl ay M odule Menus Display Module Menus Screen or Menu Item Selection Default Display Settings Backlight 0 - 100% Contrast 0 - 100% Display Inversion On / Off Screen or Menu Item Selection Default...
Page 36 Service and Repair Manual October 2019 Control System Screen or Menu Item Default Sensor Calibration Chassis Tilt Select OK to calibrate Load Sense Select OK to calibrate Load Sense Select OK to calibrate Boom Length Select OK to calibrate Screen or Menu Item Default Auto Threshold...
Page 37 October 2019 Service and Repair Manual Control System Screen or Menu Item Default Perkins 404F Threshold 2350 rpm Anti-Stall Drive Minimum Range 125 rpm Hysteresis 100 rpm Screen or Menu Item Default Perkins 404D Threshold 2350 rpm Anti-Stall Drive Minimum Range 125 rpm Hysteresis...
Page 38 Service and Repair Manual October 2019 Control System Screen or Menu Item Default Primary Lift Ramps Extend Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms Extend Decelerating Rate 5000 ms max, 250 ms min, 1000 ms Retract Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms Retract Decelerating Rate 5000 ms max, 500 ms min, 1000 ms...
Page 39: How To Replace The Display Controller (Discon) Module
October 2019 Service and Repair Manual Control System 1-7 H ow to Replace the Dis pl ay C ontroller (D ISC ON) Module Open the ground box lid (1) and disconnect the wire harness going to the display controller How to Replace the Display (DISCON).
Page 40: How To Replace The Ground Control Overlay
Service and Repair Manual October 2019 Control System 1-8 H ow to Replace the Ground Contr ol Ov erlay Install the new DISCON onto the ground box lid and fasten it using the new hex nuts and How to Replace the Ground Box washers.
Page 41 October 2019 Service and Repair Manual Control System Unscrew the nut holding the buttons and key Remove the ground box lid (1) from the switch and remove the key switch and buttons. ground box. Note the orientation of the key switch so it can be Remove the old overlay and clean the ground reassembled in the same position.
Page 42 Service and Repair Manual October 2019 Control System 15 Reinstall the E-Stop button, function enable button and key switch and the contact assemblies. 16 Reinstall the wire harness from the ground box to the DISCON. Secure the harness to the ground box lid using zip ties.
Page 43: Platform Components
October 2019 Service and Repair Manual Platform Components Platform Co mpon ents 2-2 Platform Lev eling Slav e Cyli nder 2-1 Platform Platform Leveling Cylinder Platform The slave cylinder and the rotator pivot are the two How to Remove the Platform primary supports for the platform.
Page 44: How To Bleed The Slave Cylinder
Service and Repair Manual October 2019 Platform Components 2-3 Platform Rotator Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft Platform Rotator metal drift to drive the rod-end pivot pin out. The platform rotator is a hydraulically activated Crushing hazard.
Page 45 October 2019 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses Use a soft metal drift to remove both pivot from the platform rotator manifold. Cap the pins. Remove the platform rotator from the fittings on the rotator. machine.
Page 46: How To Bleed The Platform Rotator
Service and Repair Manual October 2019 Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Open the bottom bleed screw on the rotator, but do not remove it. Rotator Bodily injury hazard. Spraying Note: This procedure will require two people. Do hydraulic oil can penetrate and not start the engine.
Page 47: Platform Overload System
October 2019 Service and Repair Manual Platform Components 2-4 Platform Ov erload System 10 Place a 1,000 lb / 454 kg test weight on the platform floor using a suitable lifting device. Platform Overload System Place the weight near the center entry point of the platform, as far away from the operator Proper calibration of the platform overload system controls as possible.
Page 48: How To Perform A Zero Load Platform Overload Calibration
Service and Repair Manual October 2019 Platform Components How to Per form a Z ero Load Platform Ov erload C alibration How to R eplac e the Platform Ov erload Load C ell How to Perform a Zero Load How to Replace the Load Cell Platform Calibration Sensor Perform this procedure when the required weight...
Page 49 October 2019 Service and Repair Manual Platform Components Install the new Load Cell Sensor Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out of the bottom of the sensor.The foot should not contact the flex plate when assembling onto the platform support.
Page 50: Jib Boom Components
Service and Repair Manual October 2019 Jib Boom Components Attach a lifting strap from an overhead crane Jib Bo om Co mpon ents 3-1 Jib Boom to the jib boom assembly. Jib Boom Place blocks under the platform leveling cylinder for support. Protect the cylinder rod How to Remove the Jib Boom from damage.
Page 51: Jib Boom Lift Cylinder
October 2019 Service and Repair Manual Jib Boom Components 3-2 Jib Boom Lift Cylinder Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the How to Remove the Jib Boom Lift opposite leveling arm.
Page 52: Boom Components
Service and Repair Manual October 2019 Boom Components Boom Com ponent s 4-1 C able Track S-80XC: Tag, disconnect and plug the hydraulic hoses from the counterbalance valve Cable Track manifold located on the platform rotator. Cap the fittings on the manifold. The boom cable track guides cables and hoses running up the boom.
Page 53 October 2019 Service and Repair Manual Boom Components 12 Tag, disconnect and plug the hydraulic hoses 17 Place blocks between the upper and lower from the jib boom lift cylinder. Cap the fittings cable tracks and secure the upper and lower on the cylinder.
Page 54: How To Repair The Cable Track
Service and Repair Manual October 2019 Boom Components How to R epair the C abl e Tr ack 4-2 Boom How to Repair the Cable Track Boom Component damage hazard. The boom cable track can be How to Shim the Boom How to Shim the Boom damaged if it is twisted.
Page 55: How To Remove The Boom
October 2019 Service and Repair Manual Boom Components Remove the jib boom. Refer to Repair How to R emove the Boom How to Remove the Boom Procedure, How to Remove the Jib Boom. Tip-over hazard. This procedure Remove the cable track. Refer to Repair requires the removal of the Procedure, How to Remove the Cable Track.
Page 56 Service and Repair Manual October 2019 Boom Components Locate and remove the counterweight 15 Remove the hose and cable guide fasteners at retaining fastener at the center of the the primary boom pivot pin. Remove the hose counterweight. Carefully lift the counterweight and cable guide.
Page 57 October 2019 Service and Repair Manual Boom Components 22 Tag, disconnect and plug the boom extension 28 Using the overhead crane, adjust the boom as cylinder hydraulic hoses. Cap the fittings on necessary to relieve pressure from the pivot the cylinder. pins.
Page 58: Boom Lift Cylinder
Service and Repair Manual October 2019 Boom Components 4-3 Boom Lift Cylinder Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the Boom Lift Cylinder cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the The boom lift cylinder raises and lowers the boom.
Page 59: Boom Extension Cylinder
October 2019 Service and Repair Manual Boom Components 4-4 Boom Extension C ylinder Fully loosen the lock nuts on the extend cables. Do not remove the nuts. Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube.
Page 60 Service and Repair Manual October 2019 Boom Components 10 Remove the fasteners from the retaining 14 Lift up the extend cable mounting plate and blocks from the extension cylinder saddle. push the extend cables towards the platform Remove the blocks. to create slack in the cables.
Page 61: Boom Extend/Retract Cables
October 2019 Service and Repair Manual Boom Components 4-5 Boom Extend/Retrac t C abl es 23 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the Boom Extend and Retract Cables number 2 boom tube. 24 Carefully support and slide the extension How to Adj ust the Ex tend/R etrac t C abl es How to Adjust the Boom...
Page 62 Service and Repair Manual October 2019 Boom Components 11 Locate the retract cable adjustment nut on the Locate the extend cable adjustment nuts on bottom of the number 1 boom tube at the the counterweight end of boom tube #1. Refer platform end of the boom.
Page 63: How To Replace The Boom Extend/Retract Cables
October 2019 Service and Repair Manual Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom 17 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch Extend/Retract Cables arm is centered in the notch of the pivot plate.
Page 64 Service and Repair Manual October 2019 Boom Components Install the boom extend cable clevis pins and 17 Repeat steps 14 through 19 for the other rue rings to the pivot plate near the cable boom retract cable. break limit switch. 18 At the platform end of the boom, install the Install the boom extend cables to the lower retract cables, clevis pins and rue rings to the...
Page 65: Platform Leveling Master Cylinder
October 2019 Service and Repair Manual Boom Components Place a rod through the barrel-end pivot pin 4-6 Platform Lev eling M aster Cylinder and twist to remove the pin. Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder.
Page 66: Primary Boom Angle Sensor Calibration
Service and Repair Manual October 2019 Boom Components 4-7 Primary Boom Angl e Sens or Cali bration Press OK on the display to continue with the procedure to capture the maximum angle Primary Boom Angle Sensor point. The primary boom angle sensor is used to limit the Operate the boom up function until the boom angle of the primary boom relative to the angle of reaches its maximum angle.
Page 67: Boom Length Sensor
October 2019 Service and Repair Manual Boom Components 4-8 Boom Length Sens or Press the OK button to continue to capture the maximum extension point. Boom Length Sensor Press the function enable and boom extend How to Calibrate the Primary buttons until the boom reaches its maximum extension.
Page 68: Engines
Service and Repair Manual October 2019 Engines Engin es 5-2 Fl ex Plate 5-1 R PM Adj ustm ent Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump.
Page 69 October 2019 Service and Repair Manual Engines Deutz TD2011L04i models: Carefully pull the pump and bell housing assembly away from the engine and secure it Tag and disconnect the wiring from the bell from moving. housing. Component damage hazard. Remove the U-bolt from the exhaust flex pipe Hoses can be damaged if they at the muffler.
Page 70 Service and Repair Manual October 2019 Engines Perkins 404D-22T models: GM 3.0L model: Tag and disconnect the wiring from the bell Tag and disconnect the wire harness from the housing. oxygen sensor. Remove the fasteners supporting the muffler Remove the exhaust pipe heat shield assembly from the bell housing.
Page 71: How To Install The Flex Plate
October 2019 Service and Repair Manual Engines How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the Install the flex plate onto the engine flywheel appropriate gap between coupler and pump with the raised spline towards the pump.
Page 72: How To Install The Pump And Bell Housing Assembly
Service and Repair Manual October 2019 Engines How to i nstall the Pum p and Bell H ousing Ass embly How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C"...
Page 73: Hydraulic Pumps
October 2019 Service and Repair Manual Hydraulic Pumps Hydr aulic Pump s 7-1 F uncti on Pump Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying How to Remove the Function hydraulic oil can penetrate and burn skin.
Page 74: Drive Pump
Service and Repair Manual October 2019 Hydraulic Pumps 7-2 Driv e Pum p Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Page 75: How To Prime The Drive Pump
October 2019 Service and Repair Manual Hydraulic Pumps How to Prime the Driv e Pum p Carefully pull the drive pump out until the pump coupler separates from the flex plate. How to Prime the Drive Pump Remove the drive pump from the machine. Component damage hazard.
Page 76: Manifolds
Service and Repair Manual October 2019 Manifolds Manifold s 8-1 F uncti on Manifold Function Manifold Components The function manifold assembly is located on the tank side tray, behind the ground control box. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Boom up 50-55 ft-lbs / 68-75 Nm...
Page 77 October 2019 Service and Repair Manual Manifolds Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF...
Page 78: Valve Adjustments - Function Manifold
Service and Repair Manual October 2019 Manifolds 8-2 Valve Adjus tments - F unc tion M anifol d How to Adj ust the Boom Dow n R elief Valv e 8-2 Valve Adjustments - How to Adjust the Boom Down Function Manifold Relief Valve Note: Perform this procedure with the boom in the...
Page 79: How To Adjust The Boom Extend Relief Valve
October 2019 Service and Repair Manual Manifolds How to Adj ust the Boom Ex tend R elief Valve How to Adjust the Boom Extend Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the boom extend relief valve.
Page 80: Brake/Two-Speed Manifold Components
Service and Repair Manual October 2019 Manifolds 8-3 Brak e/Two- Speed M anifol d C omponents Brake / Two Speed Manifold Components The brake/two speed manifold is mounted inside the drive chassis. Index Schematic Description Function Torque Item Orifice, 0.025 inch / 0.63 mm Turntable rotation brake release Check valve Brake release circuit...
Page 81: Turntable Rotation Manifold Components
October 2019 Service and Repair Manual Manifolds 8-4 T urntabl e R otation M ani fol d C omponents Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine.
Page 82: Platform Rotate Manifold Components
Service and Repair Manual October 2019 Manifolds 8-5 Platform Rotate Manifold C om ponents Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator. Index Schematic Description Function Torque Item Counterbalance valve, 3300 psi Platform rotate right 37-44 ft-lbs / 50-60 Nm Counterbalance valve, 3300 psi Platform rotate left...
Page 83: Platform Manifold Components, S-80 Xc
October 2019 Service and Repair Manual Manifolds 8-6 Platform Manifold Com ponents, S-80 XC Platform Manifold Components, S-80 XC The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm Solenoid valve, 3 position 4 way...
Page 84: Platform Manifold Components, S-85 Xc
Service and Repair Manual October 2019 Manifolds 8-7 Platform Manifold Com ponents, S-85 XC Platform Manifold Components, S-85 XC The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm Solenoid valve, 3 position 4 way...
Page 85 October 2019 Service and Repair Manual This page intentionally left blank. Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF...
Page 86: 4Wd Traction Manifold Components
Service and Repair Manual October 2019 Manifolds 8-8 4WD Tr acti on Manifold C om ponents Traction Manifold Components, 4WD The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index Schematic Description Function Torque Item Relief valve, 280 psi / 19.3 bar...
Page 87 October 2019 Service and Repair Manual Manifolds Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF...
Page 88: Valve Adjustments - Traction Manifold
Service and Repair Manual October 2019 Manifolds 8-9 Valve Adjus tments - Trac tion M ani fol d Valve Adjustments - Traction Manifold How to Adjust the Hot Oil Relief Valve Note: The pressure differential between the charge pump relief valve (located in the drive pump) and the hot oil shuttle relief valve (located in the traction manifold) is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for...
Page 89: Generator Manifold Components
October 2019 Service and Repair Manual Manifolds 8-10 Gener ator Manifold Com ponents 8-10 Generator Manifold The generator manifold is mounted on the turntable tray by the fuel tank. Index Schematic Description Function Torque Item Relief valve Generator relief valve 50 ft-lbs / 67 Nm Solenoid Valve Charge pressure circuit...
Page 90: Valve Coils
Service and Repair Manual October 2019 Manifolds 8-11 Valv e C oils Valv e C oil Resistanc e Speci ficati ons 8-11 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically...
Page 91 October 2019 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 92: Fuel And Hydraulic Tanks
Service and Repair Manual October 2019 Fuel and Hydraulic Tanks Fuel and Hyd rau lic T anks 9-1 F uel T ank Tag, disconnect, drain and plug the supply and return fuel hoses. Cap the fittings on the Fuel Tank fuel tank.
Page 93: Hydraulic Tank
October 2019 Service and Repair Manual Fuel and Hydraulic Tanks 9-2 H ydr aulic T ank Close the two hydraulic tank valves located at the hydraulic tank (if equipped). Hydraulic Tank Component damage hazard. The primary functions of the hydraulic tank are to The engine must not be started cool, clean and de-aerate the hydraulic fluid during with the hydraulic tank shut-off...
Page 94 Service and Repair Manual October 2019 Fuel and Hydraulic Tanks Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine. 10 Remove the suction strainers from the tank and clean them using a mild solvent.
Page 95: Turntable Rotation Components
October 2019 Service and Repair Manual Turntable Rotation Components Turntable Rot ation C ompon ents 10- 1 T urntable Rotati on Drive Hub Ass embly 10-1 Attach a suitable lifting device to the lifting eyes on the drive hub assembly. Turntable Rotation Drive Hub Assembly How to R emove the Tur ntabl e R otation Driv e H ub As sem bly...
Page 96: How To Remove The Turntable Rotation Hydraulic Motor
Service and Repair Manual October 2019 Turntable Rotation Components When installing the drive hub assembly: How to R emove the Tur ntabl e R otation H ydr aulic M otor How to Remove the Turntable Rotation Hydraulic Motor Install the drive hub. Apply removable thread locking compound to fastener threads.Torque Note: When removing a hose assembly or fitting, the backlash pivot plate mounting fasteners to...
Page 97: How To Adjust The Turntable Rotation Gear Backlash
October 2019 Service and Repair Manual Turntable Rotation Components Clean up any oil that may have spilled. How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear.
Page 98: How To Calibrate The Turntable Tilt Sensor
Service and Repair Manual October 2019 Turntable Rotation Components How to C alibr ate the T urntable Tilt Sensor How to Calibrate the Turntable Push the backlash pivot plate towards the turntable as far as possible (this will push the Tilt Sensor rotation gear into the turntable bearing ring gear).
Page 99 October 2019 Service and Repair Manual Turntable Rotation Components A graphic of the machine pitch will now be 13 A graphic of the machine roll will now be shown on the display. By pressing the UP or shown on the display. By pressing the UP and DOWN buttons, the graphic will change to DOWN buttons, the graphic will change to show the counterweight being uphill or...
Page 100: Steer Axle Components
Service and Repair Manual October 2019 Steer Axle Components Steer A xle Co mpon ents 11- 1 Yok e and Drive H ub 11-1 Remove the lug nuts. Remove the tire and wheel assembly. Yoke and Drive Hub Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin.
Page 101: Drive Motors
October 2019 Service and Repair Manual Steer Axle Components 11- 2 Drive Motors 11- 3 Drive Hubs 11-2 11-3 Drive Motors Drive Hub How to Remove a Drive Motor How to Remove a Drive Hub Note: When removing a hose assembly or fitting, Component damage hazard.
Page 102: Generators
Service and Repair Manual October 2019 Generators Gen er ators 12- 1 Hy draulic Gener ator 12-1 Adjust the valve counter-clockwise to increase the frequency and clockwise to decrease the Hydraulic Generator frequency, until the correct value is reached according to the table below. How to Adjust the Generator ANSI 12 kW Generator...
Page 103 October 2019 Service and Repair Manual This page intentionally left blank. Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF...
Page 104: Fault Codes
Service and Repair Manual October 2019 Fault Codes Section 4 Before Troubleshooting: Faul t Codes Intr oducti on  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.
Page 105: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes Control System F ault Cod es How to R etrieve Contr ol Sy stem F ault Codes Control System How to Retrieve Control System Fault Codes The machine control system contains two different types of fault codes Active Faults: These faults have been detected in the current operating session.
Page 106: Control System Fault Codes
Service and Repair Manual October 2019 Control System Fault Codes Control System F ault C odes - Models with R evision G Softwar e or Low er Models with Revision G Software or Lower Component Name Cause Effect Solution Keyswitch 19 Fault Signals Machine will not...
Page 107: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Foot Switch 19 Stuck ON at Foot switch Machine will not * Release foot switch and cycle power. power up, input was be functional. * If problem persists, with a voltmeter or timeout detected as...
Page 108 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution Primary 12 Joystick Circuit Boom Up and * Leave joystick in neutral position and Boom Up / voltage too C164PUD is Down functions cycle power. Down high.
Page 109 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Boom Angle 13 No signal No CAN Boom Up, * Verify sensor power P85PWR (GR, Sensor messages have Extend and TCON J6-7) is at 12 V while the system is been received by Turntable running.
Page 110 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y26. Proper Boom shorted to that C7PBE Extend and resistance should be between 5 - 60 Extend Valve circuit is shorted Retract...
Page 111 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Turntable 12 Joystick Circuit C165TTR Turntable * Leave joystick in neutral position and Rotate voltage too is above 4.5 V. Rotate cycle power. Joystick high.
Page 112 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y70. Proper Rotate CW shorted to that V17PRL Rotate CW resistance should be between 5 - 60 Valve circuit is shorted function will...
Page 113: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Brake 12 Circuit TCON detected Machine will * With a voltmeter, measure Y2. Proper Release shorted to that C32BRK not be resistance should be between 5 - 60 Valve circuit is shorted functional.
Page 114 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution ESTOP 15 ESTOP Mistmatched ESTOP * Inspect PCON J15 pins 11 and 12 for Circuit Return signals detected circuit cannot open or short circuits. Using a voltmeter, circuit on ESTOP Return complete,...
Page 115 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Contact 36 Switch state PCON detected Boom Up * Using a voltmeter, verify that the voltage on C248CA (OR/BK, PCON J12-1) is always the Alarm mismatch that inputs from...
Page 116 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution 17 Invalid The platform load * Run the platform overload calibration process and verify fault is no longer active. calibration sensor has no valid calibration data, either because the sensor was...
Page 117 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Platform 21 Internal The secondary All functions * Cycle power and verify condition clears itself. Overload check platform overload will not * If problem persists, run the platform overload calibration procedure.
Page 118 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution Turntable 13 Not The DISCON has Machine will * Verify TCON is receiving power. Check for 12 V on J5-2 (+) and J5-1 (-). Controller detected not detected the not be...
Page 119: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Function 12 Circuit TCON detected that Only * With a voltmeter, measure Y74. Proper Enable Valve shorted to C155PCE circuit is Auxiliary resistance should be between 5 - 60 shorted to 12 V.
Page 120 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution Engine Oil 21 Value too The engine oil Engine may * Stop engine as soon as possible. Pressure pressure is not attempt * Verify the engine oil level. measured as too to start until * Verify the engine oil pump.
Page 121 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 Steer Left 12 Circuit TCON detected Steer Left * With a voltmeter, measure Y3. Proper Valve shorted to that C37STL function will resistance should be between 5 - 60 circuit is shorted not operate.
Page 122 Service and Repair Manual October 2019 Control System Fault Codes Component Name Cause Effect Solution 178 Engine 21 Fault The engine has Machine will * Check the engine fault codes with an Warning triggered the function as engine diagnostic tool. Lamp Engine Warning normal.
Page 123: Models With Revision H Software Or Higher
October 2019 Service and Repair Manual Control System Fault Codes Control System F ault C odes - Models with R evision H Softw are or Hi gher Models with Revision H software or higher ID Component ID Name Cause Effect Solution Engine Can 13 Not...
Page 124 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 13 Jib 27 Active Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib Up/Down was detected as functions will not Up/Down Toggle Switch (TS8) is Switch...
Page 125: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 21 Pri Boom 11 Shorted Circuit C164PUD is Boom Up and Down * Leave joystick in neutral position and Up / Down above 4.5 V. functions will not cycle power.
Page 126 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 24 Pri Boom 13 Not No CAN messages Machine limited to * Verify sensor power P85PWR (GR, Angle detected have been received recovery functions TCON J6-7) is at 12 V while the by the TCON from system is running.
Page 127 October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 26 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y26. Ext Coil C7PBE circuit is Retract functions will Proper resistance should be between supply shorted to 12 V or...
Page 128 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 40 Jib Select 11 Shorted PCON detected Jib and platform *With a voltmeter, measure Y18. Coil V18PRR is short to functions will not Proper resistance should be between supply supply...
Page 129 October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 45 Platform 27 Active Toggle switch input Platform Level Up or *Verify with a voltmeter that the Level was detected as Down functions may Platform Level Up/Down Toggle Toggle startup...
Page 130 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 52 Drive 11 Shorted TCON detected that Drive Forward, Brake * With a voltmeter, measure Y6. Forward C30FWD circuit is Release and possibly Proper resistance should be between Pump Coil supply...
Page 131: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 61 Steer 11 Shorted Circuit C159STD or Drive and steer * Leave joystick in neutral position and Joystick C159STA is above functions will not cycle power.
Page 132 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 69 AC 11 Shorted TCON detected that Generator function * With a voltmeter, measure Y29. Generator C45GEN circuit is will not operate. Proper resistance should be between Output supply shorted to 12 V.
Page 133 October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 74 Engine 15 Sensor Engine Engine will not * With a voltmeter, check that Temperature value too temperature sensor operate C26TSR ( WH/RD, TCON J6P8) is is shorted to not shorted to ground and voltage is ground...
Page 134 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 78 Platform 13 Not TCON has not Controls from the * Verify PCON is receiving power. Controller detected detected the PCON platform will not Check for 12 V on J15-2 (+) and J15-1 (PCON) primary processor...
Page 135 October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 80 Turntable 13 Not The DISCON has Machine limited to * Verify TCON is receiving power. Controller detected not detected the recovery functions Check for 12 V on J5-2 (+) and J5-1 (TCON) TCON on the CAN...
Page 136 Service and Repair Manual October 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 85 Chassis 13 Not Tilt sensor not Machine limited to Calibrate tilt sensor. Angle detected calibrated recovery functions Safety 88 Function 11 Shorted TCON detected that Only Auxiliary Power * With a voltmeter, measure Y74.
Page 137: Control System Fault Codes
October 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 94 Primary 13 Not No CAN messages Boom Up, Extend * Verify sensor power P85PWR (GR, Boom detected have been received and Turntable Rotate TCON J6-7) is at 12 V while the Length by the TCON from...
Page 138 Service and Repair Manual October 2019 Control System Fault Codes Component ID Name Cause Effect Solution 100 Platform 11 Shorted PCON detected Platform Level Up * With a voltmeter, measure Y20. Level Up Coil to supply that V14PLU circuit and possibly Level Proper resistance should be voltage is shorted to 12 V...
Page 139 October 2019 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 LF Steer (L 11 Shorted TCON detected that Steer Left function * With a voltmeter, measure Y3. or R) Coil C37STL circuit is will not operate.
Page 140: Engine Fault Codes
Service and Repair Manual October 2019 Engine Fault Codes Engin e F ault Co des Engine Fault Codes Some engine options have their own Electronic Control Module that contains more detailed fault information that is specific to the engine. This system can be accessed by using the engine's dedicated service tool.
Page 141: Deutz D 2.9 L4 Engine Fault Codes
October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes Deutz D 2.9 L 4 Engin e F au lt Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1231 Actuator error EGR-Valve; Power KWP = Keyword Protocol stage over temp due to high SPN FMI...
Page 142 Service and Repair Manual October 2019 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
Page 143 October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
Page 144 Service and Repair Manual October 2019 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
Page 145 October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature KWP = Keyword Protocol exhaust gas mass flow; plausibility error SPN FMI Description...
Page 146 Service and Repair Manual October 2019 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of KWP = Keyword Protocol CAN-Receive-Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of 4766...
Page 147 October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
Page 148 Service and Repair Manual October 2019 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523788 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of 523717...
Page 149 October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value FMI KWP Description exceeded 523947...
Page 150 Service and Repair Manual October 2019 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
Page 151 October 2019 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame A1DOC KWP Description 524115 9 1660 Timeout error of CAN-Transmit-Frame AT1S 524102 9...
Page 152: Perkins 404-22 Engine Fault Codes
Service and Repair Manual October 2019 Perkins 404-22 Engine Fault Codes Per kin s 404- 22 Eng ine F ault Cod es SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Engine Speed Sensor #2: Voltage Description Above Normal Accelerator Pedal Position 2: Voltage Engine Speed Sensor #2: Voltage Above Normal...
Page 153 October 2019 Service and Repair Manual Perkins 404-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Description Below Normal 3251 Particulate Trap Differential Pressure: 4201 Engine Speed Sensor #1: Abnormal Voltage Above Normal Frequency, Pulse \Nidth, or Period 3251...
Page 154: Gm 3.0L Engine Fault Codes
Service and Repair Manual October 2019 GM 3.0L Engine Fault Codes GM 3.0L Eng in e F ault Cod es DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position error 520800 / 7 DTC 221: TPS1-2 higher than expected 653/6 DTC 16: Crank and/or cam no sync during DTC 222: TPS2 voltage low...
Page 155 October 2019 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-2 FMI-2 DTC 420: Catalyst inactive on gasoline (Bank DTC 1111: RPM above fuel rev limit level 520211 / 10 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank...
Page 156 Service and Repair Manual October 2019 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-2 FMI-2 DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage 520220 / 3 DTC 1316: Cylinder 6 misfire detected 1328 / 11...
Page 157 October 2019 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-2 FMI-2 DTC 1517: AUX analog Pull-Up 3 high voltage 520218 / 3 DTC 1626: CAN-J1939 Tx fault 639 / 12 DTC 1518: AUX analog Pull-Up 3 low voltage 520218 / 4 DTC 1627: CAN-J1939 Rx fault...
Page 158 Service and Repair Manual October 2019 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-2 FMI-2 DTC 2123: FPP1 voltage low 91 / 4 DTC 2328: Spark coil 10 primary shorted 1277 / 6 DTC 2125: FPP2 invalid voltage and FPP1 520250 / 31 DTC 2428: EGT temperature high...
Page 159: Schematics
October 2019 Service and Repair Manual Schematics Section 5 About This Section Schem atics Intr oducti on There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.
Page 160: Electrical Symbol Legend
Service and Repair Manual October 2019 Electrical Symbol Legend Elec trical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no...
Page 161: Hydraulic Symbols Legend
October 2019 Service and Repair Manual Hydraulic Symbols Legend Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, 3 Cylinder, double acting Differential sensing valve or motor)
Page 162: Limit Switch Location Legend
Service and Repair Manual October 2019 Limit Switch Location Legend Limit Swi tch Loc ati on Legend 1 S17 5 LST3S 2 S22 6 S8O, S8S 3 LSB2S 7 LST1O 4 LSB1RS 8 S24 Limit Switches and Sensors Boom angle sensor Boom length sensor LSB2S Limit switch cable tension- safety...
Page 163: Engine Relay Layout - Deutz Td2.9
October 2019 Service and Repair Manual Engine Relay Layout - Deutz TD2.9 Engine R elay Lay out - D eutz TD 2.9 Deutz TD 2.9 L4 Fuses CB8A See Elec Schem for circuits CB8B See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10...
Page 164: Engine Relay Layout - Deutz Td2011L04I
Service and Repair Manual October 2019 Engine Relay Layout - Deutz TD2011L04i Engine R elay Lay out - D eutz TD 2011L04i Deutz TD2011L04i Fuses CB8A See Elec Schem for circuits CB8B See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10...
Page 165: Engine Relay Layout - Perkins 404D-22T
October 2019 Service and Repair Manual Engine Relay Layout - Perkins 404D-22T Engine R elay Lay out - Perki ns 404D- 22T Perkins 404D-22T Circuit Breakers See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10 See Elec Schem for circuits CB8A...
Page 166: Engine Relay Layout - Gm 3.0L
Service and Repair Manual October 2019 Engine Relay Layout - GM 3.0L Engine R elay Lay out - GM 3.0L GM 3.0L Fuses CB8A See Elec Schem for circuits CB8B See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10...
Page 167: Connector Pin Legend
October 2019 Service and Repair Manual Connector Pin Legend Connector Pi n Legend VEC - blue - 8 pin Number Description VEC - green - 8 pin Boom cable - Controls VEC- gray - 2 pin Boom cable - Power VEC - black - 2 pin Boom sensors Function enable...
Page 168 Service and Repair Manual October 2019 Connector Pin Legend Number Description TCON power TCON engine TCON functions TCON functions TCON logic TCON limit switches TCON limit switches TCON unused TCON communication DISCON PCON power PCON functions PCON functions PCON logic PCON toggles PCON toggles PCON joysticks...
Page 169: Electrical Schematics
October 2019 Service and Repair Manual Electrical Schematics Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518)
Page 170: (To Serial Number S80Xch-513, S85Xch- 518)
Service and Repair Manual October 2019 Elec trical Schem atic, TCON (to Serial number S80XCH- 513, S85XCH- 518) Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518) ® -80 XC ™ • S ® -85 XC ™ • S ®...
Page 171: Electrical Schematic, Platform Controller (To Serial Number S80Xch-513, S85Xch- 518)
October 2019 Service and Repair Manual Elec trical Schem atic, Pl atform C ontroller ( to Serial num ber S80XCH-513, S85XCH- 518) Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518) Part No. 1280490GT ® -80 XC ™ • S ®...
Page 172 Service and Repair Manual October 2019 Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518)
Page 173 October 2019 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)
Page 174: Electrical Schematic, Turntable Controller (From S80Xch-514 To S80Xch-1393, S85Xch-519 To 1399)
Service and Repair Manual October 2019 Elec trical Schem atic, Tur ntabl e C ontroll er (from S80XCH-514 to S80XCH- 1393, S85XCH-519 to 1399) Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) ® -80 XC ™ • S ®...
Page 175 October 2019 Service and Repair Manual Elec trical Schem atic, Pl atform C ontroller ( from S80XCH-514 to S80XCH- 1393, S85XCH-519 to S85XCH- 1399) Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) Part No. 1280490GT ® -80 XC ™...
Page 176: Electrical Schematic, Platform Controller (From S80Xch-514 To S80Xch-1393, S85Xch-519 To S85Xch-1399)
Service and Repair Manual October 2019 Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)
Page 177 October 2019 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)
Page 178: Electrical Schematic, Turntable Controller (From S80Xcd-101, S85Xcd-101, S80Xch-1394, S85Xch-1400)
Service and Repair Manual October 2019 Elec trical Schem atic, Tur ntabl e C ontroll er (from S80XCD-101, S85XC D-101, S80XCH- 1394, S85XCH-1400) Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ® -80 XC ™ • S ® -85 XC ™...
Page 179: Electrical Schematic, Platform Controller (From S80Xcd-101, S85Xcd-101, S80Xch-1394, S85Xch-1400)
October 2019 Service and Repair Manual Elec trical Schem atic, Pl atform C ontroller ( from S80XCD-101, S85XCD- 101, S80XCH-1394, S85XCH- 1400) Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) Part No. 1280490GT ® -80 XC ™ • S ®...
Page 180 Service and Repair Manual October 2019 Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)
Page 181 October 2019 Service and Repair Manual Electrical Schematic Deutz TD2.9 L4 Engine...
Page 182: Electrical Schematic, Deutz Td2.9 L4 Engine
Service and Repair Manual October 2019 Elec trical Schem atic, Deutz TD2.9 L4 Engi ne Electrical Schematic Deutz TD2.9 L4 Engine ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF Part No.
Page 183: Electrical Schematic, Deutz Td2011 L04I Engine
October 2019 Service and Repair Manual Elec trical Schem atic, Deutz TD2011 L04i Engine Electrical Schematic Deutz TD22011 Engine Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF...
Page 184 Service and Repair Manual October 2019 Electrical Schematic Deutz TD2011 Engine...
Page 185 October 2019 Service and Repair Manual Electrical Schematic Perkins 404D-22T Engine...
Page 186: Electrical Schematic, Perkins 404D-22T Engine
Service and Repair Manual October 2019 Elec trical Schem atic, Perkins 404D-22T Engine Electrical Schematic Perkins 404D-22T Engine ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF Part No. 1280490GT...
Page 187: Electrical Schematic, Perkins 404F-E22Ta Engine
October 2019 Service and Repair Manual Elec trical Schem atic, Perkins 404F-E22T A Engi ne Electrical Schematic Perkins 404F-E22TA Engine Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ®...
Page 188 Service and Repair Manual October 2019 Electrical Schematic Perkins 404F-E22TA Engine...
Page 189 October 2019 Service and Repair Manual Electrical Schematic GM 3.0L Engine...
Page 190: Electrical Schematic. Gm 3.0L Engine
Service and Repair Manual October 2019 Elec trical Schem atic. GM 3.0L Engine Electrical Schematic GM 3.0L Engine ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF Part No. 1280490GT...
Page 191: Electrical Schematic, 12 Kw Welder Generator And 3 Kw Generator
October 2019 Service and Repair Manual Elec trical Schem atic, 12 kW Wel der Generator and 3 kW Generator Electrical Schematic 12 kW Welder Generator and 3 kW Generator Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™...
Page 192 Service and Repair Manual October 2019 Electrical Schematic 12 Kw Welder Generator and 3 kW Generator...
Page 193: Hydraulic Schematics
October 2019 Service and Repair Manual Hydr aulic Schematics Hydraulic Schematic, S-80 XC 4WD Models...
Page 194: Hydraulic Schematic, S80Xc 4Wd Model
Service and Repair Manual October 2019 Hydraulic Schem atic, S80XC 4WD M odel Hydraulic Schematic, S-80 XC 4WD Models ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ® -85 HF Part No. 1280490GT...
Page 195: Hydraulic Schematic, S85 Xc 4Wd Models
October 2019 Service and Repair Manual Hydraulic Schem atic, S85 XC 4WD M odels Hydraulic Schematic, S-85 XC 4WD Models Part No. 1280490GT ® -80 XC ™ • S ® -85 XC ™ • S ® -80 HF • S ®...
Page 196 Service and Repair Manual October 2019 Hydraulic Schematic, S-85 XC 4WD Models S®-80 XC™ • S®- 85 XC™ • S®-80 HF • S®- 85 HF Part No. 1280490GT Servic e and R epair M anual October 2019...

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Genie s-80 hf series Genie s80xcd-101 Genie s-85 xc series Genie s85xch-101 Genie s-85 hf series Genie s85xcd-101 ... Show all

Terex Genie S-80 XC Series Service And Repair Manual

Introduction

Safety Rules

Specifications

Repair Procedures

Control System

Platform Components

Jib Boom Components

Boom Components

Engines

Hydraulic Pumps

Manifolds

Fuel and Hydraulic Tanks

Turntable Rotation Components

Steer Axle Components

Generators

Fault Codes

Control System Fault Codes

Engine Fault Codes

Deutz D 2.9 L4 Engine Fault Codes

Perkins 404-22 Engine Fault Codes

GM 3.0L Engine Fault Codes

Schematics

Electrical Schematics

Hydraulic Schematics

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