Page 1 Service and Repair Manual Serial Number Range -80 XC ® ™ from S80XCH-104 This manual includes: to S80XCH-3100 Repair procedures -80 HF ® Fault Codes Electrical and -85 XC ® ™ from S85XCH-101 Hydraulic Schematics to S85XCH-3090 -85 HF ®...
Page 2: Find A Manual For This Model
Unrestricted with proper operation, inspection and scheduled maintenance. 1280490GT Rev E, April 2022 First Edition, Fifth Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" is a trademark of Terex South Dakota, Inc. ®...
Page 3 April 2022 Service and Repair Manual Introduction 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 April 2022 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) ® -80 XC ™ • S ® -80 HF • S ®...
Page 5: Safety Rules
April 2022 Service and Repair Manual Safety Rules Secti on 1 Safety Rul 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...
Page 6 Service and Repair Manual April 2022 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...
Page 7: Table Of Contents
April 2022 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 April 2022 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 April 2022 Table of Contents Jib Boom Components .................. 40 3-1 Jib Boom ....................40 3-2 Jib Boom Lift Cylinder ................. 41 Boom Components ..................42 4-1 Cable Track ....................42 How to Remove the Cable Track, S-80 ............42 How to Repair the Cable Track ..............
Page 10 April 2022 Table of Contents Manifolds ......................67 7-1 Function Manifold ..................67 7-2 Valve Adjustments - Function Manifold ............69 How to Adjust the System Relief Valve ............69 How to Adjust the Boom Down Relief Valve ..........69 How to Adjust the Boom Extend Relief Valve..........
Page 11 April 2022 Table of Contents Section 4 Fault Codes ..................... 94 Introduction ...................... 94 Control System Fault Codes ................95 How to Retrieve Control System Fault Codes ..........95 Control System Fault Codes - Models with Revision G Software or Lower..96 Control System Fault Codes - Models with Revision H Software or Higher .
Page 12 April 2022 Table of Contents Section 5 Schematics ....................159 Introduction ....................159 Electrical Symbol Legend ................160 Hydraulic Symbols Legend ................161 Limit Switch Location Legend ................. 162 Engine Relay Layout - Deutz TD2.9 ............... 163 Engine Relay Layout - Deutz TD2011L04i ............164 Engine Relay Layout - Perkins 404D-22T ............
Page 13: Specifications
April 2022 Service and Repair Manual Specifications Secti on 2 Specificatio ns 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 113,5 liters Tire ply rating...
Page 14: Performance Specifications
Service and Repair Manual April 2022 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position, Genie specifications require hydraulic oils which are 40 ft / 9 - 11 sec RT tires designed to give maximum protection to hydraulic 12,2 m / 9 - 11 sec systems, have the ability to perform over a wide Raised or extended...
Page 15 April 2022 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 April 2022 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid 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 15.0 cSt @ 104°F / 40°C...
Page 17: Hydraulic Component Specifications
April 2022 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Drive Pump Viscosity index Type: bi-directional variable displacement piston pump Kinematic Viscosity Displacement per revolution 0 to 2.8 cu in cSt @ 149°F / 65°C 0 to 46 cc cSt @ 104°F / 40°C Flow rate @ 2300 rpm...
Page 18: Manifold Component Specifications
Service and Repair Manual April 2022 Specifications Manifold Component Function manifold Specifications System relief valve pressure, 3200 psi maximum 221 bar Plug torque Primary boom extend relief pressure 2400 psi (measured at port) 165 bar PTEST SAE No. 2 36 in-lbs / 4 Nm Platform Manifold and Oscillate Valve SAE No.
Page 19: Deutz Td2011 L04I Engine Specifications
April 2022 Service and Repair Manual Specifications Deutz TD2011 L04i Engine Oil Temperature sender Installation torque 8 - 18 ft-lbs Displacement 220.9 cu. in 11 - 24 Nm 3,62 liters Oil Pressure sender Number of cylinders Installation torque 8 - 18 ft-lbs Bore and Stroke 3.78 x 4.92 inches 11 - 24 Nm...
Page 20: Deutz Tcd 2.2 L3 Engine Specifications
Service and Repair Manual April 2022 Specifications Deutz TCD 2.2 L3 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2,2 liters Temperature switch point 257°F Number of cylinders 125°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...
Page 21: Deutz Td 2.9 Engine Specifications
April 2022 Service and Repair Manual Specifications Deutz TD 2.9 L4 Engine Oil Temperature sender Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2,9 liters Oil Pressure sender Number of cylinders Installation torque 8 - 18 ft-lbs Bore and Stroke 3.6 x 4.3 inches 11 - 24 Nm...
Page 22: Perkins 404D-22T Engine Specifications
Service and Repair Manual April 2022 Specifications Perkins 404D-22T Engine Fuel injection system Injection pump make Zexel Displacement 134 cu in Injection pressure 2133 psi 2,2 liters 147 bar Number of cylinders Fuel requirement Bore and Stroke 3.31 x 3.94 inches 84 x 100 mm For fuel requirements, refer to the engine Operator Manual for your engine.
Page 23: Perkins 404F-E22Ta Engine Specifications
April 2022 Service and Repair Manual Specifications Perkins 404F-E22TA Engine Oil Pressure switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2,2 liters Pressure switch point 14.2 psi Number of cylinders 1 bar Bore and Stroke 3.31 x 3.94 inches Fuel injection system 84 x 100 mm...
Page 24: Machine Torque Specifications
Service and Repair Manual April 2022 Specifications Machine Torque Specifications Machine Component Weights Platform Rotator Primary boom assembly 4808 lbs 2181 kg (does not include jib assembly) 1-8 center bolt, GR 5, dull gray, 500 ft-lbs lubricated 678 Nm Turntable assembly 4441 lbs 2015 kg 1/2-13 bolts, GR 8, dull gray,...
Page 25: Hydraulic Hose And Fitting Torque Specifications
April 2022 Service and Repair Manual Specifications 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° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...
Page 26: Torque Procedure
Service and Repair Manual April 2022 Specifications 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 Replace the O-ring.
Page 27 April 2022 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 April 2022 Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es Unless otherwise specified, perform each  repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
Page 29 April 2022 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 April 2022 Control System How to Enter ALC-600 Service ALC-600 Control Module Mode Platform Controls The platform control box contains the ALC- 600 platform Control Module. The platform Control Module receives all signals from the platform switches, joysticks and foot switch, and provides operator feedback through an Indicator Module.
Page 31: Service Mode
April 2022 Service and Repair Manual Control System The Control System on this machine allows access to calibrations through the Service Mode. Full Machine Calibration The procedures that follow will require the operator to be in Service Mode. Service Mode can only be Full machine calibration must be completed in the entered at machine start up and requires a special proper sequence when the ALC-600 controller...
Page 32: Machine Functions
Service and Repair Manual April 2022 Control System 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 function times listed in Refer to Specifications, How to Adju st th e M achin e Ma ximu m Spe ed Set ting How to Adjust the Joystick Performance Specifications.
Page 33: How To Adjust The Joystick Ramp Rate Setting
April 2022 Service and Repair Manual Control System How to Adju st th e Joys tick Ra mp Ra te Setti ng 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 April 2022 Control System How to Adju st th e Joys tick T hres hold S etting 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 Go to the Genie website open and allow the function to operate.
Page 35: Display Module Menus
April 2022 Service and Repair Manual Control System 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 Model Configuration Model S-40 •...
Page 36 Service and Repair Manual April 2022 Control System Screen or Menu Item Default Sensor Calibration Chassis Tilt Select OK to calibrate Load Sense Select OK to calibrate Boom Angle Select OK to calibrate Boom Length Select OK to calibrate Platform Angle Select OK to calibrate Screen or Menu Item...
Page 37 April 2022 Service and Repair Manual Control System Screen or Menu Item Default Deutz TCD 2.2L T4 Threshold 2375 rpm Anti-Stall Drive Minimum Range 125 rpm Hysteresis 100 rpm Screen or Menu Item Default Deutz TCD 2.2L S5 Threshold 2275 rpm Anti-Stall Drive Minimum Range...
Page 38 Service and Repair Manual April 2022 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 April 2022 Service and Repair Manual Control System Screen or Menu Item Default Jib and Platform Jib Up/Down Ramp 0.2 - 2 sec. 0.75 sec Ramps Platform Level Ramp 0.2 - 2 sec. 0.5 sec Screen or Menu Item Default Machine Disable Drive Disable On / Off...
Page 40: How To Replace The Display Controller (Discon) Module
Service and Repair Manual April 2022 Control System Open the ground box lid (1) and disconnect the wire harness going to the display How to Replace the Display controller (DISCON). Controller (DISCON) Module Remove the DISCON door from the back by loosening the four Torx head screws (8) and Push in the red Emergency Stop button to the remove the two ribbon cables (6) connecting...
Page 41: How To Replace The Ground Control Overlay
April 2022 Service and Repair Manual Control System 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. All five fastening points must be Control Overlay used.
Page 42 Service and Repair Manual April 2022 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 ground box. buttons. Remove the old overlay and clean the ground Note the orientation of the key switch so it can be box lid surface from any dirt, oils or old reassembled in the same position.
Page 43 April 2022 Service and Repair Manual 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. 17 Close and fasten the ground box lid.
Page 44: Platform Components
Service and Repair Manual April 2022 Platform Components Platform How to Remove the Platform Remove the cable clamp from the top of the platform mounting weldment. Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side.
Page 45: Platform Leveling Slave Cylinder
April 2022 Service and Repair Manual Platform Components Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft Platform Leveling Cylinder metal drift to drive the rod-end pivot pin out. The slave cylinder and the rotator pivot are the two Crushing hazard.
Page 46: Platform Rotator
Service and Repair Manual April 2022 Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the rotator. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.
Page 47: How To Bleed The Platform Rotator
April 2022 Service and Repair Manual Platform Components How to Blee d th e Platf orm Rota tor How to Bleed the Platform Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the Rotator machine.
Page 48: Platform Overload System
Service and Repair Manual April 2022 Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System Bodily injury hazard. Spraying Proper calibration of the platform overload system hydraulic oil can penetrate and is essential to safe machine operation.
Page 49: How To Perform A Full Load Platform Calibration
April 2022 Service and Repair Manual Platform Components How to Pe rfor m a Full Loa d Platf orm Calibr ation How to Perform a Full Load Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode. Platform Calibration Press the settings button above the display Perform this procedure if the platform support or...
Page 50 Service and Repair Manual April 2022 Platform Components 10 Place a test weight on the platform floor using 11 Follow the prompts to accept the weight. a suitable lifting device. Place the weight near 12 Calibration is now complete. the center entry point of the platform, as far away from the operator controls as possible.
Page 51: How To Replace The Platform Overload Load Cell
April 2022 Service and Repair Manual Platform Components How to Re place the Platfo rm O verlo ad Load Cell How to Replace the Load Cell Install the new Load Cell Sensor Sensor Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out Note: The preload adjustment should only be of the bottom of the sensor.The foot should...
Page 52: Jib Boom Components
Service and Repair Manual April 2022 Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
Page 53: Jib Boom Lift Cylinder
April 2022 Service and Repair Manual Jib Boom Components 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 54: Boom Components
Service and Repair Manual April 2022 Boom Components S-80XC: Tag, disconnect and plug the hydraulic hoses from the counterbalance Cable Track valve 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 55 April 2022 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 56: How To Repair The Cable Track
Service and Repair Manual April 2022 Boom Components How to Re pair the Cable Tr ack How to Repair the Cable Track Boom Component damage hazard. The boom cable track can be How to Shi m th e Boo m How to Shim the Boom damaged if it is twisted.
Page 57: How To Remove The Boom
April 2022 Service and Repair Manual Boom Components How to Re mov e th e Boo m How to Remove the Boom Remove the jib boom. Refer to Repair Procedure, How to Remove the Jib Boom. Tip-over hazard. This procedure Remove the cable track.
Page 58 Service and Repair Manual April 2022 Boom Components Locate and remove the counterweight 15 Remove the hose and cable guide fasteners retaining fastener at the center of the at the primary boom pivot pin. Remove the counterweight. Carefully lift the counterweight hose and cable guide.
Page 59 April 2022 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 60: Boom Lift Cylinder
Service and Repair Manual April 2022 Boom Components Using auxiliary power, activate the boom down function so the cylinder will retract. Boom Lift Cylinder Retract the cylinder just enough until the rod end of the cylinder will clear the mounting The boom lift cylinder raises and lowers the boom.
Page 61: Boom Extension Cylinder
April 2022 Service and Repair Manual Boom Components 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 62 Service and Repair Manual April 2022 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 63: Boom Extend/Retract Cables
April 2022 Service and Repair Manual Boom Components 23 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside Boom Extend and Retract Cables the number 2 boom tube. How to Adju st th e Exten d/Ret ract Cables How to Adjust the Boom 24 Carefully support and slide the extension cylinder out of the boom.
Page 64 Service and Repair Manual April 2022 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 65: How To Replace The Boom Extend/Retract Cables
April 2022 Service and Repair Manual Boom Components How to Re place the Boom Exten d/Ret ract C ables 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 66 Service and Repair Manual April 2022 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 67: Platform Leveling Master Cylinder
April 2022 Service and Repair Manual Boom Components Place a rod through the barrel-end pivot pin and twist to remove the pin. Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder. It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion.
Page 68: Primary Boom Angle Sensor Calibration
Service and Repair Manual April 2022 Boom Components 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 69: Boom Length Sensor
April 2022 Service and Repair Manual Boom Components 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 70: Engines
Service and Repair Manual April 2022 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Refer to Maintenance Procedure in the appropriate engine and the pump. It is bolted to the engine Service or Maintenance Manual for your machine, flywheel and has a splined center to drive the Check and Adjust the Engine RPM.
Page 71 April 2022 Service and Repair Manual Engines Deutz TD2011L04i models: Deutz TD 2.9, TCD 2.2 models: Tag and disconnect the wiring from the bell Tag and disconnect the wiring from the bell housing. housing. Remove the U-bolt from the exhaust flex pipe Support the drive pump with an appropriate at the muffler.
Page 72 Service and Repair Manual April 2022 Engines Perkins models: GM 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 73: How To Install The Flex Plate
April 2022 Service and Repair Manual Engines How to I nstall t he Flex Plat e How to Install the Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave Install the flex plate onto the engine flywheel the appropriate gap between coupler and with the raised spline towards the pump.
Page 74: How To Install The Pump And Bell Housing Assembly
Service and Repair Manual April 2022 Engines How to ins tall th e Pum p a nd Bell Ho using Assem bly How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts in sequence to 28 ft-lbs / 38 Nm.
Page 75: 5-3 Diesel Particle Filter Regeneration - Deutz Tcd 2.2 L3
April 2022 Service and Repair Manual Engines Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3 Engine The combustion of diesel fuel results in soot, which is separated in the diesel particle filter (DPF). This must be regenerated as the contamination with soot increases.
Page 76: Hydraulic Pump
Service and Repair Manual April 2022 Hydraulic Pump Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...
Page 77: Drive Pump
April 2022 Service and Repair Manual Hydraulic Pump 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 78: How To Prime The Drive Pump
Service and Repair Manual April 2022 Hydraulic Pump How to Pri me t he D rive Pu mp How to Prime the Drive Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Component damage hazard. Remove the drive pump from the machine.
Page 79: Manifolds
April 2022 Service and Repair Manual Manifolds Function Manifold Components The function manifold assembly is located on the hydraulic tank side of the machine next to the batteries. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Boom up 50-55 ft-lbs / 68-75 Nm Solenoid Valve, 2 position 3 way...
Page 80 Service and Repair Manual April 2022 Manifolds ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 81: Valve Adjustments - Function Manifold
April 2022 Service and Repair Manual Manifolds 7-2 Valve Adjustments - Function How to Adju st th e Boo m Down Relief V alve How to Adjust the Boom Down Manifold Relief Valve Note: Perform this procedure with the boom in the How to Adju st th e Syste m Relie f Valve How to Adjust the System Relief stowed position.
Page 82: How To Adjust The Boom Extend Relief Valve
Service and Repair Manual April 2022 Manifolds How to Adju st th e Boo m Exten d Relie f Valve How to Adjust the Boom Extend Relief Valve Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions. Note: Refer to Function Manifold Component list to locate the boom extend relief valve.
Page 83: Brake/Two-Speed Manifold Components
April 2022 Service and Repair Manual Manifolds Brake / Two Speed Manifold Components The brake/two speed manifold is mounted on the engine side of the machine above the hydraulic filters. Index Schematic Description Function Torque Item Orifice, 0.025 inch / 0,635 mm Brake release circuit Check valve Brake release circuit...
Page 84: Turntable Rotation Manifold Components
Service and Repair Manual April 2022 Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine. Index Schematic Description Function Torque Item Counterbalance valve, 1000 psi / Turntable rotate left 25-30 ft-lbs / 34-41 Nm 69 bar...
Page 85: Platform Rotate Manifold Components
April 2022 Service and Repair Manual Manifolds Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator. Index Description Schematic Item Function Torque Counterbalance valve, 3300 psi / Platform rotate right 37-44 ft-lbs / 50-60 Nm 227 bar Counterbalance valve, 3300 psi / Platform rotate left...
Page 86: Platform Manifold Components, S-80 Xc
Service and Repair Manual April 2022 Manifolds 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 Platform level up/down...
Page 87: Platform Manifold Components, S-85 Xc
April 2022 Service and Repair Manual Manifolds 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 Platform level up/down...
Page 88 Service and Repair Manual April 2022 This page intentionally left blank. ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 89: 4Wd Traction Manifold Components
April 2022 Service and Repair Manual Manifolds 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 Charge pressure circuit 35-40 ft-lbs / 48-54 Nm Flow divider/combiner valve...
Page 90 Service and Repair Manual April 2022 Manifolds ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 91: Valve Adjustments - Traction Manifold
April 2022 Service and Repair Manual Manifolds 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 cooling.
Page 92: Generator Manifold Components
Service and Repair Manual April 2022 Manifolds 7-10 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 60-65 ft lbs / 81-88 Nm Needle valve...
Page 93: Valve Coils
April 2022 Service and Repair Manual Manifolds 7-11 Valve Coil Resist anc e Specific ations 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 94 Service and Repair Manual April 2022 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 95: Fuel And Hydraulic Tanks
April 2022 Service and Repair Manual Fuel and Hydraulic Tanks Tag, disconnect, drain and plug the supply and return fuel hoses. Cap the fittings on the Fuel Tank fuel tank. Remove the fuel tank retaining fasteners. How to Remove the Fuel Tank Remove the fuel tank from the machine.
Page 96: Hydraulic Tank
Service and Repair Manual April 2022 Fuel and Hydraulic Tanks 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 operation.
Page 97 April 2022 Service and Repair Manual Fuel and Hydraulic Tanks Remove the hydraulic tank from the machine. 17 Clean up any oil that may have spilled. Crushing hazard. The hydraulic 18 Open the hydraulic tank shutoff valves (if tank could become unbalanced equipped).
Page 98: Turntable Rotation Components
Service and Repair Manual April 2022 Turntable Rotation Components Attach a suitable lifting device to the lifting eyes on the drive hub assembly. Turntable Rotation Drive Hub Assembly How to Re mov e th e T urnt able R otati on D rive Hu b Asse mbly How to Remove the Turntable Rotation Drive Hub Assembly Note: When removing a hose assembly or fitting,...
Page 99: How To Remove The Turntable Rotation Hydraulic Motor
April 2022 Service and Repair Manual Turntable Rotation Components When installing the drive hub assembly: How to Re mov e th e T urnt able R otati on Hy dra ulic Mo tor How to Remove the Turntable Rotation Hydraulic Motor Install the drive hub.
Page 100: How To Adjust The Turntable Rotation Gear Backlash
Service and Repair Manual April 2022 Turntable Rotation Components Clean up any oil that may have spilled. How to Adju st th e T urn table Rota tion G ear Backlas h 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...
Page 101: How To Calibrate The Turntable Tilt Sensor
April 2022 Service and Repair Manual Turntable Rotation Components How to Cali brat e th e T urn table Tilt Se nso r 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 102 Service and Repair Manual April 2022 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 103: Steer Axle Components
April 2022 Service and Repair Manual Steer Axle Components 10-1 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. How to Remove the Yoke and Remove the drive motor mounting fasteners.
Page 104: Drive Motors
Service and Repair Manual April 2022 Steer Axle Components 10-2 10-3 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. the O-ring (if equipped) on the fitting and/or hose Repairs to the motor should only end must be replaced.
Page 105: Generators
April 2022 Service and Repair Manual Generators 11-1 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 61 Hz...
Page 106: Fault Codes
Service and Repair Manual April 2022 Fault Codes Before Troubleshooting: Secti on 4 Fault C odes 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 ...
Page 107: Control System Fault Codes
April 2022 Service and Repair Manual Control System Fault Codes Control System How to Re triev e Con trol Syst em Fa ult Cod es 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 108: Control System Fault Codes - Models With Revision G Software Or Lower
Service and Repair Manual April 2022 Control System Fault Codes Contr ol System Fa ult Co des - M odels wit h Revisi on G S oftwa re o r L ower Models with Revision G Software or Lower Component ID Name Cause Effect...
Page 109 April 2022 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Foot Switch 19 Stuck ON Foot switch Machine will not * Release foot switch and cycle power. at power input was be functional. * If problem persists, with a voltmeter up, or detected as verify that C24FS (WH, PCON J12-2) is...
Page 110 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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 111 April 2022 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 112 Service and Repair Manual April 2022 Control System Fault Codes Component ID Name Cause Effect Solution Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y26. Boom shorted to that C7PBE Extend and Proper resistance should be between 5 - Extend Valve circuit is shorted Retract...
Page 113 April 2022 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 114 Service and Repair Manual April 2022 Control System Fault Codes Component ID Name Cause Effect Solution Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y70. Rotate CW shorted to that V17PRL Rotate CW Proper resistance should be between 5 - Valve circuit is shorted function will...
Page 115 April 2022 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 - Valve circuit is shorted functional.
Page 116 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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 complete,...
Page 117 April 2022 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Contact 36 Switch PCON detected Boom Up * Using a voltmeter, verify that the voltage on C248CA (OR/BK, PCON J12-1) is always the Alarm state that inputs from and Extend...
Page 118 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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 119 April 2022 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 Detection check detected operate...
Page 120 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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...
Page 121 April 2022 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Function 12 Circuit TCON detected Only * With a voltmeter, measure Y74. Enable Valve shorted to that C155PCE Auxiliary Proper resistance should be between 5 - circuit is shorted Power is 60 ohms.
Page 122 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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 123 April 2022 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 - circuit is shorted not operate.
Page 124 Service and Repair Manual April 2022 Control System Fault Codes Component ID 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 125: Control System Fault Codes - Models With Revision H Software Or Higher
April 2022 Service and Repair Manual Control System Fault Codes Contr ol System Fa ult Co des - M odels wit h Revisi on H Sof twar e o r High er Models with Revision H software or higher ID Component ID Name Cause Effect Solution...
Page 126 Service and Repair Manual April 2022 Control System Fault Codes ID Component ID Name Cause Effect Solution 12 Machine 13 Not Machine CANBUS Machine will not be *Verify with a voltmeter that CAN+ CAN Bus detected CAN+ or CAN- functional. and CAN- lines are not shorted.
Page 127 April 2022 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 20 Pri Boom 11 Shorted Circuit C163PER is Boom Extend and * Leave joystick in neutral position Ext / Ret above 4.5 V. Retract functions will and cycle power.
Page 128 Service and Repair Manual April 2022 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 recovery functions TCON J6-7) is at 12 V while the system is running.
Page 129 April 2022 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 130 Service and Repair Manual April 2022 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 131 April 2022 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 132 Service and Repair Manual April 2022 Control System Fault Codes ID Component ID Name Cause Effect Solution 52 Drive 11 Shorted TCON detected Drive Forward, Brake * With a voltmeter, measure Y6. Forward that C30FWD Release and possibly Proper resistance should be between Pump Coil supply circuit is shorted to...
Page 133 April 2022 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 Joystick C159STA is above functions will not and cycle power.
Page 134 Service and Repair Manual April 2022 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 135 April 2022 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 operate C26TSR ( WH/RD, TCON J6P8) is sensor is shorted not shorted to ground and voltage is to ground...
Page 136 Service and Repair Manual April 2022 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 platform will not Check for 12 V on J15-2 (+) and J15- (PCON) PCON primary...
Page 137 April 2022 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 138 Service and Repair Manual April 2022 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 Only Auxiliary Power * With a voltmeter, measure Y74.
Page 139 April 2022 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 and Turntable Rotate TCON J6-7) is at 12 V while the Length received by the...
Page 140 Service and Repair Manual April 2022 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 between 5 - 60 ohms.
Page 141 April 2022 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 LF Steer (L 11 Shorted TCON detected Steer Left function * With a voltmeter, measure Y3. or R) Coil that C37STL circuit will not operate. Proper resistance should be between supply is shorted to 12 V...
Page 142: Engine Fault Codes
Service and Repair Manual April 2022 Engine Fault Codes 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 143: Deutz Td 2.9 L4 Engine Fault Codes
April 2022 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1231 Actuator error EGR-Valve; KWP = Keyword Protocol Power stage over temp due to high current SPN FMI Description...
Page 144 Service and Repair Manual April 2022 Deutz TD 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 145 April 2022 Service and Repair Manual Deutz TD 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 146 Service and Repair Manual April 2022 Deutz TD 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 147 April 2022 Service and Repair Manual Deutz TD 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 148 Service and Repair Manual April 2022 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of CAN-Receive- KWP = Keyword Protocol Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of CAN-Receive-...
Page 149 April 2022 Service and Repair Manual Deutz TD 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 150 Service and Repair Manual April 2022 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI SPN Description FMI = Failure Mode Identifier 523788 Timeout Error of CAN-Transmit- KWP = Keyword Protocol Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of CAN-Receive- Frame UAA10;...
Page 151 April 2022 Service and Repair Manual Deutz TD 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 exceeded FMI KWP Description 523947...
Page 152 Service and Repair Manual April 2022 Deutz TD 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 153 April 2022 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of CAN-Transmit- KWP = Keyword Protocol Frame A1DOC KWP Description 524115 9 1660 Timeout error of CAN-Transmit- Frame AT1S...
Page 154: Deutz Tcd 2.2 L3 Engine Fault Codes
Service and Repair Manual April 2022 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1077 411 Engine exhaust gas recirculation. SPN = Suspect Parameter Number Signal value above maximum limit. DTC SPN FMI Description 1078 411...
Page 155 April 2022 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1134 3251 3 DPF voltage above normal or SPN = Suspect Parameter Number shorted to high.
Page 156 Service and Repair Manual April 2022 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1209 157 Engine fuel injector metering rail SPN = Suspect Parameter Number pressure voltage below normal or shorted to low.
Page 157 April 2022 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1308 677 Engine starter motor relay current SPN = Suspect Parameter Number below normal or shorted to low. DTC SPN FMI Description 1310 677...
Page 158 Service and Repair Manual April 2022 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1392 51 Engine throttle valve 1, position SPN = Suspect Parameter Number 1 voltage below normal or shorted to low.
Page 159 April 2022 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 3349 Timeout Error of CAN receive SPN = Suspect Parameter Number frame TSC1TR; control signal. DTC SPN Description 1485...
Page 160 Service and Repair Manual April 2022 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier Ambient air temperature sensor SPN = Suspect Parameter Number voltage above normal or shorted to high.
Page 161 April 2022 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 5363 5 Engine cylinder 6 fuel injection SPN = Suspect Parameter Number quantity current below normal or open circuit.
Page 162 Service and Repair Manual April 2022 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 4257 14 Engine fuel 1 injector, group SPN = Suspect Parameter Number 3 missing injector adjustment value programming injector 3.
Page 163 April 2022 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier Actual engine percent torque. SPN = Suspect Parameter Number DFC to report the fault in energizing time comparison.
Page 164: Perkins 404-22 Engine Fault Codes
Service and Repair Manual April 2022 Perkins 404-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Engine Speed Sensor #2: Voltage Above Normal Description Engine Speed Sensor #2: Voltage Accelerator Pedal Position 2: Voltage Below Normal Above Normal Engine Speed Sensor#2: Abnormal...
Page 165 April 2022 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 Below Normal Description 4201 Engine Speed Sensor #1: Abnormal 3251 Particulate Trap Differential Pressure: Frequency, Pulse \Nidth, or Period Voltage Above Normal 4201...
Page 166: Gm 3.0L Engine Fault Codes
Service and Repair Manual April 2022 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position DTC 221: TPS1-2 higher than expected 520800 / 7 653/6 error DTC 16: Crank and/or cam no sync during DTC 222: TPS2 voltage low 636 / 8 520251 / 4...
Page 167 April 2022 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-2 / FMI- 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 168 Service and Repair Manual April 2022 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-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 169 April 2022 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-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 170 Service and Repair Manual April 2022 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-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 520250 / 31 DTC 2428: EGT temperature high...
Page 171: Schematics
April 2022 Service and Repair Manual Schematics About This Section Secti on 5 Schematic s 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 172: Electrical Symbol Legend
Service and Repair Manual April 2022 Electrical 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 Quick disconnect...
Page 173: Hydraulic Symbols Legend
April 2022 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...
Page 174: Limit Switch Location Legend
Service and Repair Manual April 2022 Limit Switch Location 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 LSB1RS Limit switch boom fully retracted- safety LST3S...
Page 175: Engine Relay Layout - Deutz Td2.9
April 2022 Service and Repair Manual Engine Relay Layout - Deutz TD2.9 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 See Elec Schem for circuits See Elec Schem for circuits...
Page 176: Engine Relay Layout - Deutz Td2011L04I
Service and Repair Manual April 2022 Engine Relay Layout - Deutz TD2011L04i 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 See Elec Schem for circuits See Elec Schem for circuits...
Page 177: Engine Relay Layout - Perkins 404D-22T
April 2022 Service and Repair Manual Engine Relay Layout - Perkins 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 See Elec Schem for circuits CB8B See Elec Schem for circuits Fuses...
Page 178: Engine Relay Layout - Gm 3.0L
Service and Repair Manual April 2022 Engine Relay Layout - 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 See Elec Schem for circuits See Elec Schem for circuits...
Page 179: Connector Pin Legend
April 2022 Service and Repair Manual Connector Pin 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 Function manifold...
Page 180 Service and Repair Manual April 2022 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 181: Electrical Schematics
April 2022 Service and Repair Manual Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518)
Page 182: (To Serial Number S80Xch-513, S85Xch- 518)
Service and Repair Manual April 2022 Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518) ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 183: Electrical Schematic, Platform Controller (To Serial Number S80Xch-513, S85Xch- 518)
April 2022 Service and Repair Manual Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518) Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 184 Service and Repair Manual April 2022 Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518)
Page 185 April 2022 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)
Page 186: Electrical Schematic, Turntable Controller (From S80Xch-514 To S80Xch-1393, S85Xch-519 To 1399)
Service and Repair Manual April 2022 Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 187: (From S80Xch-514 To S80Xch-1393, S85Xch-519 To S85Xch-1399)
April 2022 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 188 Service and Repair Manual April 2022 Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)
Page 189 April 2022 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)
Page 190: Electrical Schematic, Turntable Controller (From S80Xcd-101, S85Xcd-101, S80Xch-1394, S85Xch-1400)
Service and Repair Manual April 2022 Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 191: Electrical Schematic, Platform Controller (From S80Xcd-101, S85Xcd-101, S80Xch-1394, S85Xch-1400)
April 2022 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 192 Service and Repair Manual April 2022 Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)
Page 193 April 2022 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine...
Page 194: Electrical Schematic, Deutz Tcd 2.2 L3 Engine
Service and Repair Manual April 2022 Electrical Schematic, Deutz TCD 2.2 L3 Engine ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 195 April 2022 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 196 Service and Repair Manual April 2022 Electrical Schematic, Deutz TCD 2.2 L3 Engine...
Page 197 April 2022 Service and Repair Manual Electrical Schematic, Deutz TD 2.9 L4 Engine...
Page 198: Electrical Schematic, Deutz Td 2.9 L4 Engine
Service and Repair Manual April 2022 Electrical Schematic, Deutz TD 2.9 L4 Engine ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 199: Electrical Schematic, Deutz Td2011 L04I Engine
April 2022 Service and Repair Manual Electrical Schematic, Deutz TD2011 L04i Engine Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 200 Service and Repair Manual April 2022 Electrical Schematic, Deutz TD2011 L04i Engine...
Page 201 April 2022 Service and Repair Manual Electrical Schematic, Perkins 404D-22T Engine...
Page 202: Electrical Schematic, Perkins 404D-22T Engine
Service and Repair Manual April 2022 Electrical Schematic, Perkins 404D-22T Engine ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 203: Electrical Schematic, Perkins 404F-E22Ta Engine
April 2022 Service and Repair Manual Electrical Schematic, Perkins 404F-E22TA Engine Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 204 Service and Repair Manual April 2022 Electrical Schematic, Perkins 404F-E22TA Engine...
Page 205 April 2022 Service and Repair Manual Electrical Schematic, GM 3.0L Engine...
Page 206: Electrical Schematic, Gm 3.0L Engine
Service and Repair Manual April 2022 Electrical Schematic, GM 3.0L Engine ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 207: Electrical Schematic, 12 Kw Welder Generator And 3 Kw Generator
April 2022 Service and Repair Manual Electrical Schematic, 12 kW Welder Generator and 3 kW Generator Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 208 Service and Repair Manual April 2022 Electrical Schematic, 12 Kw Welder Generator and 3 kW Generator...
Page 209: Hydraulic Schematics
April 2022 Service and Repair Manual Hydraulic Schematic, S-80 XC Models...
Page 210: Hydraulic Schematic, S-80 Xc Models
Service and Repair Manual April 2022 Hydraulic Schematic, S-80 XC Models ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF Part No. 1280490GT...
Page 211: Hydraulic Schematic, S-85 Xc Models
April 2022 Service and Repair Manual Hydraulic Schematic, S-85 XC Models Part No. 1280490GT ® -80 XC ™ • S ® -80 HF • S ® -85 XC ™ • S ® -85 HF...
Page 212 Service and Repair Manual April 2022 Hydraulic Schematic, S-85 XC Models S®-80 XC™ • S®-8 0 HF • S®- 85 XC™ • S®-8 5 HF Part No. 128 049 0GT Service a nd Re pair Ma nual April 202 2...

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Genie s-80 hf Genie s-85 xc Genie s-85 hf Genie s-80 xc S80xch-3100 S85xch-101 ... Show all

Terex S80XCH-104 Service And Repair Manual

Safety Rules

Specifications

Repair Procedures

Control System

Platform Components

Jib Boom Components

Boom Components

Engines

Hydraulic Pump

Manifolds

Fuel and Hydraulic Tanks

Turntable Rotation Components

Steer Axle Components

Generators

Fault Codes

Control System Fault Codes

Engine Fault Codes

Deutz TD 2.9 L4 Engine Fault Codes

Deutz TCD 2.2 L3 Engine Fault Codes

Perkins 404-22 Engine Fault Codes

GM 3.0L Engine Fault Codes

Schematics

Electrical Schematics

Hydraulic Schematics

Quick Links

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Questions and answers

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Summary of Contents for Terex S80XCH-104

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Table of Contents