Terex Genie S-80 HF Series, Service And Repair Manual

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Service and Repair Manual October 2019
Boom Components
42 S ® -80 XC ™ • S ® -85 XC ™ • S ® - 80 HF • S ® -85 HF Part No. 1280490GT
How to R epair the C abl e Tr ack How to Repair the Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
Note: A cable track repair kit is available through
Genie Service Parts, part no. 77896. The kit
includes a 4-link section of cable track.
1 Visually inspect the cable track and determine
which 4-link section needs to be replaced.
2 Carefully remove the snap rings from each
end of the damaged section of cable track.
3 Remove the retaining fasteners from the
upper black rollers from the 4-link section of
cable track to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
5 Remove the upper rollers from the
replacement section of cable track.
6 Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
7 Connect the ends of the replacement cable
track section to the existing cable track using
the snap rings.
8 Install the rollers onto the new section of cable
track.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth
operation of the new section of cable track.
4-2 Boom 4-2
Boom
How to Shim the Boom How to Shim the Boom
1 Measure each wear pad.
Boom wear pad specifications
Boom number one
Minimum
Bottom wear pads
(extension end of boom)
0.50 inch
12.7 mm
Top and side wear pads
(extension end of boom)
0.625 inch
15.9 mm
Boom number two
Top, bottom and side wear pads
(extension end of boom)
0.50 inch
12.7 mm
Bottom wear pads
(pivot end of boom)
0.50 inch
12.7 mm
Top and side wear pads
(pivot end of boom)
0.625 inch
15.9 mm
Boom number three
Top, bottom and side wear pads
(pivot end of boom)
0.50 inch
12.7 mm
Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
minimum specification, perform the following
procedure.
2 Extend the boom until the wear pads are
accessible.
3 Loosen the wear pad mounting fasteners.
4 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
5 Tighten the mounting fasteners.
6 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
binding or scraping.
Note: Always maintain squareness between the
outer and inner boom tubes.