Terex Genie S-80 J, Service And Repair Manual

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Service and Repair Manual June 2021
Boom Components
42 S ® -80 J, S ® -80 J TraX ™ Part No. 1285307GT
4 Tag, disconnect and plug the boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5 Using a suitable lifting device, secure the
barrel-end of lift cylinder.
6 Place a block of wood measuring
4x4x24 inches / 10x10x50 cm across the top
of the turntable bulkhead and below the
cylinder.
7 Remove the pin retaining fastener from the
boom lift cylinder barrel-end pivot pin.
8 Using a soft metal drift, remove the pivot pin.
Lower the cylinder onto the wooden block.
Crushing hazard. The lift
cylinder will fall if not properly
supported when the pivot pin is
removed.
9 Adjust the lifting strap to the center of the lift
cylinder.
10 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin.
11 Using a soft metal drift, remove the pivot pin.
Note: Apply slight lifting pressure to the mid-pivot
to remove pressure from the pivot pin.
12 Carefully remove the boom lift cylinder from
the machine.
Crushing hazard. The lift
cylinder could become
unbalanced and fall if not
properly supported and secured
to the lifting device.
4-4
Primary Boom Extension
Cylinder
The primary boom extension cylinder extends and
retracts the primary boom extension tube.The
primary boom extension cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Primary
Boom Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Raise the jib boom to a horizontal position.
2 Extend the boom until the extension cylinder
rod-end pivot pins are accessible in the
extension tube.
3 Raise the primary boom to a horizontal
position.
4 At the pivot end of the boom, remove the
cover from the end of the boom tube.
5 Remove the boom extend limit switch.