Terex Genie S-80 J, Service And Repair Manual

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June 2021 Service and Repair Manual
Boom Components
Part No. 1285307GT S ® -80 J, S ® -80 J TraX ™ 37
4-1
Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Remove the Cable Track How to Remove the Cable Track
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 Open the platform control box.
2 Tag and disconnect the foot switch wiring
from the terminal strip inside the platform
control box. Pull the wiring out of the platform
control box.
3 Raise the boom to a horizontal position.
4 Disconnect the wire connectors from the
bottom of the platform control box.
Note: When installing the wire connectors to the
bottom of the platform control box, match the color
of the connectors to those on the control box to be
sure they are installed in the correct location.
5 Remove the mounting fasteners from the
power to platform outlet box bracket. Lay the
outlet box and bracket assembly off to the
side.
6 Remove the hose and cable clamps from the
platform support and jib boom.
7 Tag, disconnect and plug the platform leveling
slave cylinder hydraulic hoses from the
bulkhead fittings on the side of the primary
boom. Cap the bulkhead fittings.
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.
8 Tag, disconnect and plug the hydraulic hoses
from the platform function manifold. Cap the
fittings on the manifold.
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.
9 Remove the hose and cable cover from the
side of the jib boom.
10 Locate all electrical cables under the boom at
the pivot end that enter the cable track.
11 Tag and disconnect the electrical connectors
for all cables that enter the cable track.
12 Remove the retaining fasteners from the
electrical connector receptacles for the cables
that enter the cable track.
13 Carefully pull the cables and connector
receptacles out of the primary boom.