Post on 04-Jul-2018
Service Manual
Part No. 122149
Rev B1
June 2015
Serial Number Range
from S8007-5381to S8008-7999S-80
S-85
TM
TM
June 2015
S-80 • S-85 Part No. 122149
Introduction
Serial Number Information
Genie Industries offers the following ServiceManuals for these models:
Title Part No.
Genie S-80 and S-85 Service Manual(from serial number 101 to 785) ..........34032
Genie S-80 and S-85 Service Manual(from serial number 786 to 965) ..........52270
Genie S-80 and S-85 Service Manual(from serial number 966 to 3081) ........72062
Genie S-80 and S-85 Service Manual(from serial number 3082 to 3737) ......77832
Genie S-80 and S-85 Service Manual(from serial number 3738 to 5380) ... 111165
Introduction
Copyright © 1994 by Genie Industries
122149 Rev B February 2012Sixth Edition, First Printing
"Genie" and "S" are registered trademarks ofGenie Industries in the USA and many othercountries.
Printed on recycled paper
Printed in U.S.A.
ii
Important
Read, understand and obey the safety rules andoperating instructions in the appropriate operator'smanual on your machine before attempting anymaintenance or repair procedure.
This manual provides detailed scheduled maintenanceinformation for the machine owner and user. It alsoprovides troubleshooting fault codes and repairprocedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However, severalprocedures require specialized skills, tools, liftingequipment and a suitable workshop. In these instances,we strongly recommend that maintenance and repair beperformed at an authorized Genie dealer service center.
Compliance
Machine ClassificationGroup B/Type 3 as defined by ISO 16368
Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree ofaccuracy possible. However, continuous improvement ofour products is a Genie policy. Therefore, productspecifications are subject to change without notice.
Readers are encouraged to notify Genie of errors andsend in suggestions for improvement. Allcommunications will be carefully considered for futureprintings of this and all other manuals.
Contact Us:
http://www.genielift.come-mail: awp.techpub@terex.com
June 2015
Part No. 122149 S-80 • S-85
Revision Date Section Procedure / Schematic Page / Description
B 2/2012 2 - Spec. 2-1
3 - Maint. 3-1
4 - Repair 4-3 to 4-6
6 - Schem. 6-7, 6-11, 6-21, 6-25, 6-35, 6-39
B1 6/2015 4 - Repair 4-476 - Schem. 6-68, 6-69
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 5.6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page numberhighlighted in blue to view the update.
Revision History
June 2015
S-80 • S-85 Part No. 122149
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 5.6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page numberhighlighted in blue to view the update.
June 2015
Part No. 122149 S-80 • S-85 iii
Serial Number Legend
Introduction
S80 06 - 12345
Model
Model year
Sequencenumber
PN - 77055
Country of manufacture: USA
This machine complies with:
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
ANSI A92.5
CAN B.354.4
Model: S-80
Serial number: S8006-12345
Electrical schematic number: ES0274
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum allowable inclination of the chassis:
0 deg
Gradeability: N/A
Maximum allowable side force : 150 lb / 670 N
Maximum number of platfrm occupants: 2
Model year: Manufacture date: 01/05/062006
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 80 ft/ 24.38 m
Maximum platform reach : 72 ft 5 in/ 22.07 m
Serial number(stamped on chassis)
Serial label(located under cover)
June 2015
Part No. 122149 S-80 • S-85
DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-80 and Genie S-85Operator's Manual will result in death or seriousinjury.
Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.
Do Not Perform MaintenanceUnless:
You are trained and qualified to performmaintenance on this machine.
You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite
regulations- applicable governmental regulations
You have the appropriate tools, liftingequipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
v
June 2015
S-80 • S-85 Part No. 122149
SAFETY RULES
Section 1 - Safety Rules
vi
Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.
Read each procedure thoroughly. Thismanual and the decals on the machine usesignal words to identify the following:
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Note: Used to indicate operation or maintenanceinformation.
Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.
Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or
placing loads. Always wear approved steel-toedshoes.
Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases
and engine fuels. Always have an approved fireextinguisher within easy reach.
Be sure that all tools and working areasare properly maintained and ready for use.Keep work surfaces clean and free of
debris that could get into machine components andcause damage.
Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the
weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.
Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.
Be sure that your workshop or work area isproperly ventilated and well lit.
June 2015
Part No. 122149 S-80 • S-85
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules
General Safety Rules .................................................................................................. v
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 2
Hydraulic Component Specifications ...................................................................... 2 - 3
Valve Coil Resistance Specifications ..................................................................... 2 - 4
Continental TME27 Engine Specifications ............................................................. 2 - 5
Deutz BF4L-2011 Engine Specifications ................................................................ 2 - 6
Perkins 804C-33 Engine Specifications ................................................................. 2 - 8
Machine Torque Specifications .............................................................................. 2 - 9
Manifold Component Specifications ....................................................................... 2 - 9
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12
SAE and Metric Torque Specifications ................................................................. 2 - 11
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S-80 • S-85 Part No. 122149
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Grease the Extendable Axles ....................................................................... 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 9
A-5 Perform Function Tests .............................................................................. 3 - 10
A-6 Test the Oscillate Axle ............................................................................... 3 - 10
A-7 Test the Extendable Axles ......................................................................... 3 - 11
A-8 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 12
A-9 Perform 30 Day Service ............................................................................. 3 - 13
A-10 Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 13
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15
A-13 Perform Engine Maintenance ..................................................................... 3 - 15
A-14 Replace the Drive Hub Oil .......................................................................... 3 - 16
A-15 Perform Engine Maintenance - Perkins Models .......................................... 3 - 18
Checklist B Procedures
B-1 Inspect the Battery(s) ................................................................................. 3 - 19
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 20
B-3 Test the Key Switch ................................................................................... 3 - 22
B-4 Check the Exhaust System ....................................................................... 3 - 22
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Part No. 122149 S-80 • S-85
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
` B-5 Inspect the Engine Air Filter ....................................................................... 3 - 23
B-6 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 24
B-7 Confirm the Proper Brake Configuration...................................................... 3 - 25
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 26
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 27
B-10 Check and Adjust the Engine RPM ............................................................ 3 - 28
B-11 Perform Engine Maintenance ..................................................................... 3 - 30
B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 31
B-13 Test the Ground Control Override ............................................................... 3 - 31
B-14 Test the Platform Self-leveling ................................................................... 3 - 32
B-15 Test the Engine Idle Select Operation ........................................................ 3 - 32
B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 33
B-17 Test the Drive Enable System ................................................................... 3 - 34
B-18 Test the Drive Brakes ................................................................................ 3 - 35
B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 36
B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 36
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 37
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38
B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 39
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 41
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 42
C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 42
C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 45
C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 45
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S-80 • S-85 Part No. 122149
Section 3 Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 48
D-2 Check the Extendable Axle Wear Pads ...................................................... 3 - 49
D-3 Check the Free-wheel Configuration ........................................................... 3 - 50
D-4 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 51
D-5 Inspect the Turntable Bearing Wear ........................................................... 3 - 52
D-6 Perform Engine Maintenance ..................................................................... 3 - 54
D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 55
D-8 Replace the Drive Hub Oil .......................................................................... 3 - 56
D-9 Perform Engine Maintenance - Deutz Models ............................................. 3 - 58
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 59
E-2 Perform Engine Maintenance - Perkins Models .......................................... 3 - 61
E-3 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 61
E-4 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 63
Section 4 Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 Platform ....................................................................................................... 4 - 7
2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 8
TABLE OF CONTENTS
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June 2015
Part No. 122149 S-80 • S-85
TABLE OF CONTENTS
Section 4 Repair Procedures, continued
2-3 Platform Rotator ........................................................................................... 4 - 9
2-4 Calibrate the Platform Overload System .................................................... 4 - 11
Jib Boom Components, S-85
3-1 Jib Boom.................................................................................................... 4 - 14
3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 15
Boom Components
4-1 Cable Track ................................................................................................ 4 - 16
4-2 Boom ......................................................................................................... 4 - 19
4-3 Boom Lift Cylinder ...................................................................................... 4 - 21
4-4 Boom Extension Cylinders ......................................................................... 4 - 24
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 26
Engines
5-1 RPM Adjustment ........................................................................................ 4 - 27
5-2 Flex Plate................................................................................................... 4 - 27
Ground Controls
6-1 Control Relays ............................................................................................ 4 - 32
Hydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 33
7-2 Drive Pump ................................................................................................ 4 - 34
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S-80 • S-85 Part No. 122149
Section 4 Repair Procedures, continued
Manifolds
8-1 Function Manifold Components - View 1 .................................................... 4 - 36
8-2 Function Manifold Components - View 2 .................................................... 4 - 40
8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 42
8-4 Brake/Two-speed Manifold Components .................................................... 4 - 45
8-5 Turntable Rotation Manifold Components ................................................... 4 - 46
8-6 Jib Boom Select and Platform Manifold Components ................................. 4 - 47
8-7 Axle Select Manifold Components .............................................................. 4 - 48
8-8 2WD Traction Manifold Components .......................................................... 4 - 50
8-9 4WD Traction Manifold Components .......................................................... 4 - 52
8-10 Drive Oil Diverter Manifold Components ..................................................... 4 - 54
8-11 Valve Adjustments - Drive Manifold ........................................................... 4 - 55
8-12 Valve Coils ................................................................................................. 4 - 56
Fuel and Hydraulic Tanks
9-1 Fuel Tank ................................................................................................... 4 - 59
9-2 Hydraulic Tank ........................................................................................... 4 - 60
Turntable Rotation Components
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 62
2WD Steer Axle Components
11-1 Yoke and Hub ............................................................................................ 4 - 65
11-2 Steer Cylinder ............................................................................................ 4 - 66
11-3 Tie Rod Cylinder ......................................................................................... 4 - 67
TABLE OF CONTENTS
xii
June 2015
Part No. 122149 S-80 • S-85
Section 4 Repair Procedures, continued
4WD Steer Axle Components
12-1 Yoke and Drive Hub ................................................................................... 4 - 68
12-2 Drive Motor ................................................................................................ 4 - 69
12-3 Drive Hub ................................................................................................... 4 - 70
12-4 Steer Cylinders........................................................................................... 4 - 70
12-5 Tie Rod Cylinder ......................................................................................... 4 - 71
Non-steer Axle Components
13-1 Drive Motor ................................................................................................ 4 - 72
13-2 Drive Hub ................................................................................................... 4 - 72
Oscillating Axle Components
14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73
14-2 Valve Adjustments - Oscillate Directional Valve ......................................... 4 - 73
Extendable Axle Components
15-1 Extendable Axles ....................................................................................... 4 - 76
15-2 Axle Extension Cylinder ............................................................................. 4 - 76
Section 5 Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Engine Fault Codes - Continental Models............................................................... 5 - 6
TABLE OF CONTENTS
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June 2015
S-80 • S-85 Part No. 122149
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Electrical Schematic, S-80/85 (before S/N 5520)Deutz BF4L2011 Models ........................................................................................ 6 - 6
Electrical Schematic, S-80/85 (after S/N 5519)Deutz BF4L2011 Models ...................................................................................... 6 - 10
Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models ..................................................................................... 6 - 14
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Deutz BF4L 2011 Models ..................................................................................... 6 - 16
Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)Deutz BF4L 2011 Models ..................................................................................... 6 - 17
Electrical Schematic, S-80/85 (before S/N 5520)Perkins 804-33 Models ........................................................................................ 6 - 20
Electrical Schematic, S-80/85 (after S/N 5519)Perkins 804-33 Models ........................................................................................ 6 - 24
Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models ........................................................................................ 6 - 28
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Perkins 804-33 Models ........................................................................................ 6 - 30
Platform Control Box Wiring Diagram, S-8/85 (after S/N 5519)Perkins 804-33 Models ........................................................................................ 6 - 31
TABLE OF CONTENTS
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June 2015
Part No. 122149 S-80 • S-85
Section 6 Schematics, continued
Electrical Schematic, S-80/85 (before S/N 5520)Continental TME27 Models .................................................................................. 6 - 34
Electrical Schematic, S-80/85 (after S/N 5519)Continental TME27 Models .................................................................................. 6 - 38
Ground Control Box Wiring Diagram, S-80/85Continental TME27 Models .................................................................................. 6 - 42
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Continental TME27 Models .................................................................................. 6 - 44
Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)Continental TME27 Models .................................................................................. 6 - 45
Continental TME27 Engine Harness..................................................................... 6 - 48
Joystick Wiring Diagram ...................................................................................... 6 - 49
Connector Pin Legend - View 1 ............................................................................ 6 - 52
Connector Pin Legend - View 2 ............................................................................ 6 - 53
Dual Battery Option ............................................................................................. 6 - 56
Belt Drive Generator Option ................................................................................. 6 - 57
CE Option ............................................................................................................ 6 - 60
Platform Level Cutout, CTE Option ...................................................................... 6 - 61
12kW Hydaulic Generator Option ......................................................................... 6 - 64
Hydaulic Schematiic, 12kW Generator ................................................................. 6 - 65
Hydraulic Schematic, 2WD Models ...................................................................... 6 - 68
Hydraulic Schematic, 4WD Models ...................................................................... 6 - 69
TABLE OF CONTENTS
xv
Part No. 122149 S-80 • S-85 2 - 1
Section 2 • SpecificationsFebruary 2012
Specifications
Machine Specifications
Tires and wheels
Tire size 15-22.5 SAT385/65-22.5
Tire ply rating 16
Overall tire diameter 43.5 in110.5 cm
Tire weight, new foam-filled (minimum), RT 622 lbs282 kg
Tire pressure, RT 100 psi6.9 bar
Tire pressure, Hi-floatation 60 psi4.1 bar
Wheel diameter 22.5 in57 cm
Wheel width 11.75 in29.8 cm
Wheel lugs 10 @ 3/4 -16
Lug nut torque, dry 420 ft-lbs569 Nm
Lug nut torque, lubricated 320 ft-lbs434 Nm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Fluid capacities
Fuel tank 33 gallons125 liters
LPG tank 33.5 pounds15.2 kg
Hydraulic tank 45 gallons170 liters
Hydraulic system 80 gallons(including tank) 303 liters
Turntable rotation drive hub 40 fl oz1.2 liters
Rexroth drive hubs 61 fl oz1.8 liters
Bonfiglioli drive hubs 51 fl oz1.5 liters
Drive hub oil type:SAE 90 multipurpose hypoid gear oilAPI service classification GL5
For operational specifications, refer to theOperator's Manual.
S-80 • S-85 Part No. 1221492 - 2
Section 2 • Specifications February 2012
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Hydraulic Oil Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046Quintolubric 822
Mineral based Shell Tellus T32Shell Tellus T46
Chevron Aviation A
Performance Specifications
Drive speed, maximum
Stowed position 40 ft / 7.9-8.5 sec12.2 m / 7.9-8.5 sec
Raised or extended position 40 ft / 40-45 sec12.2 m / 40-45 sec
Braking distance, maximum
High range on paved surface 3 ft90 cm
Gradeability Refer to the Operator’s Manual
Boom function speeds, maximumfrom platform controls
Jib boom up (S-85) 60 to 70 seconds
Jib boom down (S-85) 40 to 50 seconds
Boom up 89 to 93 seconds
Boom down 90 to 94 seconds
Boom extend 73 to 79 seconds
Boom retract 79 to 84 seconds
Turntable rotate, 360° 95 to 103 secondsboom fully stowed
Turntable rotate, 360° 210 to 250 secondsboom raised or extended
Platform rotate, 160° 8 to 12 seconds
Platform level up 50 to 60 seconds
Platform level down 40 to 50 seconds
Part No. 122149 S-80 • S-85 2 - 3
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Hydraulic ComponentSpecifications
Drive pump
Type: bi-directional variable displacement piston pump
Flow rate @ 2300 rpm 30.3 gpm114.7 L/min
Drive pressure, maximum 4200 psi290 bar
Charge pump
Type: gerotor
Displacement 0.85 cu in13.9 cc
Flow rate @ 2300 rpm 8 gpm30.3 L/min
Charge pressure @ 2300 rpm 320 psiNeutral position 22 bar
Function pump
Type: two-section tandem gear pump
Displacement - Pump 1 (inner) 1.4 cu in22.9 cc
Flow rate @ 2300 rpm 12.7 gpm48 L/min
Displacement - Pump 2 (outer) 0.24 cu in4 cc
Flow rate @ 2300 rpm 2.25 gpm8.5 L/min
Auxiliary pump
Type: fixed displacement gear pump
Displacement - static 0.151 cu in2.47 cc
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.
Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.
Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.
S-80 • S-85 Part No. 1221492 - 4
Section 2 • Specifications February 2012
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.
Valve coil resistance specifications
Proportional solenoid valve 4.8 (schematic items K and W)
2 position 3 way solenoid valve 6.3 (schematic items D, R, X, TT and UU)
2 position 3 way solenoid valve 3.3 (schematic items G)
3 position 4 way solenoid valve 6.3 (schematic items A, E, N and S)
2 position 3 way solenoid valve 6.3 (schematic items AK, AM, VV and WW)
2 position 3 way solenoid valve 3.3 (schematic item G)
Function manifold
System relief pressure 2900 psi(measured at PTEST port) 200 bar
Boom down relief pressure 2100 psi(measured at PTEST port) 145 bar
Boom extend 2500 psi(measured at PTEST port) 172 bar
Steer/axle extend 3.5 gpmflow regulator 13.2 L/min
Oscillate relief pressure 850 psi58.6 bar
Drive manifold
Hot oil relief pressure 280 psi19.3 bar
Brake release pressure
Rexroth hubs 217.5 psi15 bar
Bonfiglioli hubs 189 psi13 bar
Drive motors
Displacement per revolution, variable 0.9 to 2.7 cu in(2 speed motor) 14.7 to 45 cc
Hydraulic filters
High pressure filter Beta 3 200
High pressure filter 102 psibypass pressure 7 bar
Medium pressure filter Beta 3 200
Medium pressure filter 51 psibypass pressure 3.5 bar
Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass
Part No. 122149 S-80 • S-85 2 - 5
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Continental TME27 Engine
Displacement 164 cu in2.68 liters
Number of cylinders 4
Bore and stroke 3.58 x 4.06 inches91 x 103.2 mm
Horsepower 59.03 @ 2500 rpm44 kW @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 8.2:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Low idle - computer controlled 1600 rpmFrequency 53.33 Hz
High idle - computer controlled 2500 rpmFrequency 83.33 Hz
Valve clearance, warm
Intake 0.014 in0.36 mm
Exhaust 0.018 in0.46 mm
Lubrication system
Oil pressure 40 to 60 psi2.75 to 4.14 bar
Oil capacity 7 quarts(including filter) 6.65 liters
Oil viscosity requirements
Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Fuel Requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Electronic fuel pump
Fuel pressure, static 55 psi3.8 bar
Fuel flow rate 0.42 gpm1.59 L/min
Batteries
Type 12V DC
Group 31
Quantity 2
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator output 65A @ 13.8V DC
Fan belt deflection 1/2 inch12 mm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
S-80 • S-85 Part No. 1221492 - 6
Section 2 • Specifications February 2012
Lubrication system
Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity 11 quarts(including filter) 10.4 liters
Oil viscosity requirements
Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Oil temperature switch
Torque 8-18 ft-lbs11-24 Nm
Oil temperature switch point 275°F135°C
Oil pressure switch
Torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 7 psi0.48 bar
Deutz BF4L-2011 Engine
Displacement 189.6 cu in3.1 liters
Number of cylinders 4
Bore and stroke 3.7 x 4.409 inches94 x 112 mm
Horsepower
Continuous 69.1 @ 2500 rpmNet intermittent 72.8 @ 2500 rpmContinuous 51.5 KW @ 2500 rpmNet intermittent 54.3 KW @ 2500 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1500 rpmFrequency 382.5 Hz
High idle 2350 rpmFrequency 599.25 Hz
Compression ratio 17.5:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in0.3 mm
Exhaust 0.020 in0.5 mm
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 122149 S-80 • S-85 2 - 7
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum15,000 psi/1034 bar
Injector opening pressure 3046 psi210 bar
Fuel Requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Starter motor
Current draw, normal load 140-200A
Cranking speed 200-250 rpm
Batteries
Type 12V DC
Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator output 80A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch9 to 12 mm
S-80 • S-85 Part No. 1221492 - 8
Section 2 • Specifications February 2012
SPECIFICATIONS
Injection system
Injection pump make Zexel
Injection pump pressure 1707 to 1849 psi117.7 to 127.5 bar
Injector opening pressure ~2000 psi~138 bar
Fuel Requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Engine coolant
Capacity 12.5 quarts11.8 liters
Batteries
Type 12V DC
Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator output 90A, 12V DC
Fan belt deflection 3/8 to 1/2 in9 to 12 mm
Perkins 804C-33 Engine
Displacement 201 cu in3.3 liters
Number of cylinders 4
Bore and stroke 3.70 x 4.72 inches94 x 120 mm
Horsepower 63 @ 2600 rpm47 KW @ 2600 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 22:1
Compression pressure 300 to 500 psi20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must bewithin 50 psi / 3.45 bar of highest cylinder
Low idle 1650 rpmFrequency 335.5 Hz
High idle 2300 rpmFrequency 467.67 Hz
Governor mechanical all speed
Valve clearance, cold
Intake 0.0098 in0.25 mm
Exhaust 0.0098 in0.25 mm
Lubrication system
Oil pressure @ 2000 rpm 40-60 psi2.8-4.1 bar
Oil capacity 10.6 quarts(including filter) 10 liters
Oil viscosity requirements
Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine. Continuous improvement of our products is a
Genie policy. Product specifications are subjectto change without notice.
Part No. 122149 S-80 • S-85 2 - 9
Section 2 • SpecificationsFebruary 2012
Machine Torque Specifications
Platform rotator
1-8 center bolt, GR 5, lubricated 480 ft-lbs651 Nm
3/8 -16 bolts, GR 8 35 ft-lbs**(use blue thread locking compound) 47 Nm*
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm
Rotate drive hub mounting bolts, lubricated 80 ft-lbs108 Nm
Backlash plate mounting bolts, lubricated 280 ft-lbs379 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 210 ft-lbs284 Nm
Drive hub mounting bolts, lubricated 185 ft-lbs**(use blue thread locking compound) 247 Nm
Drive motor mounting bolts, dry 110 ft-lbs149 Nm
Drive motor mounting bolts, lubricated 80 ft-lbs**(use blue thread locking compound) 108 Nm
Drive hub oil plug, O-ring seal 13 ft-lbs18 Nm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
SPECIFICATIONS
Manifold ComponentSpecifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 14 ft-lbs / 18.9 Nm
SAE No. 6 23 ft-lbs / 31.2 Nm
SAE No. 8 36 ft-lbs / 48.8 Nm
SAE No. 10 62 ft-lbs / 84.1 Nm
SAE No. 12 84 ft-lbs / 113.9 Nm
S-80 • S-85 Part No. 1221492 - 10
Section 2 • Specifications February 2012
SPECIFICATIONS
Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 14 ft-lbs / 18.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 48.8 Nm
-10 62 ft-lbs / 84.1 Nm
-12 84 ft-lbs / 113.9 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 250 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 15 ft-lbs / 20.3 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 100 ft-lbs / 135.6 Nm
-12 135 ft-lbs / 183 Nm
-16 200 ft-lbs / 271 Nm
-20 250 ft-lbs / 334 Nm
-24 305 ft-lbs / 414 Nm
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok®fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated andretained properly.
4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.
5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
Seal-Lok® Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 Nm
-6 30 ft-lbs / 40 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 80 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Part No. 122149 S-80 • S-85 2 - 11
Section 2 • SpecificationsFebruary 2012
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8
LUBED
1/4
LUBED DRY LUBED DRY
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
5/16
3/8
7/16
1/2
Size
(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •
LUBED DRY
Class 10.9Class 8.8
DRY
SPECIFICATIONS
10.9 12.98.84.6
S-80 • S-85 Part No. 1221492 - 12
Section 2 • Specifications February 2012
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Part No. 122149 S-80 • S-85 3 - 1
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every two years as specified on theMaintenance Inspection Report. The frequencyand extent of periodic examinations and testsmay also depend on national regulations.
Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial machine damage.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating machine.
Use only Genie approved replacement parts.
Machines that have been out of service for aperiod longer than three months must completethe quarterly inspection.
Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom betweenthe non-steer (yellow arrow) wheels
• Turntable secured with the turntablerotation lock pin
• Key switch in the off position with thekey removed
• Wheels chocked
• All external AC power supply disconnectedfrom the machine
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Note: Used to indicate operation or maintenanceinformation.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
3 - 2 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
Maintenance Symbols Legend
Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will be requiredto perform this procedure.
Indicates that a cold engine will berequired to perform this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service is requiredto perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report containschecklists for each type of scheduled inspection.
Make copies of the Pre-delivery PreparationReport to use for each inspection. Store completedforms as required.
Maintenance Schedule
There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.To account for repeated procedures, theScheduled Maintenance Procedures Section andthe Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Six month or every 500 hours A + B + C
Annual or every 1000 hours A + B + C + D
Two year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report containschecklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.
SCHEDULED MAINTENANCE PROCEDURES
Part No. 122149 S-80 • S-85 3 - 3
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex SouthDakota, Inc. 133192 Rev D
Genie UKThe Maltings, Wharf Road
Grantham, LincolnshireNG31- 6BH England
(44) 1476-584333
Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspectioncompleted
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.
Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.
LegendY = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before it isput into service.
A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.
Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.
Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirementslisted in the responsibilities manual.
3 - 4 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
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Part No. 122149 S-80 • S-85 3 - 5
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Instructions• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) forthe type of inspection to beperformed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Six Month or 500 hourInspection: A+B+C
Annual or 1000 hourInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
• Place a check in the appropriate boxafter each inspection procedure iscompleted.
• Use the step-by-step procedures inthis section to learn how to performthese inspections.
• If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Maintenance Inspection Report
Checklist B Y N R
B-1 Battery(s)
B-2 Electrical wiring
B-3 Key switch
B-4 Exhaust system
B-5 Engine air filter
B-6 Oil cooler and fins-Deutz models
B-7 Brake configuration
B-8 Tires, wheels andlug nut torque
B-9 Drive hub maintenance
B-10 Engine RPM
B-11 Engine maintenance
B-12 Oscillate directionalControl
B-13 Ground controloverride
B-14 Platform self-leveling
B-15 Engine idle select
B-16 Fuel select operation
B-17 Drive enable system
B-18 Drive brakes
B-19 Drive speed-stowed
B-20 Drive speed-raisedor extended
B-21 Alarm package anddescent alarm
B-22 Fuel and hydraulic tankventing systems
B-23 Hydraulic oil analysis
Checklist A Y N R
A-1 Inspect the manualsand decals
A-2 Pre-operationinspection
A-3 Grease axles
A-4 Engine maintenance
A-5 Function tests
A-6 Oscillate axle
A-7 Extendable axles
A-8 Filter condition indicator
Perform after 40 hours:
A-9 30 day service
Perform after 50 hours:
A-10 Engine maintenance -Deutz and Continentalmodels
Perform every 100 hours:
A-11 Inspect filter/separator -Diesel models
A-12 Grease rotationbearing
A-13 Engine maintenance
Perform after 150 hours:
A-14 Replace Drive Hub oil
Perform every 200 hours:
A-15 Engine maintenance -Perkins models
Comments
3 - 6 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist C Y N R
C-1 Engine maintenance
C-2 Grease platformoverload (if equipped)
C-3 Test the platformoverload (if equipped)
C-4 Air filter element
C-5 Replace filter/separator -Deutz and Perkinsmodels
Checklist D Y N R
D-1 Boom wear pads
D-2 Axle wear pads
D-3 Free-wheelconfiguration
D-4 Turntable rotationbearing bolts
D-5 Turntable bearing wear
D-6 Engine maintenance
D-7 Replace hydraulic filters
D-8 Drive hub oil
Perform every 1500 hours:
D-9 Engine maintenance -Deutz models
MAINTENANCE INSPECTION REPORT
Checklist E Y N R
E-1 Hydraulic oil
E-2 Engine maintenance - Perkins models
E-3 Grease axle bearings,2WD models
Perform every 3000 hours:
E-4 Engine maintenance -Deutz and Perkinsmodels
Instructions• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) forthe type of inspection to beperformed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Six Month or 500 hourInspection: A+B+C
Annual or 1000 hourInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
• Place a check in the appropriate boxafter each inspection procedure iscompleted.
• Use the step-by-step procedures inthis section to learn how to performthese inspections.
• If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Comments
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Part No. 122149 S-80 • S-85 3 - 7
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Checklist A Procedures
A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily.
Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.
In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.
1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.
2 Examine the pages of each manual to be surethat they are legible and in good condition.
Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.
Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.
3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.
Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.
Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.
4 Always return the manuals to the storagecontainer after use.
Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.
3 - 8 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed daily.
Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The pre-operation inspectionalso serves to determine if routine maintenanceprocedures are required.
Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.
A-3Grease the Extendable Axles
Genie specifications require that this procedure beperformed daily.
Proper lubrication of the extendable axle wearpads is essential to smooth operation andminimum wear of the wear pads.
Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldresult in the machine tipping over.
1 Locate the grease fitting on the platform side ofthe non-steer extendable axle and behind thedrive motor on the steer extendable axle.
2 Pump grease into each fitting until grease isvisible between the axle and wear pads.
3 Repeat for each axle.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
Part No. 122149 S-80 • S-85 3 - 9
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
A-4Perform Engine Maintenance
Engine specifications require that this procedurebe performed daily or every 8 hours, whichevercomes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
Continental TME27 Owner's ManualGenie part number 111901
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST A PROCEDURES
3 - 10 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
A-6Test the Oscillate Axle
Genie specifications require that this procedure beperformed daily.
Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.
Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldresult in the machine tipping over.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
3 Drive the left steer tire up onto a 6 inch / 15 cmblock or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
4 Drive both steer tires up onto a6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firmcontact with the ground.
If the chassis does not remainlevel during the test, refer toRepair Procedure 14-2, How toSet Up the Directional ValveLinkage.
CHECKLIST A PROCEDURES
A-5Perform Function TestsGenie specifications require that this procedure beperformed daily.
Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.
Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.
Part No. 122149 S-80 • S-85 3 - 11
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST A PROCEDURES
A-7Test the Extendable AxlesGenie specifications require that this procedure beperformed daily.
Tip-over hazard. Do not raise orextend the boom unless bothaxles are fully extended. If the axleextension system is not operatingcorrectly, the stability of themachine is compromised and itmay tip over.
Note: Be sure the axles are retracted beforeperforming this procedure.
1 Turn the key switch to ground control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
2 Start the engine from the ground controls.
3 Move and hold the function enable switch toeither side and activate the boom up function.
Result: The boom should raise to 5° abovehorizontal and then stop. The boom should notraise above the limit switch unless both axlesare extended.
4 Move and hold the function enable switch toeither side and activate the boom downfunction.
Result: The boom should lower and return tothe stowed position.
5 Move and hold the function enable switch toeither side and activate the boom extendfunction.
Result: The boom will extend approximately1 foot / 30 cm and then stop. The boom shouldnot extend farther unless both axles areextended.
6 Move and hold the function enable switch toeither side and activate the boom retractfunction.
Result: The boom should retract.
7 Turn the key switch to platform controls.
8 Press down the foot switch and move the drivecontrol handle in the forward direction andactivate the axle extend function.
Result: The machine will drive forward and theaxles should extend.
Note: The axle extend function will only work whilethe machine is moving.
Note: The steer function will override the axleextend or the axle retract function.
9 Turn the key switch to ground controls.
10 At the ground controls, hold the function enableswitch to either side and activate the boom upand boom down function.
Result: The boom should raise and lowernormally.
11 At the ground controls, move and hold thefunction enable switch to either side andactivate the boom extend and boom retractfunction.
Result: The boom should extend and retractnormally.
3 - 12 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-8Check the Hydraulic FilterCondition IndicatorsGenie specifications require that this procedure beperformed daily.
Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicatorswill show when the hydraulic flow is bypassing aclogged filter. If the filters are not frequentlychecked and replaced, impurities will remain in thehydraulic system and cause component damage.
Note: There are three hydraulic filters located onthe machine: one tank return filter, one mediumpressure filter and one high pressure filter. Thetank return and high pressure filter have acondition indicator on them. The medium pressurefilter does not have a filter condition indicator.
1 Start the engine from the platform controls.
2 Change the engine idle to high rpm (rabbitsymbol).
Tank return filter:
3 Open the ground control side turntable coverand inspect the filter condition indicator gauge.
Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6.
Result: The needle is operating in the red area.Proceed to step 4.
Note: The tank return filter indicator needle mayoperate in the red area when hydraulic oil is below50° F / 10° C.
REV B
a filter condition indicator gauge
4 Continue allowing the engine to run until thehydraulic oil temperature is above70° F / 21° C.
Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6.
Result: The needle is operating in the red area.Proceed to step 5.
5 Operate the machine until the hydraulic oiltemperature is above 104° F / 40° C.
Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6
Result: The needle is operating in the red area.The filter is clogged and is being bypassed.Replace the filter and repeat this procedurebeginning with step 1. See D-7, Replace theHydraulic Filter Elements.
High pressure filter:
Note: The high pressure filter is located to the leftof the medium pressure filter below the hydraulicpumps. A filter condition indicator is located on thetop of the high pressure filter.
6 Open the engine side turntable cover andInspect the filter condition indicator.
Result: The filter condition indicators should beoperating with the plungers in the green area.
Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-7, Replace the Hydraulic FilterElements.
a
Part No. 122149 S-80 • S-85 3 - 13
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
A-10Perform Engine Maintenance -Deutz and Continental Models
Engine specifications require that this one-timeprocedure be performed after the first 50 hours ofoperation.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures forcommissioning new and overhauled engines andadditional engine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theContinental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Continental TME27 Owner's ManualGenie part number 111901
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
A-9Perform 30 Day Service
The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance tables for continued scheduledmaintenance.
1 Perform the following maintenance procedures:
• A-12 Grease the Turntable Rotation Bearingand Rotate Gear
• B-8 Inspect the Tires, Wheels andLug Nut Torque
• B-9 Check the Drive Hub Oil Level andFastener Torque
• D-4 Check the Turnable Rotation BearingBolts
• D-7 Replace the Hydraulic Filter Elements
CHECKLIST A PROCEDURES
3 - 14 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-11Inspect the Fuel Filter/WaterSeparator - Deutz and PerkinsModels
Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.
Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Open the turntable cover at the engine side ofthe machine. Locate the fuel filter/waterseparator.
2 Inspect the filter bowl for water.
Result: Water is not visible in the filter bowl.
Result: There is water present. Proceedto step 3.
3 Loosen the vent plug located on the head of thefuel filter/water separator.
a head boltb vent plugc drain plugd filter bowle separator head
4 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.
5 Clean up any fuel that may have spilled.
Note: If the fuel filter/water separator is completelydrained, you must prime the fuel filter/waterseparator before starting the engine.See C-5, Replace The Fuel Filter/Water SeparatorElement, for instructions on how to prime the fuelfilter/water separator.
6 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
d
c
e
b
a
Part No. 122149 S-80 • S-85 3 - 15
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
A-13Perform Engine Maintenance
Engine specifications require that this procedurebe performed every 100 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
Continental TME27 Owner's ManualGenie part number 111901
A-12Grease the Turntable RotationBearing and Rotate Gear
Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.
Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.
1 Locate the grease fitting on the platform end ofthe tank side bulkhead.
2 Pump grease into the turntable rotation bearing.Rotate the turntable in incrementsof 4 to 5 inches / 10 to 13 cm at a time andrepeat this step until the entire bearing hasbeen greased.
3 Apply grease to each tooth of the drive gear,located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
CHECKLIST A PROCEDURES
3 - 16 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-14Replace the Drive Hub Oil
Manufacture specifications require that this one-time procedure be performed after the first 150hours.
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the initial 150 hoursof use may cause the machine to perform poorlyand continued use may cause componentdamage.
Drive hubs:
1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.
2 Remove both plugs and drain the oil into asuitable container.
3 Drive the machine until one plug is at the topand the other is at 90 degrees.
a. models with pipe plugs b. models with o-ring plugs
4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.
5 Models with pipe plugs: Apply pipe threadsealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugsinto the drive hub. Torque to Specification.Refer to Section 2, Specifications.
a
a
b
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 122149 S-80 • S-85 3 - 17
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
6 Repeat steps 1 through 4 for the other drivehub.
7 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.
Turntable rotate drive hub:
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.
4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.
Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.
CHECKLIST A PROCEDURES
5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.
a motorb drive hubc drive hub mounting bolts
6 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer to Section 2,Specifications.
7 Fill the drive hub with oil from the side plug holeuntil the oil level is even with the bottom of thehole. Apply pipe thread sealant to the plug.Install the plug.
8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.
b
a
c
3 - 18 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-15Perform Engine Maintenance -Perkins Models
Engine specifications require that this procedurebe performed every 200 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 804C-33 Operation and Maintenance ManualGenie part number
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 77832 S-80 • S-85 3 - 19
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Checklist B Procedures
B-1Inspect the Battery(s)
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions. A singlebattery configuraton is standard. A dual batteryoption is available, where one battery is used tostart the engine and the other is used to power thecontrol system and auxiliary power unit. The twobatteries are charged by the alternator through abattery separator.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections arefree of corrosion.
Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.
3 Be sure that the battery hold downs and cableconnections are tight.
4 Be sure that the battery separator wireconnections are tight (if equipped).
5 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.
7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:
• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.
Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.
8 Perform an equalizing charge, OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.
9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:
• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 11.
Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.
11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.
12 Install the vent caps and neutralize anyelectrolyte that may have spilled.
B-2Inspect the Electrical Wiring
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
1 Open the turntable cover at the engine side ofthe machine.
2 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.
a engine tray anchor holeb engine tray retaining fastener
3 Locate the engine tray anchor hole on theturntable.
Part No. 122149 S-80 • S-85 3 - 21
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
13 Inspect for a liberal coating of dielectric greasein the following location:
• All wire harness connectors toplatform control box
14 Remove the engine tray retaining fastener fromthe engine tray anchor hole at the pivot end ofthe engine tray.
15 Swing the engine tray in towards the machine.
16 Install the engine tray retaining fasteners.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
4 Install the bolt that was just removed into theanchor hole to secure the engine tray frommoving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Engine wiring harness
• Battery area wiring
6 Open the turntable cover at the ground controlsside of the machine.
7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Inside the ground control box
• Hydraulic manifold wiring
• Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric greasein the following locations:
• All wire harness connectors toground control box
9 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.
10 Inspect the turntable area for burnt, chafed andpinched cables.
11 Lower the secondary boom to the stowedposition and turn the engine off.
12 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Cable track on the boom
• Cables on the boom and jib boom
• Jib boom/platform rotate manifold
• Inside of the platform control box
CHECKLIST B PROCEDURES
3 - 22 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-3Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.
3 Check all machine function from the groundcontrols.
Result: All machine functions should notoperate.
4 Turn the key switch to ground control.
5 Check all machine function from the platformcontrols.
Result: All machine functions should notoperate.
6 Turn the key switch to the off position.
Result: The engine should stop and nofunctions should operate.
B-4Check the Exhaust System
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.
Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.
Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
2 Be sure that all nuts and bolts are tight.
3 Inspect all welds for cracks.
Part No. 122149 S-80 • S-85 3 - 23
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-5Inspect the Engine Air Filter
Genie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst. Perform this procedure more often if dustyconditions exist.
Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.
a clampb canister end capc dust discharge valve
a
b
c
4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.
5 Swing the engine pivot plate in towards themachine.
6 Install the bolts that were just removed into theoriginal holes to secure the engine pivot plate.
Crushing hazard. Failure to installthe bolts into the engine pivot plateto secure it from moving couldresult in death or serious injury.
CHECKLIST B PROCEDURES
3 - 24 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
2 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.
3 Remove the filter element.
4 Clean the inside of the canister and the end capwith a damp cloth.
5 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.Replace the filter if needed.
6 Install the filter element.
7 Install the air filter canister end cap and securethe end cap latches.
Note: Be sure the discharge slot is pointing down.
B-6Check the Oil Cooler and CoolingFins - Deutz Models
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.
Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.
Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.
Oil cooler:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 122149 S-80 • S-85 3 - 25
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
disengaged position
engaged position
3 Remove the fasteners from the engine sidecover, then remove the cover.
4 Inspect the oil cooler for leaks and physicaldamage.
a oil coolerb cylinder head cooling finsc fan blower fins
5 Clean the oil cooler of debris and foreignmaterial.
Cooling and fan blower fins:
6 Inspect the fan blower fins for physical damage.
7 Clean the fan blower fins of debris and foreignmaterial.
8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.
9 Clean the cylinder head cooling passages ofdebris and foreign material.
10 Install the engine side cover.
11 Swing the engine back to its original positionand install the engine pivot plate retainingfastener.
cba
B-7Confirm the ProperBrake Configuration
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.
1 Check each drive hub disconnect cap to besure it is in the engaged position.
CHECKLIST B PROCEDURES
3 - 26 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
B-8Inspect the Tires, Wheelsand Lug Nut Torque
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque,is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.
Bodily injury hazard. An over-inflated tire can explode and couldresult in death or serious injury.
Tip-over hazard. Do not usetemporary flat tire repair products.
Note: The tires on some machines are foam filledand do not need air added to them.
1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracked welds.
3 Check each lug nut for proper torque. Refer toSection 2, Specifications.
4 Check the pressure in each air-filled tire. Addair as necessary. Refer to Section 2,Specifications.
2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).
Note: The free-wheel valve is located on thebottom of the drive pump.
a drive pumpb screwdriverc lift pumpd free-wheel valve
Note: The free-wheel valve should always remainclosed.
a
d
c
b
CHECKLIST B PROCEDURES
Part No. 122149 S-80 • S-85 3 - 27
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
4 Models with pipe plugs: Apply pipe threadsealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugsinto the drive hub. Torque to Specification.Refer to Section 2, Specifications.
5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.
6 Repeat steps 1 through 5 for the other drivehubs.
Turntable rotate drive hub:
1 Remove the plug located on the side of the huband check the oil level.
Result: The oil level should be even with thebottom of the plug hole.
a plugb drive hub
2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole. Refer toSection 2, Specifications.
3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.
b
a
B-9Check Drive Hub Oil Level andFastener Torque
Genie specifications require that this procedure beperformed every 250 hours.
Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.
Drive hubs:
1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other one isat 90 degrees.
a. models with pipe plugs b. models with o-ring plugs
2 Remove the plug located at 90 degrees andcheck the oil level.
Result: The oil level should be even with thebottom of the side plug hole.
3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.
a
a
b
CHECKLIST B PROCEDURES
3 - 28 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
Deutz BF4L 2011 models:
1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.
Skip to step 4 if the low idle rpm is correct.
2 Loosen the locknut on the low idle adjustmentscrew.
3 Adjust the low idle adjustment screw until lowidle meets specification. Tighten the locknut.
4 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
B-10Check and Adjust theEngine RPM
Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.
Continental models:
Note: The engine rpm is controlled by the ECMand can only be adjusted by re-programming theECM. If rpm adjustment or service is required,please contact the Genie Industries ServiceDepartment.
Part No. 122149 S-80 • S-85 3 - 29
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Perkins modelsa solenoid bootb yoke lock nutc low idle adjustment screwd low idle lock nute yokef high idle adjustment nut
3 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) position.Refer to Section 2, Specifications.
If high idle rpm is correct, disregardadjustment step 4.
4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts whenactivating high idle.
CHECKLIST B PROCEDURES
If the high idle is correct, disregard adjustmentstep 5.
5 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts whenactivating high idle.
Perkins models:
1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.
Skip to step 3 if the low idle rpm is correct.
2 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.
3 - 30 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-11Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
Continental TME27 Owner's ManualGenie part number 111901
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 122149 S-80 • S-85 3 - 31
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-13Test the Ground Control OverrideGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the red EmergencyStop button at the platform controls is in the on oroff position. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.
1 Push in the red Emergency Stop button at theplatform controls to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boomfunction through a partial cycle.
Result: All boom functions should operate.
Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.
B-12Check the Oscillate DirectionalValve Linkage
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper axle oscillation is essential to safe machineoperation. If the oscillate directional valve linkageis not operating correctly, the stability of themachine is compromised and it may tip over.
1 Remove the drive chassis cover from thenon-steer end of the machine.
2 Locate the oscillate directional valve inside ofthe non-steer axle and inspect the linkage forthe following:
· Lock nut is tight against yoke
· Yoke clevis pins are installed
· Cotter pins are installed through clevis pins
· Linkage is properly attached todirectional valve
CHECKLIST B PROCEDURES
3 - 32 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-15Test the Engine Idle SelectOperationGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.
Low idle (turtle symbol) allows the operator tocontrol individual boom functions only.
High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.
Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This setting activates high idleonly when the foot switch is pressed down.
1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Start the engine from the ground controls.
4 Move and hold the function enable toggle switchin the high idle (rabbit symbol) position.
Result: The engine rpm should change to highidle.
B-14Test the Platform Self-levelingGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.
1 Start the engine from the ground controls.
2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.
3 Raise and lower the boom through a full cycle.
Result: The platform should remain level atall times to within ±5 degrees.
Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-16Test the Fuel Select Operation -Gasoline/LPG Models
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.
Note: Perform this test after checking the gasolineand LPG fuel levels, and warming the engine tonormal operating temperature.
1 Move the fuel select toggle switch to gasolineand then move the engine idle select switch tofoot switch activated high idle (rabbit and footswitch symbol).
2 Start the engine from the platform controls andallow it to run at low idle.
3 Press down the foot switch to allow the engineto run at high idle.
Result: The engine should start promptly andoperate smoothly in low and high idle.
5 Release the function enable toggle switch.
Result: The engine rpm should change to lowidle.
6 Turn the key switch to platform controls.
7 At the platform controls, move the engine idleselect toggle switch to high idle (rabbit symbol).Do not press down the foot switch.
Result: The engine rpm should change to highidle.
8 Move the engine idle select toggle switch to lowidle (turtle symbol).
Result: The engine rpm should change to lowidle.
9 Move the engine idle select toggle switch to footswitch activated high idle (rabbit and foot switchsymbol).
Result: The engine rpm should not change tohigh idle.
10 Press down the foot switch.
Result: The engine rpm should change to highidle.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
B-17Test the Drive Enable SystemGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper drive enable system operation isessential to safe machine operation. When theboom is past the non-steering wheels, drivemovement is stopped and theindicator light turns on. The driveenable switch must be held toeither side to reactivate the drivefunction and should alert theoperator that the machine maymove in the opposite direction that the drive andsteer controls are moved. An improperlyfunctioning drive enable system may allow themachine to be moved into an unsafe position.
Note: Perform this procedure with the boom in thestowed position.
1 Start the engine from the platform controls.
2 Press down the foot switch.
3 Rotate the turntable until the boom moves pastone of the the non-steer wheels.
Result: The drive enable indicator light shouldturn on and remain on while theboom is anywhere in the rangeshown.
4 Slowly move the drive controlhandle off center.
Result: The drive function should not operate.
4 Release the foot switch and shut the engine offby pushing the red Emergency Stop button in tothe off position.
5 Move the fuel select toggle switch to LPG.
6 Start the engine and allow it to run at low idle.
7 Press down the foot switch to allow the engineto run at high idle.
Result: The engine should start promptly andoperate smoothly in low and high idle.
Note: The engine may hesitate momentarily andthen continue to run on the selected fuel if the fuelsource is switched while the engine is running.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-18Test the Drive Brakes
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.
Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-7, Confirm the ProperBrake Configuration.
Note: Select a test area that is firm, level and freeof obstructions.
Note; Perform this procedure with the boom in thestowed position.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.
4 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.
5 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.
Note: The brakes must be able to hold the machineon any slope it is able to climb.
5 Rotate the turntable until the boom moves pastthe other non-steer wheel.
Result: The drive enableindicator light should come onand remain on while the boomis anywhere in the rangeshown.
6 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.
Result: The drive function should operate.
Collision hazard. Always use thecolor-coded direction arrows onthe platform controls and the drivechassis to identify the direction oftravel.
Note: When the drive enable system is in use, themachine may drive in the opposite direction thatthe drive and steer control handle is moved.
Blue
Yellow
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-20Test the Drive Speed -Raised or Extended Position
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Select a test area that is firm, level and free ofobstructions.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Extend the axles.
4 Move the engine idle select toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).
5 Press down the foot switch and raise the boom10° above horizontal.
6 Choose a point on the machine (i.e. contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.
7 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
B-19Test the Drive Speed -Stowed Position
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Note: Select a test area that is firm, level and freeof obstructions.
Note: Perform this procedure with the boom in thestowed position.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the start and finish lines.
4 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
5 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.
Note: To adjust the speed, refer to Repairprocedure 1-2, How to Adjust the Joystick Max-outSetting.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
8 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.
Note: To adjust the speed, refer to Repairprocedure 1-2, How to Adjust the Joystick Max-outSetting.
9 Press down the foot switch and lower the boomto the stowed position.
10 Extend the boom 3 feet / 90 cm.
11 Choose a point on the machine (i.e., contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.
12 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
13 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.
Note: To adjust the speed, refer to Repairprocedure 1-2, How to Adjust the Joystick Max-outSetting.
B-21Test the Alarm Package(if equipped) and the DescentAlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
The alarm package includes:
• Travel alarm
• Flashing beacons
Alarms and beacons are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable rear cover. Beacons are installed on bothturntable covers.
Note: The alarms and beacons will operate withthe engine running or not running.
Note: The descent alarm is standard beginningwith serial number 5612.
1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
Result: Both flashing beacons should be on andflashing.
2 Move and hold the function enable toggle switchto either side and activate the boom toggleswitch in the down position, hold for a momentand then release it.
Result: The descent alarm should sound whenthe toggle switch is held down.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-22Inspect the Fuel and HydraulicTank Cap Venting Systems
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.
Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.Procced to step 4.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.
When checking for positive tank cap venting, airshould pass freely through the cap.
3 Turn the key switch to platform controls.
Result: The flashing beacons should be onand flashing.
4 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.
Result: The descent alarm should sound whenthe controller is held down.
5 Press down the foot switch. Move the drivecontroller off center, hold for a moment andthen release it. Move the drive controller offcenter in the opposite direction, hold for amoment and then release it.
Result: The travel alarm should sound when thedrive controller is moved off center in eitherdirection.
Part No. 122149 S-80 • S-85 3 - 39
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulictank.
6 Check for proper venting.
Result: Air passes through the hydraulic tankcap. Procced to step 8.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.
Note: When checking for positive tank cap venting,air should pass freely through the cap.
7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.
8 Install the breather cap onto the hydraulic tank.
B-23Perform Hydraulic Oil Analysis
Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
C-1Perform Engine Maintenance
Engine specifications require that this procedurebe performed every 500 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
Continental TME27 Owner's ManualGenie part number 111901
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Checklist C Procedures
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST C PROCEDURES
C-2Grease the Platform OverloadMechanism (if equipped)
Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first. Perform this proceduremore often if dusty conditions exist.
Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.
1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.
2 Thoroughly pump grease into each greasefitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
C-3Test the Platform OverloadSystem (if equipped)
Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.
Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.
Note: Perform this procedure with the machine ona firm, level surface.
1 Turn the key switch to platform control. Start theengine and level the platform.
2 Determine the maximum platform capacity.Refer to the machine serial plate.
3 Remove all weight, tools and accessories fromthe platform.
Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.
Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.
Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).
5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.
Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.
Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).
6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.
Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.
Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).
Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.
7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.
Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.
Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).
Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.Illustration 1
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
8 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
9 Turn the key switch to ground control.
10 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
11 Activate the auxiliary power toggle switch.
Note: The engine will turn off when the auxiliarypower is activated.
12 Using auxiliary power, test all machine functionsfrom the ground controls.
Result: All ground control functions shouldoperate.
13 Using a suitable lifting device, lift the additionaltest weight from the platform.
Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.
Note: There may be an 2 second delay before theoverload indicator lights and alarm turn off.
14 Start the engine and test all machine functionsfrom the ground controls.
Result: All ground control functions shouldoperate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate.
Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).
17 Using a suitable lifting device, remove theremaining test weights from the platform.
CHECKLIST C PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
C-4Replace the Engine Air FilterElement - Deutz and PerkinsModels
Engine specifications require that this procedurebe performed every 500 hours or six months,whichever comes first.
Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.
2 Remove the filter element.
3 Use a damp cloth to wipe the filter sealingsurface and the inside of the outlet tube. Makesure that all contaminant is removed before thefilter is inserted.
4 Check new filter element gasket for damagebefore installing.
5 Install the new filter element.
6 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
C-5Replace the Fuel Filter/WaterSeparator Element -Deutz and Perkins Models
Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.
Regular replacement of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Perform this procedure with the engine off.
1 Open the engine side turntable cover and locatethe fuel filter/water separator.
Note: The fuel filter/water separator is located nearthe hydraulic pump.
2 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separatorhead.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
8 Apply a thin layer of oil onto the element gasket.Install the filter/bowl assembly onto the filterhead. Tighten the drain plug and vent plug.
Component damage hazard. Thedrain plug and vent plug can bedamaged if they areovertightened.
9 Install the fuel supply hose from the fuel tank tothe fuel filter/water separator. Tighten theclamp.
10 Clean up any diesel fuel that may have spilledduring the installation procedure.
11 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filter element.
Bleed the fuel system:
Note: Before bleeding the system, fill the fuel tank.
12 Loosen the vent plug located on thefuel filter/water separator head.
13 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the ventplug. Tighten the vent plug.
14 Loosen the air vent screw, located on top of thefuel injection pump.
15 Tighten the air vent screw when air stopscoming through the air vent.
16 Clean up any diesel fuel that may have spilledduring the bleeding procedure and dispose ofproperly.
17 Start the engine from ground controls andcheck for leaks.
3 Loosen the vent plug located on the fuel filter/water separator head.
a vent plugb drain plugc filter bowld separator head
4 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.
5 Rotate the filter bowl counterclockwise andremove it from the element.
6 Rotate the filter element counterclockwise andremove it from the filter head.
7 Install the filter bowl onto the new filter element.
c
b
d
a
CHECKLIST C PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
Checklist D Procedures
D-1Check the Boom Wear Pads
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.
Note: If the wear pads are still within specification,refer to Repair Procedure 4-2, How to Shim theBoom.
1 Start the engine from the ground controls.
2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear padif it is less than specification. If the wear pad isstill within specification, shim as necessary toobtain zero clearance and zero drag.
4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.
Note: Always maintain squareness between theouter and inner boom tubes.
Boom wear pad specifications Minimum
Boom number one
Top and bottom wear pads 1/2 inch(extension end of boom) 12.7 mm
Side wear pads 5/8 inch(extension end of boom) 15.9 mm
Boom number two
Top, bottom and side wear pads 1/2 inch(extension end of boom) 12.7 mm
Top and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm
Side wear pads 5/8 inch(pivot end of boom) 15.9 mm
Boom number three
Top, bottom and side wear pads 1/2 inch(pivot end of boom) 12.7 mm
a boom 1b boom 2c boom 3
b ca
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST D PROCEDURES
3 Extend and retract the axles through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the axletubes.
Note: Always maintain squareness between theouter and inner axle tubes.
Axle wear pad specifications Minimum
Outer axle
Top, bottom and side wear pads 1/2 inch(both ends of axle) 12.7 mm
Extendable inner axle
Top, bottom and side wear pads 1/2 inch(both ends of axle) 12.7 mm
D-2Check the Extendable AxleWear Pads
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Maintaining the axle wear pads in good condition isessential to safe machine operation. Wear padsare placed on axle tube surfaces to provice a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result incomponent damage and unsafe operatingconditions.
Note: If the wear pads are not worn belowspecification but are still within specification, referto Repair Procedure 15-1, How to Shim anExtendable Axle.
1 Start the engine from the platform controls andextend the axles.
2 Measure each wear pad.
If the wear pad is not less than specification,shim as necessary to obtain zero clearance andzero drag. Refer to Repair Procedure 15-1,How to Shim an Extendable Axle.
Replace the wear pad if it is less thanspecification. It is recommended to replace bothinner and outer wear pads. Refer to RepairProcedure 15-1, How to Remove an Inner Axle.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
D-3Check the Free-wheelConfiguration
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Proper use of the free-wheel configuration isessential to safe machine operation. The free-wheel configuration is used primarily for towing. Amachine configured to free-wheel without operatorknowledge could result in death or serious injuryand property damage.
Collision hazard. Select a worksite that is firm and level.
Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.
Non-steer wheels: All models
1 Chock the steer wheels to prevent the machinefrom rolling.
2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer wheels.
3 Lift the wheels off the ground and place blocksunder the drive chassis for support.
4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.
5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate withminimum effort.
6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the blocks.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.
Steer wheels: 4WD models
7 Chock the non-steer wheels to prevent themachine from rolling.
8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer wheels.
9 Lift the wheels off the ground and then placeblocks under the drive chassis for support.
10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each steer wheelhub.
disengaged position
engaged position
disengaged position
engaged position
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate withminimum effort.
12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.
All models:
13 Turn the valve in a clockwise direction to besure it is fully closed.
Note: The free-wheel valve is located on thebottom of the drive pump, and should alwaysremain closed.
a drive pumpb screwdriverc lift pumpd free-wheel valve
a
d
c
b
D-4Check the Turntable RotationBearing Bolts
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.
1 Start the engine from the platform controls andextend the axles.
2 Turn the key switch to ground controls.
3 Raise the boom and place a safety chock onthe lift cylinder rod. Carefully lower the boomonto the lift cylinder safety chock.
Crushing hazard. Keep handsaway from cylinder and all movingparts when lowering the boom.
Note: The lift cylinder safety chock is availablethrough Genie Service Parts.
CHECKLIST D PROCEDURES
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CHECKLIST D PROCEDURES
1
2
3
4
5
6
7
8
9
10
11
1213
14 15
1617
18
22
26
30
192327
2024 28
21
25
29
4 Remove the center turntable cover retainingfasteners. Remove the cover.
5 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.
Bolt torque sequence
6 Install the center turntable cover and tighten theretaining fasteners.
7 Raise the boom and remove the safety chock.
8 Lower the boom to the stowed position.
9 Confirm that each bearing mounting bolt underthe drive chassis is torqued in sequence tospecification. Refer to Section 2, Specifications.
Bolt torque sequence
1 15
7
12
4
17
5
14
9216
8
11
3
18
6
13
10
D-5Inspect for Turntable BearingWear
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.
Note: Perform this procedure with the machine ona firm, level surface and the boom in the stowedposition.
1 Grease the turntable bearing. See A-12, Greasethe Turntable Rotation Bearing and RotateGear.
2 Torque the turntable bearing bolts tospecification. See D-4, Check the TurntableRotation Bearing Bolts.
3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.
Part No. 122149 S-80 • S-85 3 - 51
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
7 Note the reading on the dial indicator.
Result: The measurement is less than0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.
8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero"position.
9 Remove the dial indicator and rotate theturntable 90°.
10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.
11 Lower the boom to the stowed position and turnthe machine off.
12 Remove the dial indicator from the machine.
4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no morethan 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch /2.5 cm from the turntable rotation bearing.
a turntableb dial indicatorc drive chassisd turntable rotation bearing
5 At the dial indicator, adjust it to "zero" theindicator.
6 Fully extend the boom and lower to a horizontalposition.
a
b
c
d
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
D-6Perform Engine Maintenance
Engine specifications require that this procedurebe performed every 1000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
Continental TME27 Owner's ManualGenie part number 111901
Part No. 122149 S-80 • S-85 3 - 53
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
D-7Replace the Hydraulic FilterElements
Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever come first. Perform this procedure moreoften if dusty conditions exist.
Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.
Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.
Note: Perform this procedure with the engine off.
Hydraulic return filter:
1 Open the ground controls side turntable coverand locate the hydraulic return filter mounted onthe hydraulic tank.
2 Place a suitable container under the hydraulictank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.
5 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the installation procedure.
6 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.
Medium and high pressure filters:
Note: The medium pressure filter is for the chargepump and the high pressure filter is for all machinefunctions except the drive circuit and oscillatingaxle circuit.
7 Open the engine side turntable cover and locatethe two filters mounted below the hydraulicpumps.
Note: The medium pressure filter is located on theright. The high pressure filter is located on the leftwith the condition indicator.
8 Place a suitable container under the filters.
9 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housings.
10 Remove the filter element from the housings.
11 Inspect the housing seals and replace them ifnecessary.
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
D-8Replace the Drive Hub Oil
Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.
Drive hubs:
1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.
2 Remove both plugs and drain the oil into asuitable container.
3 Drive the machine until one plug is at the topand the other is at 90 degrees.
a. models with pipe plugs b. models with o-ring plugs
4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.
5 Models with pipe plugs: Apply pipe threadsealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugsinto the drive hub. Torque to Specification.Refer to Section 2, Specifications.
12 Install the new medium and high pressure filterelements into the housings and tighten themsecurely.
13 Clean up any oil that may have spilled duringthe installation procedure.
14 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housings.
15 Start the engine from the ground controls.
16 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.
a
a
b
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
6 Repeat steps 1 through 4 for the other drivehub.
7 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.
Turntable rotate drive hub:
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.
4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.
Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.
5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.
a motorb drive hubc drive hub mounting bolts
6 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer to Section 2,Specifications.
7 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.
8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.
b
a
c
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
D-9Perform Engine Maintenance -Deutz Models
Engine specifications require that this procedurebe performed every 1500 hours of operation.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).
Deutz BF4L2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST D PROCEDURES
Part No. 122149 S-80 • S-85 3 - 57
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
E-1Test or Replace theHydraulic Oil
Genie specifications require that this procedure beperformed every 2000 hours or every two years,whichever comes first.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.
Note: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the fuel tank. Refer to RepairProcedure 9-1, How to Remove the Fuel Tank.
2 Models without hydraulic tank shutoffvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. Refer to Section 2,Specifications.
Models with hydraulic tank shutoff valves:Close the two hydraulic tank valves located atthe hydraulic tank.
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
3 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.
4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.
5 Disconnect and plug the T-fitting located at thereturn filter with the two hoses connected to it.Cap the fitting on the return filter housing.
6 Disconnect and plug the supply hose for theauxiliary power unit. Cap the fitting on thehydraulic tank.
open closed
Checklist E Procedures
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST E PROCEDURES
7 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.
8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an appropriatelifting device.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulictank may become unbalanced andfall if it is not properly supportedand secured to the lifting device.
10 Remove the suction strainers from the tank andclean them using a mild solvent.
11 Rinse out the inside of the tank using a mildsolvent.
12 Install the suction strainers using pipe threadsealant on the threads.
13 Install the drain plug using pipe thread sealanton the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supplyhose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.
17 Clean up any oil that may have spilled.
18 Open the hydraulic tank shutoff valves (ifequipped).
Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank. Refer to Repair Procedure7-2, How to Prime the Pump.
Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.
19 Operate all machine functions through a fullcycle and check for leaks.
Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.
Part No. 122149 S-80 • S-85 3 - 59
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
E-2Perform Engine Maintenance -Perkins Models
Engine specifications require that this procedurebe performed every 2000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST E PROCEDURES
E-3Grease the Steer AxleWheel Bearings, 2WD Models
Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.
Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.
1 Loosen the wheel lug nuts. Do not removethem.
2 Block the non-steering wheels. Center a liftingjack under the steer axle.
3 Raise the machine 6 inches / 15 cm Placeblocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire andwheel assembly.
5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.
Result: There should be no side to side or upand down movement.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST E PROCEDURES
14 Pack both bearings with clean, fresh grease.
15 Place the large inner bearing into the rear of thehub.
16 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease sealwhen removing the hub.
17 Slide the hub onto the yoke spindle.
Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.
Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.
21 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pinto lock it in.
23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.
Skip to step 10 if there is no movement.
6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.
Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.
8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.
9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.
Result: If there is no side to side or up anddown movement, continue to step 11 to greasethe wheel bearings.
Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.
Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.
10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.
11 Remove the castle nut.
12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.
13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.
Part No. 122149 S-80 • S-85 3 - 61
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
E-4Perform Engine Maintenance -Deutz and Perkins Models
Engine specifications require that this procedurebe performed every 3000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Deutz BF4L2011 Operation ManualGenie part number 84794
Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332
CHECKLIST E PROCEDURES
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
3 - 62 S-80 • S-85 Part No. 122149
Section 3 • Scheduled Maintenance Procedures February 2012
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Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 1
February 2012
Repair Procedures
About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.
Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Note: Used to indicate operation or maintenanceinformation.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie S-80and Genie S-85 Operator’s Manual on yourmachine.
Be sure that all necessary tools and parts areavailable and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom betweenthe non-steering wheels
• Turntable secured with the turntablerotation lock pin
• Key switch in the off position with thekey removed
• Wheels chocked
• All external AC power supply disconnectedfrom the machine
Section 4 • Repair Procedures
4 - 2 S-80 • S-85 Part No. 122149
February 2012
The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.
Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.
a ALC-500 circuit boardb drive/steer joystick controllerc boom extend/retract
joystick controllerd boom up/down and turntable rotate
left/right joystick controller
1-1ALC-500 Circuit Board
Note: When the ALC-500 circuit board is replaced,the joystick controllers will need to be calibrated.See 1-2, How to Calibrate a Joystick.
How to Remove the ALC-500Circuit Board1 Push in the Emergency Stop button to the off
position at both the ground and platformcontrols.
2 Remove the platform control box lid retainingfasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted tothe inside of the platform control box.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
4 Attach a grounded wrist strap to the groundscrew inside the platform control box.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
5 Carefully disconnect the wire connectors fromthe circuit board.
6 Remove the ALC-500 circuit board mountingfasteners.
7 Carefully remove the ALC-500 circuit boardfrom the platform control box.
Platform Controls
bcd
a
February 2012
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 3
February 2012
PLATFORM CONTROLS
February 2012
1-2Joysticks
How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.
Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.
Note: Perform this procedure with the engine off.
1 Open the platform control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Turn the key switch to platform control. Do notstart the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.
6 Move the joystick full stroke in either directionand hold for 5 seconds.
7 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds.
Result: The alarm should sound indicatingsuccessful joystick calibration.
Result: The alarm does not sound. Check theelectrical connections or replace the joystick.
8 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.
Note: No machine fuction should operate whileperforming the joystick calibration procedure.
How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
Section 4 • Repair Procedures
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February 2012
7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.
Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.
Result: The alarm does not sound. Repeat steps3 through 7.
8 Start the engine from the platform controls andpress down the foot switch.
9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).
10 Compare the machine function time with thefunction times listed in Section 2,Specifications. Determine whether the functiontime needs to increase or decrease.
11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.
Note: Each time the drive enable toggle switch ismomentarily moved, the function speed will changein 2% increments.
12 Repeat steps 9 through 11 for each joystickcontrolled machine function.
13 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Result: The alarm does not sound. Theminimum or maximum adjustment has beenobtained. No changes can be saved.
Note: Do not operate any machine function duringthe 10 second waiting time.
14 Cycle the red Emergency Stop button off, thenback on.
How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 5
February 2012
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 6 times.
Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.
Result: The alarm does not sound. Repeat steps3 through 7.
8 Start the engine from the platform controls andpress down the foot switch.
9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.
10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.
11 Release the foot switch.
12 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.
Note: Each time the drive enable toggle switch ismomentarily moved, the time will change in 5%increments.
13 Repeat steps 9 through 11 for each joystickcontrolled machine function.
14 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Note: Do not operate any machine function duringthe 10 second waiting time.
15 Cycle the red Emergency Stop button off, thenback on.
Ramp rate (factory settings)
Turntable rotateaccelerate 3 secondsdecelerate 2 second
Boom up/downaccelerate 3 secondsdecelerate 1 second
Boom extend/retractaccelerate 2.5 secondsdecelerate 1 second
Driveaccelerate 4 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.75 seconddecelerate, coasting 1 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 4 seconds
Section 4 • Repair Procedures
4 - 6 S-80 • S-85 Part No. 122149
February 2012
PLATFORM CONTROLS
How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the red Emergency Stop button to theoff position at the platform controls.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 8 times.
Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.
Result: The alarm does not sound. Repeat steps3 through 7.
8 Start the engine from the platform controls andpress down the foot switch.
9 Select a boom function joystick to set thethreshold.
10 Slowly move the joystick off center in eitherdirection just until the function begins to move.
11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.
Result: The alarm should sound indicating asuccessful calibration.
12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntable rotate).
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Note: Do not operate any machine function duringthe 10 second waiting time.
14 Cycle the red Emergency Stop button off, thenback on.
Function speeds (factory settings)
Boom up 89 to 93 seconds
Boom down 90 to 94 seconds
Boom extend 73 to 79 seconds
Boom retract 79 to 84 seconds
Turntable rotate, 360°boom fully stowed 95 to 103 seconds
Drive speeds (factory settings)
Stowed- high speed 7.9 to 8.5 seconds
Non-stowed 40 to 45 seconds
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 7
February 2012
Platform Components
2-1Platform
How to Remove the Platform1 Remove the cable clamp from the top of the
platform mounting weldment.
2 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side. Donot disconnect the wiring.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.
5 Tag and disconnect the foot switch wiring fromthe foot switch. Remove the cable from theback of the platform.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
6 Remove the platform control box mountingfasteners. Lower the control box and set itaside.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
Note: If your machine is equipped with an airline toplatform option, the airline must be disconnectedfrom the platform before removal.
7 Support and secure the platform to anappropriate lifting device.
8 Remove the platform mounting fasteners andremove the platform from the machine.
Crushing hazard. The platformcould become unstable and fallwhen it is removed from themachine if not properly supported.
Section 4 • Repair Procedures
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PLATFORM COMPONENTS
2-2Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.
How to Remove the PlatformLeveling Slave CylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is no air in theclosed loop.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Extend the primary boom until the slave cylinderbarrel-end pivot pin is accessible.
2 Raise the primary boom slightly and placeblocks under the platform for support.
3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.
Note: Do not rest the entire weight of the boom onthe blocks.
4 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to drive the rod-end pivot pin out.
Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.
5 Remove the external snap rings from the barrel-end pivot pin.
6 Use a soft metal drift to drive the barrel-endpivot pin out.
7 Carefully pull the cylinder out of the primaryboom to access the hydraulic hoses.
8 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
How to Bleed the Slave CylinderNote: Do not start the engine. Use auxiliary powerfor this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.
Section 4 • Repair Procedures
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2-3Platform Rotator
The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.
How to Remove thePlatform Rotator
Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform. See 2-1,How to Remove the Platform.
PLATFORM COMPONENTS
2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the rotator.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
3 S-85: Support the jib boom leveling arms andthe platform mounting weldment with anappropriate lifting device. Do not apply anylifting pressure.
4 Remove the mounting bolts from the platformmounting weldment. Remove the center boltand slide the platform mounting weldment off ofthe platform rotator.
Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if not properlysupported when removed from themachine.
5 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.
S-80:
6 Support the rod end of the platform levelingslave cylinder. Protect the cylinder rod fromdamage.
7 Remove the pivot pin retaining fasteners fromboth the slave cylinder rod-end pivot pin andthe rotator pivot pin.
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PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins.Remove the platform rotator from the machine.
Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.
Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.
S-85:
6 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.
7 Support the jib boom leveling arms.
8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.
Bodily injury hazard. The jib boomleveling arms may fall if notproperly supported.
9 Lower the jib boom leveling arms.
Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.
Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.
How to Bleed the PlatformRotatorNote: This procedure will require two people. Donot start the engine. Use auxiliary power for thisprocedure.
1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.
2 Place a suitable container underneath theplatform rotator.
3 Open the top bleed screw on the rotator, but donot remove it.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Section 4 • Repair Procedures
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February 2012
PLATFORM COMPONENTS
4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.
Crushing hazard. Keep clear ofthe platform during rotation.
5 Open the bottom bleed screw on the rotator, butdo not remove it.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.
Crushing hazard. Keep clear ofthe platform during rotation.
7 Clean up any hydraulic oil that may havespilled.
8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.
2-4Platform Overload System
How to Calibrate the PlatformOverload System (if equipped)
Calibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.
Note: Perform this procedure with the machine ona firm, level surface.
1 Turn the key switch to platform control. Start theengine and level the platform.
2 Determine the maximum platform capacity.Refer to the machine serial plate.
3 Remove all weight, tools and accessories fromthe platform.
Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.
4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.
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5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.
Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.
Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
6 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.
Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.
Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.
Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.
PLATFORM COMPONENTS
7 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.
Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
8 Add an additional 10 lb / 4.5 kg test weight tothe platform.
Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
9 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
Section 4 • Repair Procedures
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February 2012
PLATFORM COMPONENTS
10 Turn the key switch to ground control.
11 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
12 Using a suitable lifting device, lift the test weightoff the platform floor.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.
Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.
13 Test all machine functions from the groundcontrols.
Result: All ground control functions shouldoperate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate normally.
Section 4 • Repair Procedures
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Jib Boom Components, S-85
3-1Jib Boom
How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform. See 2-1, How to Removethe Platform.
Note: Models equipped with platform overoadsystem: If the platform overload components aredisassembled and/or removed from the platformsupport, the platform overload system will need tobe calibrated. See 2-4, How to Calibrate thePlatform Overload System.
2 Models equipped with platform overloadsystem: Tag and disconnect the electricalconnector from the platform load sense module.
3 Remove the hose and cable cover from the sideof the jib boom.
4 Remove the hose and cable clamp from the jibboom pivot pin. Lay all hoses and cables to theside.
Component damage hazard.Hoses and cables can becomedamaged if they are kinked orpinched.
5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Attach a lifting strap from an overhead crane tothe jib boom assembly.
7 Place blocks under the platform levelingcylinder for support. Protect the cylinder rodfrom damage.
8 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.
Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly attached to the overheadcrane.
9 Remove the pin retaining fastener from the jibboom bellcrank to primary boom pivot pin.
10 Use a soft metal drift to remove the pin andcarefully remove the jib boom assembly fromthe primary boom.
Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.
Section 4 • Repair Procedures
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February 2012
JIB BOOM COMPONENTS, S-85
3-2Jib Boom Lift Cylinder
How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.
Note: Do not rest the entire weight of the boom onthe blocks.
2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.
4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.
5 Attach a lifting strap from an overhead crane tothe lug at the rod end of the jib boom liftcylinder.
6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.
Crushing hazard. The jib boom liftcylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.
Section 4 • Repair Procedures
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4-1Cable Track
The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable track isnecessary when performing major repairs thatinvolve removing the boom.
How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Open the platform control box.
2 Tag and disconnect the foot switch wiring fromthe terminal strip inside the platform controlbox.
3 Loosen the squeeze connector and remove thefoot switch cable from the control box.
4 Disconnect the wire connectors from the bottomof the platform control box.
Note: When installing the wire connectors to thebottom of the platform control box, match the colorof the connectors to those on the control box to besure they are installed in the correct location.
5 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side.
Boom Components
6 S-80: Tag, disconnect and plug the hydraulichoses from the counterbalance valve manifoldlocated on the platform rotator. Cap the fittingson the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling slave cylinder at theunion and connect the hoses from the cylindertogether using a connector.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
8 S-85:Remove the hose and cable cover fromthe side of the jib boom.
9 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate selectmanifold. Cap the fittings on the manifold.
10 Tag, disconnect and plug the wiring from the jibboom/platform rotate select manifold.
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February 2012
BOOM COMPONENTS
11 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
All models:
12 From the ground controls, raise the boom to ahorizontal position.
13 Remove the fasteners from the drive speed limitswitch bracket (LS1RS) mounted on the side ofthe boom at the platform end of the boom. Donot remove the limit switch from the bracket.
14 Remove the cotter pin from the upper cabletrack at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
15 Remove the cable track guide fasteners fromthe cable track guides at the platform end of theboom. Remove the cable track guides from theboom.
16 Remove the cable clamp from the pivot end ofthe boom.
17 Place blocks between the upper and lowercable tracks and secure the upper and lowertracks together.
Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.
18 Attach a lifting strap from an overhead crane tothe cable track.
19 Remove the mounting fasteners that attach thelower cable track to the boom.
20 Remove the cable track from the machine andplace it on a structure capable of supporting it.
Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
Component damage hazard. Thecable track can be damaged if it istwisted.
Section 4 • Repair Procedures
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BOOM COMPONENTS
How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.
Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 77896. The kit includes a 4-link section ofcable track.
1 Visually inspect the cable track and determinewhich 4 link section needs to be replaced.
2 Carefully remove the snap rings from each endof the damaged section of cable track.
3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.
Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.
5 Remove the upper rollers from the replacementsection of cable track.
6 Lift up the hoses and cables and carefully insertthe new 4 link section of cable track.
Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.
7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.
8 Install the rollers onto the new section of cabletrack.
9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.
Section 4 • Repair Procedures
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February 2012
4-2Boom
How to Shim the Boom1 Measure each wear pad.
Note: Replace the pad if thickness is less thanminimum specification. If thickness is more thanminimum specification, perform the followingprocedure. Refer to Section 3, D-1, Check theBoom Wear Pads.
2 Extend the boom until the wear pads areaccessible.
3 Loosen the wear pad mounting fasteners.
4 Install the new shims under the wear pad toobtain zero clearance and zero drag.
5 Tighten the mounting fasteners.
6 Extend and retract the boom through an entirecycle. Check for tight spots that could causebinding or scraping.
Note: Always maintain squareness between theouter and inner boom tubes.
How to Remove the BoomBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the platform. See 2-1, How to Removethe Platform.
2 Remove the platform rotator and leveling slavecylinder. See 2-3, How to Remove the PlatformRotator.
3 Remove the cable track. See 4-1, How toRemove the Cable Track.
4 S-85: Remove the jib boom. See 3-1,How to Remove the Jib Boom.
BOOM COMPONENTS
Section 4 • Repair Procedures
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BOOM COMPONENTS
5 Raise the boom to a horizontal position highenough that the boom lift cylinder rod end canclear the boom lift cylinder mounting boss.
6 Remove the turntable end cover.
7 Remove the pin retaining fasteners from themaster cylinder rod-end pivot pin.
8 Place a rod through the pin and twist to removethe pin. Lower the rod end of the mastercylinder.
9 Remove the fasteners from the boom angle limitswitches (LS2RO and LS2RS) mounted to theinside of both turntable riser side plates at thepivot end of the boom. Do not disconnect thewiring.
10 Remove the fasteners from the boom extendlimit switch (LS1RO) mounted next to the boomextension cylinder at the pivot end of the boom.Do not disconnect the wiring.
11 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
12 Attach an overhead 5 ton / 5000 kg crane to thecenter point of the boom.
13 Attach a similar lifting device to the boom liftcylinder for support.
14 Place support blocks under the boom liftcylinder, across the turntable.
15 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.
Crushing hazard. The boom liftcylinder could fall if not properlysupported.
16 Lower the rod end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.
17 Remove the pin retaining fastener from theboom pivot pin.
18 Use a soft metal drift to remove the boom pivotpin. Carefully remove the boom from themachine.
Crushing hazard. The boom couldbecome unbalanced and fall if notproperly supported by theoverhead crane.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 21
February 2012
How to Disassemble the BoomNote: Complete disassembly of the boom is onlynecessary if the outer or inner boom tubes must bereplaced. The extension cylinder can be removedwithout completely disassembling the boom. See4-4, How to Remove the Boom ExtensionCylinders.
1 Remove the boom. See 4-2, How to Removethe Boom.
2 Remove the external snap rings from theextension cylinder pivot pin at the pivot end ofthe number 1 boom tube. Use a soft metal driftto remove the pin.
3 Remove and label the wear pads from the top,side, and bottom of the number 1 boom tube atthe platform end of the boom.
Note: Note the location and quantity of shims usedwith each wear pad.
4 Remove the two wear pad stop bolts from eachside of the number 1 boom tube (located on theoutside).
5 Attach a lifting strap from an overhead crane tothe number 2 and number 3 boom tubes at theplatform end of the boom for support.
6 Support and slide the number 2 and 3 boomtubes out of the number 1 boom tube. Place thenumber 2 and 3 boom tubes on blocks forsupport.
Crushing hazard. The number 2and 3 boom tubes could becomeunbalanced and fall when they areremoved from the number 1 boomtube if they are not properlysupported.
Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.
7 Tag and remove the wear pads from the top,side, and bottom of the number 2 boom tube atthe platform end of the boom.
8 Remove the trunnion pin retaining fasteners atthe base end of the number 2 boom tube. Use aslide hammer to remove the trunnion pins.
9 Attach a lifting strap from an overhead crane tothe number 3 boom tube at the platform end ofthe boom for support.
10 Support and slide the number 3 boom tube outof the number 2 boom tube. Place the number 3boom tube on blocks for support.
Crushing hazard. The number 3boom tube could becomeunbalanced and fall whenremoved from the number 2 boomtube if not properly supported.
Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.
BOOM COMPONENTS
Section 4 • Repair Procedures
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BOOM COMPONENTS
11 Remove the external snap rings from theextension cylinder pivot pin at the platform endof the number 3 boom tube. Use a soft metaldrift to remove the pin.
12 Support and slide the extension cylinder out ofthe pivot end of the number 3 boom tube. Placethe extension cylinder on blocks for support.
Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe number 3 boom tube if notproperly supported.
Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.
4-3Boom Lift Cylinder
How to Remove the BoomLift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Raise the boom to a horizontal position highenough that the boom lift cylinder rod end canclear the boom lift cylinder mounting boss.
2 Remove the center turntable cover fasteners.Remove the cover.
3 Place support blocks under the boom liftcylinder across the turntable side plates.
4 Attach an overhead 5 ton / 5000 kg crane tothe boom for support. Do not lift the boom.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 23
February 2012
5 Support the rod end of the boom lift cylinderwith an overhead crane or similar lifting device.
Crushing hazard. The boom liftcylinder could become unbalancedand fall when it is disconnectedfrom the machine if not properlysupported.
6 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin, and lower the liftcylinder onto the blocks. Protect the cylinderrod from damage.
Crushing hazard. The boom liftcylinder could become unbalancedand fall when it is disconnectedfrom the machine if not properlysupported.
8 Remove the mounting fasteners from thebarrel-end cylinder pivot pin retaining plates.
9 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform and remove it from the machine.
Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported.
Component damage hazard. Thecables and hydraulic hoses can bedamaged if the lift cylinder ispulled across them.
BOOM COMPONENTS
Section 4 • Repair Procedures
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3 Place a 4 in x 4 in x 6 ft / 10 cm x 10 cm x 1.8 mblock on top of the number 3 boom tube andplace one end of the block against theweldment at the platform end of the boom.
4 Retract the boom until the number 2 boom tubeis fully retracted into the number 1 boom tube.
Note: The number 3 boom tube will remainextended approximately 6 feet / 1.8 m.
5 Remove the external snap rings from theextension cylinder pivot pin at the platform end.Use a soft metal drift to remove the pin.
6 Remove the turntable end cover.
7 Support the rod end of the master cylinder witha lifting device.
8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Place a rodthrough the pin and twist to remove the pin.
Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe machine if not properlysupported.
Note: Use the platform level toggle switch withauxiliary power to relieve pressure on the mastercylinder barrel-end pivot pin.
9 Lay the master cylinder down. Protect thecylinder rod from damage.
BOOM COMPONENTS
4-4Boom Extension Cylinders
The extension cylinder consists of two cylindersthat are fastened together. The first cylinderextends and retracts the number 2 boom tube. Thesecond cylinder extends and retracts the number 3boom tube. The extension cylinders are equippedwith counterbalance valves to prevent movementin the event of a hydraulic line failure.
How to Remove theBoom Extension Cylinders
This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Raise the boom to a horizontal position, fullyextend the boom and fully lower the platform.
2 Remove the 2 bolts that are located on eachside of the number 3 boom tube near theplatform end of the number 2 boom tube.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 25
February 2012
10 Remove the external snap rings from theextension cylinder pivot pin at the pivot end ofthe boom. Use a soft metal drift to remove thepin through the access holes in the turntableriser.
11 Using auxiliary power, move the boomextend/retract toggle switch in the extenddirection and extend the extension cylinder outthe pivot end of the boom approximately1 foot / 30 cm.
12 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
13 Attach a lifting strap from an overhead crane tothe end of the extension cylinder and lift slightlyto relieve the pressure on the trunnion pins.
14 Remove the trunnion pin access covers fromboth sides of the number 1 boom tube at thepivot end of the boom.
15 Remove the trunnion pin retaining fastener anduse a slide hammer to remove the pins.
16 Slide the cylinder out to access the wear padson the bottom rod support bracket. Remove thewear pads.
17 Support and slide the extension cylinder out ofthe pivot end of the boom.
Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe machine if not properlysupported.
Note: Note the length of the cylinder after removal.The cylinder must be at the same length forinstallation.
Note: During re-assembly of the boom, fully retractthe boom after installing all pins. Install the two top¼-20 fasteners through the access holes locatedmid-section of the number 1 boom tube. Thenextend the boom and install the two lower ¼-20fasteners in the number 3 boom tube.
BOOM COMPONENTS
Section 4 • Repair Procedures
4 - 26 S-80 • S-85 Part No. 122149
February 2012
BOOM COMPONENTS
4-5Platform LevelingMaster Cylinder
The master cylinder acts as a pump for the slavecylinder. It is part of the closed loop hydrauliccircuit that keeps the platform level through theentire range of boom motion. The master cylinderis located inside the pivot end of the boom.
How to Remove the PlatformLeveling Master CylinderNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Raise the boom until the master cylinderrod-end pivot pin is accessible.
2 Remove the turntable end cover to access themaster cylinder.
3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin.
5 Place a rod through the barel-end pivot pin andtwist to remove the pin.
6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.
7 Remove the pin retaining fastener from therod-end pivot pin.
8 Place a rod through the rod-end pivot pin andtwist to remove the pin.
9 Remove the master cylinder from the machine.
Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properlysupported by the lifting devicewhen removed from the machine.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 27
February 2012
5-1RPM Adjustment
Refer to Maintenance Procedure B-10,Check and Adjust the Engine RPM.
Engines
a b c d e
f
5-2Flex Plate
The flex plate couples the engine to the pump. Theflex plate is bolted to the engine flywheel and has acut-out in the center for the pump coupler.
a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.36 inch / 9.14 mm gap - Continental Engine
Section 4 • Repair Procedures
4 - 28 S-80 • S-85 Part No. 122149
February 2012
ENGINES
How to Remove the Flex PlateNote: Perform this procedure with the engine offand cool to the touch.
1 Open the engine side turntable cover.
2 Tag and disconnect the battery cables from thebattery(s).
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
3 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.
a engine tray anchor holeb engine tray retaining fastener
4 Tag and disconnect the wiring plug at theelectronic displacement controller (EDC),located on the drive pump.
Deutz model:
5 Tag and disconnect the wiring from the bellhousing.
6 Remove the U-bolt from the exhaust flex pipe atthe muffler.
Burn hazard. Hot engine parts cancause severe burns.
7 Remove the muffler bracket retaining fastenersfrom bell housing. Remove the muffler andbracket assembly from the engine.
8 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing engine fasteners.
9 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched
10 Remove the flex plate mounting fasteners,and remove the flex plate from the engineflywheel.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 29
February 2012
ENGINES
Perkins model:
5 Tag and disconnect the wiring from the bellhousing.
6 Remove the exhaust pipe clamp at the muffler.
Burn hazard. Hot engine parts cancause severe burns.
7 Remove the muffler mounting bracketfasteners. Remove the muffler and bracketassembly from the engine.
8 Remove the hose clamps from the air cleanerelbow and the engine intake manifold.
9 Remove the air cleaner mounting bracketfasteners. Remove the air cleaner and bracketassembly from the engine.
10 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing to engine fasteners.
Continental model:
5 Tag and disconnect the wire harness from theoxygen sensor.
6 Remove the exhaust pipe heat shield fastenersfrom the top of the muffler.
Burn Hazard. Hot engine parts cancause severe burns.
7 Remove the muffler retainer bracket fasteners.
8 Remove the muffler fasteners securing themuffler to the exhaust manifold. Remove themuffler from the bracket.
9 Remove the relay housing from the mufflermount. Do not disconnect the relays.
10 Disconnect and remove the ECM from themuffler mount.
11 Close the shutoff valve on the Liquid PetroleumGas (LPG) tank by turning it clockwise(if equipped).
12 Unbolt the EPR valve from the muffler mount.Leave the hoses attached to the EPR valve.
13 Remove the muffler mount.
14 Support the drive pump with an appropriatelifting device. Remove all of pump platemounting fasteners.
15 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
16 Remove the flex plate mounting fasteners.Remove the flex plate from the engine flywheel.
Section 4 • Repair Procedures
4 - 30 S-80 • S-85 Part No. 122149
February 2012
ENGINES
a b c d e
f
How to Install the Flex Plate1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump. ApplyLoctite® removable thread sealant to themounting screws.
Note: Torque the flex plate mounting bolts in twostages.
Continental model: Torque the flex platemounting bolts in sequence to20.8 ft-lbs / 28 Nm.Deutz model: Torque the flex plate mountingbolts in sequence to 28 ft-lbs / 38 Nm.Perkins model:(Before serial number 6091) Torque the flexplate mounting bolts in sequence to28 ft-lbs / 38 Nm.(After serial number 6090) Torque the flexplate mounting bolts in sequence to46.7 ft-lbs / 63.3 Nm.
2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.
3 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.
4 Install the pump onto the pump mounting plate.Apply Loctite® removable thread sealant to thepump retaining fasteners. Torque the pumpretaining fasteners to 57 ft-lbs / 77 Nm.
Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.
5 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.
6 Install the pump and pump mounting plateassembly onto the engine. Apply Loctite®
removable thread sealant to the mountingscrews.Perkins model:Torque the pump mounting plate fasteners insequence to 28 ft-lbs / 38 Nm.Deutz model:Torque the pump mounting plate fasteners insequence to 46.7 ft-lbs / 63.3 Nm.Continental model:Torque the pump mounting plate fasteners insequence to 23 ft-lbs / 31.2 Nm.
Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.
Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.
a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.36 inch / 9.14 mm gap - Continental Engine
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 31
February 2012
ENGINES
1
2
3
4 5
6
Perkins, Deutz and ContinentalFlex Plate
10
6 1
8
4
11
7 5
92
12
3
C
C C
C
C
C
C
CC
C
C
C
10
6 1
8
4
11
7 5
92
12
3
Deutz BF4L-2011Pump Mounting Plate
Perkins 804C-33Pump Mounting Plate
1
8
6
10
11 12
3
5
92
7
4
Continental Pump Mounting Plate
Section 4 • Repair Procedures
4 - 32 S-80 • S-85 Part No. 122149
February 2012
Ground Controls
6-1Control Relays
Relays used for single function switching are singlepole double throw (SPDT) relays.
How to Test a Single Pole DoubleThrow Relay
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
1 Tag and disconnect all the wiring from the relayto be tested.
2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.
Test Desired result
terminal 85 to 86 with resistor 75 to 85
terminal 87 to 87a and 30 no continuity(infinite
terminal 87a to 30 continuity(zero )
3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.
Test Desired result
terminal 87 to 87a and 30 no continuity(infinite
terminal 87 to 30 continuity(zero )
terminal no. 87a - N.C.terminal no. 85 - coil negative (-)terminal no. 30 - commonterminal no. 86 - coil positive (+)terminal no. 87 - N.O.
Control Relay Schematic
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 33
February 2012
2 Tag, disconnect and plug the hydraulic hosesfrom the function pump. Cap the fittings on thepump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the pump mounting fasteners.Carefully remove the pump.
Component damage hazard.Be sure to open the two hydraulictank valves (if equipped) andprime the pump after installing thepump. See 7-2, How to Prime thePump.
Hydraulic Pumps
7-1Function Pump
How to Remove the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Close the two hydraulic tank valves located atthe hydraulic tank.
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
open closed
Section 4 • Repair Procedures
4 - 34 S-80 • S-85 Part No. 122149
February 2012
HYDRAULIC PUMPS
7-2Drive Pump
The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.
How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Disconnect the wire harness at the electronicdisplacement controller (EDC), located on thedrive pump.
2 Close the two hydraulic tank valves located atthe hydraulic tank.
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
open closed
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 35
February 2012
3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.
5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.
6 Remove the drive pump assembly from themachine.
Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.
Note: Before installing the pump, verify properpump coupler spacing. See 5-2, Flex Plate.
How to Prime the PumpComponent damage hazard. Besure that the hydraulic tank shutoffvalves (if equipped) are in theopen position before priming thepump. The engine must not bestarted with the hydraulic tankshutoff valves in the closedposition or component damage willoccur.
1 Connect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.
2 Continental models: If equipped, close thevalve on the LPG tank, then disconnect thehose from the tank. Move the fuel select toggleswitch to the LPG position.Deutz and Perkins models: Disconnect theengine wiring harness from the fuel solenoid atthe injector pump.
3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 300 psi / 20.7 bar.
4 Continental models: If equipped, connect theLPG hose to the LPG tank and open the valveon the tank.Deutz and Perkins models: Connect theengine wiring harness to the fuel solenoid.
5 Start the engine from the ground controls andcheck for hydraulic leaks.
HYDRAULIC PUMPS
Section 4 • Repair Procedures
4 - 36 S-80 • S-85 Part No. 122149
February 2012
Manifolds
8-1Function Manifold Components - View 1
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ....... A ........... Platform rotate left/right .................... 25-30 ft-lbs / 34-41 Nm
2 Check valve, 30 psi / 2 bar ................ B ........... Platform rotate circuit(prevents hydraulic hosesfrom draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
3 Check valve, 30 psi / 2 bar ................ C ........... Platform rotate circuit(prevents hydraulic hosesfrom draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
4 Solenoid valve, 2 position 3 way ....... D ........... Boom retract ..................................... 33-37 ft-lbs / 45-50 Nm
5 Solenoid valve, 3 position 4 way ....... E ........... Turntable rotate left/right ................... 25-30 ft-lbs / 34-41 Nm
6 Relief valve, 2500 psi / 172 bar ......... F ........... Boom extend/retract circuit ............... 20-25 ft-lbs / 27-34 Nm
7 Solenoid valve, 2 position 3 way ....... G ........... Boom extend ..................................... 50-55 ft-lbs / 68-75 Nm
8 Check valve ....................................... H ........... Differential sensing circuit,turntable rotate left/right ...................... 8-10 ft-lbs / 10-15 Nm
9 Differential sensing valve .................. I ............ Boom extend/retract circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
10 Differential sensing valve .................. J ............ Turntable rotate left/right circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
11 Proportional solenoid valve ............... K ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
12 Check valve ....................................... L ........... Differential sensing circuit,platform level down ............................. 8-10 ft-lbs / 10-15 Nm
13 Check valve ....................................... M .......... Differential sensing circuit,platform level up ................................. 8-10 ft-lbs / 10-15 Nm
14 Solenoid valve, 3 position 4 way ....... N ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm
15 Differential sensing valve .................. O ........... Boom up/down circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
16 Counterbalance valve ........................ P ........... Platform level down circuit ................ 35-40 ft-lbs / 47-54 Nm
17 Counterbalance valve ........................ Q ........... Platform level up circuit ..................... 35-40 ft-lbs / 47-54 Nm
18 Solenoid valve, 2 position 3 way ....... R ........... Boom down ....................................... 33-37 ft-lbs / 45-50 Nm
19 Solenoid valve, 3 position 4 way ....... S ........... Steer left/right andaxle extend/retract ............................ 35-40 ft-lbs / 47-54 Nm
20 Relief valve, 2900 psi / 200 bar ......... T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 37
February 2012
MANIFOLDS
A B C
D
E
G
K
L
M
P
R
S
Q
O
N
J
I
H
F
TUVWX
AA
CC
DD
EE
GG
FF
BB
Z
Y
1 2 3
202123 2224
25
26
27
28
29
30
31
32
33
4
5
6
7
10
8
9
11
12
13
14
16
15
17
18
19
Section 4 • Repair Procedures
4 - 38 S-80 • S-85 Part No. 122149
February 2012
MANIFOLDS
Function Manifold Components - View 1, continued
Index SchematicNo. Description Item Function Torque
21 Check valve ....................................... U ........... Blocks flow from auxiliary pumpto function pump ............................... 30-35 ft-lbs / 41-47 Nm
22 Priority flow regulator valve,3.5 gpm / 13.2 L/min .......................... V ........... Steer circuit ....................................... 30-35 ft-lbs / 41-47 Nm
23 Proportional solenoid valve ............... W .......... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
24 Solenoid valve, 2 position 3 way ....... X ........... Boom up ............................................ 33-37 ft-lbs / 45-50 Nm
25 Check valve ....................................... Y ........... Blocks flow from function pumpto auxiliary pump ............................... 30-35 ft-lbs / 41-47 Nm
26 Check valve ....................................... Z ........... Hydraulic oil cooler bypass ............... 30-35 ft-lbs / 41-47 Nm
27 Check valve ....................................... AA ......... Boom up/down circuit ......................... 8-10 ft-lbs / 10-15 Nm
28 Needle valve ...................................... AB ......... Platform level circuit .......................... 30-35 ft-lbs / 41-47 Nm
29 Proportional solenoid valve ............... AC ........ Turntable rotate circuit ...................... 20-30 ft-lbs / 27-47 Nm
30 Differential sensing valve .................. AD ........ Meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
31 Check valve ....................................... AE ......... Differential sensing circuit,boom extend/retract ............................ 8-10 ft-lbs / 10-15 Nm
32 Flow regulator valve,0.1 gpm / 0.37 L/min .......................... AF ......... Bleeds off differential
sensing valves to tank ...................... 20-25 ft-lbs / 27-34 Nm
33 Flow regulator valve,0.6 gpm / 2.27 L/min .......................... AG ........ Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 39
February 2012
MANIFOLDS
A B C
D
E
G
K
L
M
P
R
S
Q
O
N
J
I
H
F
TUVWX
AA
CC
DD
EE
GG
FF
BB
Z
Y
1 2 3
202123 2224
25
26
27
28
29
30
31
32
33
4
5
6
7
10
8
9
11
12
13
14
16
15
17
18
19
Section 4 • Repair Procedures
4 - 40 S-80 • S-85 Part No. 122149
February 2012
8-2Function Manifold Components - View 2
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index SchematicNo. Description Item Function Torque
1 Check valve, 30 psi / 2 bar ................ AH ........ Platform rotate circuit.......................................................................... (prevents hydraulic hoses.......................................................................... from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
2 Flow regulator valve,0.3 gpm / 1.14 L/min .......................... AJ ......... Dump circuit source from.......................................................................... charge pump ..................................... 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 2 way ....... AK ......... Allows boom functions tooperate with the boom inthe stowed position ........................... 26-30 ft-lbs / 34-41 Nm
4 Check valve, 30 psi / 2 bar ................ AI .......... Blocks flow from charge pumpto auxiliary pump ............................... 20-25 ft-lbs / 27-34 Nm
5 Check valve, 30 psi / 2 bar ................ AL ......... Blocks flow from auxiliary pumpto charge pump ................................. 20-25 ft-lbs / 27-34 Nm
6 Pressure Switch, 180 psi / 12.4 bar ... AY ......... Axle extend pressure switch ............. 26-30 ft-lbs / 34-41 Nm
7 Solenoid valve, 2 position 3 way ....... AM ........ Provides pilot signal to redirectsteer flow to axle extension system .. 26-30 ft-lbs / 34-41 Nm
8 Directional valve, 2 position 2 way,pilot operated ..................................... AN ........ Dump valve that allows boom
functions to operate whenaxles are fully extended .............. 90-100 ft-lbs / 122-136 Nm
9 Relief valve, 2100 psi / 145 bar ......... AO ........ Boom down ....................................... 20-25 ft-lbs / 27-34 Nm
MANIFOLDS
12345678901234567890123456789012123456789012345678901234567123456789012345678901234567890121234567890123456789012345671234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567123456789012345678901234567890121234567890123456789012345671234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567
1234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567123456789012345678901234567890121234567890123456789012345671234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 41
February 2012
MANIFOLDS
AH
AI
AL
AJ
AK
AMANAO
AY
79 8
1
2
4
3
5
6
Section 4 • Repair Procedures
4 - 42 S-80 • S-85 Part No. 122149
February 2012
MANIFOLDS
8-3Valve Adjustments -Function Manifold
How to Adjust the SystemRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom retract toggle switch with theboom fully retracted. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item T) on thefunction manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 to confirm relief valvepressure.
How to Adjust the Boom DownRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom down toggle switch with theboom fully lowered. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AO) onthe function manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 and confirm reliefvalve pressure.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 43
February 2012
How to Adjust the Boom ExtendRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 3000 psi / 0 to 200 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom extend toggle switch with theboom fully extended. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item F) on thefunction manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 to confirm relief valvepressure.
MANIFOLDS
Section 4 • Repair Procedures
4 - 44 S-80 • S-85 Part No. 122149
February 2012
MANIFOLDS
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Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 45
February 2012
MANIFOLDS
8-4Brake / Two Speed Manifold Components
The brake/two speed manifold is mounted inside the drive chassis.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 3 way .... EA ........... Releases brakes .............................. 47-52 ft-lbs / 64-70 Nm
2 Solenoid valve, 2 position 3 way .... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm
3 Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm
4 Orifice, 0.042 inch / 1.07 mm ......... ED ........... Controls flow to tank
4
3
1 2
EA EB
EC
ED
Section 4 • Repair Procedures
4 - 46 S-80 • S-85 Part No. 122149
February 2012
MANIFOLDS
8-5Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control sideof the machine.
Index SchematicNo. Description Item Function Torque
1 Shuttle valve, 2 position 3 way .......... PP ......... Turntable rotation brake release ......... 8-10 ft-lbs / 10-15 Nm
2 Counterbalance valve ........................ QQ ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
3 Counterbalance valve ........................ RR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
1 2 3
QQPP RR
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 47
June 2015
MANIFOLDS
8-6Jib Boom Select and Platform Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ...... CT ......... Platform rotate select ........................ 25-30 ft-lbs / 34-41 Nm
2 Counterbalance valve ....................... CR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
3 Counterbalance valve ....................... CS ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
Jib Manifold
Platform
Rotate Manifold
CR
CS
CT1
3
2
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MANIFOLDS
8-7Axle Select Manifold Components
The axle select manifold is mounted next to the drive manifold at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Directional valve, pilot operated2 position 3 way ................................. FA ......... Directs flow from steer cylinders
to axle extend circuit ......................... 30-35 ft-lbs / 41-47 Nm
2 Pressure reducing valve,1000 psi / 69 bar ................................ FB ......... Limits pressure to tie rod cylinder
during axle extension ........................ 30-35 ft-lbs / 41-47 Nm
3 Directional valve, pilot operated2 position 3 way ................................. FC ......... Directs flow from steer cylinders
to axle retract circuit .......................... 30-35 ft-lbs / 41-47 Nm
4 Directional valve, pilot operated2 position 2 way ................................. FD ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
5 Directional valve, pilot operated2 position 2 way ................................. FE ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
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Part No. 122149 S-80 • S-85 4 - 49
February 2012
MANIFOLDS
FA FB FC
FD
FE
4
5
1 32
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8-82WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Relief Valve, 280 psi / 19.3 bar ......... BX ......... Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
2 Flow Divider / Combiner Valve .......... BY ......... Controls flow to drive motors in.......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
3 Check Valve, 5 psi / 0.34 bar ............ BZ ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4 Check Valve, 5 psi / 0.34 bar ............ CA ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5 Shuttle Valve, 3 position 3 way ......... CB ........ Controls flow to drive motors in.......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm
6 Orifice Plug, 0.070 inch / 1.78 mm .... CC ........ Equalizes flow across flow divider/.......................................................................... combiner valve BY
MANIFOLDS
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Part No. 122149 S-80 • S-85 4 - 51
February 2012
MANIFOLDS
BX
BY
BZ
CA
CB
CC
1
6
2
5
3
4
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8-94WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar .......... CD ........ Charge pressure circuit ..................... 35-40 ft-lbs / 48-54 Nm
2 Flow divider/combiner valve .............. CE ........ Controls flow to non-steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm
3 Check valve ....................................... CF ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
4 Check valve ....................................... CG ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
5 Flow divider/combiner valve .............. CH ........ Controls flow to flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6 Check valve ....................................... CI .......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm
7 Orifice, 0.040 inch / 1 mm ................. CJ ......... Equalizes pressure on both sidesof flow divider/combiner valve 5
8 Orifice, 0.040 inch / 1 mm ................. CK ........ Equalizes pressure on both sidesof flow divider/combiner valve 2
9 Orifice, 0.040 inch / 1 mm ................. CL ......... Equalizes pressure on both sidesof flow divider/combiner valve 13
10 Check valve ....................................... CM ........ Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm
11 Check valve ....................................... CN ........ Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
12 Shuttle valve, 3 position 3 way .......... CO ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13 Flow divider/combiner valve .............. CP ........ Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm
14 Check valve ....................................... CQ ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
MANIFOLDS
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 53
February 2012
CE
CF
CG
CH
CD
CI
CJCK
CP
CO
CN
CM
CL
CQ
9 8 7
10
6
5
3
2
1
11
13
14
12
4
MANIFOLDS
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CY
CX
CU
CV
CW
1
3
4
5
2
8-10Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index SchematicNo. Description Item Function Torque
1 Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc, 0.030 inch / 0.080 cm . CV ........... Delays shift to drive
3 Solenoid valve ................................ CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve ..................................... CX ........... Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm
5 Check valve .................................... CY ........... Prevents oil to generator .................. 35-40 ft-lbs / 47-54 Nm
MANIFOLDS
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 55
February 2012
MANIFOLDS
8-11Valve Adjustments -Traction Manifold
How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in thetraction manifold) is necessary to return hot oilfrom the closed loop drive circuit to the hydraulictank for cooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.
Note: The following procedure will require twopeople.
1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.
2 Start the engine from the platform controls andallow the engine to run at low idle. Note thepressure reading on the pressure gauge.
3 Turn the engine off and connect a0 to 600 psi / 0 to 40 bar pressure gauge to thediagnostic nipple located on the tractionmanifold.
4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.
5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item BJ). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.
6 Repeat steps 4 and 5 until a pressuredifferential (between the charge pump readingand the hot oil shuttle relief valve) of40 psi / 14.5 bar is obtained.
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MANIFOLDS
Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.
Proportional solenoid valve 4.8 (schematic items K and W)
2 position 3 way solenoid valve 6.3 (schematic items D, R, X, TT and UU)
2 position 3 way solenoid valve 3.3 (schematic items G)
3 position 4 way solenoid valve 6.3 (schematic items A, E, N and S)
2 position 3 way solenoid valve 6.3 (schematic items AK, AM, VV and WW)
2 position 3 way solenoid valve 3.3 (schematic item G)
8-12Valve Coils
How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infinite resistanceindicates the coil has failed.
Since coil resistance is sensitive to temperature,resistance values outside specification canproduce erratic operation. When coil resistancedecreases below specification, amperageincreases. As resistance rises above specification,voltage increases.
While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.
1 Tag and disconnect the wiring from the coil tobe tested.
2 Test the coil resistance using a multimeter setto resistance (. Refer to the Valve CoilResistance Specification table.
Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.
REV B
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Part No. 122149 S-80 • S-85 4 - 57
February 2012
How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
1 Test the coil for resistance. Refer to, How toTest a Coil.
2 Connect a 10 resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.
Note: The battery should read 9V DC or morewhen measured across the terminals.
a multimeterb 9V DC batteryc 10 resistord coil
Note: Dotted lines in illustration indicate areversed connection as specified instep 6
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DCcurrent, should be capable of reading up to 800mA.
4 Connect the negative lead to the other terminalon the coil.
Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.
9VBATTERY
10
RESISTOR
�
AMMETERCOIL
+
-
+
-
d
a
b
b
c
c
MANIFOLDSREV B
Section 4 • Repair Procedures
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February 2012
5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.
6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.
Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.
MANIFOLDS
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 59
February 2012
Fuel and Hydraulic Tanks
9-1Fuel Tank
How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
1 Turn the manual fuel shutoff valve to theclosed position (if equipped).
2 Remove the fuel filler cap from the tank.
3 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer tocapacity specifications.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
Note: Be sure to only use a hand operated pumpsuitable for use with gasoline and diesel fuel.
4 Tag, disconnect, drain and plug the supply andreturn fuel hoses. Cap the fittings on the fueltank.
5 Remove the fuel tank retaining fasteners.
6 Remove the fuel tank from the machine.
Component damage hazard.The fuel tank is plastic and maybecome damaged if allowed to fall.
Component damage hazard.When installing the plastic fueltank, do not overtighten theretaining fasteners.
Note: Clean the fuel tank and inspect for damagebefore installing it onto the machine.
Section 4 • Repair Procedures
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February 2012
FUEL AND HYDRAULIC TANKS
9-2Hydraulic Tank
The primary functions of the hydraulic tank are tocool, clean and de-aerate the hydraulic fluid duringoperation. The tank utilizes internal suctionstrainers for the pump supply hoses and has anexternal return filter equipped with a filter conditionindicator.
How to Remove theHydraulic Tank
Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the fuel tank. See 9-1, How to Removethe Fuel Tank.
2 Close the two hydraulic tank valves located atthe hydraulic tank (if equipped).
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
3 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.
4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank.
5 Tag and disconnect and plug the hose from thereturn filter. Cap the fitting on the return filterhousing.
6 Tag and disconnect and plug the supply hosefor the auxiliary power unit. Cap the fitting onthe hydraulic tank.
open closed
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 61
February 2012
7 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.
8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedand secured to the overheadcrane.
10 Remove the suction strainers from the tank andclean them using a mild solvent.
11 Rinse out the inside of the tank using a mildsolvent.
12 Install the suction strainers using pipe threadsealant on the threads.
13 Install the drain plug using pipe thread sealanton the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supplyhose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.
FUEL AND HYDRAULIC TANKS
17 Clean up any oil that may have spilled.
18 Open the hydraulic tank shutoff valves(if equipped).
Component damage hazard.Be sure to open the two hydraulictank shutoff valves (if equipped)and prime the pump after installingthe hydraulic tank.
Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.
Section 4 • Repair Procedures
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February 2012
a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts
5 Remove the backlash pivot plate mountingbolts. Carefully remove the drive hub assemblyfrom the machine.
Crushing hazard. The turntablerotation drive hub assembly couldbecome unbalanced and fall whenit is removed from the machine ifnot properly supported.
When installing the drive hub assembly:
6 Install the drive hub. Apply removable threadlocking compound to fastener threads.Torquethe backlash pivot plate mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.
7 Install the brake and then the motor onto thedrive hub. Apply removable thread lockingcompound to fastener threads.Torque themotor/brake mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.
8 Adjust turntable rotation gear backlash.See 10-1, How to Adjust the Turntable RotationGear Backlash.
10-1Turntable Rotation Drive HubAssembly
How to Remove the TurntableRotation Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Loosen the backlash pivot plate and adjustmentbolts.
4 Attach a suitable lifting device to the lifting eyeson the drive hub assembly.
Turntable Rotation Components
unlocked locked
a b c
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 63
February 2012
TURNTABLE ROTATION COMPONENTS
How to Remove the TurntableRotation Hydraulic MotorNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the hydraulic tube that connects fromthe counterbalance manifold to the brake. Capthe fittings on the brake and manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Remove the motor/brake mounting fasteners.Carefully remove the motor from the brake.
5 Clean up any oil that may have spilled.
a motorb drive hub with brakec drive hub mounting bolts
b
a
c
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February 2012
How to Adjust the TurntableRotation Gear BacklashThe turntable rotation drive hub is mounted on anadjustable plate that controls the gap between therotation motor pinion gear and the turntablebearing ring gear.
Note: Perform this procedure with the boombetween the non-steer end tires and with themachine on a firm and level surface.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Loosen the backlash pivot plate mountingfasteners.
a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts
3 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation gear into the turntable bearing ringgear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.
6 Turn the adjustment bolt one half turncounterclockwise. Tighten the lock nut on theadjustment bolt.
7 Rotate the backlash pivot plate away from theturntable until it contacts the adjustment bolt.Then torque the mounting fasteners on thebacklash pivot plate. Refer to Section 2,Specifications.
8 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.
TURNTABLE ROTATION COMPONENTS
a b c
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 65
February 2012
2WD Steer Axle Components
11-1Yoke and Hub
How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from both
the steering cylinder and the tie rod cylinderpivot pins. Use a soft metal drift to remove thepins.
2 Loosen the wheel lug nuts. Do not removethem.
3 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.
4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
5 Remove the lug nuts. Remove the tire andwheel assembly.
6 Remove the pin retaining fasteners from theyoke pivot pins.
7 Support and secure the yoke and hub assemblyto a lifting jack.
8 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.
9 Remove the yoke and hub assembly from themachine.
Crushing hazard. The yoke andhub assembly may becomeunbalanced and fall if not properlysupported and secured to thelifting jack when it is removed fromthe machine.
How to Remove the Huband Bearings1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.
3 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
4 Remove the lug nuts. Remove the tire andwheel assembly.
5 Remove the dust cap, cotter pin and castle nut.
Note: Always replace the cotter pin with a new onewhen installing the castle nut.
6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.
Section 4 • Repair Procedures
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February 2012
2WD STEER AXLE COMPONENTS
How to Install the Hub andBearings, 2WD ModelsNote: When replacing a wheel bearing, both theinner and outer bearings including the pressed-inraces must be replaced.
1 Be sure that both bearings are packedwith clean, fresh grease.
2 Place the large inner bearing into the rearof the hub.
3 Press the bearing seal evenly into the hubuntil it is flush.
4 Slide the hub onto the yoke spindle.
Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.
5 Place the outer bearing into the hub.
6 Install the washer and castle nut.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearing.
Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.
8 Loosen the castle nut one turn, and then torqueto 35 ft-lbs / 47 Nm.
9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.
Note: Always use a new cotter pin when installinga castle nut.
10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.
11-2Steer Cylinder
How to Remove aSteer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.
3 Remove the steer cylinder from the machine.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 67
February 2012
2WD STEER AXLE COMPONENTS
11-3Tie Rod Cylinder
How to Remove theTie Rod CylinderNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Tag, disconnect and plug the hydraulic hosesfrom the tie rod cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Support and secure the tie rod cylinder to alifting jack.
3 Remove the pin retaining fasteners from eachtie rod cylinder pivot pin.
4 Remove the pivot pin from each end of the tierod cylinder.
5 Remove the tie rod cylinder from the machine.
Crushing hazard. The tie rodcylinder may become unbalancedand fall if not properly supportedand secured to the lifting jackwhen it is removed from themachine.
How to Perform the Toe-inAdjustmentNote: Perform this procedure on a firm, levelsurface. Block the non-steer tires and be sure thatthe machine is in the stowed position.
1 Straighten the steer wheels.
2 Measure the steer tires, front to front and backto back, using a measuring fixture.
3 Center a lifting jack of ample capacity under thesteer axle and raise the machine until the steertires are off the ground.
4 Loosen the jam nut on the adjustable endof the tie rod cylinder.
5 Remove the pin retaining fasteners from theadjustable end of the tie rod cylinder. Removethe pivot pin.
6 Slide the tie rod cylinder off of the yoke andadjust it by turning the end.
Note: One half turn on the adjustable end equalsapproximately1/
8 inch / 3.2 mm change in the front and rear
measurements.
7 Slide the tie rod cylinder onto the yoke. Installthe pivot pin and the pin retaining fastener.
8 Tighten the jam nut against the tie rod cylinder.
9 Lower the machine and repeat step 2.If further adjustment is needed, repeatthis procedure beginning with step 3.
Toe-in specification 0 ± 1/8 inch / 6.35 mm
Section 4 • Repair Procedures
4 - 68 S-80 • S-85 Part No. 122149
February 2012
6 Remove the lug nuts. Remove the tire andwheel assembly.
7 Remove the hydraulic hose clamp retainingfastener from the top of the yoke pivot pin.
8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the drive huband remove the drive motor from the machine.
10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.
11 Support and secure the yoke and drive hubassembly to a lifting jack.
12 Use a slide hammer to remove the upper yokepivot pin. Use a soft metal drift to drive thelower yoke pivot pin down and out.
Crushing hazard. The yoke anddrive hub assembly could becomeunbalanced and fall when the yokepivot pins are removed if notproperly supported and secured tothe lifting jack.
13 Place the yoke and drive hub assembly on a flatsurface with the drive hub facing down.
14 Remove the drive hub mounting fasteners thatattach the drive hub to the yoke. Remove theyoke from the drive hub. Refer toSection 2, Specifications.
Note: Replace the thrust washer when installingthe yoke and drive hub assembly onto the axle.
4WD Steer Axle Components
12-1Yoke and Drive Hub
How to Remove the Yokeand Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the pin retaining fasteners from boththe steer cylinder and the tie rod cylinder pivotpins. Remove the pins.
2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Loosen the wheel lug nuts. Do not removethem.
4 Block the non-steer wheels, and center a liftingjack of ample capacity under the steer axle.
5 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 69
February 2012
3 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the drive motor mounting fasteners.
5 Slide the drive motor shaft out of the drive hub,and remove the drive motor from the machine.Refer to Section 2, Specifications.
12-2Drive Motor
How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSauer dealer.
Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Extend the axles.
2 Remove the drive motor access covers fromboth sides of the inner axle.
4WD STEER AXLE COMPONENTS
Section 4 • Repair Procedures
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February 2012
4WD STEER AXLE COMPONENTS
12-4Steer Cylinders
How to Remove a Steer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Remove the hose bracket mounting fastener onthe steer cylinder barrel-end pivot pin.
3 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.
4 Remove the steer cylinder from the machine.
12-3Drive Hub
How to Remove a Drive HubNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Remove the drive motor. See 12-2, How toRemove a Drive Motor.
2 Loosen the wheel lug nuts. Do not removethem.
3 Center a lifting jack of ample capacity under thenon-steer axle.
4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
5 Remove the wheel lug nuts, then the tire andwheel assembly.
6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.
7 Remove the drive hub mounting fasteners thatattach the drive hub to the axle. Remove thedrive hub.
Crushing hazard. The drivehub could become unbalancedand fall if not properly supportedand secured to the lifting jackwhen removed from the machine.
Note: Do not re-use the drive hub mountingfasteners. Genie specifications require the use ofnew fasteners.
Section 4 • Repair Procedures
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February 2012
12-5Tie Rod Cylinder
How to Remove theTie Rod CylinderThis procedure is the same as the 2WD procedure.See 11-3, How to Remove the Tie Rod Cylinder.
How to Perform the Toe-inAdjustmentThis procedure is the same as the 2WD procedure.See 11-3, How to Perform the Toe-in Adjustment.
4WD STEER AXLE COMPONENTS
Section 4 • Repair Procedures
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February 2012
Non-steer Axle Components
13-1Drive Motor
How to Remove a Drive MotorThis procedure is the same as the steer axleprocedure. See 12-2, How to Remove a DriveMotor.
13-2Drive Hub
How to Remove a Drive HubThis procedure is the same as the steer axleprocedure. See 12-3, How to Remove a Drive Hub.
Section 4 • Repair Procedures
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February 2012
Oscillating Axle Components
14-1Oscillate Axle Cylinders
The oscillating axle cylinders extend and retractbetween the drive chassis and the axle to maintaina level chassis while driving over uneven terrain.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic hose failure.
How to Remove an Oscillate AxleCylinderNote: Perform this procedure on firm, level surfacewith the boom in the stowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.
1 Rotate the turntable until the boom is betweenthe steer tires.
2 Remove the fasteners from the drive chassiscover at the steer end. Remove the cover.
3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.
5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.
6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.
7 Remove the cylinder from the machine.
Crushing hazard. The oscillatecylinder could become unbalancedand fall if not properly attached tothe overhead crane whenremoved from the machine.
Section 4 • Repair Procedures
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OSCILLATING AXLE COMPONENTS
14-2Oscillate Directional Valve
How to Adjust the Oscillate ReliefValve Pressure1 Remove the drive chassis cover from the non-
steer end of the machine.
2 Connect a 0 to 2000 psi / 0 to 150 bar pressuregauge to the diagnostic nipple located near theoscillate directional valve.
3 Disconnect the directional valve linkage, byremoving the clevis yoke from the drivechassis.
4 Start the engine from the ground control.
5 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.
6 Turn the engine off.
7 Locate the relief valve on the directional valve.
a relief valve
8 Loosen the jam nut on the relief valve.
9 Turn the valve clockwise to increase thepressure or counterclockwise to decrease thepressure.
Tip-over hazard. Do not adjust therelief valve higher than specified.
10 Tighten the jam nut.
11 Start the engine and manually activate the valveto confirm the valve pressure.
Result: Pressure is between 800 to 900 psi / 55to 65 bar.
Result: Pressure is less than 800 psi / 55 bar ormore than 900 psi / 65 bar. Repeat thisprocedure beginning with step 5.
12 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.
13 Install the cover on the non-steer end of thedrive chassis.
a
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 75
February 2012
How to Set Up the DirectionalValve LinkageNote: Perform this procedure on a firm, levelsurface.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the surfacethe machine is on is completely level.
Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldresult in the machine tipping over.
3 Check the tire pressure in all four tires and addair if needed to meet specification.
4 Remove the drive chassis cover from thenon-steer end of the machine.
5 Disconnect the linkage clevis yoke from theaxle.
6 Place a "bubble type" level on the turntablerotate bearing plate at the non-steer end.Confirm whether the drive chassis is completelylevel.
7 If the drive chassis is not level, start the engineand push up or pull down on the linkageadjustment rod until the machine is completelylevel.
8 Verify that the ground and drive chassis arecompletely level.
9 Adjust the length of the rod by turning the clevisyoke until the clevis yoke can be pinned to theaxle.
10 Install the shoulder bolt and nut.
11 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside of the drive chassis).
Result: The measurements should be equal.
Note: If the distance is not equal and theadjustment to the linkage was completed with theground and drive chassis level, consult GenieIndustries Service Department.
OSCILLATING AXLE COMPONENTS
Section 4 • Repair Procedures
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February 2012
15-1Extendable Axles
The extendable axles are used to widen the footprint of the drive chassis for stability.
How to Shim an Extendable AxleNote: Replace the pad if thickness is less thanminimum specification. If thickness is more thanminimum specification, perform the followingprocedure. Refer to Maintenance ProcedureD-2, Check the Extendable Axle Wear Pads.
1 Extend the axles.
Side wear pads:
2 Loosen the side wear pad mounting fastenerson the outer axle.
3 Install the new shims under the wear pads toobtain zero clearance and zero drag.
4 Use a round punch to align the shim to the wearpad. Tighten the mounting fasteners.
5 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping.
Note: Always maintain squareness between theinner and outer axle tubes.
Top and bottom wear pads:
1 Center a lifting jack of sufficient capacity underthe outer axle that needs to be shimmed. Donot raise the machine.
2 Block the wheels at the opposite end of themachine.
3 Raise the machine just until the weight of themachine is relieved off of the inner axle. Do notraise the wheels off of the ground.
4 Remove the drive chassis cover.
5 Loosen the wear pad mounting fasteners fromthe top and bottom wear pads on both the innerand outer axles.
6 Install the new shims under the wear pads ofthe inner and outer axle to obtain zeroclearance and zero drag.
7 Use a round punch through the wear padmounting holes to align the shims with the wearpad. Install the wear pad retaining fasteners.
8 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping of the axle tubes.
Note: Always maintain squareness between theinner and outer axle tubes.
Extendable Axle Components
Section 4 • Repair Procedures
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February 2012
EXTENDABLE AXLE COMPONENTS
How to Remove an Inner AxleNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.
Steer end:
1 Extend the axles.
2 Remove the drive chassis cover.
3 2WD models: Remove the yoke and hubassembly. See 11-1, How to Remove the Yokeand Hub.
4WD models: Remove the yoke and drive hub.See 12-1, How to Remove the Yoke and DriveHub Assembly.
4 4WD models: Remove the hose bracket fromthe steer cylinder barrel-end pivot pin.
5 Remove the remaining steer cylinder pivot pin.Remove the steer cylinder and lay off to theside.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
6 Remove the steer cylinder mounting lug fromthe inner axle.
7 Place blocks under the axle extension cylinderfor support.
8 Remove the external snap ring from the axleextension cylinder pivot pin. Use a soft metaldrift to remove the pin.
9 Attach a lifting strap from an overhead crane tothe inner axle for support.
10 Remove all wear pads from the outer axle.
Note: Pay careful attention to the quantity andlocation of shims used when removing the wearpads.
11 Carefully remove the inner axle from the outeraxle.
Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.
Non-steer end:
12 Loosen the wheel lug nuts. Do not removethem.
13 Block the steer tires and center a lifting jackunder the outer axle.
14 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
15 Remove the lug nuts. Remove the tire andwheel assembly.
16 Remove the drive motor covers from both sidesof the inner axle.
Section 4 • Repair Procedures
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EXTENDABLE AXLE COMPONENTS
17 Tag, disconnect and plug the hydraulic hoses atthe drive motor. Cap the fittings on the drivemotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
18 Place blocks under the axle extension cylinderfor support.
19 Remove the external snap rings from the axleextension cylinder pivot pin of the inner axle tobe removed. Use a soft metal drift to removethe pin.
20 Attach a strap from a lifting device through theinner axle close to the drive hub for support.
21 Remove all wear pads from the outer axle.
Note: Pay careful attention to the location andnumber of shims used when removing the wearpads.
22 Carefully remove the inner axle from the outeraxle.
Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
15-2Axle Extension Cylinder
How to Remove the AxleExtension CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.
1 Extend the axles.
2 Remove the drive chassis cover.
Steer end:
3 Remove the engine side yoke and hub.
2WD models: Remove the yoke and hubassembly. See 11-1, How to Remove the Yokeand Hub.
4WD models: Remove the yoke and drive hub.See 12-1, How to Remove the Yoke and DriveHub Assembly.
4 Remove the access cover at the end of theinner axle.
Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 79
February 2012
5 Tag, disconnect and plug the axle extendcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
6 Place blocks under the axle extension cylinderfor support.
7 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
8 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
Non-steer end:
9 Remove the drive motor access covers fromboth sides of the axle.
10 Remove the drive motor. Refer to 12-2, How toRemove a Drive Motor.
11 Remove the drive hub. Refer to 12-3, How toRemove a Drive Hub.
12 Tag, disconnect and plug the axle extendcylinder hydraulic hoses from RAE and RAR portson the axle select manifold. Cap the fittings onthe manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
13 Place blocks under the axle extension cylinderfor support.
14 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
15 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
EXTENDABLE AXLE COMPONENTS
Section 4 • Repair Procedures
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Section 4 • Repair Procedures
Part No. 122149 S-80 • S-85 4 - 81
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REV A
5 Tag, disconnect and plug the axle extendcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
6 Place blocks under the axle extension cylinderfor support.
7 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
8 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
Non-steer end:
9 Remove the drive motor access covers fromboth sides of the axle.
10 Remove the drive motor. Refer to 12-2, How toRemove a Drive Motor.
11 Remove the drive hub. Refer to 12-3, How toRemove a Drive Hub.
12 Tag, disconnect and plug the axle extendcylinder hydraulic hoses from RAE and RAR portson the axle select manifold. Cap the fittings onthe manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
13 Place blocks under the axle extension cylinderfor support.
14 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
15 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
EXTENDABLE AXLE COMPONENTS
Section 4 • Repair Procedures
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Part No. 122149 S-80 • S-85 5 - 1
February 2012 Section 5 • Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions printed in theGenie S-80 and Genie S-85 Operator’s Manual.
Be sure that all necessary tools and testequipment are available and ready for use.
Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.
Be aware of the following hazards and followgenerally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Note: Perform all troubleshooting on a firm, levelsurface.
Note: Two persons will be required to safelyperform some troubleshooting procedures.
Fault Codes
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between the non-steer wheels
· Turntable secured with the turntable rotation lock
· Key switch in the off position with the key removed
· Wheels chocked
· All external AC power disconnectedfrom the machine
5 - 2 S-80 • S-85 Part No. 122149
February 2012Section 5 • Fault Codes
FAULT CODES
Fault Codes - Control System
How to Retrieve Control SystemFault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine off,the key switch turned to platform controls and bothred Emergency Stop button pulled out to the onposition at both the ground and platform controls.
1 Open the platform control box lid.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platformcontrol box. Do not touch the circuit board.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.
3 Determine the error source: The red LEDindidates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
Note: When the red LED is flashing the code, theyellow LED will be on solid.
4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
Note: When the yellow LED is flashing the code,the red LED will be on solid.
5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.
Part No. 122149 S-80 • S-85 5 - 3
February 2012 Section 5 • Fault Codes
Continued on next page
FAULT CODES
Error Source Error Type ID Name ID Name
Condition Solution 11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
21 Boom 1 Joystick (primary boom up/ down)
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
22 Boom 1 directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
23 Boom 1 flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
31 Boom 2 Joystick (secondary boom up/down or primary boom extend/retract)
18 Just calibrated Initiate 1 second beep of alarm.
Self-clearing. (transient)
32 Boom 2 directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
5 - 4 S-80 • S-85 Part No. 122149
February 2012Section 5 • Fault Codes
FAULT CODES
Error Source Error Type ID Name ID Name
Condition Solution
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
33 Boom 2 flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
41 Turntable rotate joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
42 Turntable rotate directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
43 Turntable rotate flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
44 Drive enable override switches 21 Fault
Enable override direction is frozen at neutral.
Power up controller with problem corrected.
Part No. 122149 S-80 • S-85 5 - 5
February 2012 Section 5 • Fault Codes
FAULT CODES
Error Source Error Type ID Name ID Name
Condition Solution 11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
51 Drive joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
53 Drive flow valve (EDC)
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
54 Drive brake valve
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
55 High speed drive motor Valve
21 Fault
Motor speed frozen in the low state. Alarm sounds indicating fault.
Power up controller with problem corrected.
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
61 Steer joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
62 Steer directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
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February 2012Section 5 • Fault Codes
FAULT CODES
How to Retrieve ContinentalEngine Fault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highestefficiency while at the same time keepingexhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault codein memory that relates to the appropriate sensorand will turn on the Check Engine Light.
Note: Perform this procedure with the key switchin the off position.
1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
Engine Fault Codes -Continental Models
3 Quickly activate and release the start toggleswitch/button. Do not start the engine.
4 Move and hold the run/test toggle switch tothe test position.
Result: The check engine light should turn on.The check engine light should begin to blink.
5 Continue to hold the run/test toggle switch inthe test position and count the blinks.
Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 threetimes. After the fault codes, the check enginelight will blink a code 123 three times againindicating the end of the stored codes.
Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree digit code, pause, blink the second digit,pause, and then blink the third digit. Forexample: the check engine light blinks 5consecutive times, blinks 3 times and then 1time. That would indicate code 531.
Note: Once a fault code has been retrieved andthe repair has been completed, the ECMmemory must be reset to clear the fault codefrom the ECM. See How to Clear Engine FaultCodes from the ECM.
Part No. 122149 S-80 • S-85 5 - 7
February 2012 Section 5 • Fault Codes
FAULT CODES
Continued on next page
How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.
1 Open the engine side turntable cover andlocate the battery.
2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings,watches and other jewelry.
3 Connect the negative battery cable to thebattery.
5 - 8 S-80 • S-85 Part No. 122149
February 2012Section 5 • Fault Codes
Continental Engine ECM Fault Code Chart
643 5V External 1 voltage high
685 Relay coil open
686 Relay control ground short
687 Relay coil short to power
1111 Fuel rev limit
1112 Spark rev limit
1151 CL (closed loop) high LPG
1152 CL (closed loop) low LPG
1155 CL (closed loop) high gasoline bank 1
1156 CL (closed loop) low gasoline bank 1
1161 Al (adaptive learning) high LPG
1162 AL (adaptive learning) low LPG
1165 LPG cat monitor
1171 EPR delivery pressure > than expected
1172 EPR delivery pressure < than expected
1173 EPR comm lost
1174 EPR voltage supply high
1175 EPR voltae supply low
1176 EPR intenal actuator fault detection
1177 EPR internal circuitry fault detection
1178 EPR internal comm fault detection
1612 RTI 1 loss
1613 RTI 2 loss
1614 RTI 3 loss
1615 A/D loss
1616 Invalid interrupt
1625 J1939 shutdown request
1626 J1939 CAN Tx failure
1627 J1939 CAN Rx failure
1628 J1939 CAN conflict failure
2111 Unable to reach < TPS
2112 Unable to reach > TPS
2122 FPP1 voltage high
2123 FPP1 voltage low
2135 TPS1/2 simultaneous voltages out of range
2229 BP (barometric pressure) high
2618 Tach output ground short
2619 Tach output short to power
Code DescriptionCode Description
16 Never crank synced at start
107 MAP (manifold absolute pressure) volt low
108 MAP (manifold absolute pressure) volt high
111 IAT (intake air temp) higher than expected 1
112 EAT (exhaust air temperature) voltage low
113 IAT (intake air temperature) voltage high
116 ECT higher than expected 1
117 ECT voltage low
118 ECT voltage high
121 TPS1 < TPS2 (throttle position sensor)
122 TPS1 (throttle position sensor) voltage low
123 TPS1 (throttle position sensor) voltage high
127 IAT (intake air temp) higher than expected 2
129 BP (barometric pressure) low
134 EGO open / lazy pre-cat 1
154 EGO open / lazy post-cat 1
171 AL (adaptive learning) high gasoline bank 1
172 AL (adaptive learning) low gasoline bank 1
217 ECT higher than expected 2
219 Max govern speed override
221 TPS1 > TPS2 (throttle position sensor)
222 TPS2 (throttle position sensor) voltage low
223 TPS2 (throttle position sensor) voltage high
261 Injector Loop Open or Low-Side short to gnd
262 Injector Coil shorted
336 Crank sync noise
337 Crank sensor loss
341 Cam sync noise
342 Cam sensor loss
420 Gasoline cat monitor
524 Oil pressure low
562 Battery voltage low
563 Battery voltage high
601 Flash checksum invalid
604 Ram failure
606 COP failure
642 5V External 1 voltage low
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 1
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions printed in theGenie S-80 and Genie S-85 Operator's Manualon your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.An illustration legend precedes the drawings.
Electrical Schematics
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Hydraulic Schematics
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
February 2012Section 6 • Schematics
6 - 2 S-80 • S-85 Part No. 122149
Electrical Symbols Legend
Connectionno terminal
P3
Horn buttonnormally open
T-circuitsconnect
FB
Flashing beacon
Diode
Circuits crossingno connection
Quick disconnectterminal
BLK
WHT
T-circuits connectat terminal
WHT #21 TB21
Battery
+
-
Circuit breakerwith amperage
15A
CB1
Horn or alarm
H1 Emergency Stopbutton normally
closed
P1
Coilsolenoid or relay
Key switch
KS1
GROUND
PLATFORM
Power relay
PR1
Toggle switch SPDT
TS2
START
ENG
INE
Toggle switch DPDT
TS6
UP
DO
WN
PLATFOR
MLEVEL
Gauge sending unit
HM
Hour meter
N.O.OTS2
Oil temperatureswitch
normally open
N.O.CTS1
Coolant temperatureswitch
normally open
Oil pressure switchnormally closed
N.C.OPS1
BLK
FS1
Foot switch
PumpAux
Auxiliary pump
FAN
Hydraulic oilcooling fan
G1
Gauge
Tilt sensorLED
L3
Limit switch
N.C.H.ON.O.H.C
LS3
Fusewith amperage
25A
F1
510
Resistor withohm value
Starting aid:glow plug orflame ignitor
Control relay contactnormally open
CR4N.O.
Battery separator
MA
INA
UX
Coil
Fuel or RPMsolenoid
PU
LL
IN
HO
LD
CA B
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 3
Hydraulic Symbols Legend
Pumpfixed displacement
Motorbi-directional
Accumulator
Shut off valve
Check valve
2 position, 3 way, shuttle valve
Double actingcylinder
Priorityflow regulator valve
Differentialsensing valve
Solenoid operatedproportional valve
Hydraulic oil cooler
Brake
Pilot operated 3 position,3 way, shuttle valve
Filter withbypass valverelief setting
25 psi(1.7 bar)
Motor2-speed,
bi-directional
Pumpbi-directional,
variable displacement
E
Pump prime mover(engine or motor)
Directional valve(mechanically activated)
o
Relief valvewith pressure setting
200 psi(13.8 bar)
Orifice with size
.035"(0.89 mm)
Solenoid operated 3 position,4 way, directional valve
Directional valvepilot operated
2 position, 2 way
Flow divider/combiner valvewith pressure balancing orifice
and flow percentages
50% 50%
Counterbalance valvewith pressure and pilot ratio
(206.8 bar)3000 psi
3:1
Solenoid operated 2 position,3 way, directional valve
2 position, 2 waysolenoid valve
February 2012Section 6 • Schematics
6 - 4 S-80 • S-85 Part No. 122149
This page intentionally left blank.
Section 6 • Schematics
6 - 5
February 2012
Electrical Schematic, S-80/85Deutz BF4L 2011 Models (before serial number 5520)
6 - 6
February 2012Section 6 • Schematics
6 - 6 S-80 • S-85 Part No. 122149
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
Electrical Schematic, S80/85Deutz BF4L 2011 Models (before serial number 5520)
P1
34
TT
SR
D
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
20AMP.RD
P2
0B
AT
RD
RE
LA
Y
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
GR
NO
CB3
RD
TB41
OP
TIO
N
GE
NE
RA
TO
R
FL
AS
HIN
GB
EA
CO
NS
HO
UR
ME
TE
R
PO
WE
RR
EL
AY
IGN
./STA
RT
RE
LA
Y
STA
RT
ER
MO
TO
R
AU
XIL
IAR
YP
UM
P
AU
XIL
IAR
YP
OW
ER
TB35
TS2
GROUNDAUX. ON
KEY PWR.BATTERY
TACHOMETER
IGN./FUEL ONENG. FAULT
KEY BYPASS
START INPUT
START RELAY
4
PUMP
RE
LA
Y
C2
7A
UX
RD
PR1
NO
C2
8T
TA
RD
/BK
NOCR1
TB21
NO
CR28765
109
TS51
TB27
RD
TS1
TS52
12
TB33
3
RD
IGN./START
MODULE
GR
/WH
FB
C3
3S
TR
BK
C4
5G
EN
GR
/WH
TS47
P24FS WH
BK
/RD
TS54
HIG
HR
PM
TS4
BRN
RDOR/BK
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
FU
EL
SO
LE
NO
ID
L5
C2
4T
PS
WH
S2
NC
S1
NO
OIL
PR
ES
SU
RE
OIL
TE
MP
ER
AT
UR
E
SW
ITC
H
SW
ITC
H
TB34
TS56
C3
4S
AB
K/W
H
TS6
CR3
NO
BK
/WH
OP
TIO
N
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TILT
AL
AR
M
RD
WH
BK
BK
H2+
_
RD
P25FS RD
P26ESTP BK
C1
-1C
27
AU
XR
D
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/ RD
CR3
TB23
TB24
TB46
D8
D7
-
DC
+
12 V
B1
D22
FAN
CR17NO
15AMP.
TB20
CB2
RD
FU
NC
.E
NA
BL
E
D6
70AFUSE
C6
-16
C6
-23
C6
-34
C6
-33
C5-3
C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-24
P1
34
FB
RD
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
R3
3S
TR
BK
C5
-11
BL
/RD
RD
P2
2B
AT
BK
C1
32
PL
IB
L/W
H
P1
34
BA
TG
R/B
K
15AMP.
CB1
C2
8T
TA
RD
/BK
7
WH
GR
/BK
TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
6
1
4
3
5
C4
6H
RN
GR
C2
B-6
C1
B-1
2 C7
B-1
C2
P-5
C1
P-2
H1
C1
P-1
2
C7
P-1
C2
P-6
P3HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1P2
NOCR39
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
T.)
SE
ND
ER
(OP
T.)
WA
TE
RT
EM
PC
26
TS
RW
H/R
D
C2
5P
SR
WH
/BK
VO
LTM
ET
ER
(OP
T.)
TB24A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
D.
OIL
TE
MP.
HY
D.
CO
OL
ING
ALT
ER
NA
TO
R
BA
TT
ER
Y
SE
PA
RA
TO
R(O
PT.)
STA
RT
BA
TT
ER
Y
FA
N(O
PT.)
SW
ITC
H(O
PT.)
D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
NOTES:
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION . C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
PR2NO
GL
OW
PL
UG
1
GL
OW
PL
UG
1R
EL
AY
RD
B2
BA
TR
DB2BAT RD
C5
-16
C5
-14
TB33A
TB26 TB25
F18
BK
BK
WH
WH
TS49
FU
SE
10
AR
D
RD
TS48
OP
TIO
N
WO
RK
LIG
HT
S
OP
TIO
N
DR
IVE
LIG
HT
CR23CR23
NO
PBOX GND
DL
ITE
OP
TIO
NW
IRE
FUSE 10A
L29 L29
L30L30
P134BAT RD
C4
-11/1
2
HO
LD
PU
LL
INW
H
BK
21
RD
3MODULE
TIME DELAY-COM
+AUX
S-613
+BAT
MOM N.O.
BRN
WH
RD
RP
MS
OL
EN
OID
C5
-18
RP
MM
OD
UL
E
CH
EC
KE
NG
INE
LE
D
J1
44
-8J1
44
-7
J1
44
-3
J1
44
-5
J1
44
-4
J1
44
-6
J1
44
-2
J1
44
-1
D44
U16NO
TIMER30
70AFUSE
PR3NO
GL
OW
PL
UG
2
GL
OW
PL
UG
2R
EL
AY
C34SA
P3
4S
A
L48
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C32CONN.PLUG
STARTER
G1
G3 G2E
NG
INE
STA
RT
EN
GIN
ES
TA
RT
GL
OW
PL
UG
GL
OW
PL
UG
ON
AU
XIL
IAR
YP
UM
P
WO
RK
LIG
HT
DR
IVE
LIG
HT
GE
NE
RA
TO
RO
FF
ON
1
2
3
2
3
CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 7
N M L K J I H G F E D C B A 1
2
3
4
5
6
7
8
Electrical Schematic, S80/85Deutz BF4L 2011 Models (before serial number 5520)
DR
IVE
/RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
BRN
DE
SC
EN
TA
LA
RM
P46 RD
C41RPM OR/BK
C1
5P
LD
OR
/BK
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
PL
AT
FO
RM
RO
TA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
LE
FT
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
TB17
TB18
GR
-17
-M.H
.
GR
/BK
-18
-M.H
.
TS9
TS59
TB14
TB15
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
TB9
C9
PE
RF
BK
/RD
TS63
TB8
BK
/WH
C8
PB
RB
K/W
H
C1
4P
LU
OR
BK
/RD
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C7
PB
BE
BK
C8
PB
RB
K/W
H
BK
TB7
C7
PB
EB
K
C4
TR
LW
H
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
TB2
TS61
C2
PB
DR
D/B
K
C1
PB
UR
D
TB3
C2
PB
DR
D/B
K
C3
PB
FR
D/W
H
TS62
C5
TR
RW
H/B
K
TB1
TB6
C6
TT
RF
WH
/RD
TB4
C1
PB
UR
D
PR
I.B
OO
ME
XT
EN
D
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TB5
BR
AK
ER
EL
EA
SE
VA
LV
E
C2
9M
SR
D/W
HM
OT
OR
ST
RO
KE
LS
1R
O-B
OO
MR
ET
RA
CT
OP.
DR
IVE
/ RO
TA
TE
SP
EE
D
LS
2A
S-B
OO
MA
NG
LE
SA
FE
TY
DR
I VE
LI M
I TS
WIT
CH
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
C4
0L
SO
R/R
D
TB42
C2
9M
SR
D/W
H
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C3
6S
TC
CB
L
C3
7S
TC
BL
/BK
TB37
C3
7S
TC
BL
/BK
C3
6S
TC
CB
L
LIM
ITS
WIT
CH
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
EN
AB
LE
GR
OU
ND
TS15
C1
2D
RE
BL
/WH
C3
0E
DC
+W
H
C3
1E
DC
-W
H/B
K
C3
2B
RK
WH
/RD
C5
-20
C3
2B
RK
WH
/RD
TB32
L1
BR
N
H4
H3
EXTEND/RETRACT
JOYSTICK CONTROL CARD
3
BR
N
OR
YE
L
1 542 3 76
12
C5
- 21
14
LS3
13
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
10 9 3
1 742 3 5 6
PRI UP/DN & TT ROTATE
1 742 3 5 6
DRIVE & STEERING
RD
1
BK
2
BR
N
OR
BR
N
OR
WH
BL
5 4
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
P23 RD
13
1411
122
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P-4
C1
P-5
C1
P-6
C1
P-3
C1
P-1
1
C1
P- 1
0
C3
P-6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P- 4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/R
D
CD
E2
BL
/BK
J2
J3 J1 J1 J1 J1
OU
T
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
C4
P-6
C4
P-5
DR
IVE
ED
CF
OR
WA
RD
CD
E1
BL
/WH
C2
9M
SR
D/W
H
H1
RD
/BK
NOHC NCNOHCNCNOHC2AO2AS1RO1RS
TS16
C4
0L
S1
OR
TB40
C2
P-2
1
C3
P-1
1C
61
AX
BL
/BK
TB46
NCCR26
D37
D38
D35 D36
D41
AX
LE
EX
T/R
ET
SE
LE
CT
C6
0A
XO
R/R
D
C2
P-4
AX
LE
DU
MP
VA
LV
E
NC
CR8
D34
D15
TB16
S3NC
NCCR29
OP
EN
WH
EN
AX
LE
FU
LLY
EX
T.
AX
LE
NO
TE
XT
PR
ES
SU
RE
SW
AX
LE
EX
TE
ND
RLY
L5
C7
-3
S3
LE
DB
L/R
D
+
5R2
D29
D2
7
D2
8
/JIB
UP
/JIB
DO
WN
C3
1E
DC
WH
/BK
C3
0E
DC
WH
CR8
C6
-36
C6
-37
C6
-11
C6
-39
C6
-13
C5
-23
C5
-24
C6
-4
C6
-5
C6
-6
C6
-1
C6
-2
C6
-3
C6
-7
C6
-8
C6
-9
C6
-12
C6
-30
C6
-14
C6
-15
C6
-18
C6
-17
C6
-19
C6
-21
C6
-22
C6
-10
C6
-31
C6
-20
LS
2A
O-B
OO
MA
NG
LE
OP.
DR
IVE
LIM
ITS
WIT
CH
LI M
I TS
WIT
CH
LI M
I TS
WIT
CH
WH
RD
C4
0L
S2
BK
U4
ADC B
C3
5-1
C3
5-2
C3
4- 1
C3
4-2
1
2
C2
9-2
C2
9-1
C1
6-1
C1
6-2
C1
7-2
C1
7-1
C2
7-2
C2
7-1
C1
3-1
C1
3-2
C1
2-1
C1
2-2
C3
1-1
C3
1-2
C1
4-1
C1
4-2
C1
5-1
C1
5-2
C2
8-2
C2
8-1
C2
6-2
C2
6-1
C2
4-2
C2
4- 1
C2
5- 2
C2
5-1
C1
2D
RE
BL
/WH
C2
3B
AT
RD
21
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
2A
XD
PW
H
C6
0A
XO
R/R
D
S3
LE
DB
L/ R
D
J4
BK
J3
WH
J1
WH
J5
BK
J2
WH
D57
C6
-32
C4
P-1
2 13 4
2
2
2
3
3
4
4
4
1
1
1
BL
C27AUX + FE RD
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
C2
1-1
C2
1-2
C2
4-2
C2
3-1
C2
2-1
C2
2-2
C2
0-1
C2
0-2
3
D41 CR38
NC
CR38
C6
-40
C4
0L
S1
OR
P24FS WH
C28TTA RD/BK
P26ESTP BK
C8
PB
RB
K/W
HC
6-3
8
C6
-29
R1
6P
BR
BK
/WH
3 4
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
XO
UT
P134BAT RD
CR20 A
CR20 B
NO
NO
UP
DO
WN
PL
AT
RO
TA
TE
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
RE
TR
AC
T
EX
TE
ND
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
EX
TE
ND
RE
TR
AC
TA
XL
E
D2
7
JIB
BO
OM
D2
7D
27
LE
FT
RIG
HTP
LA
TR
OTA
TE
LE
FT
RIG
HT
TS57
C4
P-7
TS7 TS8
JIB
VA
LV
E
C19JSV GR/WH
CR13
BRN
JIB
BO
OM
C1
7JU
/PR
LG
R
C1
8JD
/PR
RG
R/B
K
C1
9JS
VG
R/W
H
JIB
VA
LV
E
TS58
CE Option, See 6-60
7
6
5
4
3
2
1
AMP
Pin1
Pin 1 GND Pin 2
Pin 2 PWR Pin 3
Pin 3 XOUT Pin 4
Pin 4 YOUT Pin 5
Pin 5 RKOUT Pin 6
Pin 6 Pin 7
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
RE
TR
AC
TE
XT
EN
DA
XLE
Section 6 • Schematics
6 - 8
February 2012
Electrical Schematic, S80/85Deutz BF4L 2011 Models (before serial number 5520)
6 - 7
July 2007
Section 6 • Schematics
6 - 9
February 2012
Electrical Schematic, S80/85Deutz BF4L 2011 Models (after serial number 5519)
February 2012Section 6 • Schematics
6 - 10 S-80 • S-85 Part No. 122149
Electrical Schematic, S80/85Deutz BF4L 2011 Models (after serial number 5519)
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
P1
34
TT
SR
D
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
20AMP.RD
P2
0B
AT
RD
RE
LA
Y
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
GR
NO
CB3
RD
TB41
OP
TIO
N
GE
NE
RA
TO
R
FL
AS
HIN
GB
EA
CO
NS
HO
UR
ME
TE
R
PO
WE
RR
EL
AY
IGN
./STA
RT
RE
LA
Y
STA
RT
ER
MO
TO
R
AU
XIL
IAR
YP
UM
P
AU
XIL
IAR
YP
OW
ER
TB35
TS2
GROUNDAUX. ON
KEY PWR.BATTERY
TACHOMETER
IGN./FUEL ONENG. FAULT
KEY BYPASS
START INPUT
START RELAY
4
PUMP
RE
LA
Y
C2
7A
UX
RD
PR1
NO
C2
8T
TA
RD
/BK
NOCR1
TB21
NO
CR28765
109
TS51
TB27
RD
TS1
TS52
12
TB33
3
RD
IGN./START
MODULE
GR
/WH
FB
C3
3S
TR
BK
C4
5G
EN
GR
/WH
TS47
P24FS WH
BK
/RD
TS54
HIG
HR
PM
TS4
BRN
RDOR/BK
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
FU
EL
SO
LE
NO
ID
L5
C2
4T
PS
WH
S2
NC
S1
NO
OIL
PR
ES
SU
RE
OIL
TE
MP
ER
AT
UR
E
SW
ITC
H
SW
ITC
H
TB34
TS56
C3
4S
AB
K/W
H
TS6
CR3
NO
BK
/WH
OP
TIO
N
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TILT
AL
AR
M
RD
WH
BK
BK
H2+
_
RD
P25FS RD
P26ESTP BK
C1
-1C
27
AU
XR
D
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/ RD
CR3
TB23
TB24
TB46
D8
D7
-
DC
+
12 V
B1
D22
FAN
CR17NO
15AMP.
TB20
CB2
RD
FU
NC
.E
NA
BL
E
D6
70AFUSE
C6
-16
C6
-23
C6
-34
C6
-33
C5-3
C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-24
P1
34
FB
RD
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
R3
3S
TR
BK
C5
-11
BL
/RD
RD
P2
2B
AT
BK
C1
32
PL
IB
L/W
H
P1
34
BA
TG
R/B
K
15AMP.
CB1
C2
8T
TA
RD
/BK
7
WH
GR
/BK
TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
6
1
4
3
5
C4
6H
RN
GR
C2
B-6
C1
B-1
2 C7
B-1
C2
P-5
C1
P-2
H1
C1
P-1
2
C7
P-1
C2
P-6
P3HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1P2
NOCR39
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
T.)
SE
ND
ER
(OP
T.)
WA
TE
RT
EM
PC
26
TS
RW
H/R
D
C2
5P
SR
WH
/BK
VO
LTM
ET
ER
(OP
T.)
TB24A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
D.
OIL
TE
MP.
HY
D.
CO
OL
ING
ALT
ER
NA
TO
R
BA
TT
ER
Y
SE
PA
RA
TO
R(O
PT.)
STA
RT
BA
TT
ER
Y
FA
N(O
PT.)
SW
ITC
H(O
PT.)
D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
NOTES:
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION . C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
PR2NO
GL
OW
PL
UG
1
GL
OW
PL
UG
1R
EL
AY
RD
B2
BA
TR
DB2BAT RD
C5
-16
C5
-14
TB33A
TB26 TB25
F18
BK
BK
WH
WH
TS49
FU
SE
10
AR
D
RD
TS48
OP
TIO
N
WO
RK
LIG
HT
S
OP
TIO
N
DR
IVE
LIG
HT
CR23CR23
NO
PBOX GND
DL
ITE
OP
TIO
NW
IRE
FUSE 10A
L29 L29
L30L30
P134BAT RD
C4
-11/1
2
HO
LD
PU
LL
INW
H
BK
21
RD
3MODULE
TIME DELAY-COM
+AUX
S-613
+BAT
MOM N.O.
BRN
WH
RD
RP
MS
OL
EN
OID
C5
-18
RP
MM
OD
UL
E
CH
EC
KE
NG
INE
LE
D
J1
44
-8J1
44
-7
J1
44
-3
J1
44
-5
J1
44
-4
J1
44
-6
J1
44
-2
J1
44
-1
D44
U16NO
TIMER30
70AFUSE
PR3NO
GL
OW
PL
UG
2
GL
OW
PL
UG
2R
EL
AY
C34SA
P3
4S
A
L48
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C32CONN.PLUG
STARTER
G1
G3 G2E
NG
INE
STA
RT
EN
GIN
ES
TA
RT
GL
OW
PL
UG
GL
OW
PL
UG
ON
AU
XIL
IAR
YP
UM
P
WO
RK
LIG
HT
DR
IVE
LIG
HT
GE
NE
RA
TO
RO
FF
ON
1
2
3
2
3
CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 11
Electrical Schematic, S80/85Deutz BF4L 2011 Models (after serial number 5519)
N M L K J I H G F E D C B A 1
2
3
4
5
6
7
8DR
I VE
/RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
BRN
DE
SC
EN
TA
LA
RM
P46 RDC41RPM OR/BK
C1
5P
LD
OR
/BK
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
PL
AT
FO
RM
RO
TA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
LE
FT
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
GR
-17
-M.H
.
GR
/BK
-18
-M.H
.
TS9
TS59
TB14
TB15
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
TB9
C9
PE
RF
BK
/RD
TS63
TB8
BK
/WH
C8
PB
RB
K/W
H
C1
4P
LU
OR
BK
/RD
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C7
PB
BE
BK
C8
PB
RB
K/W
H
BK
TB7
C7
PB
EB
K
C4
TR
LW
H
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
TB2
TS61
C2
PB
DR
D/B
K
C1
PB
UR
D
TB3
C2
PB
DR
D/B
K
C3
PB
FR
D/W
H
TS62
C5
TR
RW
H/B
K
TB1
TB6
C6
TT
RF
WH
/RD
TB4
C1
PB
UR
D
PR
I.B
OO
ME
XT
EN
D
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TB5B
RA
KE
RE
LE
AS
EV
ALV
E
C2
9M
SR
D/W
HM
OT
OR
ST
RO
KE
LS
1R
O-B
OO
MR
ET
RA
CT
OP.
DR
I VE
/RO
TA
TE
SP
EE
D
LS
2A
S-B
OO
MA
NG
LE
SA
FE
TY
DR
IVE
LIM
ITS
WIT
CH
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
C4
0L
SO
R/R
D
TB42
C2
9M
SR
D/W
H
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C3
6S
TC
CB
L
C3
7S
TC
BL
/BK
TB37
C3
7S
TC
BL
/BK
C3
6S
TC
CB
L
LIM
ITS
WIT
CH
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
EN
AB
LE
GR
OU
ND
TS15
C1
2D
RE
BL
/WH
C3
0E
DC
+W
H
C3
1E
DC
-W
H/ B
K
C3
2B
RK
WH
/RD
C5
-20
C3
2B
RK
WH
/RD
TB32
L1
BR
N
H4
H3
JOYSTICK CONTROL CARD
3
12
C5
-21
14
LS3
13
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
P23 RD
2
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P-4
C1
P-5
C1
P-6
C1
P-3
C1
P-11
C1
P-1
0
C3
P-6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P-4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/ R
D
CD
E2
BL
/BK
J2
J3 J1
DR
IVE
ED
CF
OR
WA
RD
CD
E1
BL
/WH
C2
9M
SR
D/W
H
H1
RD
/BK
NOHC NCNOHCNCNOHC2AO2AS1RO1RS
TS16
C4
0L
S1
OR
TB40
C2
P-2
1
C3
P-11
C6
1A
XB
L/B
K
TB46
NCCR26
D37
D38
D35 D36
D41
AX
LE
EX
T/R
ET
SE
LE
CT
C6
0A
XO
R/R
D
C2
P-4
AX
LE
DU
MP
VA
LVE
NC
CR8
D34
D15
TB16
S3NC
NCCR29
OP
EN
WH
EN
AX
LE
FU
LLY
EX
T.
AX
LE
NO
TE
XT
PR
ES
SU
RE
SW
AX
LE
EX
TE
ND
RLY
L5
C7
-3
S3
LE
DB
L/R
D
+
5R2
D29
/JIB
UP
/JIB
DO
WN
C3
1E
DC
WH
/BK
C3
0E
DC
WH
CR8
C6
-36
C6
-37
C6
-1 1
C6
-39
C6
-13
C5
-23
C5
-24
C6
-4
C6
-5
C6
-6
C6
-1
C6
-2
C6
-3
C6
-7
C6
-8
C6
-9
C6
-12
C6
-30
C6
-14
C6
-15
C6
-18
C6
-17
C6
-19
C6
-21
C6
-22
C6
-10
C6
-31
C6
-20
LS
2A
O- B
OO
MA
NG
LE
OP.
DR
I VE
LI M
I TS
WIT
CH
LIM
ITS
WI T
CH
LIM
ITS
WIT
CH
WH
RD
C4
0L
S2
BK
U4
ADC B
C3
5-1
C3
5-2
C3
4-1
C3
4-2
1
2
C2
9-2
C2
9-1
C1
6-1
C1
6-2
C1
7-2
C1
7-1
C2
7-2
C2
7-1
C1
3-1
C1
3-2
C1
2-1
C1
2-2
C3
1-1
C3
1-2
C1
4-1
C1
4-2
C1
5-1
C1
5-2
C2
8- 2
C2
8-1
C2
6-2
C2
6-1
C2
4-2
C2
4- 1
C2
5-2
C2
5-1
C1
2D
RE
BL
/WH
C2
3B
AT
RD
21
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
2A
XD
PW
H
C6
0A
XO
R/R
D
S3
LE
DB
L/R
D
J4
BK
J3
WH
J1
WH
J5
BK
J2
WH
D57
C6
-32
C4
P-1
2 13 4
2
2
2
3
3
4
4
4
1
1
1
C27AUX + FE RD
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
C2
1-1
C2
1-2
C2
4-2
C2
3-1
C2
2-1
C2
2-2
C2
0-1
C2
0-2
3
D41 CR38
NC
CR38
C6
-40
C4
0L
S1
OR
P24FS WH
C28TTA RD/BK
P26ESTP BK
C8
PB
RB
K/W
HC
6-3
8
C6
-29
R1
6P
BR
BK
/WH
3 4
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
P134BAT RD
CR20 A
CR20 B
NO
NO
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
PL
AT
LE
VE
L
RE
TR
AC
T
EX
TE
ND
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
EX
TE
ND
RE
TR
AC
TA
XL
EEXTEND/RETRACT
BR
N
OR
WH
/BK
1 542 3 6
10 9 3
1 42 3 5 6
PRI UP/DN & TT ROTATE
1 42 3 5 6
DRIVE & STEERING
WH
/RD
1
RD
/WH
2
BR
N
OR
BR
N
OR
BL/W
H5 4
13
1411
12
J1 J1 J1
OU
T
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
BL/W
H
XO
UT
WH
/RD
TB17
TB18
WH
C4
P-6
C4
P-5
D2
7
D2
8
UP
DO
WN
PL
AT
RO
TA
TE
UP
DO
WN
D2
7
JIB
BO
OM
D2
7D
27
LE
FT
RIG
HTP
LAT
RO
TAT
E
LE
FT
RIG
HT
TS57
C4
P-7
TS7 TS8
JIB
VA
LVE
C19JSV GR/WH
CR13
JIB
BO
OM
C1
7JU
/PR
LG
R
C1
8JD
/PR
RG
R/B
K
C1
9JS
VG
R/W
H
TS58
CE Option, See 6 - 60
RE
TR
AC
TE
XT
EN
DA
XLE
Section 6 • Schematics
6 - 12
February 2012
Electrical Schematic, S80/85Deutz BF4L 2011 Models (after serial number 5519)
6 - 11
Section 6 • Schematics
6 - 13
February 2012
Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models
6 - 14
Section 6 • Schematics
6 - 14 S-80 • S-85 Part No. 122149
February 2012
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
CR3
CR5
CR1
CR2
TS61
CB1
TS62
L2
G6
CB2
HIGH IDLE CUTOUT RELAY
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
SERVICE HORN RELAY
IGNITION POWER RELAY
IGNITION / START RELAY
HOUR METER
TURNTABLE ROTATE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
PLATFORM ROTATE SWITCH
PLATFORM LEVEL SWITCH
START ENGINE SWITCH
FUNCTION ENABLE SWITCH
AUXILIARY SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPT.)
OIL PRESSURE GAUGE (OPT.)
WATER TEMP. GAUGE (OPT.)
BK C1B-7 33 BK-S.P.
HOUR METER
HARNESS:TO BASE
WIRING
CONNECTIONSCONTROL BOX
WH/BK-5AWH-4A
WH-23D
START ENG
GLOW PLUG
STEER RT/AXLE EXTENGINE RPM
LIMIT SW #1
L.P.
ENG RPM
BRN-GND STUD
GR C2B-5
CR5
CR1 CR2
BK C6-16
OR-14A
WH/RD-6A
GR-17A
GR/BK-18A
GR/WH C4B-7
RD-B1-20A
RD-24A
BK-22B
ALL BRN WIRES
BK/RD-35A
TS54
D14
D13
OR/BK-15A
OR/BK C2B-3
OR C6-10
BL/BK C6-37
OR C6-40
OR/BK C5-2
RD C6-31
41
46B
40
BL/BK C1B-11
BK/RD C1B-9BK/WH C1B-8
39
37
35
34
BK/RD-9A
GROUND STUD
BK-33
RD-1A
WH-21A
OR C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
RD-27A
TS57
LEVELPLAT. PLATFORM
ROTATE
CB1 CB2
START
TS52
TURNTABLE
TS59
ROTATE
TS62
TS63
BOOM EXTEND/RETRACT UP/DOWN
BOOM
TS61
PRI. BOOM UP
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
BOOM EXTEND
BOOM RETRACTEXT./RET. F.C.
TURN. ROT. F.C.
PLAT. LEVEL. UP
PLAT. LEVEL DN.
PLAT. ROT. R.
PLAT. ROT. L.
KEYSWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V
IGNITION PWR.
PRI. BOOM DOWN
12V BATT. SUPPLY
AUX PUMP
BRAKE WH/RD C5-23RD
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3OR C4B-2
21
WH/RD C1B-6
RD CR39#86&C1B-1
WH C7B-2
24 RD CR2#30
WH/RD C6-3227
32
BK CR5#30
23
22
GR C6-17
GR/BK C6-18
OR C6-14OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3WH C6-4
WH/BK C6-5
RD C6-1
3
5
4
2
1
WH/BK C5-14
WH S.P.
RD-S.P.-CB3RD-S.P.
BK-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
WH/RD-S.P.
BK/RD-S.P.
BK-S.P.
BK/WH-S.P.
RD/WH-S.P.WH-S.P.
WH/BK-S.P.
RD-S.P.RD/BK-S.P.
WH/RD C5-16
E-STOP
D2
NC
P1
NC
AUXILIARY PUMPTS51
CB3
RD-B2-S.P.
RD-B1-20C
RD-24AA
RD-B2-H1
RD CR1#30
RD-B1-H1 RD-B1-S.P.
24A
WH-S.P.-D2
42 OR/RD C6-22OR/RD C4B-4
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER WH/RD C5-16 WH/RD-S.P
26 WATER TEMP SENDER WH/BK C5-14 WH/BK-S.P.
29 2WD/4WD RD/WH C5-24 RD/WH C1B-3
30 E.D.C. FWD WH C1B-4 WH C5-21
31 E.D.C. REV WH/BK C5-20 WH/BK C1B-5
36 STEER LEFT/AXLE RETRACT BL C1B-10 BL C6-36
43 HORN GR C2B-5 GR CR5#86
45 GEN. OPTION GR/WH C2B-7 GR/WH C5-12
RD CR17#30
RD C6-30
33A
R2
OR/RD CR20A#86
38
BL/BK C6-20
OR/RD CR29#86
CR17
CR25
CR29
HYDRAULIC COOLER FAN RELAY
AXLE RET L/O RELAY
AXLE EXTEND LED RELAY
AXLE DUMP VALVE
HORN
START RELAY
LIMIT SW #2
LIMIT SW PWR
60 AXLE EXT/RET SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
HIGH/LOWRPM
RD-S.P.-CB1
U1 IGNITION/START MODULE
WH CR17 #86
CONTROLSENGINE
OIL COOLER/OPTION
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
RD-B1-20D
RD-B1-H1
BRN(GND)
R2 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
OR/RD CR8#87A
CR29CR8
RD/BK 2B
BL/RD C4B-1
OR/RD 42B
OR/RD 16B
BL/RD C6-13
BK 7B
CR8 BOOM FUNCTION CUTOUT
RD C6-23 RD C2B-6 134 RD-H6 RD-KSI-SPKS POWER
CHECK ENGLED L2
WH-23A
BK-22A
KSI
RD-134A
PLATFORM OVERLOAD MODULEU33
RD C6-24 134A
28 TILT ALARM RD/BK C1B-2 RD/BK C6-28
KS POWER
D42
OR/RD CR38#87A
RD CR38#86
BK/WH C6-38
AUXILARY PUMP RELAY
EXTEND FUNCTION CUTOUT
CR39
CR38
KEYSWITCH
B
B11
24
3
CR38
CR39
BK/WH C6-29
OR/RD 16C
RD-1B
RD-27D
RD-24C
RD C6-27
CR17
WH-21B
RD-24AB
WH-C6-34
OR C6-33
BL/RD C2B-1
CR20B LOW VOLTAGE DROP RELAY
CR20A LOW VOLTAGE DROP RELAY
OR/RD C6-11
TB16D OR/RD
TB134A-A
CR20A
CR20B
GR
OU
ND
ST
UD
-
+
-
+
TS58 JIB UP/DOWN (JIB OPTION ONLY)
TS58
JIB
OIL PRESSURE
G2G1
VOLT METER
G3
WATER TEMP.
CR23 DRIVE LIGHT RELAY OPTION
BRN GND
CR23
10 AMP FUSE
RD C4B-11
RD C4B-12
OPTION WIRE TO PBOX
TB24AD
DRIVE LIGHT OPTION RELAY
(SPARE WIRE)
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
DIESEL ENGINE: C2-1 BL/RD
TS56 GLOW PLUG SWITCH (DIESEL ONLY)
BK ISM#3
BK-C23-5
KEY PWR.WH-23B7
TB33AB
10
WH-CR2#86
ENG. FAULT
KEY BYPASS
IGN./FUEL ON9
8
BK/WH-34A
RD-27B
BRN GND
OR/BK-41BBK-33B
4 AUX. ON
BATTERY6
5 GROUND
START RELAY
TACHOMETER
START INPUT3
1
2
BK/RD CR3#30
BK/WH C5-22
OR/BK ISM#2
BK/WH-S.P.
BK C23-4
ISM#4
WH L2
U1
BK-CR1#87BK C5-5 D51
IGN./STARTMODULE
BK CR1#86
GLOW PLUG SW
TS56
RD C23-6
RD-C23-7
-
PLATFORMOVERLOADLED L45
+
GR/BK-H6
PLATFORM OVERLOAD LEDL45
WH ISM#7
WH ISM #10
WH C5-3
RD-24D
C3
2
BK-22DBL/WH C1-12
BK C7B-1
GR/BK-C3B-10
GR/BK H6
P134PWR RD-134BRD H6
BRN
RD-TS51
+
GR/BK-L45
RD-TS52
43
5
8
1
12
67
H6CE ONLY
BK/RD-35B
BK/RD C5-18
CR3
WH-21C
WH C5-11
WH CR3#86
WH C5-15
RD ISM#6
D6
1
3
5
2 RD TB23
BR GND STUD
BK/WH TB34D
BK TB33C
U16
BK/WH U16-5
BK U16-5
+RD U16-2
EN
GIN
E
C5
12
VT
OP
LA
T
C1
B
FU
NC
TIO
NS
C6
C3
B
19
/18
CA
BL
ES
C2
BC
4B
3
2
C7
B 1
BASE TERMINATION BLOCK
D7
CD AB
G6
H1
868686
D34
RD/BK C6-19
D8
CR8#86+
D15
GND STUDD57
RD/BK CR8#30
8686 86
D42
86
86
8686 86
PL
UG
AN
SI/C
SA
ON
LYC
32
CO
NN
EC
TO
R
NOTE: CE OPTION- LOADSENSEMODULE CONNECTS TO C32.
Section 6 • Schematics
6 - 15
February 2012
Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (before serial number 5520)
6 - 16
February 2012Section 6 • Schematics
6 - 16 S-80 • S-85 Part No. 122149
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (before serial number 5520)
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
U13
JC1
JIB BOOM CUTOUT RELAY
AXLE CUTOUT RELAY
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
TS8
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
CR13
CR26
H1
TS48
TS49
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM
CR27WH-TS7
WH-TS1
BRN BATGND
GND STUD
WH/RD C32BRK
OR/RD R40LS2
(SPLICE TO C32BRK)
(SPLICE TO R40LS2)
CR30
OR
C4
P-2
OR
/BK
C4
P-3
GR
C2
P-5
NO
BL
/BK
J1
-7
RD
C1
P-1
GR
/BK
C4
P-6
GR
C4
P-5
YE
LJ1
-3
RD
J1
-1
BK
/RD
C1
P-9
BL
/RD
J1
-16
RD
C9
-3
BK
C1
P-7
OR
J1
-9
RD
/WH
J1
-8
BK
C9
-1
NC
HORN
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
CR26AXLE CUTOUT
P2EMERGENCY
STOP
TS4HIGH/LOW
RPMTS2
ENGINESTART
L1
TS1AUXILIARY
PUMP
TS14DRIVESPEED
TS7PLATFORM
ROTATE
TS9PLATFORM
LEVEL
P3
JC2PRIMARY BOOMUP/DOWN AND
TURNTABLEROTATE
JC1BOOM
EXTEND/RETRACT
BK
/WH
C1
P-8
JC3DRIVE
GND STUD
H1TILT
ALARM
RD
LS
18
BRN
C1
2D
RE
BL
/WH
C3
P-1
2
C5
TR
RW
H/B
KC
3P
-5
C4
TR
LW
HC
3P
-4
C3
PB
FR
D/W
HC
3P
-3
C8
PB
RB
K/W
HC
3P
-8
C6
TR
FW
H/R
DC
3P
-6
C9
PE
RF
BK
/RD
C3
P-9
C7
PB
EB
KC
3P
-7
C2
PB
DR
D/B
KC
3P
-2
C1
PB
UR
DC
3P
-1
HI-C
13
3P
LA
GN
/BL
C3
P-1
0
TS
9-C
15
PL
DO
R/B
KC
4P
-3
FOOT SWITCH
C3
P(G
R)
C1
P(G
Y)
C2
P(B
K)
12V DCBATTERY
C4
P(B
R) C7P
BATGND C7P-3
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
14
PL
UO
RC
4P
-2
C9 JIB
P2
-P2
3S
WB
AT
WH
C7
P-2
R4
0L
S2
OR
/RD
C4
P-4
TS
7-C
18
JD
GR
/BK
C4
P-6
TS
7-C
17
JU
GR
C4
P-5
J3
-P2
4C
ON
TW
HC
9-2
P2
-P2
2B
AT
BK
C7
P-1
TS
2-P
25
ST
RR
DC
9-3
TS
6-C
34
SA
BK
/WH
C1
P-8
C3
2B
RK
WH
/RD
C1
P-6
C28TTA RD/BK C1P-2
C2
9M
SR
D/W
HC
1P
-3
C3
1E
DC
-W
H/B
KC
1P
-5
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C3
0E
DC
+W
HC
1P
-4
TS
1-C
27
AU
XR
DC
1P
-1
P2
-P2
6F
SB
KC
9-1
TS
2-C
33
ST
RB
KC
1P
-7
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
C4
1R
PM
OR
/BK
C2
P-3
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C3
7S
TC
BL
/BK
C1
P-11
DL
ITE
GR
/BK
C2
P-6
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE
ENABLE
19/18 CONTROL CABLE
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
D12
TS6GLOW PLUG
OPTION
LS18(OPTION)
7
6
5
4
3
2
1
4
2
1
3
5
6
7
4
2
1
3
5
6
7
BR
NJ1
-10
+-
+-
+-
OR
J1
-13
BR
NJ1
-14
OR
J1
-11
BR
NJ1
-12
1
11
1
9
3
1
JC
3-5
WH
JC
2-2
BR
N
JC
3-6
BL
JC
2-3
OR
JC
1-5
YE
L
JC
1-2
BR
N
JC
2-5
BK
JC
2-4
RD
JC
1-3
OR
TS
14
-C2
9M
SR
D/W
H
L1
-C1
3L
ED
BL
/RD
TS
15
-DR
EB
BL
/BK
JC
3-2
BR
N
TS
15
-DR
EA
BL
/WH
JC
3-3
OR
GND STUD
J1 J2
J3
WH
J1
-5
BL
J1
-4
BR
N
+
L40
EX/RET
TS16
AXLE
WH
J3
-2
BL
/RD
C4
P-1
OR
/RD
C2
P-4
J2
-DIO
DE
WH
D12D12
WH
TS
4
WH
CR
26
#8
5
BL
C1
P-1
0
BL
/BK
C3
P-11
BK
P2
BL
/WH
J1
-6
WH
C9
-2
BK
J3
-3
BL
TS
16
TS
16
-C6
1A
XB
L/B
KC
3P
11
CR13 BRN
RD
LS
18
U13ALC-500
D2
CE MODELS (SEE DETAIL A)
RD
/BK
H1
RD LS CABLERD-H1
RD-P2
+
L4
BK LS CABLE CIP-12
RD
C2
P-6
GN
/BK
L4
L4 PLATFORM OVERLOAD LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
GN
/BK
C3
P-1
0
RD
/BK
L4
8
OPT.
GN
/BK
H1
(D3
9)
L48
BK
+
TS48/TS49
RD WL1
RD WL2
TS15
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
L48 TILT ALARM LED
D40
D39
TS2
GR
/WH
C2
P-7
DETAIL B: GENERATOR OPTION
TS8JIB BOOM
JIB
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
RD/BK JIB CABLE
GND
CR13
CUTOUT
JIB
GR/WH C4P-7
GR/WH TS7
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 17
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (after serial number 5519)
GR
C2
P-5
OR
/BK
C4
P-3
OR
C4
P-2
BL
/BK
C3
P-11
BL
C1
P-1
0
OR
/RD
C2
P-4
BL
/RD
C4
P-1
BRN
J2
-DIO
DE
WH
GR
/WH
JIB
CA
BL
E
RD
/WH
J1
-8
GR
C4
P-5
GR
/BK
C4
P-6
RD
C1
P-1
RD
BK
BK
RD RD
RD
/BK
H1
BL
/WH
J1
-6
WH
J3
-2
BK
C1
P-7
RD
C9
-3
BK
/WH
C1
P-8
BK
/RD
C1
P-9
BL
/BK
J1
-7
GN
/ BK
H1
(D3
9)
BK
J3
-3
BK
C7
P-1
WH
C7
P-2
BK
C9
-1
GN
/BK
C3
P-1
0
GN
/BK
L4
RD
C2
P-6
RD
LS
18
RD
/BK
H1
TS
15
-DR
EB
BL
/BK
L1
-C1
3L
ED
BL
/RD
TS
14
-C2
9M
SR
D/W
H
C1
34
PW
RG
R/B
KC
2P
-6
U13
BL
TS
16
WH
C9
-2
BK
P2
WH
CR
26
#8
5
WH
TS
4
ALC-500
RD
/BK
L4
8
TS
2-C
33
ST
RB
KC
1P
-7
TS
1-C
27
AU
XR
DC
1P
-1
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C2
9M
SR
D/W
HC
1P
-3
TS
6-C
34
SA
BK
/WH
C1
P-8
BATGND C7P-3
C28TTA RD/BK C1P-2
JC
3-3
OR
TS
15
-DR
EA
BL
/WH
JC
3-2
BR
NJC
3-6
BL
(1)
JC
2-2
BR
N
JC
3-5
WH
JC
1-3
OR
JC
2-4
RD
JC
2-5
BK
JC
1-2
BR
N
JC
1-5
YE
L
JC
2-3
OR
JC
3-4
BL
(2)
P3
-C4
3H
RN
GR
C2
P-5
C3
6S
TC
CB
LC
1P
-10
C4
0L
S1
OR
C2
P-2
C3
7S
TC
BL
/BK
C1
P-11
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C4
1R
PM
OR
/BK
C2
P-3
C3
0E
DC
+W
HC
1P
-4
C3
1E
DC
-W
H/B
KC
1P
-5
C3
2B
RK
WH
/RD
C1
P-6
R4
0L
S2
OR
/RD
C4
P-4
C1
PB
UR
DC
3P
-1
C2
PB
DR
D/B
KC
3P
-2
C7
PB
EB
KC
3P
-7
C9
PE
RF
BK
/RD
C3
P-9
C6
TR
FW
H/R
DC
3P
-6
C8
PB
RB
K/W
HC
3P
-8
C3
PB
FR
D/W
HC
3P
-3
C4
TR
LW
HC
3P
-4
C5
TR
RW
H/B
KC
3P
-5
C1
2D
RE
BL
/WH
C3
P-1
2
GND STUD
CC
13
2P
LI
BL
/WH
C3
P-1
2
TS
16
-C6
1A
XB
L/B
KC
3P
11
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
P2
-P2
6F
SB
KC
9-1
TS
2-P
25
ST
RR
DC
9-3
P2
-P2
2B
AT
BK
C7
P-1
J3
-P2
4C
ON
TW
HC
9-2
TS
7-C
17
JU
GR
C4
P-5
TS
7-C
18
JD
GR
/BK
C4
P-6
P2
-P2
3S
WB
AT
WH
C7
P-2
TS
9-C
14
PL
UO
RC
4P
-2
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
15
PL
DO
R/B
KC
4P
-3
C1
33
PL
AB
LC
3P
-10
RD
LS
18
P3
HORN
NO
TILT ALARM
D39
H1
CE SEE DETAIL A
PLATFORM
LEVEL
TS9TS7
ROTATE
PLATFORM
TS1
AUX. PUMPTS14
SPEEDDRIVE
19/18 CONTROL CABLE
C2
P(B
K)
D2 TS16
L40
+
AXLE
EX/RET
GND STUD
C1
P(G
Y)
12V BATT
C4
P(B
R)
C3
P(G
R) C7P C9
F.S.
RPM
TS2
START
+
L1
HIGH/LOW
+
L4
TS4
E- STOP
P2
NC
TS15
DRV.ENA
+
D12
L48
OPT.
D40
J2J1
1
9
D12 D12
1
J31
3
11
PLATFORM CONTROL BOX
PLATFORM OVERLOAD LIMIT SWITCHLS18
L48 TILT ALARM LED
PLATFORM OVERLOAD LED (OPTION)
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
DRIVE SPEED LOW/HIGH SWITCH
PLATFORM ROTATE SWITCH
GENERATOR SWITCH ( OPTION )
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
AXLE EXTENDED LED
DRIVE ENABLE LED
ALC500
JC1
H1
JC2
U13
L4
L40
JC3
L1
TILT ALARM
AXLE EXT/RET SWITCH
DRIVE ENABLE SWITCH
HIGH RPM SWITCH
PLATFORM LEVEL SWITCH
TS16
TS47
TS14
TS15
TS7
TS4
TS9
EMERGENCY STOP BUTTON
COMPONENT INDEX
START ENGINE SWITCH
AUXILIARY SWITCH
HORN SWITCH
P2
TS1
P3
TS2
TT ROTATE
UP/DOWN
PRI. BOOM BOOM
EXT/RET
DRIVE/STEERAXLE CUTOUT
C2P-9 & 10CR13 BRN
CR
26
BK LS CABLE CIP-12
RD LS CABLE RD-P2
RD-H1
YY
TS
3-C
39
LP
BL
/RD
C2
P-1
TS
48
-WL
1R
DC
2P
-12
TS
48
-WL
2R
DC
2P
-11
RD WL1
DETAIL C: WORKLIGHT OPTION
TS48
E-STOP BK
F18 10A
RD WL2
(SPARE WIRE)
OPTION WIRE TO GBOX
DRIVELIGHT OPTION
TS49
TS48 PIN2
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
C32BRK)
R40LS2)
(SPLICE TO
OR/RD R40LS2
CR30
(SPLICE TO
WH/RD C32BRK
WH TS7CR27
GENERATOR OPTION
DETAIL B:
TS47
WH TS1
(GND STUD)
BRN BATGND GR
/WH
C2
P-7
TS2 RD
DRIVE LIGHT RELAY (OPTION)
WORK LIGHT RELAY (OPTION)
GLOW PLUG
TS48
TS48
TS6
2
GN
DB
RN
JIB UP/DOWN (JIB OPTION ONLY)
JIB CUTOUT RELAY ( JIB ONLY )CR13
TS8
D27
J1
-2R
D/W
HJC
2-4
J1
-1W
H/R
DJC
2-3
J1
-11O
RJC
2-2
J1
-12
BR
NJC
2-1
JC2
J1
-3W
H/B
KJC
1-4
J1
-9O
RJC
1-2
J1
-10
BR
NJC
1-1
JC1
JC3
J1
-5B
L/W
HJC
3-5
J1
-4W
H/R
DJC
3-4
J1
- 13
OR
JC
3-2
J1
-14
BR
NJC
3- 1
J1
-5B
L/W
HJC
3-3
TS6
GLOW PLUG
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
GR/WH TS7BK JIB CABLE YY
GR/WH C4P-7
JIB
CUTOUT
JIB
CR13
TS8
JIB
GND
OPT.LS18
Section 6 • Schematics
6 - 18
February 2012
Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (after serial number 5519)
6 - 17
Section 6 • Schematics
6 - 19
February 2012
Electrical Schematic, S-80/85Perkins 804-33 Models (before serial number 5520)
6 - 20
February 2012Section 6 • Schematics
6 - 20 S-80 • S-85 Part No. 122149
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-80/85Perkins 804-33 Models (before serial number 5520)
P1
34
TT
SR
D
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
20AMP.RD
P2
0B
AT
RD
RE
LA
Y
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
GR
NO
CB3
RD
TB41
OP
TIO
N
GE
NE
RA
TO
R
FL
AS
HIN
GB
EA
CO
NS
HO
UR
ME
TE
R
PO
WE
RR
EL
AY
IGN
./STA
RT
RE
LA
Y
STA
RT
ER
MO
TO
R
AU
XIL
IAR
YP
UM
P
AU
XIL
IAR
YP
OW
ER
TB35
TS2
GROUNDAUX. ON
KEY PWR.BATTERY
TACHOMETER
IGN./FUEL ONENG. FAULT
KEY BYPASS
START INPUT
START RELAY
4
PUMP
RE
LA
Y
C2
7A
UX
RD
PR1
NO
C2
8T
TA
RD
/BK
NOCR1
TB21
NO
CR28765
109
TS51
TB27
RD
TS1
TS52
12
TB33
3
RD
IGN./START
MODULE
GR
/WH
FB
C3
3S
TR
BK
C4
5G
EN
GR
/WH
TS47
P24FS WH
BK
/RD
TS54
HIG
HR
PM
TS4
BRN
RDOR/BK
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
FU
EL
SO
LE
NO
ID
L5
C2
4T
PS
WH
S2
NC
S1
NO
OIL
PR
ES
SU
RE
WA
TE
RT
EM
PE
RA
TU
RE
SW
ITC
H
SW
ITC
H
TB34
TS56
C3
4S
AB
K/W
H
TS6
CR3
NO
BK
/WH
OP
TIO
N
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TILT
AL
AR
M
RD
WH
BK
BK
H2+
_
RD
P25FS RD
P26ESTP BK
C1
-1C
27
AU
XR
D
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/ RD
CR3
TB23
TB24
TB46
D8
D7
-
DC
+
12 V
B1
D22
FAN
CR17NO
15AMP.
TB20
CB2
RD
FU
NC
.E
NA
BL
E
D6
70AFUSE
C6
-16
C6
-23
C6
-34
C6
-33
C5-3
C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-24
P1
34
FB
RD
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
R3
3S
TR
BK
C5
-11
BL
/RD
RD
P2
2B
AT
BK
C1
32
PL
IB
L/W
H
P1
34
BA
TG
R/B
K
15AMP.
CB1
C2
8T
TA
RD
/BK
7
WH
GR
/BK
TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
6
1
4
3
5
C4
6H
RN
GR
C2
B-6
C1
B-1
2 C7
B-1
C2
P-5
C1
P-2
H1
C1
P-1
2
C7
P-1
C2
P-6
P3HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1P2
NOCR39
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
T.)
SE
ND
ER
(OP
T.)
WA
TE
RT
EM
PC
26
TS
RW
H/R
D
C2
5P
SR
WH
/BK
VO
LTM
ET
ER
(OP
T.)
TB24A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
D.
OIL
TE
MP.
HY
D.
CO
OL
ING
ALT
ER
NA
TO
R
BA
TT
ER
Y
SE
PA
RA
TO
R(O
PT.)
STA
RT
BA
TT
ER
Y
FA
N(O
PT.)
SW
ITC
H(O
PT.)
D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
NOTES:
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION . C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
PR2NO
GL
OW
PL
UG
1
GL
OW
PL
UG
1R
EL
AY
RD
B2
BA
TR
DB2BAT RD
C5
-16
C5
-14
TB33A
TB26 TB25
F18
BK
BK
WH
WH
TS49
FU
SE
10
AR
D
RD
TS48
OP
TIO
N
WO
RK
LIG
HT
S
OP
TIO
N
DR
IVE
LIG
HT
CR23CR23
NO
PBOX GND
DL
ITE
OP
TIO
NW
IRE
FUSE 10A
L29 L29
L30L30
P134BAT RD
C4
-11/1
2
C5
-18
RP
MS
OL
EN
OID
J1
44
-8J1
44
-7
J1
44
-3
J1
44
-5
J1
44
-4
J1
44
-6
J1
44
-2
J1
44
-1
L48
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C32CONN.PLUG
STARTER
G1
G3 G2E
NG
INE
STA
RT
EN
GIN
ES
TA
RT
GL
OW
PL
UG
GL
OW
PL
UG
ON
AU
XIL
IAR
YP
UM
P
WO
RK
LIG
HT
DR
IVE
LIG
HT
GE
NE
RA
TO
RO
FF
ON
C3
4S
A
CR4
RP
MR
EL
AY
CR4NO
FUELPUMP
FU
EL
PU
MP
FU
EL
SO
LE
NO
ID
M4
HM
1
2
3
2
3CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 21
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Electrical Schematic, S-80/85Perkins 804-33 Models (before serial number 5520)
DR
IVE
/RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
BRN
DE
SC
EN
TA
LA
RM
P46 RD
C41RPM OR/BK
C1
5P
LD
OR
/BK
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
PL
AT
FO
RM
RO
TA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
LE
FT
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
TB17
TB18
GR
-17
-M.H
.
GR
/BK
-18
-M.H
.
TS9
TS59
TB14
TB15
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
TB9
C9
PE
RF
BK
/RD
TS63
TB8
BK
/WH
C8
PB
RB
K/W
H
C1
4P
LU
OR
BK
/RD
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C7
PB
BE
BK
C8
PB
RB
K/W
H
BK
TB7
C7
PB
EB
K
C4
TR
LW
H
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
TB2
TS61
C2
PB
DR
D/B
K
C1
PB
UR
D
TB3
C2
PB
DR
D/B
K
C3
PB
FR
D/W
H
TS62
C5
TR
RW
H/B
K
TB1
TB6
C6
TT
RF
WH
/RD
TB4
C1
PB
UR
D
PR
I.B
OO
ME
XT
EN
D
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TB5
BR
AK
ER
EL
EA
SE
VA
LV
E
C2
9M
SR
D/ W
HM
OT
OR
ST
RO
KE
LS
1R
O- B
OO
MR
ET
RA
CT
OP.
DR
IVE
/ RO
TA
TE
SP
EE
D
LS
2A
S-B
OO
MA
NG
LE
SA
FE
TY
DR
IVE
LIM
ITS
WIT
CH
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
C4
0L
SO
R/R
D
TB42
C2
9M
SR
D/W
H
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C3
6S
TC
CB
L
C3
7S
TC
BL
/ BK
TB37
C3
7S
TC
BL
/BK
C3
6S
TC
CB
L
LIM
ITS
WIT
CH
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
EN
AB
LE
GR
OU
ND
TS15
C1
2D
RE
BL
/WH
C3
0E
DC
+W
H
C3
1E
DC
-W
H/B
K
C3
2B
RK
WH
/ RD
C5
-20
C3
2B
RK
WH
/RD
TB32
L1
BR
N
H4
H3
EXTEND/RETRACT
JOYSTICK CONTROL CARD
3
BR
N
OR
YE
L
1 542 3 76
12
C5
-21
14
LS3
13
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
10 9 3
1 742 3 5 6
PRI UP/DN & TT ROTATE
1 742 3 5 6
DRIVE & STEERING
RD
1
BK
2
BR
N
OR
BR
N
OR
WH
BL
5 4
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
P23 RD
13
1411
122
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P- 4
C1
P-5
C1
P-6
C1
P-3
C1
P- 1
1
C1
P-1
0
C3
P- 6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P- 4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/R
D
CD
E2
BL
/BK
J2
J3 J1 J1 J1 J1
OU
T
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
C4
P-6
C4
P-5
DR
IVE
ED
CF
OR
WA
RD
CD
E1
BL
/WH
C2
9M
SR
D/W
H
H1
RD
/BK
NOHC NCNOHCNCNOHC2AO2AS1RO1RS
TS16
C4
0L
S1
OR
TB40
C2
P-2
1
C3
P-1
1C
61
AX
BL
/BK
TB46
NCCR26
D37
D38
D35 D36
D41
AX
LE
EX
T/R
ET
SE
LE
CT
C6
0A
XO
R/ R
D
C2
P-4
AX
LE
DU
MP
VA
LV
E
NC
CR8
D34
D15
TB16
S3NC
NCCR29
OP
EN
WH
EN
AX
LE
FU
LLY
EX
T.
AX
LE
NO
TE
XT
PR
ES
SU
RE
SW
AX
LE
EX
TE
ND
RLY
L5
C7
-3
S3
LE
DB
L/R
D
+
5R2
D29
D2
7
D2
8
/JIB
UP
/JIB
DO
WN
C3
1E
DC
WH
/ BK
C3
0E
DC
WH
CR8
C6
-36
C6
-37
C6
-11
C6
-39
C6
-13
C5
- 23
C5
-24
C6
-4
C6
-5
C6
-6
C6
-1
C6
-2
C6
-3
C6
-7
C6
-8
C6
-9
C6
-12
C6
-30
C6
-14
C6
-15
C6
-18
C6
-17
C6
-19
C6
- 21
C6
-22
C6
-10
C6
-31
C6
-20
LS
2A
O-B
OO
MA
NG
LE
OP.
DR
IVE
LIM
ITS
WI T
CH
LIM
ITS
WIT
CH
LIM
ITS
WIT
CH
WH
RD
C4
0L
S2
BK
U4
ADC B
C3
5-1
C3
5-2
C3
4-1
C3
4-2
1
2
C2
9-2
C2
9-1
C1
6-1
C1
6-2
C1
7-2
C1
7-1
C2
7-2
C2
7-1
C1
3-1
C1
3-2
C1
2-1
C1
2-2
C3
1-1
C3
1-2
C1
4-1
C1
4-2
C1
5-1
C1
5-2
C2
8-2
C2
8- 1
C2
6- 2
C2
6-1
C2
4-2
C2
4-1
C2
5-2
C2
5- 1
C1
2D
RE
BL
/WH
C2
3B
AT
RD
21
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
2A
XD
PW
H
C6
0A
XO
R/ R
D
S3
LE
DB
L/R
D
J4
BK
J3
WH
J1
WH
J5
BK
J2
WH
D57
C6
-32
C4
P-1
2 13 4
2
2
2
3
3
4
4
4
1
1
1
BL
C27AUX + FE RD
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
C2
1-1
C2
1-2
C2
4-2
C2
3-1
C2
2-1
C2
2-2
C2
0-1
C2
0-2
3
D41 CR38
NC
CR38
C6
-40
C4
0L
S1
OR
P24FS WH
C28TTA RD/BK
P26ESTP BK
C8
PB
RB
K/W
HC
6-3
8
C6
-29
R1
6P
BR
BK
/WH
3 4
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
XO
UT
P134BAT RD
CR20 A
CR20 B
NO
NO
UP
DO
WN
PL
AT
RO
TA
TE
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
RE
TR
AC
T
EX
TE
ND
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
EX
TE
ND
RE
TR
AC
TA
XL
E
D2
7
JIB
BO
OM
D2
7D
27
LE
FT
RIG
HTP
LA
TR
OTA
TE
LE
FT
RIG
HT
TS57
C4
P-7
TS7 TS8
JIB
VA
LV
E
C19JSV GR/WH
CR13
BRN
JIB
BO
OM
C1
7JU
/PR
LG
R
C1
8JD
/PR
RG
R/B
K
C1
9JS
VG
R/W
H
JIB
VA
LV
E
TS58
CE Option, See 6 - 60
7
6
5
4
3
2
1
AMP
Pin1
Pin 1 GND Pin 2
Pin 2 PWR Pin 3
Pin 3 XOUT Pin 4
Pin 4 YOUT Pin 5
Pin 5 RKOUT Pin 6
Pin 6 Pin 7
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
RE
TR
AC
TE
XT
EN
DA
XLE
Section 6 • Schematics
6 - 22
February 2012
Electrical Schematic, S-80/85Perkins 804-33 Models (before serial number 5520)
6 - 21
Section 6 • Schematics
6 - 23
February 2012
Electrical Schematic, S-80/85Perkins 804-33 Models (after serial number 5519)
6 - 24
February 2012Section 6 • Schematics
6 - 24 S-80 • S-85 Part No. 122149
Electrical Schematic, S-80/85Perkins 804-33 Models (after serial number 5519)
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
P1
34
TT
SR
D
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
20AMP.RD
P2
0B
AT
RD
RE
LA
Y
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
GR
NO
CB3
RD
TB41
OP
TIO
N
GE
NE
RA
TO
R
FL
AS
HIN
GB
EA
CO
NS
HO
UR
ME
TE
R
PO
WE
RR
EL
AY
IGN
./STA
RT
RE
LA
Y
STA
RT
ER
MO
TO
R
AU
XIL
IAR
YP
UM
P
AU
XIL
IAR
YP
OW
ER
TB35
TS2
GROUNDAUX. ON
KEY PWR.BATTERY
TACHOMETER
IGN./FUEL ONENG. FAULT
KEY BYPASS
START INPUT
START RELAY
4
PUMP
RE
LA
Y
C2
7A
UX
RD
PR1
NO
C2
8T
TA
RD
/BK
NOCR1
TB21
NO
CR28765
109
TS51
TB27
RD
TS1
TS52
12
TB33
3
RD
IGN./START
MODULE
GR
/WH
FB
C3
3S
TR
BK
C4
5G
EN
GR
/WH
TS47
P24FS WH
BK
/RD
TS54
HIG
HR
PM
TS4
BRN
RDOR/BK
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
FU
EL
SO
LE
NO
ID
L5
C2
4T
PS
WH
S2
NC
S1
NO
OIL
PR
ES
SU
RE
WA
TE
RT
EM
PE
RA
TU
RE
SW
ITC
H
SW
ITC
H
TB34
TS56
C3
4S
AB
K/W
H
TS6
CR3
NO
BK
/WH
OP
TIO
N
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TILT
AL
AR
M
RD
WH
BK
BK
H2+
_
RD
P25FS RD
P26ESTP BK
C1
-1C
27
AU
XR
D
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/ RD
CR3
TB23
TB24
TB46
D8
D7
-
DC
+
12 V
B1
D22
FAN
CR17NO
15AMP.
TB20
CB2
RD
FU
NC
.E
NA
BL
E
D6
70AFUSE
C6
-16
C6
-23
C6
-34
C6
-33
C5-3
C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-24
P1
34
FB
RD
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
R3
3S
TR
BK
C5
-11
BL
/RD
RD
P2
2B
AT
BK
C1
32
PL
IB
L/W
H
P1
34
BA
TG
R/B
K
15AMP.
CB1
C2
8T
TA
RD
/BK
7
WH
GR
/BK
TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
6
1
4
3
5
C4
6H
RN
GR
C2
B-6
C1
B-1
2 C7
B-1
C2
P-5
C1
P-2
H1
C1
P-1
2
C7
P-1
C2
P-6
P3HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1P2
NOCR39
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
T.)
SE
ND
ER
(OP
T.)
WA
TE
RT
EM
PC
26
TS
RW
H/R
D
C2
5P
SR
WH
/BK
VO
LTM
ET
ER
(OP
T.)
TB24A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
D.
OIL
TE
MP.
HY
D.
CO
OL
ING
ALT
ER
NA
TO
R
BA
TT
ER
Y
SE
PA
RA
TO
R(O
PT.)
STA
RT
BA
TT
ER
Y
FA
N(O
PT.)
SW
ITC
H(O
PT.)
D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
NOTES:
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION . C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
PR2NO
GL
OW
PL
UG
1
GL
OW
PL
UG
1R
EL
AY
RD
B2
BA
TR
DB2BAT RD
C5
-16
C5
-14
TB33A
TB26 TB25
F18
BK
BK
WH
WH
TS49
FU
SE
10
AR
D
RD
TS48
OP
TIO
N
WO
RK
LIG
HT
S
OP
TIO
N
DR
IVE
LIG
HT
CR23CR23
NO
PBOX GND
DL
ITE
OP
TIO
NW
IRE
FUSE 10A
L29 L29
L30L30
P134BAT RD
C4
-11/1
2
C5
-18
RP
MS
OL
EN
OID
J1
44
-8J1
44
-7
J1
44
-3
J1
44
-5
J1
44
-4
J1
44
-6
J1
44
-2
J1
44
-1
L48
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C32CONN.PLUG
STARTER
G1
G3 G2E
NG
INE
STA
RT
EN
GIN
ES
TA
RT
GL
OW
PL
UG
GL
OW
PL
UG
ON
AU
XIL
IAR
YP
UM
P
WO
RK
LIG
HT
DR
IVE
LIG
HT
GE
NE
RA
TO
RO
FF
ON
C3
4S
A
CR4
RP
MR
EL
AY
CR4NO
FUELPUMP
FU
EL
PU
MP
FU
EL
SO
LE
NO
ID
M4
HM
1
2
3
2
3CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 25
Electrical Schematic, S-80/85Perkins 804-33 Models (after serial number 5519)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
DR
IVE
/ RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
BRN
DE
SC
EN
TA
LA
RM
P46 RDC41RPM OR/BK
C1
5P
LD
OR
/BK
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
PL
AT
FO
RM
RO
TA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
LE
FT
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
GR
-17
-M.H
.
GR
/BK
-18
-M.H
.
TS9
TS59
TB14
TB15
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
TB9
C9
PE
RF
BK
/RD
TS63
TB8
BK
/WH
C8
PB
RB
K/W
H
C1
4P
LU
OR
BK
/RD
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C7
PB
BE
BK
C8
PB
RB
K/W
H
BK
TB7
C7
PB
EB
K
C4
TR
LW
H
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
TB2
TS61
C2
PB
DR
D/B
K
C1
PB
UR
D
TB3
C2
PB
DR
D/B
K
C3
PB
FR
D/W
H
TS62
C5
TR
RW
H/B
K
TB1
TB6
C6
TT
RF
WH
/RD
TB4
C1
PB
UR
D
PR
I.B
OO
ME
XT
EN
D
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TB5B
RA
KE
RE
LE
AS
EV
ALV
E
C2
9M
SR
D/W
HM
OT
OR
ST
RO
KE
LS
1R
O-B
OO
MR
ET
RA
CT
OP.
DR
I VE
/RO
TA
TE
SP
EE
D
LS
2A
S-B
OO
MA
NG
LE
SA
FE
TY
DR
IVE
LIM
ITS
WIT
CH
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
C4
0L
SO
R/R
D
TB42
C2
9M
SR
D/W
H
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C3
6S
TC
CB
L
C3
7S
TC
BL
/BK
TB37
C3
7S
TC
BL
/BK
C3
6S
TC
CB
L
LIM
ITS
WIT
CH
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
EN
AB
LE
GR
OU
ND
TS15
C1
2D
RE
BL
/WH
C3
0E
DC
+W
H
C3
1E
DC
-W
H/ B
K
C3
2B
RK
WH
/RD
C5
-20
C3
2B
RK
WH
/RD
TB32
L1
BR
N
H4
H3
JOYSTICK CONTROL CARD
3
12
C5
-21
14
LS3
13
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
P23 RD
2
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P-4
C1
P-5
C1
P-6
C1
P-3
C1
P-11
C1
P-1
0
C3
P-6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P-4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/ R
D
CD
E2
BL
/BK
J2
J3 J1
DR
IVE
ED
CF
OR
WA
RD
CD
E1
BL
/ WH
C2
9M
SR
D/W
H
H1
RD
/ BK
NOHC NCNOHCNCNOHC2AO2AS1RO1RS
TS16
C4
0L
S1
OR
TB40
C2
P-2
1
C3
P-11
C6
1A
XB
L/B
K
TB46
NCCR26
D37
D38
D35 D36
D41
AX
LE
EX
T/R
ET
SE
LE
CT
C6
0A
XO
R/ R
D
C2
P- 4
AX
LE
DU
MP
VA
LVE
NC
CR8
D34
D15
TB16
S3NC
NCCR29
OP
EN
WH
EN
AX
LE
FU
LL Y
EX
T.
AX
LE
NO
TE
XT
PR
ES
SU
RE
SW
AX
LE
EX
TE
ND
RLY
L5
C7
-3
S3
LE
DB
L/R
D
+
5R2
D29
/JIB
UP
/JIB
DO
WN
C3
1E
DC
WH
/BK
C3
0E
DC
WH
CR8
C6
-36
C6
-37
C6
-1 1
C6
-39
C6
-13
C5
- 23
C5
-24
C6
-4
C6
-5
C6
-6
C6
-1
C6
-2
C6
-3
C6
-7
C6
-8
C6
-9
C6
-12
C6
-30
C6
-14
C6
-15
C6
-18
C6
-17
C6
-19
C6
-21
C6
- 22
C6
- 10
C6
- 31
C6
- 20
LS
2A
O- B
OO
MA
NG
LE
OP.
DR
I VE
LI M
ITS
WI T
CH
LIM
ITS
WIT
CH
LIM
ITS
WIT
CH
WH
RD
C4
0L
S2
BK
U4
ADC B
C3
5-1
C3
5-2
C3
4-1
C3
4-2
1
2
C2
9-2
C2
9-1
C1
6-1
C1
6-2
C1
7-2
C1
7-1
C2
7-2
C2
7-1
C1
3-1
C1
3-2
C1
2-1
C1
2-2
C3
1-1
C3
1-2
C1
4-1
C1
4-2
C1
5-1
C1
5-2
C2
8- 2
C2
8-1
C2
6-2
C2
6-1
C2
4-2
C2
4- 1
C2
5-2
C2
5-1
C1
2D
RE
BL
/WH
C2
3B
AT
RD
21
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
2A
XD
PW
H
C6
0A
XO
R/R
D
S3
LE
DB
L/R
D
J4
BK
J3
WH
J1
WH
J5
BK
J2
WH
D57
C6
-32
C4
P-1
2 13 4
2
2
2
3
3
4
4
4
1
1
1
C27AUX + FE RD
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
C2
1-1
C2
1-2
C2
4-2
C2
3-1
C2
2-1
C2
2-2
C2
0-1
C2
0-2
3
D41 CR38
NC
CR38
C6
-40
C4
0L
S1
OR
P24FS WH
C28TTA RD/BK
P26ESTP BK
C8
PB
RB
K/W
HC
6-3
8
C6
-29
R1
6P
BR
BK
/WH
3 4
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
P134BAT RD
CR20 A
CR20 B
NO
NO
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
PL
AT
LE
VE
L
RE
TR
AC
T
EX
TE
ND
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
EX
TE
ND
RE
TR
AC
TA
XL
EEXTEND/RETRACT
BR
N
OR
WH
/BK
1 542 3 6
10 9 3
1 42 3 5 6
PRI UP/DN & TT ROTATE
1 42 3 5 6
DRIVE & STEERING
WH
/RD
1
RD
/WH
2
BR
N
OR
BR
N
OR
BL/W
H5 4
13
1411
12
J1 J1 J1
OU
T
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
BL/W
H
XO
UT
WH
/RD
TB17
TB18
WH
C4
P-6
C4
P-5
D2
7
D2
8
UP
DO
WN
PL
AT
RO
TA
TE
UP
DO
WN
D2
7
JIB
BO
OM
D2
7D
27
LE
FT
RIG
HTP
LAT
RO
TAT
E
LE
FT
RIG
HT
TS57
C4
P-7
TS7 TS8
JIB
VA
LVE
C19JSV GR/WH
CR13
JIB
BO
OM
C1
7JU
/PR
LG
R
C1
8JD
/PR
RG
R/B
K
C1
9JS
VG
R/W
H
TS58
CE Option, See 6 - 60
RE
TR
AC
TE
XT
EN
DA
XLE
Section 6 • Schematics
6 - 26
February 2012
Electrical Schematic, S-80/85Perkins 804-33 Models (after serial number 5519)
6 - 25
Section 6 • Schematics
6 - 27
February 2012
Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models
6 - 28
Section 6 • Schematics
6 - 28 S-80 • S-85 Part No. 122149
February 2012
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH
CR3
CR5
CR1
CR2
TS61
CB1
TS62
L2
G6
CB2
HIGH IDLE CUTOUT RELAY
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
SERVICE HORN RELAY
IGNITION POWER RELAY
IGNITION / START RELAY
HOUR METER
TURNTABLE ROTATE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
PLATFORM ROTATE SWITCH
PLATFORM LEVEL SWITCH
START ENGINE SWITCH
FUNCTION ENABLE SWITCH
AUXILIARY SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPT.)
OIL PRESSURE GAUGE (OPT.)
WATER TEMP. GAUGE (OPT.)
BK C1B-7 33 BK-S.P.
HOUR METER
HARNESS:TO BASE
WIRING
CONNECTIONSCONTROL BOX
WH/BK-5AWH-4A
WH-23D
START ENG
GLOW PLUG
STEER RT/AXLE EXTENGINE RPM
LIMIT SW #1
L.P.
ENG RPM
BRN-GND STUD
GR C2B-5CR5CR1 CR2
BK C6-16
OR-14A
WH/RD-6A
GR-17A
GR/BK-18A
GR/WH C4B-7
RD-B1-20A
RD-24A
BK-22B
ALL BRN WIRES
BK/RD-35A
TS54
D14
D13
OR/BK-15A
OR/BK C2B-3
OR C6-10
BL/BK C6-37
OR C6-40
OR/BK C5-2
RD C6-31
41
46B
40
BL/BK C1B-11
BK/RD C1B-9BK/WH C1B-8
39
37
35
34
BK/RD-9A
GROUND STUD
BK-33
RD-1A
WH-21A
OR C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
RD-27A
TS57
LEVELPLAT. PLATFORM
ROTATE
CB1 CB2
START
TS52
TURNTABLE
TS59
ROTATE
TS62
TS63
BOOM EXTEND/RETRACT UP/DOWN
BOOM
TS61
PRI. BOOM UP
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
BOOM EXTEND
BOOM RETRACTEXT./RET. F.C.
TURN. ROT. F.C.
PLAT. LEVEL. UP
PLAT. LEVEL DN.
PLAT. ROT. R.
PLAT. ROT. L.
KEYSWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V
IGNITION PWR.
PRI. BOOM DOWN
12V BATT. SUPPLY
AUX PUMP
BRAKE WH/RD C5-23RD
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3OR C4B-2
21
WH/RD C1B-6
RD CR39#86&C1B-1
WH C7B-2
24 RD CR2#30
WH/RD C6-3227
32
BK CR5#30
23
22
GR C6-17
GR/BK C6-18
OR C6-14OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3WH C6-4
WH/BK C6-5
RD C6-1
3
5
4
2
1
WH/BK C5-14
WH S.P.
RD-S.P.-CB3RD-S.P.
BK-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
WH/RD-S.P.
BK/RD-S.P.
BK-S.P.
BK/WH-S.P.
RD/WH-S.P.WH-S.P.
WH/BK-S.P.
RD-S.P.RD/BK-S.P.
WH/RD C5-16
E-STOP
D2
NC
P1
NC
AUXILIARY PUMPTS51
CB3
RD-B2-S.P.
RD-B1-20C
RD-24AA
RD-B2-H1
RD CR1#30
RD-B1-H1 RD-B1-S.P.
24A
WH-S.P.-D2
42 OR/RD C6-22OR/RD C4B-4
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER WH/RD C5-16 WH/RD-S.P
26 WATER TEMP SENDER WH/BK C5-14 WH/BK-S.P.
29 2WD/4WD RD/WH C5-24 RD/WH C1B-3
30 E.D.C. FWD WH C1B-4 WH C5-21
31 E.D.C. REV WH/BK C5-20 WH/BK C1B-5
36 STEER LEFT/AXLE RETRACT BL C1B-10 BL C6-36
43 HORN GR C2B-5 GR CR5#86
45 GEN. OPTION GR/WH C2B-7 GR/WH C5-12
RD CR17#30
RD C6-30
33A
R2
OR/RD CR20A#86
38
BL/BK C6-20
OR/RD CR29#86
CR17
CR25
CR29
HYDRAULIC COOLER FAN RELAY
AXLE RET L/O RELAY
AXLE EXTEND LED RELAY
AXLE DUMP VALVE
HORN
START RELAY
LIMIT SW #2
LIMIT SW PWR
60 AXLE EXT/RET SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
HIGH/LOWRPM
RD-S.P.-CB1
U1 IGNITION/START MODULE
WH CR17 #86
CONTROLSENGINE
OIL COOLER/OPTION
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
RD-B1-20D
RD-B1-H1
BRN(GND)
R2 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
OR/RD CR8#87A
CR29CR8
RD/BK 2B
BL/RD C4B-1
OR/RD 42B
OR/RD 16B
BL/RD C6-13
BK 7B
CR8 BOOM FUNCTION CUTOUT
RD C6-23 RD C2B-6 134 RD-H6 RD-KSI-SPKS POWER
CHECK ENGLED L2
WH-23A
BK-22A
KSI
RD-134A
PLATFORM OVERLOAD MODULEU33
RD C6-24 134A
28 TILT ALARM RD/BK C1B-2 RD/BK C6-28
KS POWER
D42
OR/RD CR38#87A
RD CR38#86
BK/WH C6-38
AUXILARY PUMP RELAY
EXTEND FUNCTION CUTOUT
CR39
CR38
KEYSWITCH
B
B11
24
3
CR38
CR39
BK/WH C6-29
OR/RD 16C
RD-1B
RD-27D
RD-24C
RD C6-27
CR17
WH-21B
RD-24AB
WH-C6-34
OR C6-33
BL/RD C2B-1
CR20B LOW VOLTAGE DROP RELAY
CR20A LOW VOLTAGE DROP RELAY
OR/RD C6-11
TB16D OR/RD
TB134A-A
CR20A CR20B
GR
OU
ND
ST
UD
-
+
-
+
TS58 JIB UP/DOWN (JIB OPTION ONLY)
TS58
JIB
OIL PRESSURE
G2G1
VOLT METER
G3
WATER TEMP.
CR23 DRIVE LIGHT RELAY OPTION
BRN GND
CR23
10 AMP FUSE
RD C4B-11
RD C4B-12
OPTION WIRE TO PBOX
TB24AD
DRIVE LIGHT OPTION RELAY
(SPARE WIRE)
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
DIESEL ENGINE: C2-1 BL/RD
EN
GIN
E
C5
12
VT
OP
LA
T
C1
B
FU
NC
TIO
NS
C6
C3
B
19
/18
CA
BL
ES
C2
BC
4B
3
2
C7
B 1
BASE TERMINATION BLOCK
D7
CD AB
G6
H1
868686
D34
RD/BK C6-19
D8
CR8#86+
D15
GND STUDD57
RD/BK CR8#30
8686 86
D42
86
86
8686 86
BK-C23-5IGN./STARTMODULE
WH-CR2#86
TB33AB
WH C5-11
WH L2
WH-23B
RD-24D
CR3
BK/RD C5-18
WH-21C
BK/RD-35B
IGN./FUEL ON
KEY BYPASS
ENG. FAULT
KEY PWR.
BATTERY
10
8
9
7
6
U1
GLOW PLUG SWBK/WH-34A
RD-C23-7
TS56
BK CR1#86
OR/BK-41B
BRN GND
RD-27B
BK-33B
WH CR3#86
D51
RD ISM#6
BK C23-4
BK C5-5
WH C5-3
3 BL/WH C1-12
76
128
5
4C
23
RD-TS52GR/BK H6BRN
RD-TS51BK C7B-1
BK-22D2
1 RD H6
START INPUT
TACHOMETER
START RELAY
GROUND
AUX. ON
3
5
4
2
1
OR/BK ISM#2
BK/RD CR3#30
BK ISM#3
WH ISM#7
BK-CR1#87
ISM#4D6
BK/WH-S.P.
WH C5-15
WH ISM #10
GR/BK-H6
P134PWR RD-134B
GR/BK-L45GR/BK-C3B-10 CE ONLY
H6
+
RD C23-6
PLATFORMOVERLOADLED L45
-
+
L45
TS56
PLATFORM OVERLOAD LED
GLOW PLUG SWITCH (DIESEL ONLY)
NOTE: CE OPTION- LOADSENSEMODULE CONNECTS TO C32.
Section 6 • Schematics
6 - 29
February 2012
Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (before serial number 5520)
6 - 30
February 2012Section 6 • Schematics
6 - 30 S-80 • S-85 Part No. 122149
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (before serial number 5520)
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
U13
JC1
JIB BOOM CUTOUT RELAY
AXLE CUTOUT RELAY
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
TS8
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
CR13
CR26
H1
TS48
TS49
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM
CR27WH-TS7
WH-TS1
BRN BATGND
GND STUD
WH/RD C32BRK
OR/RD R40LS2
(SPLICE TO C32BRK)
(SPLICE TO R40LS2)
CR30
OR
C4
P-2
OR
/BK
C4
P-3
GR
C2
P-5
NO
BL
/BK
J1
-7
RD
C1
P-1
GR
/BK
C4
P-6
GR
C4
P-5
YE
LJ1
-3
RD
J1
-1
BK
/RD
C1
P-9
BL
/RD
J1
-16
RD
C9
-3
BK
C1
P-7
OR
J1
-9
RD
/WH
J1
-8
BK
C9
-1
NC
HORN
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
CR26AXLE CUTOUT
P2EMERGENCY
STOP
TS4HIGH/LOW
RPMTS2
ENGINESTART
L1
TS1AUXILIARY
PUMP
TS14DRIVESPEED
TS7PLATFORM
ROTATE
TS9PLATFORM
LEVEL
P3
JC2PRIMARY BOOMUP/DOWN AND
TURNTABLEROTATE
JC1BOOM
EXTEND/RETRACT
BK
/WH
C1
P-8
JC3DRIVE
GND STUD
H1TILT
ALARM
RD
LS
18
BRN
C1
2D
RE
BL
/WH
C3
P-1
2
C5
TR
RW
H/B
KC
3P
-5
C4
TR
LW
HC
3P
-4
C3
PB
FR
D/W
HC
3P
-3
C8
PB
RB
K/W
HC
3P
-8
C6
TR
FW
H/R
DC
3P
-6
C9
PE
RF
BK
/RD
C3
P-9
C7
PB
EB
KC
3P
-7
C2
PB
DR
D/B
KC
3P
-2
C1
PB
UR
DC
3P
-1
HI-C
13
3P
LA
GN
/BL
C3
P-1
0
TS
9-C
15
PL
DO
R/B
KC
4P
-3
FOOT SWITCH
C3
P(G
R)
C1
P(G
Y)
C2
P(B
K)
12V DCBATTERY
C4
P(B
R) C7P
BATGND C7P-3
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
14
PL
UO
RC
4P
-2
C9 JIB
P2
-P2
3S
WB
AT
WH
C7
P-2
R4
0L
S2
OR
/RD
C4
P-4
TS
7-C
18
JD
GR
/BK
C4
P-6
TS
7-C
17
JU
GR
C4
P-5
J3
-P2
4C
ON
TW
HC
9-2
P2
-P2
2B
AT
BK
C7
P-1
TS
2-P
25
ST
RR
DC
9-3
TS
6-C
34
SA
BK
/WH
C1
P-8
C3
2B
RK
WH
/RD
C1
P-6
C28TTA RD/BK C1P-2
C2
9M
SR
D/W
HC
1P
-3
C3
1E
DC
-W
H/B
KC
1P
-5
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C3
0E
DC
+W
HC
1P
-4
TS
1-C
27
AU
XR
DC
1P
-1
P2
-P2
6F
SB
KC
9-1
TS
2-C
33
ST
RB
KC
1P
-7
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
C4
1R
PM
OR
/BK
C2
P-3
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C3
7S
TC
BL
/BK
C1
P-11
DL
ITE
GR
/BK
C2
P-6
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE
ENABLE
19/18 CONTROL CABLE
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
D12
TS6GLOW PLUG
OPTION
LS18(OPTION)
7
6
5
4
3
2
1
4
2
1
3
5
6
7
4
2
1
3
5
6
7
BR
NJ1
-10
+-
+-
+-
OR
J1
-13
BR
NJ1
-14
OR
J1
-11
BR
NJ1
-12
1
11
1
9
3
1
JC
3-5
WH
JC
2-2
BR
N
JC
3-6
BL
JC
2-3
OR
JC
1-5
YE
L
JC
1-2
BR
N
JC
2-5
BK
JC
2-4
RD
JC
1-3
OR
TS
14
-C2
9M
SR
D/W
H
L1
-C1
3L
ED
BL
/RD
TS
15
-DR
EB
BL
/BK
JC
3-2
BR
N
TS
15
-DR
EA
BL
/WH
JC
3-3
OR
GND STUD
J1 J2
J3
WH
J1
-5
BL
J1
-4
BR
N
+
L40
EX/RET
TS16
AXLE
WH
J3
-2
BL
/RD
C4
P-1
OR
/RD
C2
P-4
J2
-DIO
DE
WH
D12D12
WH
TS
4
WH
CR
26
#8
5
BL
C1
P-1
0
BL
/BK
C3
P-11
BK
P2
BL
/WH
J1
-6
WH
C9
-2
BK
J3
-3
BL
TS
16
TS
16
-C6
1A
XB
L/B
KC
3P
11
CR13 BRN
RD
LS
18
U13ALC-500
D2
CE MODELS (SEE DETAIL A)
RD
/BK
H1
RD LS CABLERD-H1
RD-P2
+
L4
BK LS CABLE CIP-12
RD
C2
P-6
GN
/BK
L4
L4 PLATFORM OVERLOAD LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
GN
/BK
C3
P-1
0
RD
/BK
L4
8
OPT.
GN
/BK
H1
(D3
9)
L48
BK
+
TS48/TS49
RD WL1
RD WL2
TS15
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
L48 TILT ALARM LED
D40
D39
TS2
GR
/WH
C2
P-7
DETAIL B: GENERATOR OPTION
TS8JIB BOOM
JIB
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
RD/BK JIB CABLE
GND
CR13
CUTOUT
JIB
GR/WH C4P-7
GR/WH TS7
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 31
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (after serial number 5519)
GR
C2
P-5
OR
/BK
C4
P-3
OR
C4
P-2
BL
/BK
C3
P-11
BL
C1
P-1
0
OR
/RD
C2
P-4
BL
/RD
C4
P-1
BRN
J2
-DIO
DE
WH
GR
/WH
JIB
CA
BL
E
RD
/WH
J1
-8
GR
C4
P-5
GR
/BK
C4
P-6
RD
C1
P-1
RD
BK
BK
RD RD
RD
/BK
H1
BL
/WH
J1
-6
WH
J3
-2
BK
C1
P-7
RD
C9
-3
BK
/WH
C1
P-8
BK
/RD
C1
P-9
BL
/BK
J1
-7
GN
/ BK
H1
(D3
9)
BK
J3
-3
BK
C7
P-1
WH
C7
P-2
BK
C9
-1
GN
/BK
C3
P-1
0
GN
/BK
L4
RD
C2
P-6
RD
LS
18
RD
/BK
H1
TS
15
-DR
EB
BL
/BK
L1
-C1
3L
ED
BL
/RD
TS
14
-C2
9M
SR
D/W
H
C1
34
PW
RG
R/B
KC
2P
-6
U13
BL
TS
16
WH
C9
-2
BK
P2
WH
CR
26
#8
5
WH
TS
4
ALC-500
RD
/BK
L4
8
TS
2-C
33
ST
RB
KC
1P
-7
TS
1-C
27
AU
XR
DC
1P
-1
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C2
9M
SR
D/W
HC
1P
-3
TS
6-C
34
SA
BK
/WH
C1
P-8
BATGND C7P-3
C28TTA RD/BK C1P-2
JC
3-3
OR
TS
15
-DR
EA
BL
/WH
JC
3-2
BR
NJC
3-6
BL
(1)
JC
2-2
BR
N
JC
3-5
WH
JC
1-3
OR
JC
2-4
RD
JC
2-5
BK
JC
1-2
BR
N
JC
1-5
YE
L
JC
2-3
OR
JC
3-4
BL
(2)
P3
-C4
3H
RN
GR
C2
P-5
C3
6S
TC
CB
LC
1P
-10
C4
0L
S1
OR
C2
P-2
C3
7S
TC
BL
/BK
C1
P-1 1
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C4
1R
PM
OR
/BK
C2
P-3
C3
0E
DC
+W
HC
1P
-4
C3
1E
DC
-W
H/B
KC
1P
-5
C3
2B
RK
WH
/RD
C1
P-6
R4
0L
S2
OR
/RD
C4
P-4
C1
PB
UR
DC
3P
-1
C2
PB
DR
D/B
KC
3P
-2
C7
PB
EB
KC
3P
-7
C9
PE
RF
BK
/RD
C3
P-9
C6
TR
FW
H/R
DC
3P
-6
C8
PB
RB
K/W
HC
3P
-8
C3
PB
FR
D/W
HC
3P
-3
C4
TR
LW
HC
3P
-4
C5
TR
RW
H/B
KC
3P
-5
C1
2D
RE
BL
/WH
C3
P-1
2
GND STUD
CC
13
2P
LI
BL
/WH
C3
P-1
2
TS
16
-C6
1A
XB
L/B
KC
3P
11
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
P2
-P2
6F
SB
KC
9-1
TS
2-P
25
ST
RR
DC
9-3
P2
-P2
2B
AT
BK
C7
P-1
J3
-P2
4C
ON
TW
HC
9-2
TS
7-C
17
JU
GR
C4
P-5
TS
7-C
18
JD
GR
/BK
C4
P-6
P2
-P2
3S
WB
AT
WH
C7
P-2
TS
9-C
14
PL
UO
RC
4P
-2
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
15
PL
DO
R/B
KC
4P
-3
C1
33
PL
AB
LC
3P
-10
RD
LS
18
P3
HORN
NO
TILT ALARM
D39
H1
CE SEE DETAIL A
PLATFORM
LEVEL
TS9TS7
ROTATE
PLATFORM
TS1
AUX. PUMPTS14
SPEEDDRIVE
19/18 CONTROL CABLE
C2
P(B
K)
D2 TS16
L40
+
AXLE
EX/RET
GND STUD
C1
P(G
Y)
12V BATT
C4
P(B
R)
C3
P(G
R) C7P C9
F.S.
RPM
TS2
START
+
L1
HIGH/LOW
+
L4
TS4
E- STOP
P2
NC
TS15
DRV.ENA
+
D12
L48
OPT.
D40
J2J1
1
9
D12 D12
1
J31
3
11
PLATFORM CONTROL BOX
PLATFORM OVERLOAD LIMIT SWITCHLS18
L48 TILT ALARM LED
PLATFORM OVERLOAD LED (OPTION)
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
DRIVE SPEED LOW/HIGH SWITCH
PLATFORM ROTATE SWITCH
GENERATOR SWITCH ( OPTION )
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
AXLE EXTENDED LED
DRIVE ENABLE LED
ALC500
JC1
H1
JC2
U13
L4
L40
JC3
L1
TILT ALARM
AXLE EXT/RET SWITCH
DRIVE ENABLE SWITCH
HIGH RPM SWITCH
PLATFORM LEVEL SWITCH
TS16
TS47
TS14
TS15
TS7
TS4
TS9
EMERGENCY STOP BUTTON
COMPONENT INDEX
START ENGINE SWITCH
AUXILIARY SWITCH
HORN SWITCH
P2
TS1
P3
TS2
TT ROTATE
UP/DOWN
PRI. BOOM BOOM
EXT/RET
DRIVE/STEERAXLE CUTOUT
C2P-9 & 10CR13 BRN
CR
26
BK LS CABLE CIP-12
RD LS CABLE RD-P2
RD-H1
YY
TS
3-C
39
LP
BL
/RD
C2
P-1
TS
48
-WL
1R
DC
2P
-12
TS
48
-WL
2R
DC
2P
-11
RD WL1
DETAIL C: WORKLIGHT OPTION
TS48
E-STOP BK
F18 10A
RD WL2
(SPARE WIRE)
OPTION WIRE TO GBOX
DRIVELIGHT OPTION
TS49
TS48 PIN2
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
C32BRK)
R40LS2)
(SPLICE TO
OR/RD R40LS2
CR30
(SPLICE TO
WH/RD C32BRK
WH TS7CR27
GENERATOR OPTION
DETAIL B:
TS47
WH TS1
(GND STUD)
BRN BATGND GR
/WH
C2
P-7
TS2 RD
DRIVE LIGHT RELAY (OPTION)
WORK LIGHT RELAY (OPTION)
GLOW PLUG
TS48
TS48
TS6
2
GN
DB
RN
JIB UP/DOWN (JIB OPTION ONLY)
JIB CUTOUT RELAY ( JIB ONLY )CR13
TS8
D27
J1
-2R
D/W
HJC
2-4
J1
-1W
H/R
DJC
2-3
J1
-11O
RJC
2-2
J1
-12
BR
NJC
2-1
JC2
J1
-3W
H/B
KJC
1-4
J1
-9O
RJC
1-2
J1
-10
BR
NJC
1-1
JC1
JC3
J1
-5B
L/W
HJC
3-5
J1
-4W
H/R
DJC
3-4
J1
- 13
OR
JC
3-2
J1
-14
BR
NJC
3- 1
J1
-5B
L/W
HJC
3-3
TS6
GLOW PLUG
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
GR/WH TS7BK JIB CABLE YY
GR/WH C4P-7
JIB
CUTOUT
JIB
CR13
TS8
JIB
GND
OPT.LS18
Section 6 • Schematics
6 - 32
February 2012
Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (after serial number 5519)
6 - 31
Section 6 • Schematics
6 - 33
February 2012
Electrical Schematic, S-80/85Continental TME27 Models (before serial number 5520)
6 - 34
February 2012Section 6 • Schematics
6 - 34 S-80 • S-85 Part No. 122149
Electrical Schematic, S-80/85Continental TME27 Models (before serial number 5520)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
NOTES:
STA
RT
BA
TT
ER
Y
P2
0B
AT
RD
FA
N(O
PT.)
HY
D.C
OO
LIN
G
ALT
ER
NA
TO
R
OP
TIO
N
FL
AS
HIN
GB
EA
CO
NS
FANFB
HY
D.O
ILT
EM
P.
SW
ITC
H(O
PT.)
TILT
AL
AR
M
RE
LA
Y
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
H2
B
BK
NOCR17
P1
34
FB
RD
R11
6H
YD
OR
R16
51
0C
21
IGN
WH
C5
-3
C6
-24 C
6-3
3
R2
1IG
NW
H
C4
3H
RN
BK
CA
RD
WH
C6
-34
C6
-16
NOCR5
C2
8T
TA
RD
/BK
P1
34
TT
SR
D
TS64
RE
LA
Y
AU
XIL
IAR
YP
OW
ER
AU
XIL
IAR
YP
UM
P
STA
RT
ER
MO
TO
R
M3
PUMPSTARTER
PUMP
C2
7A
UX
RD
PR1
NO
C6
-27
C5
-10
C5
-18
C5
-2
C5
-19
C5
-11
C5
-9
C2
5P
SR
BL
/BK
TE
ST
SW
ITC
H
CH
EC
KE
NG
INE
LE
D
HO
UR
ME
TE
R
GE
NE
RA
TO
R
OP
TIO
N
_
+
OIL
PR
ES
SU
RE
SE
ND
ER
&
GA
UG
E(O
PT.)
WA
TE
RT
EM
P
VO
LTM
ET
ER
(OP
T.)
BRN
GR
/WH
L2
C5
-12
C5
-16
C5
-14
G1G3G2
C2
P-5
P1
34
BA
TG
R/B
K
P2
2B
AT
BK
RD
TB20
RD
15AMP.
CB1
C2
B-5
C1
B-2
TB24ARD
CB3
20AMP.
15AMP.
CB2
RD
WH
RD
C6
-28
C6
-23
TB
28
TB23D2
C2
B-6
BK
GRD
PLAT
P1
RD
RD
TB22
TB134
C4
6H
RN
GR
C2
8T
TA
RD
/BK
WH
C7
B-1
C1
B-1
2
C1
P-2
C2
P-6 C
7P
-1
C1
P-1
2
HORN
C1
32
PL
IB
L/W
H
P3
H1
RD
P2
C7
B-2 TB33R
D
CR1NO
CR39A
TB27
TB24CR39B
TB21
NO
TB41
P23BAT
NO
CR2
P2
3B
AT
WH
TS51
C2
7A
UX
RD
C7
P-2
C1
-1
C3
3S
TR
BK
TS52
C1
-7
C21IGN WH
D7
D8
TB46 D13
TB35
D14 D42
C3
9L
PB
L/R
D
TB39
D11
TS53 C4
5G
EN
GR
/WH
C2
-1
C2
-7
FU
NC
.E
NA
BL
EL
OW
RP
M
HIG
HR
PM
TS54
C3
5R
PM
BK
/RD
OR/BK
RDRDRD
C1
-9
P25FS RD
P24FS WH
D43
FS1
C9P-1
P26ESTP BK
TS1
TS2
D10
TS3 TS47
EN
GIN
ES
PE
ED
HIG
H(F
S)
D12
TS4
WH
BK
P134BAT RD
RD/BK
P46 RD
C2
7A
UX
RD
P23 RD
C41RPM OR/BK
C9P-3
C9P-2
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
B1
B3
1
4
2
KS1
L48
C3
P-1
0
D40
C3
B-1
0
C3
8F
P-B
L/W
H
C1
28
RP
M-O
R/R
D
BK
-12
GA
RD
-12
GA
WH
-14
GA
HARNESS
1 2 365 41011 12 987
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
C1
08
ES
L-B
L/W
H
C1
27
TS
W-G
N
C3
5R
PM
-BK
/RD
VS
W-R
D
R3
3S
TR
-BK
C3
9L
P-B
L/R
D
C3
8R
ET
-BL
C1
33
PL
AB
L
RD
WH
GN
DB
R
RD
1K
R1
RD
TB21
C4
1R
PM
-OR
/BK
C2
6T
SR
-GN
/BK
NC
FU
EL
PU
MP
GA
UG
E(O
PT.)
FU
SE
10
AR
D
RD
WO
RK
LIG
HT
SO
PT
ION
DR
IVE
LIG
HT
&
CR23CR23
NO
L29
BK
BK
WH
WH
TS49 TS48
PBOX GND
OP
TIO
NW
IRE
FUSE 10A
L30
C4
-11/1
2
2
5
6
AUX AUX
WO
RK
LIG
HT
DR
IVE
LIG
HT
HM
C5
-13
C5
-8
C5
-5
BK
7 FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13
E2
1IG
N-W
H
C21IGN WH
B1
-
+
12 VDC
7
12 8
6
1
4
3
5
C32
GR
/BK
GR
/BK
BL
/WH
CONN.PLUG
6
5
A B C D E F G H I J K L M N1
2
3
4
5
6
7
8
CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 35
Electrical Schematic, S-80/85Continental TME27 Models (before serial number 5520)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
DR
IVE
/RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
BRN
DE
SC
EN
TA
LA
RM
P46 RD
C41RPM OR/BK
C1
5P
LD
OR
/BK
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
PL
AT
FO
RM
RO
TA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
LE
FT
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
TB17
TB18
GR
-17
-M.H
.
GR
/BK
-18
-M.H
.
TS9
TS59
TB14
TB15
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
TB9
C9
PE
RF
BK
/RD
TS63
TB8
BK
/WH
C8
PB
RB
K/W
H
C1
4P
LU
OR
BK
/RD
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C7
PB
BE
BK
C8
PB
RB
K/W
H
BK
TB7
C7
PB
EB
K
C4
TR
LW
H
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
TB2
TS61
C2
PB
DR
D/B
K
C1
PB
UR
D
TB3
C2
PB
DR
D/B
K
C3
PB
FR
D/W
H
TS62
C5
TR
RW
H/B
K
TB1
TB6
C6
TT
RF
WH
/RD
TB4
C1
PB
UR
D
PR
I.B
OO
ME
XT
EN
D
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TB5
BR
AK
ER
EL
EA
SE
VA
LV
E
C2
9M
SR
D/ W
HM
OT
OR
ST
RO
KE
LS
1R
O- B
OO
MR
ET
RA
CT
OP.
DR
IVE
/ RO
TA
TE
SP
EE
D
LS
2A
S-B
OO
MA
NG
LE
SA
FE
TY
DR
IVE
LIM
ITS
WIT
CH
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
C4
0L
SO
R/R
D
TB42
C2
9M
SR
D/W
H
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C3
6S
TC
CB
L
C3
7S
TC
BL
/ BK
TB37
C3
7S
TC
BL
/BK
C3
6S
TC
CB
L
LIM
ITS
WIT
CH
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
EN
AB
LE
GR
OU
ND
TS15
C1
2D
RE
BL
/WH
C3
0E
DC
+W
H
C3
1E
DC
-W
H/B
K
C3
2B
RK
WH
/ RD
C5
-20
C3
2B
RK
WH
/RD
TB32
L1
BR
N
H4
H3
EXTEND/RETRACT
JOYSTICK CONTROL CARD
3
BR
N
OR
YE
L
1 542 3 76
12
C5
-21
14
LS3
13
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
10 9 3
1 742 3 5 6
PRI UP/DN & TT ROTATE
1 742 3 5 6
DRIVE & STEERING
RD
1
BK
2
BR
N
OR
BR
N
OR
WH
BL
5 4
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
P23 RD
13
1411
122
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P- 4
C1
P-5
C1
P-6
C1
P-3
C1
P- 1
1
C1
P-1
0
C3
P- 6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P- 4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/R
D
CD
E2
BL
/BK
J2
J3 J1 J1 J1 J1
OU
T
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
C4
P-6
C4
P-5
DR
IVE
ED
CF
OR
WA
RD
CD
E1
BL
/WH
C2
9M
SR
D/W
H
H1
RD
/BK
NOHC NCNOHCNCNOHC2AO2AS1RO1RS
TS16
C4
0L
S1
OR
TB40
C2
P-2
1
C3
P-1
1C
61
AX
BL
/BK
TB46
NCCR26
D37
D38
D35 D36
D41
AX
LE
EX
T/R
ET
SE
LE
CT
C6
0A
XO
R/ R
D
C2
P-4
AX
LE
DU
MP
VA
LV
E
NC
CR8
D34
D15
TB16
S3NC
NCCR29
OP
EN
WH
EN
AX
LE
FU
LLY
EX
T.
AX
LE
NO
TE
XT
PR
ES
SU
RE
SW
AX
LE
EX
TE
ND
RLY
L5
C7
-3
S3
LE
DB
L/R
D
+
5R2
D29
D2
7
D2
8
/JIB
UP
/JIB
DO
WN
C3
1E
DC
WH
/ BK
C3
0E
DC
WH
CR8
C6
-36
C6
-37
C6
-11
C6
-39
C6
-13
C5
- 23
C5
-24
C6
-4
C6
-5
C6
-6
C6
-1
C6
-2
C6
-3
C6
-7
C6
-8
C6
-9
C6
-12
C6
-30
C6
-14
C6
-15
C6
-18
C6
-17
C6
-19
C6
- 21
C6
-22
C6
-10
C6
-31
C6
-20
LS
2A
O-B
OO
MA
NG
LE
OP.
DR
IVE
LIM
ITS
WI T
CH
LIM
ITS
WIT
CH
LIM
ITS
WIT
CH
WH
RD
C4
0L
S2
BK
U4
ADC B
C3
5-1
C3
5-2
C3
4-1
C3
4-2
1
2
C2
9-2
C2
9-1
C1
6-1
C1
6-2
C1
7-2
C1
7-1
C2
7-2
C2
7-1
C1
3-1
C1
3-2
C1
2-1
C1
2-2
C3
1-1
C3
1-2
C1
4-1
C1
4-2
C1
5-1
C1
5-2
C2
8-2
C2
8- 1
C2
6- 2
C2
6-1
C2
4-2
C2
4-1
C2
5-2
C2
5- 1
C1
2D
RE
BL
/WH
C2
3B
AT
RD
21
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
2A
XD
PW
H
C6
0A
XO
R/ R
D
S3
LE
DB
L/R
D
J4
BK
J3
WH
J1
WH
J5
BK
J2
WH
D57
C6
-32
C4
P-1
2 13 4
2
2
2
3
3
4
4
4
1
1
1
BL
C27AUX + FE RD
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
C2
1-1
C2
1-2
C2
4-2
C2
3-1
C2
2-1
C2
2-2
C2
0-1
C2
0-2
3
D41 CR38
NC
CR38
C6
-40
C4
0L
S1
OR
P24FS WH
C28TTA RD/BK
P26ESTP BK
C8
PB
RB
K/W
HC
6-3
8
C6
-29
R1
6P
BR
BK
/WH
3 4
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
XO
UT
P134BAT RD
CR20 A
CR20 B
NO
NO
UP
DO
WN
PL
AT
RO
TA
TE
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
PL
AT
LE
VE
L
UP
DO
WN
RE
TR
AC
T
EX
TE
ND
BO
OM
UP
DO
WN
PR
IMA
RY
BO
OM
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
EX
TE
ND
RE
TR
AC
TA
XL
E
D2
7
JIB
BO
OM
D2
7D
27
LE
FT
RIG
HTP
LA
TR
OTA
TE
LE
FT
RIG
HT
TS57
C4
P-7
TS7 TS8
JIB
VA
LV
E
C19JSV GR/WH
CR13
BRN
JIB
BO
OM
C1
7JU
/PR
LG
R
C1
8JD
/PR
RG
R/B
K
C1
9JS
VG
R/W
H
JIB
VA
LV
E
TS58
CE Option, See 6 - 60
7
6
5
4
3
2
1
AMP
Pin1
Pin 1 GND Pin 2
Pin 2 PWR Pin 3
Pin 3 XOUT Pin 4
Pin 4 YOUT Pin 5
Pin 5 RKOUT Pin 6
Pin 6 Pin 7
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
RE
TR
AC
TE
XT
EN
DA
XLE
Section 6 • Schematics
6 - 36
February 2012
Electrical Schematic, S-80/85Continental TME27 Models (before serial number 5520)
6 - 35
Section 6 • Schematics
6 - 37
February 2012
Electrical Schematic, S-80/85Continental TME27 Models (after serial number 5519)
6 - 38
February 2012Section 6 • Schematics
6 - 38 S-80 • S-85 Part No. 122149
A B C D E F G H I J K L M N1
2
3
4
5
6
7
8
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
NOTES:
STA
RT
BA
TT
ER
Y
P2
0B
AT
RD
FA
N(O
PT.)
HY
D.C
OO
LIN
G
ALT
ER
NA
TO
R
OP
TIO
N
FL
AS
HIN
GB
EA
CO
NS
FANFB
HY
D.O
ILT
EM
P.
SW
ITC
H(O
PT.)
TILT
AL
AR
M
RE
LA
Y
SE
RV
ICE
HO
RN
LE
VE
LS
EN
SO
R
SE
RV
ICE
HO
RN
H2
B
BK
NOCR17
P1
34
FB
RD
R11
6H
YD
OR
R16
51
0C
21
IGN
WH
C5
-3
C6
-24 C
6-3
3
R2
1IG
NW
H
C4
3H
RN
BK
CA
RD
WH
C6
-34
C6
-16
NOCR5
C2
8T
TA
RD
/BK
P1
34
TT
SR
D
TS64
RE
LA
Y
AU
XIL
IAR
YP
OW
ER
AU
XIL
IAR
YP
UM
P
STA
RT
ER
MO
TO
R
M3
PUMPSTARTER
PUMP
C2
7A
UX
RD
PR1
NO
C6
-27
C5
-10
C5
-18
C5
-2
C5
-19
C5
-11
C5
-9
C2
5P
SR
BL
/BK
TE
ST
SW
ITC
H
CH
EC
KE
NG
INE
LE
D
HO
UR
ME
TE
R
GE
NE
RA
TO
R
OP
TIO
N
_
+
OIL
PR
ES
SU
RE
SE
ND
ER
&
GA
UG
E(O
PT. )
WA
TE
RT
EM
P
VO
LTM
ET
ER
(OP
T.)
BRN
GR
/WH
L2
C5
-12
C5
-16
C5
-14
G1G3G2
C2
P-5
P1
34
BA
TG
R/B
K
P2
2B
AT
BK
RD
TB20
RD
15AMP.
CB1
C2
B-5
C1
B-2
TB24ARD
CB3
20AMP.
15AMP.
CB2
RD
WH
RD
C6
-28
C6
-23
TB
28
TB23D2
C2
B-6
BK
GRD
PLAT
P1
RD
RD
TB22
TB134
C4
6H
RN
GR
C2
8T
TA
RD
/BK
WH
C7
B-1
C1
B-1
2
C1
P-2
C2
P-6 C
7P
-1
C1
P-1
2
HORN
C1
32
PL
IB
L/W
H
P3
H1
RD
P2
C7
B-2 TB33R
D
CR1NO
CR39A
TB27
TB24CR39B
TB21
NO
TB41
P23BAT
NO
CR2
P2
3B
AT
WH
TS51
C2
7A
UX
RD
C7
P-2
C1
-1
C3
3S
TR
BK
TS52
C1
-7
C21IGN WH
D7
D8
TB46 D13
TB35
D14 D42
C3
9L
PB
L/R
D
TB39
D11
TS53 C4
5G
EN
GR
/WH
C2
-1
C2
-7
FU
NC
.E
NA
BL
EL
OW
RP
M
HIG
HR
PM
TS54
C3
5R
PM
BK
/RD
OR/BK
RDRDRD
C1
-9
P25FS RD
P24FS WH
D43
FS1
C9P-1
P26ESTP BK
TS1
TS2
D10
TS3 TS47
EN
GIN
ES
PE
ED
HIG
H(F
S)
D12
TS4
WH
BK
P134BAT RD
RD/BK
P46 RD
C2
7A
UX
RD
P23 RD
C41RPM OR/BK
C9P-3
C9P-2
REGULATORIND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
B1
B3
1
4
2
KS1
L48
C3
P-1
0
D40
C3
B-1
0
C3
8F
P-B
L/W
H
C1
28
RP
M-O
R/R
D
BK
-12
GA
RD
-12
GA
WH
-14
GA
HARNESS
1 2 365 41011 12 987
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
C1
08
ES
L-B
L/W
H
C1
27
TS
W-G
N
C3
5R
PM
-BK
/RD
VS
W-R
D
R3
3S
TR
-BK
C3
9L
P-B
L/R
D
C3
8R
ET
-BL
C1
33
PL
AB
L
RD
WH
GN
DB
R
RD
1K
R1
RD
TB21
C4
1R
PM
-OR
/BK
C2
6T
SR
-GN
/BK
NC
FU
EL
PU
MP
GA
UG
E(O
PT.)
FU
SE
10
AR
D
RD
WO
RK
LIG
HT
SO
PT
ION
DR
IVE
LIG
HT
&
CR23CR23
NO
L29
BK
BK
WH
WH
TS49 TS48
PBOX GND
OP
TIO
NW
IRE
FUSE 10A
L30
C4
-11/1
2
2
5
6
AUX AUX
WO
RK
LIG
HT
DR
IVE
LIG
HT
HM
C5
-13
C5
-8
C5
-5
BK
7 FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13
E2
1IG
N-W
H
C21IGN WH
B1
-
+
12 VDC
7
12 8
6
1
4
3
5
C32
GR
/BK
GR
/BK
BL
/WH
CONN.PLUG
6
5
Electrical Schematic, S-80/85Continental TME27 Models (after serial number 5519)
CE Option, See 6 - 60
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 39
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
Electrical Schematic, S-80/85Continental TME27 Models (after serial number 5519)
P134BAT RD
C28TTA RD/BK
P24FS WH
P26ESTP BK
C41RPM OR/BK
P23 RDC27AUX RD
P46 RD
C4
2L
S2
GR
C6
1A
XR
TB
L
C4
0L
S1
OR
C4
0L
S2
BK
C4
0L
S1
OR
DR
IVE
/RO
TA
TE
SP
EE
D
PR
I.B
OO
MR
ET
RA
CT
LIM
ITS
WIT
CH
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
PL
AT
FO
RM
RO
TA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
21
C2
1-1
C2
3-1
C2
2-1
C2
0-1
DE
SC
EN
TA
LA
RM
PL
AT
FO
RM
RO
TA
TE
LE
FT
/JIB
UP
/JIB
DO
WN
H4
C2
4-2
C2
2-2
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
LIM
ITS
WIT
CH
DR
IVE
EN
AB
LE
C2
0-2
C2
1-2
LS3
NOHC
13 14
GR
/BK
-18
-M.H
.
GR
-17
-M.H
.
C6
-19
C6
-18
C6
-17
D29
OR
/BK
-15
-M.H
.
OR
-14
-M.H
.
C1
2D
RE
BL
/WH
R1
6P
BR
BK
/WH
C2
3B
AT
RD
C8
PB
RB
K/W
H
3 4
C6
-15
C6
-14
C6
-30
C6
-38
C6
-12
C6
-29
C2
8-1
C2
9-1
C1
6-1
C1
7-1
C2
7-1
C1
3-1
C1
2-1
C3
1-1
C1
4-1
C1
5-1
PR
IMA
RY
BO
OM
DO
WN
FL
OW
CO
NT
RO
LP
RIM
AR
YB
OO
M
BO
OM
EX
T/R
ET
FL
OW
CO
NT
RO
L
PR
I.B
OO
ME
XT
EN
D
PR
I.B
OO
ME
XT
EN
D
CU
TO
UT
RE
LA
Y
C1
7-2
C2
7-2
C1
6-2
CR8
C2
9-2
D57
MO
TO
RS
TR
OK
E
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
UP
FL
OW
CO
NT
RO
L
CU
TO
UT
RE
LA
Y
PR
I.B
OO
MU
P
C3
1-2
C1
4-2
C1
3-2
C1
2-2
CR38
C2
8-2
C1
5-2
C9
PE
RF
BK
/RD
C8
PB
RB
K/W
H
C7
PB
EB
K
C3
PB
FR
D/W
H
C6
-8
C6
-9
C6
-7
C6
-3
C5
TR
RW
H/B
K
C6
TT
RF
WH
/RD
C2
PB
DR
D/B
K
C1
PB
UR
D
C2
9M
SR
D/W
H
C4
TR
LW
H
C6
-1
C6
-2
C6
-5
C6
-6
C6
-4
C5
-24
CR38
NCCR8
AN
GL
ES
AF
ET
Y
PR
ES
SU
RE
SW
AX
LE
FU
LLY
EX
T.
RE
TR
AC
TO
P.
LS
1R
S-B
OO
MR
ET
RA
CT
SA
FE
TY
CR20 B
C3
5-1
C2
6-1
C2
4-1
C2
5-1
NC
1RO
DR
IVE
/RO
TA
TE
SP
D.
LIM
ITS
WIT
CH
BR
AK
ER
EL
EA
SE
VA
LVE
TR
AV
EL
AL
AR
MO
PT
ION
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
ED
CF
OR
WA
RD
C2
4-2
C2
6-2
C B
D
U4
A
C2
5-2
NOHC1RS
DR
IVE
LIM
ITS
WIT
CH
DR
IVE
LIM
ITS
WIT
CH
AN
GL
EO
P.
AX
LE
DU
MP
VA
LVE
2AO
NCNOHC
2AS
C3
5-2
C3
6S
TC
CB
L
C3
0E
DC
WH
C3
2B
RK
WH
/RD
C3
1E
DC
WH
/BKH3
J5
BK
J2
WH
C3
7S
TC
BL
/BK
32 14
WH
RD 2
C6
-36
C5
-20
C5
-23
C6
-32
C5
-21
C6
-37
C6
-20
C6
-31
3
J1
WH
J3
WH
J4
BK
2 3 14
1 3 2 C4
2A
XD
PW
H
4
C6
-11
4 1NO
C3
4-1
AX
LE
EX
TE
ND
RLY
AX
LE
EX
T/R
ET
GR
OU
ND
C3
4-2
2
S3
NC
S3
LE
DB
L/R
D
C6
0A
XO
R/R
D
1
C6
-39
C6
-13
20
1110
TB9
C1
7JU
/PR
LG
R
TB17
TB18
TS57
C1
8JD
/PR
RG
R/B
K
TB15
TB14
C1
5P
LD
OR
/BK
C1
4P
LU
OR
TS59
C1
2D
RE
BL
/WH
C4
P-5 C
2P
-3
C3
P-1
2
C4
P-6
C4
P-2
C4
P-3
5 3
BK
BK
/WH
BK
/RD
TB7
TB8 TB2
TB3
C7
PB
BE
BK
C8
PB
RB
K/W
H
C1
PB
UR
D
C9
PE
RF
BK
/RD
C3
PB
FR
D/W
H
C2
PB
DR
D/B
K
TB1
TB6
TB5
NC
TB4
D41D15
5R2
C2
9M
SR
D/W
H
C6
TR
FW
H/R
D
C5
TR
RW
H/B
K
C4
TR
LW
H
TS61
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C3
P-8
C3
P-7
TS63
14
12
13 8 7 6
C1
P-3
C3
P-6
C3
P-5
C3
P-4
TS62
9
TS7 TS9
J2
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
JOYSTICK CONTROL CARD
J3
3 4 12
BR
N
18
17
15
16
19
C6
1A
XB
L/B
K
C4
0L
SO
R/R
D
C6
0A
XO
R/R
D
C4
0L
S1
OR
TB32
TB37
TB46
C3
6S
TC
CB
L
C3
0E
DC
+W
H
C3
1E
DC
-W
H/B
K
C3
2B
RK
WH
/RD
C3
7S
TC
BL
/BK
C6
-40
C6
-10
C6
-40
TB40TB16
C6
-22
C6
-21
CR20 A
NO
D34
TB42
C1
P-6 C
1P
-5
C1
P-4
C1
P-1
0
C1
P-11
D35 D36 D37
D38
C2
P-2
C4
P-4
C2
P-4
C3
P-11
1 4
S3
LE
DB
L/R
D
NCCR29
BR
N
C4
P-1
C7
-3
DR
IVE
MO
DE
H1
RD
/BK
LE
DB
L/R
D
CD
E2
BL
/BK
CD
E1
BL
/WH
C2
9M
SR
D/W
H
DR
IVE
EN
AB
LE
6
167
J1
8
15
LE
FT
RIG
HT
TS15L1
TS14
TS16
CR26
D41
NC
L5
+
AX
LE
NO
TE
XT
OP
EN
WH
EN
AX
LE
DU
MP
RE
LA
Y
SE
LE
CT
LS
2A
OB
OO
M
LS
2A
SB
OO
M
LS
1R
O-B
OO
M
EX
TE
ND
RE
TR
AC
TA
XL
E
LE
FT
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
PR
IMA
RY
BO
OM
DO
WN
UP
EX
TE
ND
RE
TR
AC
TB
OO
M
PL
AT
FO
RM
LE
VE
LD
OW
N
UP
PL
AT
RO
TA
TE
LE
FT
RIG
HT
RIG
HT
LE
FT
PL
AT
RO
TA
TE
UP
DO
WN
PL
AT
FO
RM
LE
VE
L
J1 J1 J1
EXT/RET
BR
OR
WH
/BK
431 2 65
10 9 3
1 42 3 5 6
PRI UP/DN & TT ROTATE
631 2 4 5
DRIVE & STEERING
WH
/RD
1
RD
/WH
2
BR
OR
BR
OR
WH
/RD
BL
/WH
5 4
13
1411
12
YO
UT
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
BL
/WH
XO
UT
C1
9JS
VG
R/W
HC
4P
-7
BRN
WH
JIB
VA
LVE
S
D2
7
D2
8
TS58
CR13
JIB
VA
LVE
CR13
TS8
NC
DO
WN
UP
JIB
JIB
UP
DO
WN
CE Option, See 6 - 60
Section 6 • Schematics
6 - 40
February 2012
Electrical Schematic, S-80/85Continental TME27 Models (after serial number 5519)
6 - 39
Section 6 • Schematics
6 - 41
February 2012
Ground Control Box Wiring Diagram, S-80/85Continental TME27 Models
6 - 42
Section 6 • Schematics
6 - 42 S-80 • S-85 Part No. 122149
February 2012
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80/85Continental Models
41OR/BK C2B-3 OR/BK C5-2ENG RPM
CR8 CR29
CR20A CR20B
GROUND
ALL BRN WIRES
OR/RD -16D
RD-134AA
WH-C5-19
WH-23B
RD-27D
OR/RD-42B
CR39B
OR/RD-16B
OR-C6-33
WH-21B
WH-C6-34
RD-24AB
CR17
RD/BK-2B
BL/RD-C4B-1
CR39
OR/RD-C6-11
OR/RD CR29#86
RD C2B-6
RD C6-31
OR/RD C4B-4
RD C6-23
RD C6-24
LIMIT SW #2
LIMIT SW PWR
KS POWER
KS POWER
BRN-GND STUD
CR1 CR2
WH-23D
RD-B1-20C
RD-B1-20D
RD-B2-S.P.
BK C5-5
BK-33C
WH C5-3
WH-21C
BK-22D
46B
42 OR/RD C6-22
RD-KSI-SP134
134A
RD-H6
WH-C5-11
RD-1B
RD-24C
GR C2B-5
BK-C6-16
BK-7B
RD-C6-27
CR5 BK-22BCR38
BL/RD-C6-13
BK/WH-C6-29
OR/RD-16C
RD/BK C3B-2&C6-2
WH C6-4
BK C6-7
WH/RD C6-6
WH/BK C6-5
OR C6-14
OR/BK C6-15
BK/RD C6-9
BK/WH C6-8
GR C6-17
RD-B1-H1WH CR2#87
GR/BK C6-18
RD CR1#30
RD C6-30
WH/RD C1B-6
OR/RD CR38#87A
BK CR1#86
BK/RD C1B-9BK/WH C1B-8
OR C6-40
BL/RD C2B-1
BL/BK C1B-11
RD/WH C6-3
RD C6-1RD C3B-1PRI. BOOM UP
PRI. BOOM DOWN
WH/RD C3B-6
BK C3B-7
WH/BK C3B-5
WH C3B-4
OR/BK C4B-3
OR C4B-2
BK/RD C3B-9
BK/WH C3B-8
GR C4B-5
GR/BK C4B-6
RD-B1-H1OR/RD C5-9
WH/RD C5-23
RD CR39#86&C1B-1
WH C7B-2
BK C7B-1
OR/RD CR20A/B #86
TURN. ROT. L
TURN. ROT. R
BOOM EXTEND
BOOM RETRACTEXT./RET. F.C.
TURN. ROT. F.C.
PLAT. LEVEL. UP
PLAT. LEVEL DN.
FUSED 12V
AUX PUMP
BRAKE
HORN
PLAT. ROT. R.
PLAT. ROT. L.
KEYSWITCH PWR/PWR TO PLAT
OIL COOLER FAN
IGNITION PWR.
12V BATT. SUPPLY
AXLE DUMP VALVE
BK C1B-7
BL/BK C6-37BK/RD C5-18
OR C2B-2BL/RD C5-10
START ENG
GLOW PLUG
ENGINE RPM
L.P.
LIMIT SW #1
STEER RT/AXLE EXT
START RELAY
PRI. BOOM F.C. RD/WH C3B-3
RD-S.P.
RD/BK-S.P.2
1 RD CR38#86
WH/RD-S.P.
BK-S.P.
WH-S.P.
WH/BK-S.P.
OR-S.P.
OR/BK-S.P.
BK/RD-S.P.
BK/WH-S.P.
3
5
4
6
7
10
9
15
14
11
8 BK/WH C6-38
WH S.P.
GR-S.P.
GR/BK-S.P.
RD-B1-S.P.
RD-S.P.-CB3
RD-S.P.
WH-S.P.-D2
RD-S.P.-CB1
BK-S.P.
18
17
16
21
20WH CR17 #86
24
23
RD27
32
24A
RD CR2#30
WH/RD C6-32
RD CR39#30
RD CR17#30
BK CR5#3022
OR/RD CR8#87A
BK-S.P.
BK/RD-S.P.
BL/RD TS53
33
34
33A
37
35
BL/BK C6-20
40
39OR C6-10
38
RD/WH-S.P.
BL/WH C5-13
UP/DOWN
TS57
PLATFORM
TURNTABLE
ROTATE
BOOM
PLAT.CONTROLSENGINE
HARNESS:TO BASE
CONNECTIONSCONTROL BOX
WIRING
WH/BK-5AWH-4A
OR-14A
WH/RD-6A
GR-17A
GR/BK-18A
GR/WH C4B-7
RD-B1-20A
RD-24AROTATELEVEL
TS52
HOUR METER
WH-21A
BK/WH-8A
BK-7A
BRN(GND)
BL/RD-39A
D14
D42
TS54
HIGH/LOWRPM
D13BK/RD-35A
OR/BK-15A
BK-33
RD-1A
RD-24AA
RD-B2-H1
BK/RD-9A
TS61
TS62
TS63
TS53LP/GASSEL SW
D11
CB3
OIL COOLER/OPTION
CB2CB1
START
BOOM EXTEND/RETRACT
P1
NC
NC
E-STOP
RD/WH-3A
RD/BK-2A
RD-27A
WH/BK C5-14
WH/RD C5-16
WH-23A
BK-22A
RD-134A
TS51KSI
KEYSWITCH
1
2
B
B13
D2
4
CHECK ENGLED L2
AUXILIARY PUMP
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
PRIMARY BOOM EXTEND/RETRACT SWITCH
CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
GR/WH-S.P.
WH/RD-S.P
WH/BK-S.P.
BL/WH C3B-12
RD/BK C6-28
WH C5-21
WH/BK C1B-5
BL C6-36
GR CR5#86
GR/WH C5-12
OR/RD C2B-4
BL/BK C6-21
RD/WH C1B-3
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
RD/WH C5-2429 2WD/4WD
36 STEER LEFT/AXLE RETRACT
60 AXLE EXT/RET SELECT
30 E.D.C. FWD
31 E.D.C. REV
43 HORN
45 GEN. OPTION
61 AXLE RETRACT BL/BK C3B-11
WH C1B-4
WH/BK C5-20
BL C1B-10
GR C2B-5
GR/WH C2B-7
OR/RD C6-39
25 OIL PRESSEURE SENDER
26 WATER TEMP SENDER
19 JIB VALVE
12 DRIVE ENABLE
28 TILT ALARM
CIRCUIT DESCRIPTION
CR8
CR17
CR25
CR29
CR38
CR20B
CR20A
HYDRAULIC COOLER FAN RELAY
AXLE RET L/O RELAY
AXLE EXTEND LED RELAY
BOOM FUNCTION CUTOUT
EXTEND FUNCTION CUTOUT
LOW VOLTAGE DROP RELAY
LOW VOLTAGE DROP RELAY
TO
U1
R2
U33
FROM
GR/WH C4B-7
WH/RD C5-16
WH/BK C5-14
BL/WH C6-12
IGNITION/START MODULE
PLATFORM OVERLOAD MODULE
RD/BK C1B-2
AUXILARY PUMP RELAYCR39
TS54
TS57 PLATFORM ROTATE SWITCH
FUNCTION ENABLE SWITCH
CB1
CB2
TS63
TS61
TS62
TS59
G6
G1
G2
G3
L2
CB3
CHECK ENGINE LED YELLOW (#110395)
HOUR METER
TURNTABLE ROTATE SWITCH
PLATFORM LEVEL SWITCH
VOLT METER GAUGE (OPT.)
OIL PRESSURE GAUGE (OPT.)
WATER TEMP. GAUGE (OPT.)
CR1
CR2
CR5
CR3 HIGH IDLE CUTOUT RELAY
SERVICE HORN RELAY
IGNITION POWER RELAY
IGNITION / START RELAY
DESCRIPTION
P1
LABEL
KS1
TS51
TS52 START ENGINE SWITCH
AUXILIARY SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
STUD
R1 RESISTOR, 1K OHM/2W, CHECK ENGINE (#104333)
RD CR20A #30
TS64
SWITCHRUN/TEST
GN C5-8
GND
1
2
3
RUN
TEST
R1
R2
-
+
AUXILARY PUMP/ENGINE SHUT DOWN RELAY
CR23 DRIVE LIGHT RELAY OPTION
CR39A
OPTION WIRE TO PBOX
RD C4B-11
RD C4B-12
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
DIESEL ENGINE: C2-1 BL/RD
BRN GND
TB24AD
(SPARE WIRE)CR23
10 AMP FUSE
DRIVE LIGHT OPTION RELAY
TS53 GAS/LP (DUAL FUEL OPTION)
TS58
TS59
JIB
JIB UP/DOWN (JIB OPTION ONLY)TS58
D28
G1 G3G2
VOLT METER OIL PRESSURE WATER TEMP.
FU
NC
TIO
NS
EN
GIN
E1
9/1
8C
AB
LE
S1
2V
TO
PL
AT
8686
8686
C6
C5
8686
86
BASE TERMINATION BLOCK
3
8686
2
1
H1
C3
BC
1B
C2
BC
4B
C7
B
D8D7
8686
D
RD/BK C6-19
AB
D15 RD/BK CR8#30
D57CR8#86+ GND STUD
D34
C
D42
G6
Section 6 • Schematics
6 - 43
February 2012
Platform Control Box Wiring Diagram, S-80/85Continental models (before serial number 5520)
6 - 44
February 2012Section 6 • Schematics
6 - 44 S-80 • S-85 Part No. 122149
Platform Control Box Wiring Diagram, S-80/85Continental models (before serial number 5520)
A B C D E F G H I J K L M N1
2
3
4
5
6
7
8
GR
C2
P-5
OR
/BK
C4
P-3
OR
C4
P-2
BL
/BK
C3
P-11
BL
C1
P-1
0
OR
/RD
C2
P-4
BL
/RD
C4
P-1
J2
-DIO
DE
WH
GR
/WH
JIB
CA
BL
E
RD
/WH
J1
-8
GR
C4
P-5
GR
/BK
C4
P-6
RD
C1
P-1
RD
BK
BK
RD RD
RD
/BK
H1
BL
/WH
J1
-6
WH
J3
-2
BK
C1
P-7
RD
C9
-3
BL
/RD
J1
-16
BK
/RD
C1
P-9
BL
/BK
J1
-7
GN
/BK
H1
(D3
9)
BK
J3
- 3
BK
C7
P- 1
WH
C7
P- 2
BK
C9
-1
RD
LS
18
P3
HORN
NO
CE SEE DETAIL A
PLATFORM
LEVEL
TS9TS7
ROTATE
PLATFORM
TS1
AUX. PUMPTS14
SPEEDDRIVE
D2 TS16
L40
+
AXLE
EX/RET
RPM
TS2
START
+
L1
HIGH/LOW
+L4
TS4
E- STOP
P2
NC
TS15
DRV.ENA
+
D12
L48
PLATFORM OVERLOAD LIMIT SWITCHLS18
L48 TILT ALARM LED
PLATFORM OVERLOAD LED (OPTION)
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
DRIVE SPEED LOW/HIGH SWITCH
PLATFORM ROTATE SWITCH
GENERATOR SWITCH ( OPTION )
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
AXLE EXTENDED LED
DRIVE ENABLE LED
ALC500
JC1
H1
JC2
U13
L4
L40
JC3
L1
TILT ALARM
AXLE EXT/RET SWITCH
DRIVE ENABLE SWITCH
HIGH RPM SWITCH
PLATFORM LEVEL SWITCH
TS16
TS47
TS14
TS15
TS7
TS4
TS9
EMERGENCY STOP BUTTON
COMPONENT INDEX
START ENGINE SWITCH
AUXILIARY SWITCH
HORN SWITCH
P2
TS1
P3
TS2
TT ROTATE
UP/DOWN
PRI. BOOM BOOM
EXT/RET
DRIVE/STEER
AXLE CUTOUT
CR
26
FUEL SELECT
TS3
D10
D12
BL
/RD
C2
P-1
RD WL1
DETAIL C: WORKLIGHT OPTION
TS48
E-STOP BK
F18 10A
RD WL2
(SPARE WIRE)
OPTION WIRE TO GBOX
DRIVELIGHT OPTION
TS49
TS48 PIN2
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
C32BRK)
R40LS2)
(SPLICE TO
OR/RD R40LS2
CR30
(SPLICE TO
WH/RD C32BRK
WH TS7CR27
GENERATOR OPTION
DETAIL B:
TS47
WH TS1
(GND STUD)
BRN BATGND GR
/WH
C2
P-7
TS2 RD
DRIVE LIGHT RELAY (OPTION)
WORK LIGHT RELAY (OPTION)
FUEL SELECT SWITCH (FORD)
TS48
TS48
TS3
2
GN
DB
RN
JIB UP/DOWN (JIB OPTION ONLY)
JIB CUTOUT RELAY ( JIB ONLY )CR13
TS8
D27
CUTOUT
JIB
CR13
TS8
JIB
YE
LJ1
-3
OR
J1
-9
4
2
1
3
5
6
7
BR
NJ1
-10
+-
4
2
1
3
5
6
7
+-
OR
J1
-13
BR
NJ1
-14
WH
J1
-5
BL
J1
-4
RD
J1
-1
BK
J1
-2
7
6
5
4
3
2
1
+-
OR
J1
-11
BR
NJ1
-12
BRN
GN
/BK
C3
P-1
0
GN
/BK
L4
RD
C2
P-6
RD
LS
18
RD
/BK
H1
TS
15
-DR
EB
BL
/BK
L1
-C1
3L
ED
BL
/RD
TS
14
-C2
9M
SR
D/W
H
C1
34
PW
RG
R/B
KC
2P
-6
U13
BL
TS
16
WH
C9
-2
BK
P2
WH
CR
26
#8
5
WH
TS
4
ALC-500
RD
/BK
L4
8
TS
2-C
33
ST
RB
KC
1P
-7
TS
1-C
27
AU
XR
DC
1P
-1
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C2
9M
SR
D/W
HC
1P
-3
TS
6-C
34
SA
BK
/WH
C1
P-8
BATGND C7P-3
C28TTA RD/BK C1P-2
JC
3-3
OR
TS
15
-DR
EA
BL
/WH
JC
3-2
BR
NJC
3-6
BL
(1)
JC
2-2
BR
N
JC
3-5
WH
JC
1-3
OR
JC
2-4
RD
JC
2-5
BK
JC
1-2
BR
N
JC
1-5
YE
L
JC
2-3
OR
JC
3-4
BL
(2)
P3
-C4
3H
RN
GR
C2
P-5
C3
6S
TC
CB
LC
1P
-10
C4
0L
S1
OR
C2
P-2
C3
7S
TC
BL
/BK
C1
P-11
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C4
1R
PM
OR
/BK
C2
P-3
C3
0E
DC
+W
HC
1P
-4
C3
1E
DC
-W
H/B
KC
1P
-5
C3
2B
RK
WH
/RD
C1
P-6
R4
0L
S2
OR
/RD
C4
P-4
C1
PB
UR
DC
3P
-1
C2
PB
DR
D/B
KC
3P
-2
C7
PB
EB
KC
3P
-7
C9
PE
RF
BK
/RD
C3
P-9
C6
TR
FW
H/R
DC
3P
-6
C8
PB
RB
K/W
HC
3P
-8
C3
PB
FR
D/W
HC
3P
-3
C4
TR
LW
HC
3P
-4
C5
TR
RW
H/B
KC
3P
-5
C1
2D
RE
BL
/WH
C3
P-1
2
GND STUD
CC
13
2P
LI
BL
/WH
C3
P-1
2
TS
16
-C6
1A
XB
L/B
KC
3P
11
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
P2
-P2
6F
SB
KC
9-1
TS
2-P
25
ST
RR
DC
9-3
P2
-P2
2B
AT
BK
C7
P-1
J3
-P2
4C
ON
TW
HC
9-2
TS
7-C
17
JU
GR
C4
P-5
TS
7-C
18
JD
GR
/BK
C4
P-6
P2
-P2
3S
WB
AT
WH
C7
P-2
TS
9-C
14
PL
UO
RC
4P
-2
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
15
PL
DO
R/B
KC
4P
-3
C1
33
PL
AB
LC
3P
-10
TILT ALARM
D39
H1
19/18 CONTROL CABLE
C2
P(B
K)
GND STUD
C1
P(G
Y)
12V BATT
C4
P(B
R)
C3
P(G
R) C7P C9
F.S.
OPT.
D40
J2J1
1
9
D12 D12
1
J31
3
11
PLATFORM CONTROL BOX
C2P-9 & 10CR13 BRNBK LS CABLE CIP-12
RD LS CABLE RD-P2
RD-H1
YY
TS
3-C
39
LP
BL
/RD
C2
P-1
TS
48
-WL
1R
DC
2P
-12
TS
48
-WL
2R
DC
2P
-11
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
GR/WH TS7BK JIB CABLE YY
GR/WH C4P-7
JIB
GND
OPT.LS18
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 45
Platform Control Box Wiring Diagram, S-80/85Continental models (after serial number 5519)
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
GR
C2
P-5
OR
/BK
C4
P-3
OR
C4
P-2
BL
/BK
C3
P-11
BL
C1
P-1
0
OR
/RD
C2
P-4
BL
/RD
C4
P-1
J2
-DIO
DE
WH
GR
/WH
JIB
CA
BL
E
RD
/WH
J1
-8
GR
C4
P-5
GR
/BK
C4
P-6
RD
C1
P-1
RD
BK
BK
RD RD
RD
/BK
H1
BL
/WH
J1
-6
WH
J3
-2
BK
C1
P-7
RD
C9
-3
BL
/RD
J1
-16
BK
/RD
C1
P-9
BL
/BK
J1
-7
GN
/BK
H1
(D3
9)
BK
J3
- 3
BK
C7
P- 1
WH
C7
P- 2
BK
C9
-1
RD
LS
18
P3
HORN
NO
CE SEE DETAIL A
PLATFORM
LEVEL
TS9TS7
ROTATE
PLATFORM
TS1
AUX. PUMPTS14
SPEEDDRIVE
D2 TS16
L40
+
AXLE
EX/RET
RPM
TS2
START
+
L1
HIGH/LOW
+
L4
TS4
E- STOP
P2
NC
TS15
DRV.ENA
+
D12
L48
PLATFORM OVERLOAD LIMIT SWITCHLS18
L48 TILT ALARM LED
PLATFORM OVERLOAD LED (OPTION)
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
DRIVE SPEED LOW/HIGH SWITCH
PLATFORM ROTATE SWITCH
GENERATOR SWITCH ( OPTION )
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
AXLE EXTENDED LED
DRIVE ENABLE LED
ALC500
JC1
H1
JC2
U13
L4
L40
JC3
L1
TILT ALARM
AXLE EXT/RET SWITCH
DRIVE ENABLE SWITCH
HIGH RPM SWITCH
PLATFORM LEVEL SWITCH
TS16
TS47
TS14
TS15
TS7
TS4
TS9
EMERGENCY STOP BUTTON
COMPONENT INDEX
START ENGINE SWITCH
AUXILIARY SWITCH
HORN SWITCH
P2
TS1
P3
TS2
TT ROTATE
UP/DOWN
PRI. BOOM BOOM
EXT/RET
DRIVE/STEERAXLE CUTOUT
CR
26
FUEL SELECT
TS3
D10
D12
BL
/RD
C2
P-1
RD WL1
DETAIL C: WORKLIGHT OPTION
TS48
E-STOP BK
F18 10A
RD WL2
(SPARE WIRE)
OPTION WIRE TO GBOX
DRIVELIGHT OPTION
TS49
TS48 PIN2
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
C32BRK)
R40LS2)
(SPLICE TO
OR/RD R40LS2
CR30
(SPLICE TO
WH/RD C32BRK
WH TS7CR27
GENERATOR OPTION
DETAIL B:
TS47
WH TS1
(GND STUD)
BRN BATGND GR
/WH
C2
P-7
TS2 RD
DRIVE LIGHT RELAY (OPTION)
WORK LIGHT RELAY (OPTION)
FUEL SELECT SWITCH (FORD)
TS48
TS48
TS3
2
GN
DB
RN
JIB UP/DOWN (JIB OPTION ONLY)
JIB CUTOUT RELAY ( JIB ONLY )CR13
TS8
D27
J1
-5
BL
/WH
JC
3-
5
J1
-4
WH
/RD
JC
3-
4
J1
-5
BL
/WH
JC
3-
3
J1
-1
3O
RJC
3-
2
J1
-1
4B
RN
JC
3-
1
JC3
J1
-5
BL
/WH
JC
3-
3
J1
-1
3O
RJC
3-
2
J1
-1
4B
RN
JC
3-
1
JC3
J1
-3
WH
/BK
JC
1-
4
J1
-9
OR
JC
1-
2
J1
-1
0B
RN
JC
1-
1
JC1
J1
-2
RD
/WH
JC
2-
4
J1
-1
WH
/RD
JC
2-
3
J1
-11
OR
JC
2-
2
JC1
J1
-1
2B
RN
JC
2-
1
BRN
GN
/BK
C3
P-1
0
GN
/BK
L4
RD
C2
P-6
RD
LS
18
RD
/BK
H1
TS
15
-DR
EB
BL
/BK
L1
-C1
3L
ED
BL
/RD
TS
14
-C2
9M
SR
D/W
H
C1
34
PW
RG
R/B
KC
2P
-6
U13
BL
TS
16
WH
C9
-2
BK
P2
WH
CR
26
#8
5
WH
TS
4
ALC-500
RD
/BK
L4
8
TS
2-C
33
ST
RB
KC
1P
-7
TS
1-C
27
AU
XR
DC
1P
-1
TS
4-C
35
ES
PD
BK
/RD
C1
P-9
C2
9M
SR
D/W
HC
1P
-3
TS
6-C
34
SA
BK
/WH
C1
P-8
BATGND C7P-3
C28TTA RD/BK C1P-2
JC
3-3
OR
TS
15
-DR
EA
BL
/WH
JC
3-2
BR
NJC
3-6
BL
(1)
JC
2-2
BR
N
JC
3-5
WH
JC
1-3
OR
JC
2-4
RD
JC
2-5
BK
JC
1-2
BR
N
JC
1-5
YE
L
JC
2-3
OR
JC
3-4
BL
(2)
P3
-C4
3H
RN
GR
C2
P-5
C3
6S
TC
CB
LC
1P
-10
C4
0L
S1
OR
C2
P-2
C3
7S
TC
BL
/BK
C1
P-11
TS
16
-C6
0A
XO
R/R
DC
2P
-4
C4
1R
PM
OR
/BK
C2
P-3
C3
0E
DC
+W
HC
1P
-4
C3
1E
DC
-W
H/B
KC
1P
-5
C3
2B
RK
WH
/RD
C1
P-6
R4
0L
S2
OR
/RD
C4
P-4
C1
PB
UR
DC
3P
-1
C2
PB
DR
D/B
KC
3P
-2
C7
PB
EB
KC
3P
-7
C9
PE
RF
BK
/RD
C3
P-9
C6
TR
FW
H/R
DC
3P
-6
C8
PB
RB
K/W
HC
3P
-8
C3
PB
FR
D/W
HC
3P
-3
C4
TR
LW
HC
3P
-4
C5
TR
RW
H/B
KC
3P
-5
C1
2D
RE
BL
/WH
C3
P-1
2
GND STUD
CC
13
2P
LI
BL
/WH
C3
P-1
2
TS
16
-C6
1A
XB
L/B
KC
3P
11
TS
47
-C4
5G
EN
GR
/WH
C2
P-7
P2
-P2
6F
SB
KC
9-1
TS
2-P
25
ST
RR
DC
9-3
P2
-P2
2B
AT
BK
C7
P-1
J3
-P2
4C
ON
TW
HC
9-2
TS
7-C
17
JU
GR
C4
P-5
TS
7-C
18
JD
GR
/BK
C4
P-6
P2
-P2
3S
WB
AT
WH
C7
P-2
TS
9-C
14
PL
UO
RC
4P
-2
L4
0-S
3L
ED
BL
/RD
C4
P-1
TS
9-C
15
PL
DO
R/B
KC
4P
-3
C1
33
PL
AB
LC
3P
-10
TILT ALARM
D39
H1
19/18 CONTROL CABLE
C2
P(B
K)
GND STUD
C1
P(G
Y)
12V BATT
C4
P(B
R)
C3
P(G
R) C7P C9
F.S.
OPT.
D40
J2J1
1
9
D12 D12
1
J31
3
11
PLATFORM CONTROL BOX
C2P-9 & 10CR13 BRNBK LS CABLE CIP-12
RD LS CABLE RD-P2
RD-H1
YY
TS
3-C
39
LP
BL
/RD
C2
P-1
TS
48
-WL
1R
DC
2P
-12
TS
48
-WL
2R
DC
2P
-11
JIB
CA
BL
E-C
19
JS
VG
R/W
HC
4P
-7
GR/WH TS7BK JIB CABLE YY
GR/WH C4P-7
JIB
GND
OPT.LS18
Section 6 • Schematics
6 - 46
February 2012
Platform Control Box Wiring Diagram, S-80/85Continental models (after serial number 5519)
6 - 45
February 2012Section 6 • Schematics
6 - 48 S-80 • S-85 Part No. 122149
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Continental TME27 Engine Harness
WHITE/LT GREEN 1854
TAN/BLACK 18
PINK/TAN 18
RED/TAN 14
WHITE/BLUE 18
RED 14
85
30
86
86
85
AUX PWM4 RECIRC
AUX PWM3 RECIRC
AUX PWM5 RECIRC
BLACK/RED 1686
PINK/BLACK 18AUX PWM4AUX PWM2AUX PWM1AUX PWM3
87888990
RED/BLACK 18GRAY/RED 18
RED/TAN 14
PINK/TAN 18
PINK/BLACK 18
WHITE/BLUE 18
RED 14 30
86
85
WHITE 14 30
85
PINK/YELLOW 16
86
30
70
TAN/ORANGE 18
77AUX PWM5
FPUMP
V BAT
GROUNDDBW+/STEP +
DBW-/STEP -8485
78
80
8281
79
83
MIL
EGOH 2EGOH 3
FUEL LOCKOFF
BUZZ
RELAYEGOH 1
STARTER
76
71
73
7574
72
TAN/BLACK 18
LT BLUE/BLK 18
PINK/WHITE 18
PINK/YELL 16
BLACK 16
RED/TAN 16
BLACK/YELLOW 16BLACK/WHITE 16
WHITE/BLACK 18
WHITE/BLUE 18
YELLOW/LT GREEN 18
ORANGE 18
61INJ1 LS
INJ8 LSINJ7 LSINJ6 LSINJ5 LSINJ4 LSINJ3 LSINJ2 LS
GROUND
68
62
6463
6667
65
69
TACHPULSE IN
V BATV BAT PROT
PC RXPC TX
AUX ANA PUD1
57
5958
60
5655
BROWN/BLUE 16
BROWN/WHITE 16
BROWN/GREEN 16BROWN/YELLOW 16
BLACK 16
PINK/YELLOW 16
DK GREEN 18
RED/TAN 16
F4
BAT +
PINK/TAN 18
RED/TAN 14
5A
F2
F1
20A
FUEL PUMP RELAY
PINK/DK GREEN 16
POWER RELAY
87
PINK/YELLOW 1687
F3
15A
15A
RED 12
RED 14
PINK 18
RED 14
PINK/DK GREEN 16
PINK/YELLOW 16
PINK/DK GREEN 16
PIN
K/D
KG
RE
EN
16
BL
AC
K1
6
PINK/TAN 18
WHITE/BLACK 18
STARTER RELAY
LT BLUE/PINK 14
BLUE/GREEN 14
EPR RELAY
87A
87
PINK/YELLOW 1687
15A
F5
FUEL LOCKOFF
PINK/YELLOW 16
WHITE 14
A
B
STARTER RELAY
BLACK 16BLACK 16 BLACK 12
GROUND
SPLICE WITHIN 6" FROM CONNECTOR
WHITE/PURPLE 18
TAN/BROWN 18
GRAY/WHITE 18GRAY/DK BLUE 18
TAN/BROWN 18
LT GREEN/BLACK 18
GRAY/DK BLUE 18GRAY/WHITE 18
YELLOW/GRAY 18
5V EXTAUX ANA PU3AUX ANA PU2AUX ANA PU1
OIL PGOV 2GOV 1
5V RTN
4748
46
49
5253
5150
SPK COIL 4B
ECT
V SWITCHAUX DIG 3AUX DIG 2AUX DIG 1
EGT
38
4039
41
IAT
45
4344
42
DK BLUE/YELLOW 18
LT GREEN/WHITE 18
DK BLUE/YELLOW 18
TAN 18
PINK/TAN 18
YELLOW/BLACK 18
30KNK 2 -
SPK COIL 4ASPK COIL 3BSPK COIL 3ASPK COIL 2BSPK COIL 2ASPK COIL 1BSPK COIL 1A 31
32
3637
353433
CAM POSCRK NEG
SPD NEGSPD POSCAM NEG
KNK 1 -KNK 2 +
KNK 1 +
2223
2928
2627
2524
YELLOW/RED 18
YELLOW/LT GREEN 18
YELLOW 18
PURPLE/ORANGE 18GRAY/BROWN 18
LT BLUE/DK BLUE 186TPS1/STEP2 +
PURPLE/YELLOW 18DK BLUE 18
WHITE/RED 18
DK BLUE 18
LT GREEN 18
14CAN 1 +
5V RTN5V EXT
CAN 2 TERM +CAN 2 +
CRK POS
CAN 2 -
CAN 1 - 15
21
17
1920
18
16
TPS2/STEP2 -MAP
AUX ANA PD2FPP2-IVS
AUX ANA PD1FPP1
AUX ANA PD3CAN 1 TERM + 13
10
1211
987
PURPLE/WHITE 18
LT GREEN/RED 18BLACK/LT GREEN 18
TAN/DK GREEN 18
PURPLE/LT BLUE 18
DK GREEN/ORANGE 18
EGO 2
EGO 4EGO 3
EGO 1
3
54
12
LT GREEN/BLACK 18
TXDK GREEN 18
BLK/LT GREEN 18
LT GREEN/RED 18
B
C5V
DRTN
COMM
ORANGE 18 ARX
OIL PRESSURE SWITCH
DK BLUE/YELLOW 18
PIN
K/D
KG
RE
EN
16
PIN
K/D
KG
RE
EN
16
YE
LL
OW
/BL
AC
K1
8
BL
AC
K/L
TG
RE
EN
18
PIN
K/D
KG
RE
EN
16
YE
LL
OW
/RE
D1
8
BL
AC
K/L
TG
RE
EN
18
PIN
K/D
KG
RE
EN
16
BL
AC
K/L
TG
RE
EN
18
BL
AC
K/L
TG
RE
EN
18
YE
LL
OW
/LT
GR
EE
N1
8
NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B
NOTE: INECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER
INJECTOR 2
BROWN/GREEN 16
BROWN/YELLOW 16
INJECTOR 4 INJECTOR 3
BROWN/WHITE 16
COIL 4
BA
BL
AC
K1
6
C D
COIL 3
A B
BL
AC
K1
6
C D
BROWN/BLUE 16
INJECTOR 1
COIL 2
A
BL
AC
K1
6
DCB
COIL 1
A
BL
AC
K1
6
DB C
YE
LL
OW
18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
BLUE/WHITE 18
WHITE/ORANGE 18
LT BLUE/BLACK 18
TAN/BROWN 18
ORANGE 18
GRAY/RED 18
ESL/TEST SWITCH
FUEL SELECTTEMP SENDER12
11
109 MIL
BLACK 16BLUE/GREEN 14
PURPLE/YELLOW 18
WHITE/ORANGE 18
BLUE/WHITE 18
RED/BLACK 18
LT BLUE/PINK 14
BLACK/RED 16
GRAY/WHITE 18GRAY/DK BLUE 18
YELLOW/LT GREEN 18
PINK/YELLOW 16
PINK 18
VEHICLE INTERFACE 1
DEUTSCH DT04 RECEPTACLE
FUEL PUMP -FUEL PUMP +
GOV SELECT 2GOV SELECT 1
START COMMAND
2
4
678
3
5TACH
IGN OUT1 VSW
NOT USED (PLUGGED)NOT USED (PLUGGED)
START IN (AUTOCRANK)
NOT USED (PLUGGED)CAN LOW11
12
FPP2 IVS
GROUND
CAN HIGH
AUX ANA PU14
765
8910
POST CAT HEGO
DBW THROTTLE CONNECTOR
A
C
A
C
PRE CAT HEGO
TAN/ORANGE 18BLK/LT GREEN 18LT GREEN/RED 18
PURPLE/LT BLUE 18LT BLUE/DK BLUE 18
PINK/WHITE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
PURPLE/ORANGE 18
GRAY/BROWN 18
2
6
345
1
BLK/LT GREEN 18
PURPLE/ORANGE 18
GRAY/BROWN 18 B
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
WHITE/PURPLE 18
PURPLE/WHITE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
LT GREEN/RED 18
BLK/LT GREEN 18
PURPLE/WHITE 18
WHITE/PURPLE 18
B
LT GREEN/RED 18
LT GREEN 18
BLACK/LT GREEN 18TAN/DK GREEN 18PINK/DK GREEN 16BLACK/YELLOW 16
BLACK/LT GREEN 18DK GREEN/ORANGE 18
PINK/DK GREEN 16BLACK/WHITE 16
AB
DC
4
AB
DC
LT GREEN/RED 18TAN 18
BLACK/LT GREEN 18
BLACK/LT GREEN 18
YELLOW/GRAY 18 ECT
321
B
TMAP
A
SPLICE WITHIN 6" OF CONNECTOR
BLACK/LT GREEN 18
LT GREEN/RED 18
DK BLUE 18
GASOLINE SENSOR INTERFACE
WHITE/LT GREEN 18 4
LT GREEN/WHITE 18LT GREEN/RED 18
BLACK/LT GREEN 18
CAM SENSOR
3
12
VEHICLE INTERFACE 2
DEUTSCH DT06 PLUG
VREF
ANA RETURNFPP1
1
32
PINK/YELLOW 16
CRANK SENSOR
BLACK/LT GREEN 18
WHITE/RED 18 A
BLPG TEMP
WHITE/ORANGE 18WHITE/ORANGE 18
BLUE/WHITE 18
JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
BLUE/WHITE 18
WHITE/ORANGE 18
WHITE/ORANGE 18
BLUE/WHITE 18
WHITE/ORANGE 18
COBRA EPR
3
6
7
BLACK 16 GROUND
CAN +
VBAT
WHITE/ORANGE 18
BLUE/WHITE 18
CAN + TERM2
1 CAN -
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 49
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Joystick Wiring Diagram
TS15L1
JOYSTICK CONTROL CARD
3
12
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
2
BR
N
C2
P-3
C3
P- 1
C3
P-2
C3
P-9
C3
P-3
C1
P-4
C1
P-5
C1
P-6
C1
P- 3
C1
P- 11
C1
P-1
0
C3
P-6
C3
P- 5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P- 4
C3
P-1
2
LE
DB
L/R
D
CD
E2
BL
/BK
J2
J3 J1
CD
E1
BL
/WH
C2
9M
SR
D/W
H
H1
RD
/BK
C2
P-2
1
D35 D36
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
P24FS WH
C28TTA RD/BK
P26ESTP BK
EXTEND/RETRACTB
RN
OR
YE
L
1 542 3 6
10 9 3
1 42 3 5 6
PRI UP/DN & TT ROTATE
1 42 3 5 6
DRIVE & STEERING
RD
1
BK
2
BR
N
OR
BR
N
OR
BL
5 4
13
1411
12
J1 J1 J1
YO
UT
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
BL
XO
UT
WH
TS15L1
JOYSTICK CONTROL CARD
3
12
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
2
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P- 4
C1
P-5
C1
P-6
C1
P-3
C1
P-11
C1
P-1
0
C3
P-6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P-4
C3
P-1
2
LE
DB
L/R
D
CD
E2
BL
/BK
J2
J3 J1C
DE
1B
L/W
H
C2
9M
SR
D/W
H
H1
RD
/BK
C2
P-2
1
D35 D36
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
P24FS WH
C28TTA RD/BK
P26ESTP BK
EXTEND/RETRACT
BR
N
OR
WH
/BK
1 542 3 6
10 9 3
1 42 3 5 6
PRI UP/DN & TT ROTATE
1 42 3 5 6
DRIVE & STEERING
WH
/RD
1
RD
/WH
2
BR
N
OR
BR
N
OR
BL/W
H5 4
13
1411
12
J1 J1 J1
YO
UT
PW
R
GN
D
PW
R
GN
D
YO
UT
XO
UT
RK
OU
T
YO
UT
PW
R
GN
D
JC1 JC2 JC3
BL/W
H
XO
UT
WH
/RD
7 7 7
TT ROTATE
UP/DOWN
PRI. BOOM
BOOM
EXT/RETDRIVE/STEER
JC2 JC1
JC3
J1
-14
BR
NJ
C3
-PIN
1
J1
-13
OR
JC
3-P
IN2
J1
-5B
L/W
HJ
C3
-PIN
3
J1
-4W
H/R
DJ
C3
-PIN
4
J1
-5B
L/W
HJ
C3
-PIN
5
J1
-10
BR
NJ
C1
-PIN
1
J1
-9O
RJ
C1
-PIN
2
J1
-3W
H/B
KJ
C1
-PIN
4
J1
-12
BR
NJ
C2
-PIN
1
J1
-11O
RJ
C2
-PIN
2
J1
-1W
H/R
DJ
C2
-PIN
3
J1
-2R
D/W
HJ
C2
-PIN
4
Deutsch - 6 Pin Connector
AMP - 7 Pin Connector
Note: Production changed to Deutsch 6 pin connectors at serial number 5520.
YE
LJ1
-3
RD
J1
-1
OR
J1
-9
JC2PRIMARY BOOMUP/DOWN AND
TURNTABLEROTATE
JC1BOOM
EXTEND/RETRACT
JC3DRIVE
BK
J1
-2
7
6
5
4
3
2
1
4
2
1
3
5
6
7
4
2
1
3
5
6
7
BR
NJ1
-10
+-
+-
+-
OR
J1
-13
BR
NJ1
-14
OR
J1
-11
BR
NJ1
-12
WH
J1
-5
BL
J1
-4
7
6
5
4
3
2
1
AMP
Pin1
Pin 1 GND Pin 2
Pin 2 PWR Pin 3
Pin 3 XOUT Pin 4
Pin 4 YOUT Pin 5
Pin 5 RKOUT Pin 6
Pin 6 Pin 7
Joystick Adaptor Harness
1
2
34
5
6
Deutsch
February 2012Section 6 • Schematics
6 - 52 S-80 • S-85 Part No. 122149
WH/RD
10
12
11
C34SA
C35RPM
C36STCC
C33STR
C32BRK
BK/WH
BL
BK/RD
BK
C4
8
9
7
6
COLOR
WH
CKT # PIN #
C27AUX
C30EDC+
C31EDC-
C29MS
C28TTA
RD/WH
WH/BK
RD/BK
RD
3
4
5
2
1
BL/BK C37STC
BL/WH
6C134BATGR/BK
12
10
C45GEN
NC
GR/WH
9
11
8
7
OR/RD
COLOR CKT # PIN #
C40LS1
C41RPM
C43HRN
C60AX
C39LP
GR
OR/BK
OR
BL/RD
5
4
2
3
1
C2
C1 DT06-12SC
C2 DT06-12SD
NC
NC
NC
NC
BROWN
BLACK
GRAY
GREEN
C3
C1
C7
BK
WH
BRN
COLOR CKT # PIN #
P23SWBAT
BATGND
N/C
P22BAT
C7: DTP06-4S
4
2
3
1
A
WH/RD-3
OR-1C40LS1
WH/BK-3
BK/RD-3
WH-3
BK-3
BK/WH-3C8PBR
C7PBE
C45GEN
C6TRF
C4TRL
C9PERF
C5TRR
GR/BK-3
GR-3
OR/BK-3
OR-3
RD/BK-3
RD-3
RD/WH-3
COLOR
C15PLD
C14PLU
C2PBD
C1PBU
C3PBF
C18JD
C17JU
RD-1
BL-1
BL/BK-1C37STC
C36STCC
C27AUX
OR
BL/WH-3
WH
RD/BK
RD
BKR43HRN
P23BAT
C28TTA
C42LD
C12DRE
C40LS2
C6
C1
C2
11R1DRVLITE
R2DRVLITE 12
6C6TRFWH/RD
GR/BK
GR/WH
OR/RD
COLOR
OR/BK
BL/RD
BL/WH
BL/BK
BK
BK/RD
BL
BK/WH
GR
OR
C18JD
NC
C19JSV
NC
NC
S3LED (AX)
C14PLU
C15PLD
C17JU
C40LS2
8
10
9
7
6
3
4
5
2
1
CKT # PIN #
C4 DT06-12SB
11
12
10
C12DRE
C61AX
C7PBE
C133PLA
C9PERF
C8PBR
9
8
7
RD
RD/BK
WH/BK
RD/WH
WH
COLOR
C3 DT06-12SA
CKT # PIN #
C2PBD
C3PBF
C5TRR
C4TRL
C1PBU
5
4
2
3
1
C4
C3
C3
RD
RD
RD
RD
BRN
BRN
P24BAT
C21IGN
C30EDC+
C31EDC-
C32BRK
C29MS
C34SA
P23BAT
22
24
23
20
21
19
C24SW
C35RPM
16
18
17
15
14
P134BAT
C39LP10
C108ESL13
12
11
C127TSW8
9
7
C107AF
C41RPM
R33STR5
6
4
2
3
1
CKT #PIN
#
BL/WH
BL/RD
BK/RD
WH
BK/WH
RD/WH
WH/RD
WH/BK
WH
WH/BK
WH
WH/RD
RD/WH
BK/WH
WH/RD
RD/WH
WH
WH/BK
BK/RD(14)
WH
WH(14)WH
GR
WH(14)
DEUTZ
ENGINE
OR/BKOR/BK
BK(14)
WH
BK(14)
WH
C5-GBOX
FORD
ENGINE
OR/BK
BK(14)
WH
ENGINE
PERKINS
C108ESL
C39LP
C127TSW
C29MS
C32BRK
C34SA
C30EDC
C31EDC
P23BAT
C35RPM
P24BAT
C24SW
C21IGN
R33STR
C107AF
C41RPM
P24BAT
CKT #
6
15
20
24
23
22
21
18
19
17
16
14
13
12
11
10
9
8
7
3
5
4
2
1
#
PIN
WH
WH(14)
BK/RD(14)
WH/BK
WH
BK/WH
WH/RD
RD/WH
WH
RD/WH
WH/RD
WH
WH/BK
RD
WH/BK
WH
BK/WH
WH/RD
RD/WH
BK/RD(14)
WH
BL/WH
GR
WH(14)
ENGINE
PERKINS
OR/BK
BL/RD
OR/BK
ENGINE
FORD
WH
BK(14)
OR/BK
BK(14)
WH
BK(14)
DEUTZ
ENGINE
C5-ENGINE HARNESS
MARK NUMBER ON CABLE 3
WH
WHWH
CIRCUIT #
C9 FS DT04-4P
RD
WH
BK
COLOR
3P25BAT
N/C 4
P24BAT
CKT # PIN #
P22BAT 1
2
WH/RD
RD/WH
WH/BK
WH
WH
BK(14)
OR/BK
WH
3.0L GM
ENGINE
WH/RD
RD/WH
WH/BK
WH
WH
BK(14)
OR/BK
WH
3.0L GM
ENGINE
BL/RD BL/RD
BK/RD BK/RD
17
28
27
24
18
15
14
11
10
9
8
7
6
5
4
3
2
1
12
13 S3LED BL/RD-3
16
19
20
C2DA
C37STC
RD/BK
BL/BK
C42LS2
C61AXRT21
22 OR/RD-1
BL/BK
23 P23BATSR RD
25
26
29
30
31 C46PWR
C46PWR RD
RD
32 C32TA WH/RD-1
33
34
35
36
37
38
39
40
C60AX OR/RD
R116HYD OR
R21IGN WH
C9
C45GENGR/WH GR/WH GR/WH GR/WH GR/WH GR/WH
WH
RD
BL/RD
C132PLI
C46BBR
C46BBR RD
GR
GR GR
GR/WH GR/WH
BK/RD(14) BK/RD
WH
XX
2
3
1
4
COLOR
GRN
BK
WH
C9 FS DT04-4P
CHASSIC
LINE
NEUTRAL
CKT # PIN #
N/C
AC
DC
RD
WHWH WH
BL/WH BL/WH
WH(14) WH(14)
R16PBR BK/WH
C8PBR BK/WH
C26TSR OPT.
C25PSR OPT.
C128RPM(OPT)
WH/RD
WH/BK WH/BK
WH/RD
C128RPM(OPT)
C25PSR OPT.
C26TSR OPT. WH/RD
WH/BKWH/BK
WH/RD
OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD
WH/RD
WH/BK
Connector Pin Legend - Sheet 1
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 53
Connector Pin Legend - Sheet 2
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
GRAY
C1
C41RPM
GND1
PUMP+
-----
P23BATSA
C27AUX
C21IGN
C38ESL
C35RPM
C33STR
C39LP
RD/WH
WH/RD
BLC36STCC
C32BRK
C29MS20
19
18
OR/RD
WIRE
RD
RD/WH
RD/BK
OR/BK
OR
BL/WH
BK/RD
BK/WH
BK
WH/RD
WH/BK
BL/BK
WH/BK
WH
WH
CKT#PIN#
1
2
C3PBF
6
8
7
5
4
3
C8PBR
C9PERF14
13
12
11
10
C37STC
C31EDC-
17
16
15
C4TRL9
C30EDC+
C7PBE
C6TRF
C5TRR
C12DRE
C1PBU
C2PBD
C41RPM
C40LS1
R40LS2
NC
JC2-5
JC2-4
JC3-5
JC3-6
DRE B
DRE A
JC1-5
JC1-2
JC2-3
JC2-2
H1
9 JC1-3
15
16 C13LED
10
11
12
13
14 JC3-2
JC3-3
3
4
5
7
8
6
C29MS
2
1
PIN# CKT#
OR
RD/BK
BL/RD
BRN
OR
BRN
OR
BRN
YL
WH
BL
BL/BK
RD/WH
BL/WH
WIRE
RD
BK BK/RD
BL/RD
HARN
WH
OR/BK
BL/RD
RD
RD
BK
BRN
BL/WH
-----
BRN
CKT#PIN#
1
2
6
8
7
5
4
3
12
11
10
9
ALC500 JOYSTICKS/INPUT
ALC500 OUTPUT
GM PLUG
----- YL/BK
-----
RD/BL
PU
GR/BK
WH/BL
DK BL
RD
YL
LT BL
PU/BK
BK
GM ENGINE
J1
J2
11
0
20
119
16
81
February 2012Section 6 • Schematics
6 - 56 S-80 • S-85 Part No. 122149
20ARD
P2
0B
AT
RD
C1
07
AF
WH
C4
1R
PM
OR
/BK
CB3
RD
REGULATOR
IND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
W
-
+
12V DC
B1
D22
15A
TB20
CB1
RD
C5
-3 C5
-2
15A
CB2
WH
RDRD
PLAT
GRD
KS1
P1 RD
ALT
ER
NA
TO
R
STA
RT
BA
TT
ER
YSINGLE BATTERY (STANDARD)
CB215A
WH
RDRD
PLAT
GRD
KS1 TB22
P1 RD
+
-
RD
P2
0B
AT
RD
C1
07
AF
WH
C4
1R
PM
OR
/BK
CB320A
RD
12 VDC
12 VDC
REGULATOR
IND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
-
+
BATTERYSEPARATOR
B1B2
D22
TB20
CB115A
RD
C5
-3 C5
-2
ALT
ER
NA
TO
R
BA
TT
ER
YS
EP
AR
AT
OR
(OP
TIO
N)
STA
RT
BA
TT
ER
Y
CO
NT
RO
LB
AT
TE
RY
(OP
TIO
N)
DUAL BATTERY (OPTION)
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Dual Battery Option
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 57
N M L K J I H G F E D C B A1
2
3
4
5
6
7
8
Belt Drive Generator Option
120VAC / 60HZ
LINE BK
NEUTRAL WH
GND GR
GND BR
P20BAT
TG3
TG1TG4
TG2
CR1
CB2
15A
LINE BK
FIELD BK/WH
GND BR
NEUTRAL WH
R20BAT RD
C45GEN
TO GBOX
GENERATOR
FIELD GR
NEUTRAL WH
OUTLET
NEU
LINE
GND
LINE BK
BA
T
30A
CB1
BELT DRIVEN
VO
LTA
GE
RE
GU
LA
TO
R
220VAC / 50HZ
LINE BK
NEUTRAL WH
GND GR
GND BR
P20BAT
TG3
TG1TG4
TG2
CR1
CB2
12.5A
LINE BK
FIELD BK/WH
GND BR
NEUTRAL WH
R20BAT RD
C45GEN
TO GBOX
GENERATOR
FIELD GR
NEUTRAL WH
OUTLET
NEU
LINE
GND
LINE BK
BA
T
30A
CB1
BELT DRIVEN
VO
LTA
GE
RE
GU
LA
TO
R
87A
87
8586
30
87A
87
8586
30
B
YY
YY
YF
-
+
LINE
FIELD
CB1
CB2
VOLTAGE
BK/WH 14GA
BK 12GA
5
54321
VOLTAGE REGULATOR
3
4
1
PIN#
2 WH 12GA
COLOR
NEUTRAL
CKT#
RD 12GA
BR 12GA
R20BAT
GND
LINE
NEUTRAL
BK
WH
CKT#COLORPIN#
1
4
3
GENERATOR
REGULATOR
C45GEN
GENERATOR
BATTERY-
OUTLET4
3
2
1
12.5A- 220V15A- 120V
30A
A B
BATTERY+
PLUG
CR1
BA
BAFIELDGR2
TG
120 VAC / 60 HZ with Regulator
220 VAC / 50 HZ with Regulator
-
+
February 2012Section 6 • Schematics
6 - 60 S-80 • S-85 Part No. 122149
CE Option
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
P2
0B
AT
RD
C2
P-5
P1
34
BA
TG
R/B
K
P2
2B
AT
BK
RD
TB20
RD
15AMP.
CB2
C2
B-5
C1
B-2
TB24
RD
CB3
20AMP.
15AMP.
CB1
RD
WH
C6
-28
C6
-23
TB
28
TB23D2
C2
B-6
BK
GRD
PLAT
P1
RD
RD
TB22
TB134
C4
6H
RN
GR
C2
8T
TA
RD
/BK
WH
C7
B-1
C1
B-1
2
C1
P-2
C2
P-6 C
7P
-1
C1
P-1
2
HORN
C1
32
PL
IB
L/W
H
P3
H1
RD
P2
C7
B-2
P2
3B
AT
WH
C7
P-2
D43
C9P-1
B1
B3
1
4
2
KS1
C3
P-1
0C
3B
-10
C1
33
PL
AB
L
RD
WH
BK
7
12 8
6
1
4
3
5
U33
H6
L45
LS18
L4
D39
GR
/BK
GR
/BK
BL
/WH
LOADSENSEMODULE
TB24A
P134BAT RD
P26ESTP BK
P28TTA RD/BK
TO TS52, TS54
TO TS51
TO
SE
RV
ICE
HO
RN
BK
TO AUX PUMP
TO
GR
OU
ND
TO
FB
OP
T
TS9
TS15L1
WH
JOYSTICK CONTROL CARD
3
12
13
14 8 7 6 10 9 11 43 20
17
18
19
16
15
4 1 10 9 3 1 2 5 4
TS14
6
16 8
15
DR
IVE
MO
DE
7
5
NC
CR27 CE
13
1411
12
2
BR
N
C2
P-3
C3
P-1
C3
P-2
C3
P-9
C3
P-3
C1
P-4
C1
P-5
C1
P-6
C1
P-3
C1
P- 11
C1
P- 1
0
C3
P-6
C3
P-5
C3
P-4
P2
4F
SW
H
P2
4F
SW
H
P2
6E
ST
PB
K
C3
P-8
C3
P-7
C4
P-4
C3
P-1
2
C4
P-2
C4
P-3
LE
DB
L/R
D
CD
E2
BL
/ BK
J2
J3 J1 J1 J1 J1
C4
P-6
C4
P-5
CD
E1
BL
/ WH
C2
9M
SR
D/W
H
H1
RD
/ BK
TS16
C2
P-2
1
C3
P-11
NCCR26
D37
D38
D35 D36
D41
C2
P-4
L5
C7
-3
+
D2
7
C4
P-1
CR30
NO
LE
FT
RIG
HT
DR
IVE
EN
AB
LE
P24FS WH
C28TTA RD/BK
UP
DO
WN
PL
AT
LE
VE
L
LE
FT
RIG
HT
PL
AT
RO
TA
TE
EX
TE
ND
RE
TR
AC
TA
XL
E
TS7
C3
2B
RK
WH
/RD
C4
0L
SO
R/ R
D
P26ESTP BK
RE
TR
AC
TE
XT
EN
D
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 61
N M L K J I H G F E D C B A
1
2
3
4
5
6
7
8
Platform Level Cutout, CTE Option
February 2012Section 6 • Schematics
6 - 64 S-80 • S-85 Part No. 122149
12 kW Hydraulic Generator Option
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
TB24
TIME DELAY
MODULE 4S
5 SW INPUT3 GND
1 N.O.
2 COM
8 N.C.
C1P-4C1P-5
C3
0E
DC
WH
C3
1E
DC
WH
/BK
C1
B-4
C1
B-5
C5
-20
C5
-21
C32BRK WH/RD C2
P-7
P25FS-RD
P24FS-WH
TS4
C1
P-9
RP
MH
I
GENERATOR
D12
RP
MLO
FOOTSWITCH
P26ESTP-BK
TS47
P22PWR-BK
ON
C1
P-3
CR66
753
18
642
C2
B-7
C4
5G
EN
GR
/WH
TB45TB35
C3
5R
PM
BK
/RD
C1
B-9
CR
4
HIG
HID
LE
RE
LA
Y
TB29
C1
B-3
C2
9M
SR
D/W
HM
OT
OR
ST
RO
KE
VA
LVE
C5
-18
C5
-24
D98
D99
C57
BK
-2Y75
Y75
C57
RD
-1
PR
ES
SU
RE
SW
ITC
H
20
0P
SI
OMRON
RELAY
SX Controller
BY
PA
SS
CO
IL
3
1
2
A
B
C
124 ohms
124 ohms1k ohms
V150HG GR/BK
V151HG GR
RS232TxD
A1BATTERY +
A2SENSOR POWER +5 VDC
A3BATTERY-
B1VALVE 0 FWD COIL
B2VALVE 1 NC
B3DIGITAL OUTPUT BYPASS
C1TxD
C2RxD
C3/BOOT
D1ANALOG 0 JOYSTICK
D2ANALOG 1 NC
D3C41 RPM
E1NOT USED
E2NOT USED
E3NOT USED
F1DIG IN 0
F2DIG IN 1 GENERATOR ON
F3DIG IN 2
RS232RxD
75
31 8
6
42
C1
B-4
C1
B-5
C5
-20
C5
-21
D A
U4
CB
DR
IVE
ED
C+
DR
IVE
ED
C-
PILOT PRESSURE SIGNAL
FROM GENERATOR MANIFOLD
DIVERTER MANIFOLD
N.O.
NC
CR50
PS4
C4
5G
EN
GR
/WH
C6
-39
C5
-12
BK 16-2
C5
-23
BR
AK
E
RE
LE
AS
E
TB32
C1
P-6
C3
2B
RK
WH
/RD
D65
BR-2
(16-2)
TB21
TB41
C5
-4W
H
C5
-12
OR
/BK
C4
1R
PM
OR
/BK
P2
OMRON
RELAY
20
ALC-500
15
16
19
February 2012 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 65
Hydraulic Schematic, 12kW Generator
A B C D E F G H I J K L M N
1
2
3
4
5
6
7
8
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
OIL COOLER
0.031 inch /0.79 mm
WELDERMANIFOLD
DRIVE PUMP
B
A
3.5 GPM / 13.25L/min
PMP B CLR PMP A
270 PSI / 18.6 BAR@ 3.5 GPM / 13.25 L/min
MTR B MTR A G1
G2
21 GPM / 79.5 L/min G2 G1
21CC
TANK
13
GENERATOR12.5 KW
HY
DR
AU
LIC
RO
TA
RY
CO
UP
LE
R
PRESSURE SWITCH200 PSI / 13.8 BARN.O.
CASE
CY
CX
CU
CV
CW
CZ
HS0166C
JUne 2015Section 6 • Schematics
6 - 68 S-80 • S-85 Part No. 122149
Hydraulic Schematic, 2WD Models
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
RESERVOIR
OIL COOLER
OPTION
BRAKE/2 SPEED
MANIFOLD
DRIVE PUMP
E
3625 psi
250 bar
3 psi
0.2 bar
3 psi
0.2 bar
FUNCTION
PUMP
2139
TEST
A
B
TEST310 psi
21.4 bar
51 psi
3.5 bar
T2
CP
2 SPEED
RETURN
FILTER25 psi
1.7 bar
102 psi
7 bar
BRAKE
OC1 LS TESTOC2
T1
PRESS
PR2
0.030 in
0.076 mm
0.070 in
1.77 mm
30 psi
2 bar
T2
PR1
30 psi
2 bar
30 psi
2 bar
TANK
SW2
V1
SW1
2500 psi
172 bar
V2
T3
S1
RET
TURNTABLE
ROTATE
1200 psi
82.7 bar
ST2ST1
PTEST
AUX
EXTACCUM
2900 psi
200 bar
SECONDARY
RETRACT
4 GPM
PRIMARY
BOOM EXTENSION CYLINDER
3300 PSI3:1D
E 3:1 3500 PSI
COUNTERBALANCE VALVE
3:1
C
B
3:1
3:1
RATIO
1000 PSI
3000 PSI
2000 PSI
PRESSURE
AXLE CP LIM SW
1.7M
PS
3.5 gpm
13.2 L/min
HIGH
PRESSURE
FILTER
EXTEND
7 GPM (REGEN)
FUNCTION
MANIFOLD
ACCUMULATOR450 psi
22 bar
AXLE EXTEND
PRESSURE SWITCH0.1 gpm
0.38 L/min0.3 gpm
1.1 L/min
AUXILIARY
PUMP
MEDIUM
PRESSURE
FILTER
DUMP
MANIFOLD
150 psi
10.3 bar
A
F 5:1 3500 PSI
B
B
B A A
C
C
DD
6 8 3 1
HYDRAULIC ROTARY COUPLER
2 954 10
AXLE SELECT
MANIFOLD
FLB
FLR
V2 PILOT
FAR
RAR
FAE
RAEAXLE EXTEND
CYLINDERS
FRONT REAR
2A 2D 2B136A8A8B6B 9A 9B2C
TE
54 10
STEER
CYLINDERS
TIE ROD
CYLINDER
RIGHT
LEFT
C C
C C CC
FRB
FRR
1000 psi
68.9 barTEST
V1
7
7
M1REAR
LEFT
M4
50%
280 psi
19.3 bar
REAR
RIGHT
M2
50%
M3
T
CP
X
A B
T1
2WD DRIVE MANIFOLD
30 psi
2 bar
0.6 gpm
2.27 L/min
PL2PL1
SLAVE
MASTER
0.6 gpm
2.27 L/min
PLATFORM LEVEL
CYLINDERS
F F
EE
P2
2100 psi
145 bar
P1
PRIMARY LIFT
CYLINDER
C C
A
B
DE
F
H
EE
FF
FA
FB
FD
FE
FC
BYCC
CB
BX
GG
HH
NN
CT
LL
MM
II
JJ
KK
J
K
L
PQ
NO
OO
W
M
S
Z
VU
Y
T
R
X
AA
PP
RRQQ
CC
DD
BB
I
G
C
GENERATOR
MANIFOLD
OPTIONAL
2400 PSI
OPTIONAL
GENERATOR
T4
PTEST
150 psi
10.3 bar
150 psi
10.3 bar
LIM SW
BZ
CA
V2 V1
PR2 PR1
J1
J2
PR2 PR1
L R
S85 JIB BOOM
PLATFORM
ROTATE
MANIFOLD
SELECT
JIB
.030
.042
C
C
C
C
OSCILLATE VALVE
850 psi
58.6 bar
OSCILLATE CYLINDERS
LEFT
RIGHT
A
B
OUT
IN
TEST
HS0076L
EA
EB
EC
ED
Ø.030
31
B
A
T4
21CC
MTR B MTR A
21 GPMG2
CLRPMP B
HY
DR
AU
LIC
RO
TA
RY
21
GP
M
G1
3.5 GPM
PMP A
12.5 KW GENERATOR
270 PSI @
3.5 GPM
G2 G1
CO
UP
LE
R
NO PRESS SW
200 PSI
DRIVE
PUMP
HYDRAULIC WELDER OPTION
FUNCTION
MANIFOLD
WELDER
MANIFOLD
1
2
1
2
0.030 orifice added at
SN 4139
0.042 orifice added at
SN 5381
June 2015 Section 6 • Schematics
Part No. 122149 S-80 • S-85 6 - 69
1
2
3
4
5
6
7
8
Hydraulic Schematic, 4WD Models
Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.
A B C D E F G H I J K L M N
REAR
RIGHT
REAR
LEFTM1
CDL
T
M2
FRONT
LEFT
M3
50%
0.040 in/
1 mm
1000 psi
69 bar
50%
M7
M5
CDR
50%
280 psi
19.3 bar
50%
TEST
TEST
BA
6 8 3 1
M4
50%
50%
FRONT
RIGHT
M8
M6
HYDRAULIC ROTARY COUPLER
2 954 10
OC1 LS TESTOC2
DRIVE MANIFOLD
PL2PL1
SLAVE
MASTER
0.030 in
0.076 mm
30 psi
2 bar
T2
P2
2100 psi
145 bar
P1
TANK
SW2
V1
SW1
2500 psi
172 bar
V2
T3
S1
RET
TURNTABLE
ROTATE
1200 psi
82.7 bar
ST2ST1
PTEST
AUX
EXTACCUM
2900 psi
200 bar
SECONDARY
RETRACT
4 GPM
PRIMARY
BOOM EXTENSION CYLINDER
3300 PSI3:1D
E 3:1 3500 PSI
COUNTERBALANCE VALVE
3:1
C
B
3:1
3:1
RATIO
1000 PSI
3000 PSI
2000 PSI
PRESSURE
AXLE CP LIM SW
PS
3.5 gpm
13.2 L/min
AXLE SELECT
MANIFOLD
EXTEND
7 GPM (REGEN)
FUNCTION
MANIFOLD
FLB
FLR
V1 V2 PILOT
FAE
FAR
RAR
RAE
ACCUMULATOR
FRONT REAR
450 psi
22 bar
AXLE EXTEND
PRESSURE SWITCH
2A 2D2B138A6A6B8B 9A 9B2C
0.6 gpm
2.27 L/min
0.1 gpm
0.38 L/min
0.3 gpm
1.1 L/min
TE
54 10
PLATFORM LEVEL
CYLINDERS
PRIMARY LIFT
CYLINDER
DUMP
MANIFOLD
STEERING
CYLINDERS
150 psi
10.3 bar
TIEROD
CYLINDER
LEFT
RIGHT
A
F 5:1 3500 PSI
B
B
B A A
C C
F F
EE
C C
C C CC
FRB
FRR
DE
F
H
EE
FF
FA
FB
FD
FE
FC
CD
CMCI
CL
CK
CE
CF
CQ
CP
CO
CG
CH
NN
LL
MM
II
JJ
KK
J
K
L
PQ
NO
OO
W
M
S
Z
V
T
R
X
AA
PP
RRQQ
CC
DD
BB
I
G
OIL COOLER
OPTION
RESERVOIR
BRAKE/2 SPEED
MANIFOLD
DRIVE PUMP
E
3625 psi
250 bar
3 psi
0.2 bar
3 psi
0.2 bar
FUNCTION
PUMP
2139
TEST
A
B
TEST310 psi
21.4 bar
51 psi
3.5 bar
T2
CP
2 SPEED
RETURN
FILTER25 psi
1.7 bar
102 psi
7 bar
BRAKE
T1
PRESS
AUX
1.7M
HIGH
PRESSURE
FILTER
AUXILIARY
PUMP
MEDIUM
PRESSURE
FILTER
U
Y
GENERATOR
MANIFOLD
OPTIONAL
2400 PSI
OPTIONAL
GENERATOR
T4
PTEST
150 psi
10.3 bar
150 psi
10.3 bar
LIM SW
CN
0.040 in/
1 mm
0.040 in/
1 mm
CJ
PR2 PR1
30 psi
2 bar
30 psi
2 bar
C
C
DD
30 psi
2 bar
0.6 gpm
2.27 L/min
A
B
GG
HH
CT
C
V2 V1
PR2 PR1
J1
J2
PR2 PR1
L R
S85 JIB BOOM
PLATFORM
ROTATE
MANIFOLD
SELECT
JIB
.030
.042
7
7
C
C
C
C
OSCILLATE VALVE
850 psi
58.6 bar
OSCILLATE CYLINDERS
LEFT
RIGHT
A
B
OUT
IN
TEST
HS0076L
EA
EB
EC
ED
Ø.030
31
B
A
T4
21CC
MTR B MTR A
21 GPMG2
CLRPMP B
HY
DR
AU
LIC
RO
TA
RY
21
GP
M
G1
3.5 GPM
PMP A
12.5 KW GENERATOR
270 PSI @
3.5 GPM
G2 G1
CO
UP
LE
R
NO PRESS SW
200 PSI
DRIVE
PUMP
HYDRAULIC WELDER OPTION
FUNCTION
MANIFOLD
WELDER
MANIFOLD
1
2
1
2
0.030 orifice added at
SN 4139
0.042 orifice added at
SN 5381
Dis
trib
ute
d B
y:
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800.536.1800
Fax 425.883.3475
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Fax +61 7 3375 1002
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Fax +46 31 57 51 04
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Phone +49 4221 491 810
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Fax +52 55 5666 3241
California Proposition 65
WarningThe exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.