February 2012 - cigpower.com.t manual/service111165.pdf · February 2012 S-80 • S-85 Part No....

February 2012

S-80 • S-85 Part No. 111165

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie S-80 andS-85 Operator's Manual 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: [email protected]

Serial Number Information

Genie 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 5381 to 7999) ... 122149

Genie S-80, S-85 and S-80X Service Manual(from serial number 8000)

Introduction

Copyright © 2011 by Terex Corporation

111165 Rev C February 2012Fifth Edition, Third Printing

"Genie" and "S" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.

ii

February 2012

Part No. 111165 S-80 • S-85

Revision History

Revision Date Section Procedure / Schematic Page / Description

C 2/2012 Introduction Revision History Added

3 - Maint. 3-1

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.A-6,B-3,C-7_Section 3_Maintenance Procedure.3-2, 6-4, 9-1_Section 4_Repair Procedure.Fault Codes_Section 5.6-35, 6-56, 6-104_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

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February 2012

S-80 • S-85 Part No. 111165iv

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Kubota Engine_Section 2_Specifications.A-6,B-3,C-7_Section 3_Maintenance Procedure.3-2, 6-4, 9-1_Section 4_Repair Procedure.Fault Codes_Section 5.6-35, 6-56, 6-104_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

February 2012

Part No. 111165 S-80 • S-85 v

Serial Number Legend

Introduction

S80 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

ANSI A92.5CAN B.354.4

Model: S-80

Serial number: S8006-12345

Electrical schematic number: E0180

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 : 60 ft 6 in/ 18.3 m

Maximum platform reach : 34 ft 3 in/ 10.4 m

Sequence number(stamped on chassis)

Serial label(located under cover)

Terex South Dakota, Inc.500 Oak Wood RoadPO Box 1150Watertown, SD 57201USA

February 2012

S-80 • S-85 Part No. 111165

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.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in minor or moderateinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.

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

vi

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.

February 2012

Part No. 111165 S-80 • S-85

SAFETY RULES

Section 1 - Safety Rules

vii

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.

February 2012

S-80 • S-85 Part No. 111165

Table of Contents

Introduction

Important Information ................................................................................................... ii

Serial Number Information............................................................................................ ii

Revision History.......................................................................................................... iii

Serial Number Legend ................................................................................................. v

Section 1 Safety Rules

General Safety Rules .................................................................................................. vi

Section 2 Specifications

Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 1

Hydraulic Specifications ........................................................................................ 2 - 2

Manifold Component Specifications ....................................................................... 2 - 3

GM 3.0L EFI Engine Specifications ....................................................................... 2 - 4

Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 5

Deutz F4L-913 Engine Specifications .................................................................... 2 - 7

Deutz BF4L-2011 Engine Specifications ................................................................ 2 - 8

Perkins 804C-33 Engine Specifications ............................................................... 2 - 10

Machine Torque Specifications ............................................................................ 2 - 11

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12

SAE and Metric Torque Specifications ................................................................. 2 - 13

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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 Perform Function Tests ................................................................................ 3 - 8

A-4 Perform Engine Maintenance ....................................................................... 3 - 9

A-5 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10

A-6 Grease the Extendable Axles ..................................................................... 3 - 11

A-7 Test the Oscillate Axle ............................................................................... 3 - 11

A-8 Test the Extendable Axles ......................................................................... 3 - 12

A-9 Perform 30 Day Service ............................................................................. 3 - 13

A-10 Perform Engine Maintenance - Deutz Models ............................................. 3 - 13

A-11 Inspect the Fuel Filter/Water Separator - Deutz and Perkins Models .......... 3 - 14

A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15

A-13 Perform Engine Maintenance ..................................................................... 3 - 15

A-14 Perform Engine Maintenance- Deutz Models .............................................. 3 - 16

A-15 Replace the Drive Hub Oil .......................................................................... 3 - 17

A-16 Perform Engine Maintenance - GM, Ford and 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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S-80 • S-85 Part No. 111165

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 - GM and Ford 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) ........................................................ 3 - 37

B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38

B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 39

B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 40

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 -Deutz and Perkins Models ......................................................................... 3 - 45

C-6 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 47

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Part No. 111165 S-80 • S-85

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 - Deutz and Perkins Models ......................... 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 - 8

2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 9

TABLE OF CONTENTS

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S-80 • S-85 Part No. 111165

TABLE OF CONTENTS

Section 4 Repair Procedures, continued

2-3 Platform Rotator ......................................................................................... 4 - 10

2-4 Calibrate the Platform Overload System .................................................... 4 - 12

Jib Boom Components, S-85

3-1 Jib Boom.................................................................................................... 4 - 15

3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 16

Boom Components

4-1 Cable Track ................................................................................................ 4 - 17

4-2 Boom ......................................................................................................... 4 - 20

4-3 Boom Lift Cylinder ...................................................................................... 4 - 23

4-4 Boom Extension Cylinders ......................................................................... 4 - 25

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 27

Engines

5-1 RPM Adjustment ........................................................................................ 4 - 28

5-2 Flex Plate................................................................................................... 4 - 28

Ground Controls

6-1 Control Relays ............................................................................................ 4 - 34

6-2 Power Relay ............................................................................................... 4 - 35

6-3 Terminal Strip ............................................................................................. 4 - 35

Hydraulic Pumps

7-1 Function Pump ........................................................................................... 4 - 36

7-2 Drive Pump ................................................................................................ 4 - 37

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Manifolds

8-1 Function Manifold Components - View 1 .................................................... 4 - 39

8-2 Function Manifold Components - View 2 .................................................... 4 - 40

8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 45

8-4 Brake/Two-speed Manifold Components(before serial number 5002) ........................................................................ 4 - 47

8-5 Brake/Two-speed Manifold Components(after serial number 5001) ........................................................................... 4 - 48

8-6 Turntable Rotation Manifold Components ................................................... 4 - 49

8-7 Jib Boom Select Manifold Components, S-85 ............................................ 4 - 50

8-8 Axle Select Manifold Components .............................................................. 4 - 51

8-9 2WD Traction Manifold Components(before serial number 3853) ........................................................................ 4 - 53

8-10 2WD Traction Manifold Components(after serial number 3582) ........................................................................... 4 - 55

8-11 4WD Traction Manifold Components(before serial number 3835) ........................................................................ 4 - 57

8-12 4WD Traction Manifold Components(after serial number 3834) ........................................................................... 4 - 59

8-13 Drive Oil Diverter Manifold Components ..................................................... 4 - 61

8-14 Valve Adjustments - Drive Manifold ........................................................... 4 - 62

8-15 Valve Coils ................................................................................................. 4 - 63

Fuel and Hydraulic Tanks

9-1 Fuel Tank ................................................................................................... 4 - 66

9-2 Hydraulic Tank ........................................................................................... 4 - 67

TABLE OF CONTENTS

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S-80 • S-85 Part No. 111165


Turntable Rotation Components

10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 69

2WD Steer Axle Components

11-1 Yoke and Hub ............................................................................................ 4 - 72

11-2 Steer Cylinder ............................................................................................ 4 - 73

11-3 Tie Rod Cylinder ......................................................................................... 4 - 74


12-1 Yoke and Drive Hub ................................................................................... 4 - 75

12-2 Drive Motor ................................................................................................ 4 - 76

12-3 Drive Hub ................................................................................................... 4 - 77

12-4 Steer Cylinders........................................................................................... 4 - 77

12-5 Tie Rod Cylinder ......................................................................................... 4 - 78

Non-steer Axle Components

13-1 Drive Motor ................................................................................................ 4 - 79

13-2 Drive Hub ................................................................................................... 4 - 79

Oscillating Axle Components

14-1 Oscillate Axle Cylinders ............................................................................. 4 - 80

14-2 Valve Adjustments - Oscillate Directional Valve ......................................... 4 - 81

Extendable Axle Components

15-1 Extendable Axles ....................................................................................... 4 - 83

15-2 Axle Extension Cylinder ............................................................................. 4 - 85

TABLE OF CONTENTS

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Part No. 111165 S-80 • S-85

Section 5 Fault Codes

Introduction ............................................................................................................ 5 - 1

Fault Codes- Control System ................................................................................. 5 - 2

Engine Fault Codes- GM and Ford Models ............................................................. 5 - 6

Section 6 Schematics

Introduction ............................................................................................................ 6 - 1

Electrical Symbols Legend - Rev A ........................................................................ 6 - 2

Hydraulic Symbols Legend - Rev A ........................................................................ 6 - 3

Ford LRG-425 Engine Wiring Harness .................................................................... 6 - 6

GM 3.0L Engine Wiring Harness ............................................................................ 6 - 7

Electrical Schematic, S-80Deutz F4L 913 Models ......................................................................................... 6 - 10

Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models ......................................................................................... 6 - 14

Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models ......................................................................................... 6 - 15

Electrical Schematic, S-80Deutz BF4L2011 Models ...................................................................................... 6 - 18

Ground Control Box Wiring Diagram, S-80Deutz BF4L 2011 Models ..................................................................................... 6 - 22

Platform Control Box Wiring Diagram, S-80Deutz BF4L 2011 Models ..................................................................................... 6 - 23

TABLE OF CONTENTS

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S-80 • S-85 Part No. 111165

Section 6 Schematics, continued

Electrical Schematic, S-80GM 3.0L Models .................................................................................................. 6 - 26

Ground Control Box Wiring Diagram, S-80GM 3.0L Models .................................................................................................. 6 - 30

Platform Control Box Wiring Diagram, S-80GM 3.0L Models .................................................................................................. 6 - 31

Electrical Schematic, S-80Perkins 804-33 Models ........................................................................................ 6 - 34

Ground Control Box Wiring Diagram, S-80Perkins 804-33 Models ........................................................................................ 6 - 38

Platform Control Box Wiring Diagram, S-80Perkins 804-33 Models ........................................................................................ 6 - 39

Electrical Schematic, S-80Ford LRG-425 Models .......................................................................................... 6 - 42

Ground Control Box Wiring Diagram, S-80Ford LRG-425 Models .......................................................................................... 6 - 46

Platform Control Box Wiring Diagram, S-80Ford LRG-425 Models .......................................................................................... 6 - 47

Electrical Schematic, S-85Deutz F4L 913 Models ......................................................................................... 6 - 50

Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models ......................................................................................... 6 - 54

Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models ......................................................................................... 6 - 55

TABLE OF CONTENTS

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Part No. 111165 S-80 • S-85

TABLE OF CONTENTS

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Electrical Schematic, S-85Deutz BF4L2011 Models ...................................................................................... 6 - 58

Ground Control Box Wiring Diagram, S-85Deutz BF4L2011 Models ...................................................................................... 6 - 62

Platform Control Box Wiring Diagram, S-85Deutz BF4L2011 Models ...................................................................................... 6 - 62

Electrical Schematic, S-85GM 3.0L Models .................................................................................................. 6 - 66

Ground Control Box Wiring Diagram, S-85GM 3.0L Models .................................................................................................. 6 - 70

Platform Control Box Wiring Diagram, S-85GM 3.0L Models .................................................................................................. 6 - 71

Electrical Schematic, S-85Perkins 804-33 Models ........................................................................................ 6 - 74

Ground Control Box Wiring Diagram, S-85Perkins 804-33 Models ........................................................................................ 6 - 78

Platform Control Box Wiring Diagram, S-85Perkins 804-33 Models ........................................................................................ 6 - 79

February 2012

S-80 • S-85 Part No. 111165

TABLE OF CONTENTS

xviii


Electrical Schematic, S-85Ford LRG-425 EFI Models ................................................................................... 6 - 82

Ground Control Box Wiring Diagram, S-85Ford LRG-425 EFI Models ................................................................................... 6 - 86

Platform Control Box Wiring Diagram, S-85Ford LRG-425 EFI Models ................................................................................... 6 - 87

Connector Pin Legend - View 1 ............................................................................ 6 - 90

Connector Pin Legend - View 2 ............................................................................ 6 - 91

Dual Battery Option ............................................................................................. 6 - 94

Belt Drive Generator Option ................................................................................. 6 - 95

CE Option ............................................................................................................ 6 - 98

Platform Level Cutout, CTE Option ...................................................................... 6 - 99

12 kW Hydraulic Generator Wiring Diagram.........................................................6 - 102

12 kW Hydraulic Welder Option...........................................................................6 - 103

Hydraulic Schematic, 2WD Models .....................................................................6 - 106

Hydraulic Schematic, 4WD Models .....................................................................6 - 107

Part No. 111165 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 pressure 100 psi6.9 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 310 ft-lbs420 Nm

Fluid capacities

Fuel tank 30 gallons114 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 57 gallons(including tank) 215 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 the

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

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

S-80 • S-85 Part No. 1111652 - 2

Section 2 • Specifications February 2012

Hydraulic ComponentSpecifications

Drive pump

Type: bi-directional variable displacement piston pump

Flow rate @ 2300 rpm 0 to 30.3 gpm0 to 114.7 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

SPECIFICATIONS

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

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 GenieService Department before use.


Part No. 111165 S-80 • S-85 2 - 3


SPECIFICATIONS

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

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 / 20°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve coil resistance specifications

Proportional solenoid valve 4.8 Ω(schematic items K and W)

2 position 3 way solenoid valve 6.3 Ω(schematic items D, R, X, TT and UU)

2 position 3 way solenoid valve 3.3 Ω(schematic items G)

3 position 4 way solenoid valve 6.3 Ω(schematic items A, E, N and S)

2 position 3 way solenoid valve 6.3 Ω(schematic items AK, AM, VV and WW)

2 position 3 way solenoid valve 3.3 Ω(schematic item G)


S-80 • S-85 Part No. 1111652 - 4


GM 3.0L EFI Engine

Displacement 181 cu in3 liters

Number of cylinders 4

Bore & stroke 4 x 3.6 inches101.6 x 91.44 mm

HorsepowerIntermittent 67 @ 2300 rpmContinuous 60 @ 2300 rpmIntermittent 50 kW @ 2300 rpmContinuous 45 kW @ 2300 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1650 rpmFrequency 386.1 Hz

High idle 2300 rpmFrequency 538.2 Hz

Compression ratio 9.25:1

Compression pressure - minimum 100 psiPressure (psi or bar) of lowest cylinder 6.9 barmust be at least 75% of highest cylinder

Valve clearances Zero lash + 1 full turn

Lubrication system

Oil pressure - minimum 18 psi(operating temp. @ 2000 rpm) 1.24 bar

Oil capacity 5 quarts(including filter) 4.7 liters

Oil viscosity requirements

Extreme operating temperatures may require the use ofalternative engine oil. 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.

Starter motor

Normal engine cranking speed 350 rpm

Current draw, normal load 400A

Current draw, maximum load 600A

Current draw, minimum 100A

Batteries

Type 12V DC

Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Electronic fuel pump

Fuel pressure, static 9 to 11 psi0.6 to 0.76 bar

Fuel flow rate 0.3 gpm1.14 L/min

Ignition system

Spark plug type AC ACMR-43-LTS

Spark plug gap 0.040 in1.01 mm

Engine coolant

Capacity 12 quarts11.4 liters

Alternator

Output 66A, 12V DC

Fan belt deflection 1/2 inch12 mm

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

SPECIFICATIONS

Part No. 111165 S-80 • S-85 2 - 5


Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 3-5 psi0.21-0.34 bar

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, no load 70A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Batteries

Type 12V DC

Group 31

Quantity 1



Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min

Fuel requirement


Ignition system

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 in1.07 to 1.18 mm

Spark plug torque 5 to 10 ft-lbs7 to 14 Nm

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters


Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

Horsepower

Continuous 60 @ 2500 rpmIntermittent 70 @ 2500 rpmContinuous 44.7kW @ 2500 rpmIntermittent 52 kW @ 2500 rpm



High idle 2500 rpmFrequency 620 Hz


Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder.

Valve clearances - 0.035 to 0.055 incollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar



Unit ships with 5W-30.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.


SPECIFICATIONS

S-80 • S-85 Part No. 1111652 - 6


Engine coolant

Capacity 11.5 quarts10.9 liters

Coolant temperature switch


Temperature switch point 230° F112° C

Alternator

Output 95A, 13.8V DC

SPECIFICATIONS


Part No. 111165 S-80 • S-85 2 - 7


Injection system

Injection pump make IMSA

Injection pump pressure 8702 psi600 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement


Batteries

Type 12V DC

Group 31

Quantity 1



Alternator 55A, 12V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

Deutz F4L-913 Engine

Displacement 249.3 cu in4.085 liters


Bore and stroke 4.02 x 4.92 inches102.1 x 125 mm

Horsepower 76 @ 2300 rpm57 kW @ 2300 rpm


Compression ratio 18:1

Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Low idle - no load 1300 rpmFrequency 385.7 Hz

High idle - no load 2300 rpmFrequency 570.4 Hz

Valve clearance, cold

Intake 0.006 in0.15 mm

Exhaust 0.006 in0.15 mm

Lubrication system

Oil pressure 40 to 60 psi2.75 to 4.14 bar

Oil capacity 14.3 quarts(including filter) 13.5 liters


Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oil. For oil requirements, refer to theEngine Operator Handbook on your machine.

SPECIFICATIONS

S-80 • S-85 Part No. 1111652 - 8


Lubrication system

Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar



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


Oil temperature switch point 275°F135°C

Oil pressure switch


Oil pressure switch point 7 psi0.48 bar

Deutz BF4L-2011 Engine

Displacement 189.6 cu in3.1 liters


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





Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Governor centrifugal mechanical




SPECIFICATIONS


Part No. 111165 S-80 • S-85 2 - 9


SPECIFICATIONS


Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum15,000 psi/1034 bar

Injector opening pressure 3046 psi210 bar

Fuel Requirement


Starter motor

Current draw, normal load 140-200A

Cranking speed 200-250 rpm

Batteries

Type 12V DC

Group 31

Quantity 1



Alternator output 80A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

S-80 • S-85 Part No. 1111652 - 10



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.

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


Engine coolant

Capacity 12.5 quarts11.8 liters

Batteries

Type 12V DC

Group 31

Quantity 1



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


Bore and stroke 3.70 x 4.72 inches94 x 120 mm

Horsepower 63 @ 2600 rpm47 KW @ 2600 rpm


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



Governor mechanical all speed




Lubrication system

Oil pressure @ 2000 rpm 40-60 psi2.8-4.1 bar

Oil capacity 10.6 quarts(including filter) 10 liters


SPECIFICATIONS

Part No. 111165 S-80 • S-85 2 - 11


SPECIFICATIONS

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


Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 14 ft-lbs / 18.9 Nm




SAE No. 12 84 ft-lbs / 113.9 Nm

S-80 • S-85 Part No. 1111652 - 12


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)


-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)


-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. 111165 S-80 • S-85 2 - 13


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

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 Nm18 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 5DRYLUBED

• 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

10.9 12.98.84.6

S-80 • S-85 Part No. 1111652 - 14


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Part No. 111165 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.

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


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. 111165

Section 3 • Scheduled Maintenance Procedures February 2012

Maintenance Symbols Legend

Note: The following symbols have been used in thismanual 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 Preparation Reportto use for each inspection. Store completed formsas 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. Maintain completedforms for a minimum of 4 years or in compliancewith your employer, jobsite and governmentalregulations and requirements.

SCHEDULED MAINTENANCE PROCEDURES

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-Delivery 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

Make copies of this form to use for each Pre-DeliveryPreparation.

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 re-inspect 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. 111165



Part No. 111165 S-80 • S-85 3 - 5


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


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

B-22 Fuel and hydraulic tankventing systems

B-23 Hydraulic oil analysis

Perform every 400 hours:

B-24 Engine maintenance -GM and Ford models

Checklist A Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Function tests

A-4 Engine maintenance

A-5 Filter condition indicator

A-6 Grease Axles

A-7 Oscillate axle

A-8 Extendable axles

Perform after 40 hours:

A-9 30 day service


A-10 Engine maintenance -Deutz models


A-11 Inspect filter/separator -Diesel models

A-12 Grease rotationbearing

A-13 Engine maintenance


A-14 Engine maintenance -Deutz models


A-15 Replace Drive Hub oil


A-16 Engine maintenance -GM, Ford and Perkinsmodels

Comments

3 - 6 S-80 • S-85 Part No. 111165


Checklist C Y N R

C-1 Engine maintenance -Deutz and Perkinsmodels

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


C-6 Engine maintenance -GM and Ford models

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 -Deutz and Perkinsmodels

D-7 Replace hydraulic filters

D-8 Drive hub oil


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


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


Inspector signature

Inspector title

Inspector company

Part No. 111165 S-80 • S-85 3 - 7


Checklist A Procedures

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with each machineand should be stored in the container provided inthe platform. An illegible or missing manual will notprovide safety and operational informationnecessary for a safe operating condition.

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 could resultin 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 not appropriatefor the machine or all manuals are not in goodcondition or is illegible. Remove the machinefrom service until the manual is replaced.

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 and ingood 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 if replacement manuals or decals areneeded.

3 - 8 S-80 • S-85 Part No. 111165


CHECKLIST A PROCEDURES

A-2Perform Pre-operationInspectionGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

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 apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves 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-3Perform Function TestsGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

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. 111165 S-80 • S-85 3 - 9


A-4Perform Engine Maintenance

Engine specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in the:Deutz 913 Operator Handbook(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theGM 3.0L Operator Handbook(GM part number 36100007) OR theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).

Deutz 913 Operator HandbookGenie part number 62446

Deutz BF4L2011 Operation ManualGenie part number 84794

GM 3.0L Operator HandbookGenie part number 101095

Ford LRG-425 EFI Operator HandbookGenie part number 84792

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.


3 - 10 S-80 • S-85 Part No. 111165



A-5Check the Hydraulic FilterCondition IndicatorsGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

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. The tankreturn and high pressure filter have a conditionindicator on them. The medium pressure filter doesnot have a filter condition indicator.

1 Start the engine from the platform controls.

2 Change the engine idle to high rpm (rabbitsymbol).

a filter condition indicator gauge

Tank return filter:

3 Open the ground control side turntable cover andinspect the filter condition indicator gauge.

Result: The needle on the gauge should beoperating in the green area.

Result: If the needle is in the red area, thisindicates that the hydraulic filter is beingbypassed and the filter should be replaced. SeeD-7, Replace the Hydraulic 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.

4 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. 111165 S-80 • S-85 3 - 11


A-7Test the Oscillate Axle

Genie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

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 to performthis procedure on a firm, levelsurface will compromise thestability of the machine and couldresult in the machine tipping over.


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.

Note: If the chassis does not remain level duringthe test, refer to Repair Procedure 14-2, How to SetUp the Directional Valve Linkage.

A-6Grease the Extendable Axles

Genie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Proper lubrication of the extendable axle wear padsis essential to smooth operation and minimum wearof the wear pads.


Before serial number 4952:

1 Spread a liberal coating of grease on the top ofthe inner axle extension and bottom of the outeraxle.

2 Repeat for each axle.

After serial number 4951:

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


3 - 12 S-80 • S-85 Part No. 111165



A-8Test the Extendable AxlesGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Tip-over hazard. Do not raise orextend the boom unless both axlesare 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 to thestowed 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.

Part No. 111165 S-80 • S-85 3 - 13


A-10Perform Engine Maintenance -Deutz Models

Engine specifications require that this one-timeprocedure be performed after 50 hours of operation.


Required maintenance procedures forcommissioning new and overhauled engines andadditional engine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).






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


3 - 14 S-80 • S-85 Part No. 111165



d

c

e

b

aA-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/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and/or hard starting, and continueduse may result in component damge. Extremelydirty conditions may require this procedure beperformed 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 an approvedfire extinguisher within easy 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.

Part No. 111165 S-80 • S-85 3 - 15


A-13Perform Engine Maintenance

Engine specifications require that this procedure beperformed every 100 hours.









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 has beengreased.

3 Apply grease to each tooth of the drive gear,located under the turntable.



3 - 16 S-80 • S-85 Part No. 111165






A-14Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 125 hours of operation.

Required maintenance procedures forcommissioning new and overhauled engines andadditional engine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).






Part No. 111165 S-80 • S-85 3 - 17


6 Repeat steps 1 through 4 for the other drive hub.

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.

A-15Replace 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 hours ofuse may cause 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 plugs intothe drive hub. Torque to Specification. Refer toSection 2, Specifications.

a

a

b


3 - 18 S-80 • S-85 Part No. 111165


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 the machine.Torque the drive hub mounting bolts tospecification. 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


A-16Perform Engine Maintenance -GM, Ford and Perkins Models



Required maintenance procedures and additionalengine information are available in theGM 3.0L Operator Handbook(GM part number 36100007) OR theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).



Perkins 804C-33 Operation and Maintenance ManualGenie part number




Part No. 111165 S-80 • S-85 3 - 19


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 good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions. A single battery configuraton isstandard. A dual battery option is available, whereone battery is used to start the engine and the otheris used to power the control system and auxiliarypower unit. The two batteries are charged by thealternator through a battery separator.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

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 corrosion onthe 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.

3 - 20 S-80 • S-85 Part No. 111165


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 specificgravity of 1.277 or greater. The battery is fullycharged. 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


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/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

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. 111165 S-80 • S-85 3 - 21


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.


• 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.


• Cable track on the boom

• Cables on the boom and jib boom

• Jib boom/platform rotate manifold

• Inside of the platform control box


3 - 22 S-80 • S-85 Part No. 111165



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 cause ahazardous 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 no functionsshould operate.

B-4Check the Exhaust System


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 is running.Remove the key to secure fromoperation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.




2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

Part No. 111165 S-80 • S-85 3 - 23


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.


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.


3 - 24 S-80 • S-85 Part No. 111165



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 andCooling Fins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine 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 hot enginecomponents. Contact with hotengine components may result insevere 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.


Part No. 111165 S-80 • S-85 3 - 25


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


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 be sureit is in the engaged position.


3 - 26 S-80 • S-85 Part No. 111165


B-8Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque, isessential to safe operation and good performance.Tire and/or wheel failure could result in a machinetip-over. Component damage may also result ifproblems are not discovered and repaired in atimely 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. Add airas 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 the bottomof the drive pump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

Note: The free-wheel valve should always remainclosed.

a

d

c

b


Part No. 111165 S-80 • S-85 3 - 27




5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

6 Repeat steps 1 through 5 for the other drivehubs.


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 and continueduse 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.


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


3 - 28 S-80 • S-85 Part No. 111165



a primary idle adjustment screwb secondary idle adjustment screw

3 Turn the secondary adjustment screwcounterclockwise until the adjustment screw isloose. Tighten the locknut.

Note: Be sure the adjustment screw is looseneduntil there is no spring tension felt.

4 Remove the primary idle adjustment screw capfrom the primary idle adjustment screw on theinjection pump. Loosen the locknut.

5 Adjust the primary idle adjustment screw untillow idle is 1250 rpm. Tighten the locknut.

6 Install the primary idle adjustment screw capand tighten. Do not over tighten.

7 Loosen the secondary idle adjustment screwlocknut.

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.

GM models:

Note: The engine rpm is controlled by the ECM andcan only be adjusted by re-programming the ECM.If rpm adjustment or service is required, pleasecontact the Genie Service Department or your localGM dealer.

Ford models:

Note: The engine rpm is controlled by the ECM andcan only be adjusted by re-programming the ECM.If rpm adjustment or service is required, pleasecontact Genie Service Department or your localFord dealer.

Deutz F4L 913 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 10 if the low idle rpm is correct.

2 Remove the secondary idle adjustment screwcap from the secondary idle adjustment screwon the injection pump. Loosen the locknut.

Part No. 111165 S-80 • S-85 3 - 29


Perkins models:



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.

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, disregard adjustmentstep 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.

8 Adjust the secondary adjustment screw until thelow idle meets specification. Tighten thelocknut.

9 Install the secondary idle adjustment screw capand tighten. Do not over tighten.

10 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.Refer to Section 2, Specifications.

If the high idle is correct, disregard adjustmentstep 11.



Deutz BF4L 2011 models:



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.

If the high idle is correct, disregard adjustmentstep 5.




3 - 30 S-80 • S-85 Part No. 111165



B-11Perform Engine Maintenance

Engine specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.











Part No. 111165 S-80 • S-85 3 - 31


B-13Test the Ground ControlOverrideGenie 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 allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton at the platform controls is in the on or offposition. 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.


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 than 12 inches /30.5 cm unless both axles are fully extended.

B-12Check the Oscillate DirectionalValve Linkage


Note: Perform this test only on models equippedwith an oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the oscillate directional valve linkage isnot operating correctly, the stability of the machineis 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


3 - 32 S-80 • S-85 Part No. 111165



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.




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.


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.

Part No. 111165 S-80 • S-85 3 - 33


B-16Test the Fuel Select Operation -GM and Ford Models


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 indicate fuelsystem 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.


7 At the platform controls, move the engine idleselect toggle switch to high idle (rabbit symbol).Do not press down the foot switch.


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.



3 - 34 S-80 • S-85 Part No. 111165



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.

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 improperly functioningdrive enable system may allow the machine to bemoved into an unsafe position.

Note: Perform this procedure with the boom in thestowed position.


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.

Part No. 111165 S-80 • S-85 3 - 35


Blue

Yellow


B-18Test the Drive Brakes


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 Proper BrakeConfiguration.

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.


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 range shown.

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 on theplatform 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 that thedrive and steer control handle is moved.

3 - 36 S-80 • S-85 Part No. 111165



B-20Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Select a test area that is firm, level and free ofobstructions.

1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


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


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Note: Select a test area that is firm, level and freeof obstructions.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


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.


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.

Part No. 111165 S-80 • S-85 3 - 37



8 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.


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.


13 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.


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 with theengine running or not running.

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.

3 - 38 S-80 • S-85 Part No. 111165




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 and thenrelease it. Move the drive controller off center inthe opposite direction, hold for a moment andthen release it.

Result: The travel alarm should sound when thedrive controller is moved off center in eitherdirection.

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.



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.

Part No. 111165 S-80 • S-85 3 - 39



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


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 and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed 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.

3 - 40 S-80 • S-85 Part No. 111165


B-24Perform Engine Maintenance -GM and Ford Models



Required maintenance procedures and additionalengine information are available in theGM 3.0L Operator Handbook(GM part number 36100007) OR theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302).




1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.



Part No. 111165 S-80 • S-85 3 - 41


C-1Perform Engine Maintenance -Deutz and Perkins Models



Required maintenance procedures and additionalengine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).







Checklist C Procedures

3 - 42 S-80 • S-85 Part No. 111165


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 procedure moreoften 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.



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. Continued useof 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 on afirm, 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.

Part No. 111165 S-80 • S-85 3 - 43


Illustration 1


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 lights areon 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 lights areon 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.

3 - 44 S-80 • S-85 Part No. 111165



8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


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.


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.

Part No. 111165 S-80 • S-85 3 - 45



C-4Replace the Engine Air FilterElement - Deutz and PerkinsModels

Engine specifications require that this procedure beperformed 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.


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 engine performance.Failure to perform this procedure can lead to poorengine performance and/or hard starting, andcontinued use may result in component damge.Extremely dirty conditions may require thisprocedure be performed more often.


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.

3 - 46 S-80 • S-85 Part No. 111165



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 are overtightened.

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 on thefilter 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 and checkfor 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

Part No. 111165 S-80 • S-85 3 - 47


C-6Perform Engine Maintenance -GM and Ford Models



Required maintenance procedures and additionalengine information are available in theGM 3.0L Operator Handbook(GM part number 36100007) OR theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302).







3 - 48 S-80 • S-85 Part No. 111165


Checklist D Procedures

D-1Check the Boom Wear Pads

Genie specifications require that this procedure beperformed every 1000 hours or annually, whichevercomes 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.


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 pad ifit 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 innerboom 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 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

Top, bottom and side wear pads 1/2 inch(pivot end of boom) 12.7 mm

Boom number three

Top and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm

a boom 1b boom 2c boom 3

b ca

Part No. 111165 S-80 • S-85 3 - 49


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


Maintaining the axle wear pads in good condition isessential to safe machine operation. Wear pads areplaced 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 in componentdamage and unsafe operating conditions.

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, Howto 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.

3 - 50 S-80 • S-85 Part No. 111165



D-3Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. The free-wheelconfiguration 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 work sitethat 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 injury andproperty 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

Part No. 111165 S-80 • S-85 3 - 51


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 injury andproperty 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 the bottomof the drive pump, and should always remainclosed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

a

d

c

b

D-4Check the Turntable RotationBearing Bolts


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 on thelift cylinder rod. Carefully lower the boom ontothe 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.


3 - 52 S-80 • S-85 Part No. 111165



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


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 on afirm, level surface and the boom in the stowedposition.

1 Grease the turntable bearing. See A-12, Greasethe Turntable Rotation Bearing and Rotate Gear.

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. 111165 S-80 • S-85 3 - 53


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 more than1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch / 2.5 cm fromthe 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


3 - 54 S-80 • S-85 Part No. 111165






D-6Perform Engine Maintenance -Deutz and Perkins Models







Part No. 111165 S-80 • S-85 3 - 55


D-7Replace the Hydraulic FilterElements

Genie specifications requires that this procedure beperformed every 1000 hours or annually, whichevercome first. Perform this procedure more often ifdusty 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 of hotoil. Contact with hot oil may causesevere burns.


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 on theoil 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.


3 - 56 S-80 • S-85 Part No. 111165



D-8Replace the Drive Hub Oil


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 and continueduse 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.


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.



12 Install the new medium and high pressure filterelements into the housings and tighten themsecurely.

13 Clean up any oil that may have spilled during theinstallation procedure.

14 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


16 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

a

a

b

Part No. 111165 S-80 • S-85 3 - 57


6 Repeat steps 1 through 4 for the other drive hub.

7 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.


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.



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 the machine.Torque the drive hub mounting bolts tospecification. 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


3 - 58 S-80 • S-85 Part No. 111165


D-9Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 1500 hours of operation.


Required maintenance procedures and additionalengine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).







Part No. 111165 S-80 • S-85 3 - 59


open closed

Checklist E Procedures

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 and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed 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: 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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Remove the fuel tank. Refer to Repair Procedure9-1, How to Remove the Fuel Tank.

2 Models without hydraulic tank shutoff valves:Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. 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 with thehydraulic tank shutoff valves in theCLOSED position or component

damage 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.

3 - 60 S-80 • S-85 Part No. 111165


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 GenieService Department before use.

Part No. 111165 S-80 • S-85 3 - 61


E-2Perform Engine Maintenance -Perkins Models



Required maintenance procedures and additionalengine information are available in thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).






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 remove them.

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 and wheelassembly.

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.

3 - 62 S-80 • S-85 Part No. 111165



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 hub bypressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease seal whenremoving 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.

24 Center a lifting jack under the steer axle.

25 Raise the machine approximately6 inches / 15 cm. Remove the blocks fromunder the drive chassis.

26 Lower the machine

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.


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 the rearbearing.

Part No. 111165 S-80 • S-85 3 - 63


E-4Perform Engine Maintenance -Deutz and Perkins Models











3 - 64 S-80 • S-85 Part No. 111165



Section 4 • Repair Procedures

Part No. 111165 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 point whererepairs can be completed. Then to re-assemble,perform the disassembly steps in reverse order.

Symbols Legend


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.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rules andoperating instructions in the Genie S-80 andGenie S-85 Operator’s Manual on your machine.

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:


• 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


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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/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other 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.

Platform Controls

bcd

a


Part No. 111165 S-80 • S-85 4 - 3

February 2012

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

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.



2 Turn the key switch to platform control. Do notstart the engine.

3 Press down the foot switch and select a joystickto calibrate.

4 Move the joystick full stroke in either directionand hold for 5 seconds.

5 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds andreturn the joystick to the neutral position.

Result: The alarm should sound indicatingsuccessful joystick calibration.

6 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

Note: No machine fuction should operate whileperforming the joystick calibration procedure.


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PLATFORM CONTROLS

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.

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 thetable below and 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 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 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.

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.

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: If a max-out adjustment has been made toany joystick function other than the limited drivespeed (raised or extended), the limited drive speedmust be checked. Refer to steps 14 thru 19.



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.


Part No. 111165 S-80 • S-85 4 - 5

February 2012

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 78 to 86 seconds

Drive speeds (factory settings)

Stowed- high speed 7.9 to 8.5 seconds

Non-stowed 40 to 45 seconds

PLATFORM CONTROLS

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.The ramp rate settings of a joystick can bechanged to compensate for hydraulic pump wear tomaintain peak performance from the machine.









Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.


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PLATFORM CONTROLS

Ramp rate (factory settings)

Boom up/down and turntable rotateaccelerate 3 secondsdecelerate 1 second

Boom extend/retractaccelerate 4 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


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 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.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.






Part No. 111165 S-80 • S-85 4 - 7

February 2012

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.









Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.


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).





PLATFORM CONTROLS


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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.


6 Remove the platform control box mountingfasteners. Lower the control box and set itaside.

Component damage hazard.Cables can be damaged if they arekinked 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.


Part No. 111165 S-80 • S-85 4 - 9

February 2012

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 noair in the closed 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. RefertoSection 2, Hydraulic Hose and Fitting TorqueSpecifications.

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 the slavecylinder rod-end pivot pin. Use a soft metal driftto 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.


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February 2012

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.


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.

S-85:

3 Support the jib boom leveling arms and theplatform mounting weldment with an appropriatelifting device. Do not apply any lifting 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.


Part No. 111165 S-80 • S-85 4 - 11

February 2012

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 rotator fasteners,torque the fasteners to specifications. Refer toSection 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 rotator fasteners,torque the fasteners to specifications. Refer toSection 2, Specifications.

How to Bleed the PlatformRotatorNote: This procedure will require two people. Do notstart 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.



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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 of theplatform during rotation.

5 Open the bottom bleed screw on the rotator, butdo not remove it.


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 of theplatform during rotation.

7 Clean up any hydraulic oil that may have spilled.

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. Continued useof 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 on afirm, 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.


Part No. 111165 S-80 • S-85 4 - 13

February 2012

PLATFORM COMPONENTS

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 are flashingat the platform and ground controls, and thealarm is sounding. Slowly tighten the load springadjustment nut in a clockwise direction in 10°increments until the overload indicator lightturns off, and the alarm does not sound.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.


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 are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning 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.


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.


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.



Result: All platform control functions should notoperate.


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February 2012

PLATFORM COMPONENTS



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.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.


Part No. 111165 S-80 • S-85 4 - 15

February 2012

Jib Boom Components, S-85

3-1Jib Boom

How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.


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. Hosesand cables can become damagedif they are kinked or pinched.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Attach a lifting strap from an overhead crane tothe jib boom assembly.

7 Place blocks under the platform leveling cylinderfor support. Protect the cylinder rod fromdamage.

8 Remove the pin retaining fastener from the slavecylinder rod-end pivot pin. Use a soft metal driftto 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.


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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.


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.


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.


Part No. 111165 S-80 • S-85 4 - 17

February 2012

Boom Components

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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Open the platform control box.

2 Tag and disconnect the foot switch wiring fromthe terminal strip inside the platform control box.

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.

S-80:

6 Tag, disconnect and plug the hydraulic hosesfrom the counterbalance valve manifold locatedon the platform rotator. Cap the fittings on themanifold.


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.


S-85:

8 Remove the hose and cable cover from the sideof 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.


4 - 18 S-80 • S-85 Part No. 111165

February 2012

BOOM COMPONENTS

11 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.


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 lower cabletracks and secure the upper and lower trackstogether.

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.


Part No. 111165 S-80 • S-85 4 - 19

February 2012

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. Hosesand cables can be damaged if theyare kinked or pinched.

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 be damagedif they are kinked or pinched.

7 Connect the ends of the replacement cable tracksection to the existing cable track using thesnap 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.


4 - 20 S-80 • S-85 Part No. 111165

February 2012

BOOM COMPONENTS

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.



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.


Part No. 111165 S-80 • S-85 4 - 21

February 2012

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.


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 the overheadcrane.


4 - 22 S-80 • S-85 Part No. 111165

February 2012

BOOM COMPONENTS

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. See 4-4, How to Remove the Boom Extension Cylinders.

1 Remove the boom. See 4-2, How to Remove theBoom.

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 strap willneed to be carefully adjusted for proper balancing.

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 when removedfrom the number 2 boom tube if notproperly supported.



Part No. 111165 S-80 • S-85 4 - 23

February 2012

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.


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.


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 to theboom for support. Do not lift the boom.


4 - 24 S-80 • S-85 Part No. 111165

February 2012

BOOM COMPONENTS

5 Support the rod end of the boom lift cylinder withan 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 the cylinder.


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.


Part No. 111165 S-80 • S-85 4 - 25

February 2012

BOOM COMPONENTS

3 Place a 4 in x 4 in x 6 ft / 10 cm x 10 cm x1.8 m block on top of the number 3 boom tubeand place 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 with alifting 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.

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 movement inthe 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.


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.


4 - 26 S-80 • S-85 Part No. 111165

February 2012

BOOM COMPONENTS

9 Lay the master cylinder down. Protect thecylinder rod from damage.

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 the cylinder.


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. Then extend theboom and install the two lower ¼-20 fasteners inthe number 3 boom tube.


Part No. 111165 S-80 • S-85 4 - 27

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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

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.


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.


4 - 28 S-80 • S-85 Part No. 111165

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 Engines

0.15 inch / 3.8 mm gap - GM Engines0.25 inch / 6.35 mm gap - Ford Engine0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.3 inch / 7.6 mm gap - Perkins 704-30 Engine


Part No. 111165 S-80 • S-85 4 - 29

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).


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.

GM models:

5 Remove the fasteners securing the muffler tothe exhaust manifold.

Burn hazard. Hot engine parts cancause severe burns.

6 Remove muffler mounting bracket fasteners.Remove the muffler and bracket assembly fromthe engine.

7 Remove the hose clamp securing the air filterassembly to the air inlet tube.

8 Remove the air cleaner bracket fasteners.Remove the air cleaner and bracket assemblyfrom the engine.

9 Support the drive pump with an appropriatelifting device. Do not apply any lifting pressure.

10 Remove all of the remaining bell housing toengine fasteners. Carefully pull the pump awayfrom the engine and secure it from moving.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched

11 Remove the flex plate mounting fasteners,and remove the flex plate from the engineflywheel.

Ford models:

5 Tag and disconnect the wire harness from theoxygen sensor on the exhaust pipe.

6 Remove the exhaust pipe heat shield fastenersfrom the top of the muffler.


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 muffler bracket retaining fasteners.Remove the muffler bracket from the engine.

10 Close the shutoff valve on the Liquid PetroleumGas (LPG) tank by turning it clockwise(if equipped).

11 Tag and disconnect the wiring from the LPGsolenoid.

12 Remove the engine starter retaining fastenersand remove the starter from the engine. Do notdisconnect the wiring.

13 Remove the dipstick tube bracket fasteners.

14 Attach a lifting strap from an overhead crane tothe lifting eyes on the engine.

15 Remove the bell housing to engine trayfasteners.


4 - 30 S-80 • S-85 Part No. 111165

February 2012

ENGINES


Deutz BF4L-2011 models:

5 Tag and disconnect the wiring from the bellhousing.

6 Remove the U-bolt from the exhaust flex pipe atthe muffler.


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.



16 Raise the engine slightly using the overheadcrane. Do not apply any lifting pressure.

17 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing engine fasteners.



19 Remove the flex plate mounting fasteners.Remove the flex plate from the engine fly wheel.

Deutz F4L-913 models:

5 Tag and disconnect the wiring from the bellhousing.

6 Remove the exhaust tailpipe and air inlet tubeU-bolts from the air cleaner mounting bracket.


7 Remove the fuel filter/water separator retainingfasteners. Remove the filter/separator from theengine. Do not disconnect the fuel hoses.

8 Remove the air cleaner mounting bracketfasteners. Remove the air cleaner and bracketassembly from the engine.

9 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing to engine fasteners.




Part No. 111165 S-80 • S-85 4 - 31

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.

2 Ford models: Torque the flex plate mountingbolts in sequence to 14 ft-lbs / 19 Nm. Thentorque the flex plate mounting bolts in sequenceto 20 ft-lbs / 27 Nm.GM models: Torque the flex plate mountingbolts in sequence to 22 ft-lbs / 30 Nm. Thentorque the flex plate mounting bolts in sequenceto 31 ft-lbs / 42 Nm.Deutz models: Torque the flex plate mountingbolts in sequence to 26 ft-lbs / 35 Nm. Thentorque the flex plate mounting bolts in sequenceto 37 ft-lbs / 51 Nm.Perkins models: Torque the flex platemounting bolts in sequence to 13 ft-lbs / 18 Nm.Then torque the flex plate mounting bolts insequence to 19 ft-lbs / 26 Nm.

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

5 Install the pump onto the bell housing/mountingplate. Torque the pump retaining fasteners to57 ft-lbs / 83 Nm.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

6 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

7 Install the pump and bellhousing assembly ontothe engine. Apply Loctite® removable threadsealant to the mounting screws.Perkins 704 modelsTorque the bellhousing mounting bolts insequence to 14 ft-lbs / 19.1 Nm.Deutz 913, Perkins 804 and GM modelsTorque the bellhousing mounting bolts insequence to 28 ft-lbs / 38 Nm.Deutz 2011 ModelsTorque the bellhousing mounting bolts insequence to 46.7 ft-lbs / 63.3 Nm.Ford ModelsTorque the bellhousing mounting bolts insequence to 37 ft-lbs / 50.1 Nm.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay 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 Engines

0.15 inch / 3.8 mm gap - GM Engines0.25 inch / 6.35 mm gap - Ford Engine0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.3 inch / 7.6 mm gap - Perkins 704-30 Engine


4 - 32 S-80 • S-85 Part No. 111165

February 2012

ENGINES

10

6 1

8

4

11

7 5

92

12

3

1

2

3

4 5

6 1

2

34

5

1

2

3

4 5

6

1

2

3

4

56

7

8

Ford, Perkins andDeutz BF4L-2011

Flex Plate

Deutz F4L-913Flex Plate

GM Flex 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 Plate

Deutz F4L-913 and Perkins 704-30Pump Plate

Perkins 804C-33 and GMPump Plate

1 6

5 2

34

C C

CC

CC

CC

7 8

9

C

Ford Pump Plate


Part No. 111165 S-80 • S-85 4 - 33

February 2012



4 - 34 S-80 • S-85 Part No. 111165

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


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 85Ω

terminal 87 to 87a and 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

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 Ω)

terminal 87 to 30 continuity(zero Ω)

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


Part No. 111165 S-80 • S-85 4 - 35

February 2012

GROUND CONTROLS

6-2Power Relay


Note: The power relay is mounted on the AuxiliaryPower Unit.

How to Test the Power RelayElectrocution/burn hazard.Disconnect the ground cable fromthe battery before performing thisprocedure.

1 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.

Test Desired result

2 small posts 12 to 16Ω

2 large posts no continuity(infinite Ω)

Any small post to no continuityany large post (infinite Ω)

2 Connect 12V DC to one of the small posts and aground wire to the other small post, then testthe following terminal combination.

Test Desired result

2 large posts continuity (zero Ω)

a solenoid activate coil terminal(small post)

b high amp power contact terminal

a b

a

b

6-3Terminal Strip

How to Remove a Terminal StripSection

Electrocution/burn hazard. Contactwith electrically charged circuitscould cause death or seriousinjury. Remove all rings, watchesand other jewelry.

1 Disconnect the battery(s) from the machine.

2 Label the wiring from the terminal strip section tobe removed.

3 Use a small flat blade screwdriver to push in andrelease the wire from the terminal strip.

4 Locate the removal tab on the bottom or top ofthe terminal strip section.

5 Use a small flat blade screwdriver to gently pryup on the tab of the terminal strip section andremove it.


4 - 36 S-80 • S-85 Part No. 111165

February 2012

2 Tag, disconnect and plug the hydraulic hosesfrom the function pump. Cap the fittings on thepump.


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 FunctionPumpWhen removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose endmust be replaced. All connections must be torquedto specification during installation. Refer to Section2, Hydraulic Hose and Fitting TorqueSpecifications.



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


Part No. 111165 S-80 • S-85 4 - 37

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.


1 Disconnect the wire harness at the electronicdisplacement controller (EDC), located on thedrive pump.



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


4 - 38 S-80 • S-85 Part No. 111165

February 2012

3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.


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 GM and Ford models: Close the valve on theLPG tank, then disconnect the hose from thetank. Move the fuel select toggle switch to theLPG 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 GM and Ford models: Connect the LPG hoseto the LPG tank and open the valve on 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


Part No. 111165 S-80 • S-85 4 - 39

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.


4 - 40 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

A B C

D

E

G

K

L

M

P

R

S

Q

O

N

J

I

H

F

TUVWX

AA

AC

AD

AE

AG

AF

AB

Z

Y

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

1


Part No. 111165 S-80 • S-85 4 - 41

February 2012

MANIFOLDS

Function Manifold Components - View 1, continued


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


4 - 42 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

A B C

D

E

G

K

L

M

P

R

S

Q

O

N

J

I

H

F

TUVWX

AA

AC

AD

AE

AG

AF

AB

Z

Y

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

1


Part No. 111165 S-80 • S-85 4 - 43

February 2012

8-2Function Manifold Components - View 2

The function manifold assembly is located on the tank side tray, behind the ground control box.


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

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1234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567123456789012345678901234567890121234567890123456789012345671234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567


4 - 44 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

AH

AI

AL

AJ

AK

AMANAO

AY

79 8

1

2

4

3

5

6


Part No. 111165 S-80 • S-85 4 - 45

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) on thefunction manifold.


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.



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.


6 Repeat steps 2 through 5 and confirm reliefvalve pressure.


4 - 46 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

How to Adjust the Boom ExtendRelief ValveNote: Perform this procedure with the boom in thestowed position.



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.


6 Repeat steps 2 through 5 to confirm relief valvepressure.


Part No. 111165 S-80 • S-85 4 - 47

February 2012

8-4Brake/Two-Speed Manifold Components(from serial number 4436 to 4617 and before 4212)

The brake/two-speed manifold is mounted on the engine tray.


1 Check valve ....................................... SS ......... Brake circuit ........................................ 8-10 ft-lbs / 10-15 Nm

2 Solenoid valve, 2 position 3 way ...... TT ......... Brake release ................................. 25-30 ft-lbs / 34-41 Nm

3 Solenoid valve, 2 position 3 way ...... UU ........ 2-Speed wheel motors(energized in high range todestroke the drive motorswash plates) .................................. 25-30 ft-lbs / 34-41 Nm

MANIFOLDS

TT UUSS

21 3


4 - 48 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

8-5Brake / Two Speed Manifold Components(from serial number 4212 to 4435 and after 4617)

The brake/two speed manifold is mounted inside the drive chassis.


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


Part No. 111165 S-80 • S-85 4 - 49

February 2012

MANIFOLDS

8-6Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor at the ground control sideof the machine.


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


4 - 50 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

8-7Jib Boom Select Manifold Components, S-85

The jib boom/platform rotate manifold is mounted on the platform end of the boom.


1 Solenoid valve, 2 position 3 way ...... VV ......... Platform rotate select .......................... 8-10 ft-lbs / 11-14 Nm

2 Solenoid valve, 2 position 3 way ...... WW ....... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm

3 Orifice Plug, 0.035 inch / 0.89 mm .... XX ......... Jib boom circuit

VV WW XX

1 2 3


Part No. 111165 S-80 • S-85 4 - 51

February 2012

MANIFOLDS

8-8Axle Select Manifold Components

The axle select manifold is mounted next to the drive manifold at the non-steer end of the machine.


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


4 - 52 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

FA FB FC

FD

FE

4

5

1 32


Part No. 111165 S-80 • S-85 4 - 53

February 2012

MANIFOLDS

8-92WD Traction Manifold Components(before serial number 3853)

The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.


1 Relief valve, 280 psi / 19.3 bar ......... BF ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm

2 Flow divider/combiner valve ............. BG ........ Controls flow to drive motorsin forward and reverse .............. 90-100 ft-lbs / 122-136 Nm

3 Orifice - plug, 0.070 inch / 1.77 mm .. BH ........ Equalizes flow across flowdivider/combiner valve (item BG)

4 Shuttle valve ...................................... BI .......... Charge pressure circuit thatgets hot oil out of low pressureside of drive pump ............................ 50-55 ft-lbs / 68-75 Nm

5 Diagnostic nipple ............................................. Testing


4 - 54 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

BF BG

BH

BI

1 2

3

4

5


Part No. 111165 S-80 • S-85 4 - 55

February 2012

8-102WD Traction Manifold Components(after serial number 3852)



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 combiner/.......................................................................... divider valve BY

MANIFOLDS

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4 - 56 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

BX

BY

BZ

CA

CB

CC

1

6

2

5

3

4


Part No. 111165 S-80 • S-85 4 - 57

February 2012

MANIFOLDS

8-114WD Traction Manifold Components(before serial number 3835)



1 Relief valve, 280 psi / 19.3 bar ......... BJ ......... Charge pressure circuit .................... 20-25 ft-lbs / 27-34 Nm

2 Check valve, 5 psi / 0.34 bar ............. BK ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm

3 Flow divider/combiner valve ............. BL ......... Controls flow to flow 90-100 ft-lbs /divider/combiner valves BQ and BW................. 122-136 Nm

4 Check valve, 5 psi / 0.34 bar ............. BM ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm

5 Check valve, 5 psi / 0.34 bar ............. BN ........ Drive motor anti-cavitation ............... 30-35 ft-lbs / 41-47 Nm

6 Shuttle valve ...................................... BO ........ Charge pressure circuitthat gets hot oil out of low pressureside of drive pump ............................ 50-55 ft-lbs / 68-75 Nm

7 Check valve, 5 psi / 0.34 bar ............. BP ......... Drive motor anti-cavitation ............... 30-35 ft-lbs / 41-47 Nm

8 Flow divider/combiner valve ............. BQ ........ Controls flow to steer enddrive motors in forward 90-100 ft-lbs /and reverse ........................................................ 122-136 Nm

9 Check valve, 5 psi / 0.34 bar ............. BR ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm

10 Flow regulator valve,2 gpm / 7.6 L/min ............................... BS ......... Equalizes pressure on both sides

of flow divider/combiner valve BQ .... 30-35 ft-lbs / 41-47 Nm

11 Flow regulator valve,2 gpm / 7.6 L/min ............................... BT ......... Equalizes pressure on both sides

of flow divider/combiner valve BL .... 30-35 ft-lbs / 41-47 Nm

12 Flow regulator valve,2 gpm / 7.6 L/min ............................... BU ........ Equalizes pressure on both sides

of flow divider/combiner valve BW ... 30-35 ft-lbs / 41-47 Nm

13 Check valve, 5 psi / 0.34 bar ............. BV ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm

14 Flow divider/combiner valve ............. BW ........ Controls flow to non-steer enddrive motors in forward 90-100 ft-lbs /and reverse ........................................................ 122-136 Nm


4 - 58 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

STEER END

NON-STEER END

14

13

12

11

10

8

9

7 6 5

4

3

21

BJ BK

BL

BMBNBOBP

BQ

BS

BR

BT

BU

BV

BW


Part No. 111165 S-80 • S-85 4 - 59

February 2012

8-124WD Traction Manifold Components(after serial number 3834)



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


4 - 60 S-80 • S-85 Part No. 111165

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


Part No. 111165 S-80 • S-85 4 - 61

February 2012

CY

CX

CU

CV

CW

1

3

4

5

2

8-13Drive Oil Diverter Manifold Components (welder option)

The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.


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


4 - 62 S-80 • S-85 Part No. 111165

February 2012

MANIFOLDS

8-14Valve 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 the tractionmanifold) is necessary to return hot oil from theclosed loop drive circuit to the hydraulic tank forcooling. 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 pressure differential(between the charge pump reading and the hotoil shuttle relief valve) of 40 psi / 14.5 bar isobtained.


Part No. 111165 S-80 • S-85 4 - 63

February 2012

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 / 20°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Proportional solenoid valve 4.8 Ω(schematic items K and W)

2 position 3 way solenoid valve 6.3 Ω(schematic items D, R, X, TT and UU)

2 position 3 way solenoid valve 3.3 Ω(schematic items G)

3 position 4 way solenoid valve 6.3 Ω(schematic items A, E, N and S)

2 position 3 way solenoid valve 6.3 Ω(schematic items AK, AM, VV and WW)

2 position 3 way solenoid valve 3.3 Ω(schematic item G)

8-15Valve 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 can produceerratic operation. When coil resistance decreasesbelow specification, amperage increases. Asresistance rises above specification, voltageincreases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.


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 to betested.

2 Test the coil resistance using a multimeter setto resistance (Ω). Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.


4 - 64 S-80 • S-85 Part No. 111165

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.


1 Test the coil for resistance. Refer to, How toTest a Coil.

2 Connect a 10Ω 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 more whenmeasured across the terminals.

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC current,should be capable of reading up to 800 mA.

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.

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6.

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.

9V

BATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

d

a

b

b

c

c

MANIFOLDS


Part No. 111165 S-80 • S-85 4 - 65

February 2012



4 - 66 S-80 • S-85 Part No. 111165

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.


Part No. 111165 S-80 • S-85 4 - 67

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.


1 Lower and retract the boom to the stowedposition.

2 Remove the fuel tank. See 9-1, How to Removethe Fuel Tank.

3 Close the two hydraulic tank valves located atthe hydraulic tank (if equipped).

Component damage hazard. Theengine must not be started with thehydraulic tank shutoff valves in theCLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

4 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.

5 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank.

6 Tag and disconnect and plug the hose from thereturn filter. Cap the fitting on the return filterhousing.

7 Tag and disconnect and plug the supply hose forthe auxiliary power unit. Cap the fitting on thehydraulic tank.

8 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.

open closed


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February 2012

9 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.

10 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedand secured to the overheadcrane.

11 Remove the suction strainers from the tank andclean them using a mild solvent.

12 Rinse out the inside of the tank using a mildsolvent.

13 Install the suction strainers using pipe threadsealant on the threads.

14 Install the drain plug using pipe thread sealanton the threads.

15 Install the hydraulic tank onto the machine.

16 Install the two suction hoses and the supplyhose for the auxiliary power unit.

17 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.


19 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.

FUEL AND HYDRAULIC TANKS


Part No. 111165 S-80 • S-85 4 - 69

February 2012

a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts

4 Attach a suitable lifting device to the lifting eyeson the drive hub assembly.

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 the motor/brake mounting fasteners to specification. Referto Section 2, Machine Torque 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. RefertoSection 2, Hydraulic Hose and Fitting TorqueSpecifications.


2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.


3 Loosen the backlash pivot plate and adjustmentbolts.

Turntable Rotation Components

unlocked locked

a b c


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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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.



2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.


3 Remove the hydraulic tube that connects fromthe counterbalance manifold to the brake. Capthe fittings on the brake and manifold.


4 Remove the motor/brake mounting fasteners.Carefully remove the motor from the brake.

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 turntable bearingring gear.

Note: Perform this procedure with the boombetween the non-steer end tires and with themachine on a firm and level surface.



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


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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.



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 the rearbearing.


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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.


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 installing acastle 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 same hydrauliccircuit, but move in opposite directions. The tie rodcylinder maintains equal movement of the tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.


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.


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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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Tag, disconnect and plug the hydraulic hosesfrom the tie rod cylinder. Cap the fittings on thecylinder.


2 Support and secure the tie rod cylinder to alifting jack.

3 Remove the pin retaining fasteners from each tierod 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


Part No. 111165 S-80 • S-85 4 - 75

February 2012


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 installing theyoke and drive hub assembly onto the axle.


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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

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.



4 Block the non-steer wheels, and center a liftingjack of ample capacity under the steer axle.



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February 2012

3 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


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.


1 Extend the axles.

2 Remove the drive motor access covers fromboth sides of the inner axle.



Part No. 111165 S-80 • S-85 4 - 77

February 2012


12-4Steer Cylinders

How to Remove a Steer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the same hydrauliccircuit, but move in opposite directions. The tie rodcylinder maintains equal movement of the tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.


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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Remove the drive motor. See 12-2, How toRemove a Drive Motor.


3 Center a lifting jack of ample capacity under thenon-steer axle.


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.


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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.



Part No. 111165 S-80 • S-85 4 - 79

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.


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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.


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.


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.


Part No. 111165 S-80 • S-85 4 - 81

February 2012

OSCILLATING AXLE COMPONENTS

14-2Oscillate Directional Valve

How to Adjust the OscillateRelief Valve 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


4 - 82 S-80 • S-85 Part No. 111165

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.


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 drive chassisand the non-steer axle on both sides (from theinside 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


Part No. 111165 S-80 • S-85 4 - 83

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 Procedure D-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. Do notraise 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 of theinner and outer axle to obtain zero clearanceand 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


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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.


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. Hosescan be damaged if they are kinkedor pinched.

6 Remove the steer cylinder mounting lug from theinner 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:


13 Block the steer tires and center a lifting jackunder the outer axle.


15 Remove the lug nuts. Remove the tire and wheelassembly.

16 Remove the drive motor covers from both sidesof the inner axle.


Part No. 111165 S-80 • S-85 4 - 85

February 2012


17 Tag, disconnect and plug the hydraulic hoses atthe drive motor. Cap the fittings on the drivemotor.



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. Hosescan be damaged if they are kinkedor 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.


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.


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February 2012

5 Tag, disconnect and plug the axle extendcylinder hydraulic hoses. Cap the fittings on thecylinder.



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.



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.


Part No. 111165 S-80 • S-85 5 - 1

February 2012 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating 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.



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.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• 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. 111165

February 2012Section 5 • Fault Codes

FAULT CODES

Fault Codes - Control System

How to Retrieve ControlSystem Fault 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 andboth red Emergency Stop button pulled out to theon position at both the ground and platformcontrols.

1 Open the platform control box lid.

Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and 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)can damage printed circuit boardcomponents. If the circuit boarddoes need to be handled,maintain firm contact with ametal part of the machine that isgrounded at all times whenhandling the printed circuit boardOR use a grounded wrist strap.

3 Determine the error source: The red LEDindidates the error source and will flash twoseparate codes. The first code will indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 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 indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 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 followingpages to aid in troubleshooting the machineby pinpointing the area or componentaffected.

Part No. 111165 S-80 • S-85 5 - 3


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



12 15

Value too high Value too low



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.


11 12 15 16





Calibrate joystick.

31 Boom 2 Joystick (secondary boom up/down or primary boom extend/retract)

18 Just calibrated Initiate 1 second beep of alarm.


32 Boom 2 directional valves

21 Fault



5 - 4 S-80 • S-85 Part No. 111165


FAULT CODES


Condition Solution

12 15





33 Boom 2 flow control valve

18 Just calibrated



11 12 15 16





Calibrate joystick.

41 Turntable rotate joystick



42 Turntable rotate directional valves

21 Fault



12 15





43 Turntable rotate flow control valve

18 Just calibrated



44 Drive enable override switches 21 Fault

Enable override direction is frozen at neutral.


Part No. 111165 S-80 • S-85 5 - 5


FAULT CODES


Condition Solution 11 12 15 16





Calibrate joystick.

51 Drive joystick



12 15





53 Drive flow valve (EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drive motor Valve

21 Fault

Motor speed frozen in the low state. Alarm sounds indicating fault.


11 12 15 16





Calibrate joystick.

61 Steer joystick



62 Steer directional valves

21 Fault



5 - 6 S-80 • S-85 Part No. 111165


FAULT CODES

How to Retrieve Ford EngineFault 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 highest efficiencywhile at the same time keeping exhaustemissions to a minimum. When a sensor fails orreturns signals that are outside of setparameters, the ECM will store a fault code inmemory 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.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

Engine Fault Codes -GM and Ford Models

How to Retrieve GM EngineFault CodesWhen an engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn on atthe ground controls. Special equipment isrequired to retrieve fault codes stored within theECM. Contact Genie Service Department forassistance in retrieving fault codes.

Note: If the check engine light is on and theengine is stopped, tag the machine and removefrom service. Contact service personnelimmediately.

Note: If the check engine light is on and theengine is still running, contact service personnelwithin 24 hours.

Part No. 111165 S-80 • S-85 5 - 7


FAULT CODES


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/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

3 Connect the negative battery cable to thebattery.

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. For example:the check engine light blinks 5 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.

Note: Once a fault code has been retrieved andthe repair has been completed, the ECM memorymust be reset to clear the fault code from theECM. See How to Clear Engine Fault Codes fromthe ECM.

5 - 8 S-80 • S-85 Part No. 111165


FAULT CODES

Code Problem Cause Solution

111 Closed Loop Multiplier High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112 HO2S Open/Inactive (Bank 1)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

113 HO2S Open/Inactive S(Bank 2)



114 Post-cat oxygen sensor open

The post cat Heated Oxygen Sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer.

Repair wiring and/or connections OR replace the post cat oxygen sensor.

121 Closed Loop Multiplier High (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

122 Closed Loop Multiplier Low (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair fuel injectors.

124 Closed Loop Multiplier Low (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR replace fuel OR test and repair the fuel system components.

133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.

Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance.

134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


141 Adaptive Lean Fault - High Limit (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low.

Repair heated oxygen sensor wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

142 Adaptive Rich Fault - Low Limit (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair fuel injectors.

143 Adaptive Learn High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components.

111 Closed Loop Multiplier High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112 HO2S Open/Inactive (Bank 1)



113 HO2S Open/Inactive S(Bank 2)



114 Post-cat oxygen sensor open

The post cat Heated Oxygen Sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer.

Repair wiring and/or connections OR replace the post cat oxygen sensor.

121 Closed Loop Multiplier High (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

Part No. 111165 S-80 • S-85 5 - 9


FAULT CODES



144 Adaptive Learn Low (LPG) Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty.

Repair short in engine wire harness OR test and repair the fuel system components.

161 System Voltage Low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repair battery supply wiring to ECM.

162 System Voltage High Alternator is overcharging the battery when engine RPM is greater than 1500 rpm. Repair or replace the alternator.

211 IAT High Voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold.

Repair wiring and/or connections OR replace sensor OR direct warmer air into air intake.

212 IAT Low Voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot.

Repair wiring and/or connections OR replace sensor OR direct cooler air into air intake.

213 IAT Higher Than Expected (1)

Air intake temperature is greater than 200° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

214 IAT Higher Than Expected (2)

Air intake temperature is greater than 210° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

215 Oil Pressure Low Faulty oil pressure sensor OR sensor wiring and/or connections open or shorted OR engine oil level too low.

Replace oil pressure sensor OR repair sensor wiring and/or connections OR fill engine oil level to specification.

221 CHT/ECT High Voltage Engine cooling system is malfunctioning OR sensor wires and/or connections open or shorted OR sensor is faulty.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor.

222 CHT/ECT Low Voltage

Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification.

223 CHT Higher Than Expected (1)

Coolant temperature at the cylinder head is 240° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


224 CHT Higher Than Expected (2)

Coolant temperature at the cylinder head is 250° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


231 MAP High Pressure Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

232 MAP Low Voltage Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

234 BP High Pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

235 BP Low Pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

242 Crank Sync Noise Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor.

243 Never Crank Synced At Start

Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


5 - 10 S-80 • S-85 Part No. 111165


FAULT CODES


245 Camshaft Sensor Noise Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


253 Knock Sensor Open Knock sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections to knock sensor OR replace knock sensor.

254 Excessive Knock Signal Knock sensor wiring and/or connections open or shorted OR there is excessive engine vibration OR sensor is faulty.

Check for excessive engine vibration OR repair wiring and/or connections to knock sensor OR replace knock sensor.

311 Injector Driver #1 Open Open wiring and/or connections to fuel injector #1 OR fuel injector #1 is faulty OR ECM is faulty.

Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM.

312 Injector Driver #1 Shorted Wiring and/or connections to fuel injector #1 shorted OR fuel injector #1 is faulty OR ECM is faulty.














351 Fuel Pump Loop Open or High Side Short To Ground

Open wiring and/or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

352 Fuel Pump High Side Shorted To Power

Wiring and/or connections to fuel pump shorted to power OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

353 MegaJector delivery pressure higher than expected

Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector.

354 Megajector delivery pressure lower than expected

Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector.

355 MegaJector communication lost

The ECM doesn’t get any response from the MegaJector, or an incorrect response for 500ms period or longer.

Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector.

361 MegaJector voltage supply high

The MegaJector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running.

Repair charging system OR replace the MegaJector.

362 MegaJector voltage supply low

The MegaJector detects voltage less than 9.5 volts for 5 seconds anytime the engine is cranking or running.

Repair VBAT power or ground circuit to ECM and MegaJector OR replace battery OR repair charging system OR replace the MegaJector.

Part No. 111165 S-80 • S-85 5 - 11


FAULT CODES


363 Megajector internal actuator fault detection

The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s

Check Power, Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance.

364 Megajector internal circuitry fault detection

The MegaJector detects an internal circuitry failure. Open or short in power, ground or CAN circuits.


365 MegaJector internal communication fault detection

The MegaJector detects an internal communications failure. Open or short in power, ground or CAN circuits.


411 Coil Driver #1 Open Open wiring and/or connections to ignition coil #1 OR ignition coil #1 is faulty.

Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1.

412 Coil Driver #1 Shorted Wiring and/or connections to ignition coil #1 shorted OR ignition coil #1 is faulty.


413 Coil Driver #2 Open Open wiring and/or connections to ignition coil #2 OR ignition coil #2 is faulty.


414 Coil Driver #2 Shorted Wiring and/or connections to ignition coil #2 shorted OR ignition coil #2 is faulty.


511 FPP1 High Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

512 FPP1 Low Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

513 FPP1 Higher than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

514 FPP1 Lower than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

521 FPP2 High Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

522 FPP2 Low Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

531 TPS1 (Signal Voltage) High

The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #1.

532 TPS1 (Signal Voltage) Low



533 TPS2 (Signal Voltage) High



534 TPS2 (Signal Voltage) Low



363 Megajector internal actuator fault detection

The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s



5 - 12 S-80 • S-85 Part No. 111165



535 TPS1 Higher than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

536 TPS1 Lower than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

537 Throttle Unable to Open Governor actuator is stuck closed OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

538 Throttle Unable to Close Governor actuator is stuck open OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

545 Governor Interlock Failure Engine harness wiring and/or connections open or shorted OR there is a poor system ground connection OR ECM is faulty.

Repair wiring and/or connections in engine harness OR replace the ECM.

551 Max Governor Speed Override

ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.

Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head.

552 Fuel Rev Limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


553 Spark Rev Limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


611 COP Failure Loose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM.

612 Invalid Interrupt Loose wire connections to ECM OR ECM is faulty.


613 A/D Loss Loose wire connections to ECM OR ECM is faulty.


614 RTI 1 Loss Loose wire connections to ECM OR ECM is faulty.


615 Flash Checksum Invalid Loose wire connections to ECM OR ECM is faulty.


616 RAM Failure Loose wire connections to ECM OR ECM is faulty.


631 External 5V DC Ref Lower than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.

632 External 5V DC Ref Higher than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.

655 RTI 2 Loss Loose wire connections to ECM OR ECM is faulty.


656 RTI 3 Loss Loose wire connections to ECM OR ECM is faulty.S


February 2012 Section 6 • Schematics

Part No. 111165 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.



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


Hydraulic Schematics


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. 111165

Electrical Symbols Legend

Connection

no terminal

P3

Horn button

normally open

T-circuits

connectFB

Flashing beacon

Diode

Circuits crossing

no connection

Quick disconnect

terminal

BLK

WHT

T-circuits connect

at terminal

WHT #21 TB21

Battery

+

-

Circuit breaker

with amperage

15A

CB1

Horn or alarm

H1 Emergency Stop

button normally

closed

P1

Coil

solenoid or relay

Key switch

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

STA

RT

EN

GIN

E

Toggle switch DPDT

TS6

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

Gauge sending unit

HM

Hour meter

N.O.

OTS2

Oil temperature

switch

normally open

N.O.

CTS1

Coolant temperature

switch

normally open

Oil pressure switch

normally closed

N.C.

OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oil

cooling fan

G1

Gauge

Tilt sensor

LED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fuse

with amperage

25A

F1

510

Resistor with

ohm value

Starting aid:

glow plug or

flame ignitor

Control relay contact

normally open

CR4

N.O.

Battery separator

MA

INA

UX

Coil

Fuel or RPM

solenoid

PU

LL

IN

HO

LD

CA B


Part No. 111165 S-80 • S-85 6 - 3

Hydraulic Symbols Legend

Pump

fixed displacement

Motor

bi-directional

Accumulator

Shut off valve

Check valve

2 position, 3 way, shuttle valve

Double acting

cylinder

Priority

flow regulator valve

Differential

sensing valve

Solenoid operated

proportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,

3 way, shuttle valve

Filter with

bypass valve

relief setting

25 psi

(1.7 bar)

Motor

2-speed,

bi-directional

Pump

bi-directional,

variable displacement

E

Pump prime mover

(engine or motor)

Directional valve

(mechanically activated)

o

Relief valve

with pressure setting

200 psi

(13.8 bar)

Orifice with size

.035"

(0.89 mm)Solenoid operated 3 position,

4 way, directional valve

Directional valve

pilot operated

2 position, 2 way

Flow divider/combiner valve

with pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valve

with pressure and pilot ratio

(206.8 bar)

3000 psi

3:1

Solenoid operated 2 position,

3 way, directional valve

2 position, 2 way

solenoid valve

February 2012Section 6 • Schematics

6 - 4 S-80 • S-85 Part No. 111165



6 - 5

Ford LRG-425 EFI Engine Wiring Harness

6 - 6

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

Section 6 • Schematics February 2012

6 - 6 S-80 • S-85 Part No. 111165

351 BR-W 18

359 GY-R 18

358 LG-BK 18

TWR

B

A

C

MAP_CONN

361 R 16 361 R 16 361 R 16

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

ACT

151 LB-BK

307 BK-Y 18

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

34 GROUND

25 IVS

14 FPP1

39 R-W 18570 BK-W 1616 WATER TEMP

WATER

TEMP

30AF1

16 R-LG 181 VSW

5AF216 R-LG 18

20AF3

ECT

361 R 12361 R 14361 R 14

351 BR-W 18

359 GY-R 18

351 BR-W 18

359 GY-R 1833 ANA RTN

31 VREF

9 VBATT

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 1838 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM

41 EGR REC360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

361 R 16

16 R-LG 18

307 BK-Y 18

351 BR-W 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

354 LG-R 18

151 LB-BK 18

198 DG-O 18

18 O-Y 18

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

358 LG-BK 18

743 GY 18

145 VOLT REF

3VSW

23EGR RECIRC

22EGR PWM

2POWER GROUND

1POWER GROUND

21EGR

20MAP

27IAT

16FPP 2

15FPP 1

11INJ 5

6INJ +

7INJ 1

12INJ 6

28ECT

17IVS

13ANA_RTN

18AUX ANA PU1

19AUX ANA PD1

31AUX OUT 2

8INJ 3

9INJ 4

10INJ 2

J1 BLACK

74 GY-LB 1824EGO 1

452 GY-R 18

282 DB-O 18

349 DB 18

350 GY 18

34CAM +

35CAM -

32CRANK +

33CRANK -

30KNK -

29KNK +

26EGO 3

570 BK-W 16

570 BK-W 16

351 BR-W 18

359 GY-R 18

354 LG-R 18

358 LG-BK 18

361 R 16

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

359 GY-R 18

743 GY 18

16 R-LG 18

151 LB-BK

570 BK-W 16

CRANK361 R 14361 R 16

361 R 16

5VBAT

VBAT4

392 R-LG 1825EGO 2

570 BK-W 16

359 GY-R 18

74 GY-LB 18

361A R 16

392 R-LG 18

361A R 16

359 GY-R 18

570 BK-W 16

O2 SENSOR

O2

SENSOR

361 R 14

CAM

307 BK-Y 18

359 GY-R 18

361A R 16

851 Y-R 18

850 Y-BK 18

LOCKOFF SOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

361A R 16

172 LB-R 18

169 LG-BK 18

148 Y-R 18

317 GY-O 18

15 R-Y 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

77 DB-Y 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

238 DG-Y 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

926A LB-O 18

242 DG 18

342 LG-P 18

570 BK-W 16

TWR

B

A

WPTWR2_GY

TWR

A

B

J2 GREY

33OVERSPEED

5AUX OUT 1

13COIL 4

3COIL 3

2COIL 2

1COIL 1

4SPK PWR GROUND

35RS 232 RX

34RS 232 TX

21RS 485 -

20RS 485 +

19CAN -

18CAN +

12ROAD SPEED -

11ROAD SPEED +

17GOV SELECT 2

16GOV SELECT 1

10FUEL PUMP MON

8TACH

7OIL PRESSURE

6BRAKE SWITCH

31TPS2

30TPS1

23FUEL LOCKOFF

22STARTER LOCKOUT

14FUEL SELECT

15AUX ANA PU2

27MIL

26GASEOUS TRIM

29DBW -

28DBW +

24COIL 5

25COIL 6

32RELAY CONTROL

9FUEL PUMP

COIL 2

VBAT

COIL 11

12

2

3

3

15 R-Y 18

926A LB-O 18

172 LB-R 18

169 LG-BK 18

148 Y-R 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

238 DG-Y 18

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18SHD

A

E

F

B

C

D

MTRSHD6

TWR

D

C

B

F

E

A

MTRTWR6

2

3

1

4

5

6

THROTTLE

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

351 BR-W 18

359 GY-R 18351 BR-W 18

359 GY-R 18

FPP_COMMD

C

A

TWR

RTN

5V

RX

BTX

351 BR-W 18

359 GY-R 18

458 O-BK 18

669 DG-W 18

87A85

86 30

87

458 O-BK 18

342 LG-P 18

15 STARTER IN (INTERUPT)

13 STARTER CONTROL

39 STARTER IN (AUTOCRANK)32 R-LB 16

32 R-LB 16

32 R-LB 16

5 FUEL PUMP787A PK-BK 16

87A85

86 30

87

16 R-LG 18

342 LG-P 18

361 R 14

87A85

86 30

87

15AF4

FUEL PUMP

RELAY

787A PK-BK 16

361 R 16

15AF5

21 AUX OUT1

20 RS 232+

18 RS 232-

3 RS 485-

11 RS 485+

172 LB-R 18

169 LG-BK 18

148 Y-R 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 184 BRAKE

26 OIL PRES

2 TACH

6 MIL

7 FUEL SELECT

10 AUX ANA PU2

24 GOV SELECT 1

23 GOV SELECT 2

35 ROADSPEED +

36 ROADSPEED -

30 OVERSPEED

28 CAN +

29 CAN -

570 BK-W 16

361A R 16

459 O-LG 18

662 DG-P 18

MTRSHD4

TWR

D

C

B

A

MTRTWR4

PLUG (GROUND)

PLUG (RELAY POWER)

PLUG (CAN +)

PLUG (CAN -)

SHD

D

B

A

C

253 DG-W 18OIL PRESSURE

361 R 16

STARTER

RELAY

POWER

RELAY

FORD

42 PIN

CONNECTOR

Ford LRG-425 EFI Engine Wiring Harness

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Section 6 • SchematicsFebruary 2012

Part No. 111165 S-80 • S-85 6 - 7

1

2

3

4

5

6

7

8


GM 3.0L Engine Wiring Harness

#305 GREEN/BLACK

CAVITY "A"

GOVERNOR

ACTUATOR

CONNECTOR

OIL PRESSURE SWITCH

#105 GREEN

STARTER

INTERLOCK

RELAY

#3002 RED/BLUE

#2004 YELLOW/BLACK

#6002 RED/WHITE

#2000 BLACK/WHITE

#1004 YELLOW

#1007 PURPLE

MOLD #

#1

00

0B

LA

CK N

O.

85

30

87a

87

BLACK CONNECTOR

#1

00

6LT.

BL

UE

WHITE CONNECTOR

81 16

23

#2001 BROWN

#1001 BROWN/WHITE

#1008 GRAY

#1

00

0B

LA

CK

GASOLINE

INJECTOR

CONNECTOR

RED/BLACK

#1002

#2002 RED

#2002 RED

L.P.G. INJECTOR CONNECTOR

CAVITY "B"

AB

#2009 WHITE/BLUE

1

16

8

23

#106 DK. BLUE

#103 ORANGE

CAVITY "B"

#100 BLACK

#205 LT. GREEN

#104 YELLOW/BLACK

#102 PINK

CAVITY "C"

#2006 BLUE/WHITE

#2007 PURPLE

#1009 WHITE/BLACK

86 8587a

30

87

86 85

#7002 RED

#3002 RED/BLUE

86

30

87a

87

87a85

30

86

87

#7012 18 GA. FUSE LINK

#4002 RED#5002 RED

20 AMP FUSE

B A

CAVITY "A"

CAVITY "B"

A B C D

CAVITY "D"

COOLANT TEMPERATURE SENSOR

#2

00

2R

ED

FUEL SUPPLY

SELECT RELAY

#4

00

7

PU

RP

LE

/WH

ITE

#1

00

0B

LA

CK

#1

00

5G

RE

EN

/BL

AC

K

#1000 BLACK

COIL POWER

RELAY

#1

00

2R

ED

/BL

AC

K

TO STARTER

SOLENOID

#1

00

0B

LA

CK

#3

00

7

PU

RP

LE

/BL

AC

K

#1

00

4Y

EL

LO

W

#1

00

7P

UR

PL

E

MAIN

POWER

RELAY

CAVITY "B"

CAVITY "B"

CAVITY "A"

L.P.G. LOCK-OFF

GROUND CONNECTOR

L.P.G. LOCK-OFF

POSITIVE CONNECTOR

PED

B A CAVITY "A"

AB

CAVITY "A"

CB

A

CAVITY "C"

CAVITY "A"

#5007 PURPLE COIL WIRE

#1006 LT. BLUE

AIR TEMPERATURE SENSOR

CAVITY "B"

AB

MAP SENSOR

12 PIN CONNECTOR CAVITY #'S

#1 L.P. FUEL REQUEST (+12VDC ENABLES)

#2 HI SPEED REQUEST (+12VDC ENABLES)

#3 +12VDC STARTER INPUT

#4 +12VDC IGN. POWER TO COIL POWER RELAY

#5 AUX. INPUT SHUTDOWN

#6 ENGINE RUN SIGNAL (+12 VDC)

#7 CHECK ENGINE LAMP

#8 AUX. TACH. SIGNAL

#9 MID. SPEED REQUEST (GROUND ENABLES)

#10 EMPTY

#11 +12VDC OUTPUT TO GASOLINE FUEL PUMP

#12 GROUND TO GASOLINE FUEL PUMP

3 AMP DIODE

1000 PRV MIN.

#3

00

2R

ED

/BL

UE

TO +12V DC BATTERY

STUD ON STARTER

#1000 BLACK

ENGINE HARNESS

GROUND TERMINAL

5

6

3

4

1

2

8

7

10

9

12

11

DISTRIBUTOR

CONNECTOR

#2007 PURPLE

#3

00

6D

K.

BL

UE

COIL POWER CONNECTOR

LOOSE INSIDE CABLE LOOM

GRAY

ALT. EXCITE WIRE

#2002 RED

CAVITY "A"

ALT. SENSE

WIRE

(+12VDC)

#8

00

2R

ED

A

CAVITY "B"

B

ALT. CONNECTOR

(FOR MODEL 7SI)

TACHOMETER SIGNAL

FROM ALTERNATOR

#104 YELLOW/BLACK


6 - 8

GM 3.0L Engine Wiring Harness

6 - 7


6 - 9

Electrical Schematic, S-80Deutz F4L 913 Models

6 - 10

1

2

3

4

5

6

7

8



6 - 10 S-80 • S-85 Part No. 111165


P1

34

RD

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

RD

P2

0B

AT

RD

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

20A

RD

TB41

GE

NE

RA

TO

R

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

IN/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TB35

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

TB21

CR2

NO

8

7

6

5

10

9

TS51

TB27

RD

TS1

TS52

1

2

TB33

3

RD

IGN./START

MODULE

WH

-21

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RD

OR/BK

OIL

TE

MP

ER

AT

UR

EA

ND

OIL

PR

ES

SU

RE

LE

D

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

ST

PB

L/R

D

S2

NC

S1

NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

PR2

NO

BK

/WH

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TIL

TA

LA

RM

RD

WH

BK

BK

H2HM

+

_

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

-

+

12 V

DC

B1

D22

AUX

FAN

CR17

NO

TB20

CB1

15A

RD

B1

BA

TT

ER

Y

3 1 2

FU

NC

.E

NA

BL

E

PU

LL

IN

HO

LD

A

WH

RD

BK

CB

D6

CR1CR1

NO

FUSE

70A

HO

LD

PU

LL

INW

H

BK

21

RD

3

MODULE

TIME DELAY

-COM

+AUX

S-613

+BAT

MOM N.O.

BRN

WH

RD

RP

MS

OL

EN

OID

CR28

NO

C6

-16

C6

-23

C6

-34

C6

-33

C5

-3 C5

-2

C6

-28

C6

-27

C5

-15

C5

-5

R3

3S

TR

BK

C2

1IG

NW

H

TB33A

GL

OW

PL

UG

RE

LA

Y

GL

OW

PL

UG

GL

OW

PL

UG

FU

EL

VA

LV

E

C5

-22

C6

-13

4R

D

C5

-12

C5

-18

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

C3

3S

TR

BK

C5

-7

C5

-11

BL/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RG

R/B

K

CB2

15A

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

P3

HORN

RD

P2

3B

AT

WH

AU

XIL

IAR

Y

PO

WE

R

AU

XIL

IAR

Y

PO

WE

R

EN

GIN

E

STA

RT

EN

GIN

E

STA

RT

GL

OW

PL

UG

GL

OW

PL

UG GE

NE

RA

TO

R

ON

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1

P2

CR39

NO

D42

EN

GIN

ER

PM

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

TIO

N)

OIL

TE

MP

ER

AT

UR

E

SE

ND

ER

(OP

TIO

N)

C2

6T

SR

GR

/BK

C2

5P

SR

BL

/BK

G3 G2

VO

LT

ME

TE

R(O

PT

ION

)

G1

TB24A

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

DR

AU

LIC

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H(O

PT

ION

)

HY

DR

AU

LIC

CO

OL

ING

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

Y

5D40

L48+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:

3 ROCKER STEER OPTION ONLY.

5 ADD D40 ONLY IF UNIT HAS L4 AND L48.

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .

2 C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.

6CE Option, See 6 - 98

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 11


PR

IMA

RY

BO

OM

RE

TR

AC

T

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WNP

LA

TF

OR

ML

EV

EL

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

RIG

HTP

LA

TF

OR

MR

OTA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

LE

FT

TS7

TS57

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

WH

H4

H3

SECONDARY BOOM UP/DOWN

JOYSTICK CONTROL CARD

3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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

PRIMARY BOOM UP/DOWN

AND TURNTABLE 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

NC

CR27 CE

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

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

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

CR8

NC

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

CR30

NO

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 12


6 - 11


6 - 13

Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models

6 - 14

1

2

3

4

5

6

7

8



6 - 14 S-80 • S-85 Part No. 111165


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 PRESSURE SENDER BL/BK C5-16 BL/BK-S.P

26 OIL TEMP SENDER GR/BK C5-14 GR/BK-S.P.

28 TILT ALARM RD/BK C1-2 RD/BK C6-28

29 2WD/4WD RD/WH C5-24 RD/WH C1B-3

30 E.D.C. REV WH C1B-4 WH C5-21

31 E.D.C. FWD WH/BK C5-20 WH/BK C1B-5

36 STEER LEFT/AXLE RETRACT BL CB1-10 BL C6-36

43 HORN GR C2B-5 GR CR5#86

45 GEN. OPTION GR/WH C2B-7 GR/WH C5-12

60 AXLE EXT/RET SELECT OR/RD C6-39 OR/RD C2B-4

12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12

CHECK ENGINE LED

TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH

CR23

CR3

CR5

CR2

TS61

CB1

TS62

L2

G6

CB2

CB3

DRIVE LIGHT RELAY OPTION

HIGH IDLE CUTOUT RELAY

CIRCUIT BREAKER, ENGINE, 15A

PRIMARY BOOM UP/DOWN TOGGLE SWITCH

CIRCUIT BREAKER, CONTROLS, 15A

CIRCUIT BREAKER, OIL COOLER/OPTION, 15A

HORN RELAY

IGNITION POWER RELAY

HOUR METER

TURNTABLE ROTATE TOGGLE SWITCH

LABEL

TS51

KS1

TS56

TS54

TS59

TS57

TS52

P1

GLOW PLUG TOGGLE SWITCH

PLATFORM ROTATE TOGGLE SWITCH

PLATFORM LEVEL TOGGLE SWITCH

ENGINE START TOGGLE SWITCH

FUNCTION ENABLE TOGGLE SWITCH

AUXILIARY TOGGLE SWITCH

RED EMERGENCY STOP BUTTON

KEY SWITCH

DESCRIPTION

G1

G2

G3

VOLT METER GAUGE (OPTIONAL)

OIL PRESSURE GAUGE (OPTIONAL)

OIL TEMPERATURE GAUGE (OPTIONAL)

CR17

CR29

CR38

CR39

HYDRAULIC COOLER FAN RELAY

EXTEND FUNCTION CUTOUT RELAY

AUXILIARY PUMP RELAY

AXLE EXTEND LED RELAY

R2 5 OHM RESISTOR

U1 IGNITION/START MODULE

CR28 TROMBETTA PULL IN RELAY

86

87

30

85

BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

GR/BK C2B-6

TB24AD

DRIVE LIGHT OPTION RELAY

BK C1B-7 BK ISM#333 BK-S.P.

HOUR METER

EN

GIN

E

C5

WIRING

HARNESS:

TO BASE

CONTROL BOX

CONNECTIONS

WH/BK-5A

WH-4A

WH-23AB

BK-C23-5

ENGINE START

GLOW PLUG

STEER RT/AXLE EXT

ENGINE RPM

LIMIT SWITCH #1

L.P.

ENGINE RPM

BRN-GND STUD

12

VD

CT

O

PL

AT

FO

RM

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

KEY PWR.WH-23B

7

GR C2B-5

CR5

RD 24B

10

WH-CR2#86

CR2

ENG. FAULT

KEY BYPASS

IGN./FUEL ON9

8

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

HIGH/LOW

RPM

D14

D42

D13

OR/BK-15A

RD-27B

BRN GND

OR/BK-41B

BK-33B

4 AUX. ON

BATTERY6

5 GROUND

START RELAY

TACHOMETER

START INPUT3

1

2

BASE TERMINATION BLOCK

OR/BK C2B-3

OR C6-10

BL/BK C6-37

BK/RD CR3#30

BK/WH C5-22

OR C6-40

OR/BK C5-2 OR/BK ISM#2

RD C6-31

41

46

40

BL/BK C1B-11

BK/RD C1B-9

BK/WH C1B-8

39

37

35

34

BK/RD-9A

BRN

GROUND STUD

BK-33

RD-1A

WH-21A

WH C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

PLATFORM

ROTATE

CB1

ENGINE

TS52

ENGINE

START

TS59

PLATFORM

LEVEL

TS62

TURNTABLE

ROTATE

-

+

TS63

BOOM EXTEND/

RETRACT

TS61

BOOM

UP/DOWN

PRIMARY BOOM UP

TURNTABLE ROTATE LEFT

TURNTABLE ROTATE RIGHT

PRIMARY BOOM FLOW CONTROL

BOOM EXTEND

BOOM RETRACT

EXTEND/RETRACT FLOW CONTROL

TURNTABLE ROTATE F.C.

PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT

PLATFORM ROTATE RIGHT

KEYSWITCH PWR/PWR TO PLAT

OIL COOLER FAN

FUSED 12V DC

IGNITION POWER

PRIMARY BOOM DOWN

12V DC BATTERY SUPPLY

AUXILIARY PUMP

SBD/DESCENT ALARM

BRAKE

CD AB

WT/RD C5-23

BK C23-4

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3

OR C4B-2

21

WH/RD C1B-6

RD C5-6

WH C7B-2

24 RD CR2#30

WH/RD C6-32

RD ISM#427

32

BK CR5#30

23

22

GR C6-17

GR/BK C6-18

OR C6-14

OR/BK C6-15

OR/RD CR38#87A

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

CR39#30

BK C6-7

BK/WH C6-8

BK/RD C6-9

11

10

7

8

9

RD/WH C6-3

WH C6-4

WH/BK C6-5

RD C6-1 RD CR38#86

BK/WH C6-38

3

5

4

2

1

GR/BK C5-14

WH S.P.

RD-S.P.-CB3

RD-S.P.

D6

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.

BL/BK C5-16

D2

NC

P1

EMERGENCY

STOP

NC

TS51

AUXILIARY

PUMP

OIL PRESSURE

G2G1

VOLT METER

G3

OIL TEMPERATURE

BL/RD L2

GR

OU

ND

ST

UD

G6

U1IGNITION/

START

MODULE

CB3

OIL COOLER/

OPTION

BRN-CR19#85

H1

RD-B2-S.P.

RD-B1-20C

RD-24AA

868686

RD-B2-H1

RD-B1-H1 RD-B1-S.P.

CR3

86

RD-CR28#30

RD-CR39#87&C1B1

24A

WH-S.P.-D2

BK-33AA

42

D34

OR/RD C6-22OR/RD C4B-4

RD CR17#30

RD/BK C6-19

RD C6-30

33A BK ISM#1BK-CR28#86BK C5-5D51

R2

OR/RD C6-11

38

BK/WH-S.P.

BL/BK C6-20

OR/RD CR29#86

CR25 AXLE RET L/O RELAY

AXLE DUMP VALVE

HORN

START RELAY

LIMIT SWITCH #2

LIMIT SWITCH POWER

BK/RD C5-18

BK/WH-34A

BK/RD-35B

RD-S.P.-CB1

D52 GND STUD

D8D7

WH CR17 #86

CB2

CONTROLSBK-33AB

BR

N

OR

/RD

-16

C

BK

/WH

C6

-29

RD

-1B

RD

C6

-27

RD

-27

D

RD

-24

C

BK C5-7

RD-B1-20D

RD-B1-H1

OR/RD CR8#87A

CR8#86+

D15

GND STUD

D57

D42

RD/BK CR8#30

86

86

CR29

CR39

86

86

CR8

CR38

86

CR17

RD/BK 2B

BL/RD C4B-1

WH-C6-34

RD-24AD

OR/RD 42C

OR/RD 16B

OR C6-33

WH-21B

BL/RD C6-13

BK 7B

86

CR28

3

1

BL/WH C1-12

RD H6

BK-22D2

BK C7B-1

RD-TS52

GR//BK H6

RD-TS51

BRN

8

12

5

6

7

4

P134PWR RD-134B

H6

C32

CONNECTOR

PLUG

RD C6-23 C2-6 134 RD-H6 RD-KSI-SP

TS56

GLOW PLUG

L2

CHECK ENG. LED

-

+

WH-23A

BK-22A

RD C23-6

KS1

KEY SWITCH

RD-134A

RD-C23-7

-

L45

PLATFORM

OVERLOAD

LED

+

GR/BK-H6

PLATFORM OVERLOAD LEDL45

GR/BK-C3B-10

GR/BK-L45

RD C6-24 134A

WH ISM#7

KEY SWITCH POWER

KEY SWITCH POWER BL/RD ISM #10

WH C5-3 & C5-11

NOTE: CE OPTION- LOADSENSEMODULE CONNECTS TO C32.

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 15

Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models

BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2

U13

CR26

JC1

TILT ALARM

ALC500

AXLE CUTOUT RELAY

BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE

COMPONENT INDEX

TS2

TS9

TS15

P3

TS1

TS14

L1

P2

DRIVE ENABLE LED


HORN SWITCH

EMERGENCY STOP BUTTON


ENGINE START SWITCH

TS47 GENERATOR TOGGLE SWITCH (OPTION)

TS4

TS7

HIGH RPM SWITCH


LOW/HIGH SWITCHDRIVE SPEED TOGGLE

DRIVE ENABLE TOGGLE SWITCH

JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT

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

CR27

WH-TS7WH-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

CR26

AXLE CUTOUT

P2

EMERGENCY

STOP

TS4

HIGH/LOW

RPMTS2

ENGINE

START

L1

TS1

AUXILIARY

PUMP

TS14

DRIVE

SPEED

TS7

PLATFORM

ROTATE

TS9

PLATFORM

LEVEL

P3

JC2

PRIMARY BOOM

UP/DOWN AND

TURNTABLE

ROTATE

JC1

BOOM

EXTEND/

RETRACT

BK

/WH

C1

P-8

JC3

DRIVE

GND STUD

H1

TILT

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 DC

BATTERY

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-1

1

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

+

TS15

DRIVE

ENABLE

19/18 CONTROL CABLE

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

TS6

GLOW 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-1

1

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

U13

ALC-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


6 - 16


6 - 15


6 - 17

Electrical Schematic, S-80Deutz BF4L 2011 Models

6 - 18

1

2

3

4

5

6

7

8



6 - 18 S-80 • S-85 Part No. 111165


CE Option, See 6 - 98

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 19


PR

IMA

RY

BO

OM

RE

TR

AC

T

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WNP

LA

TF

OR

ML

EV

EL

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

RIG

HTP

LA

TF

OR

MR

OTA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

LE

FT

TS7

TS57

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

WH

H4

H3



3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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



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

NC

CR27 CE

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

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

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

CR8

NC

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

CR30

NO

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 20


6 - 19


6 - 21

Ground Control Box Wiring Diagram, S-80Deutz BF4L 2011 Models

6 - 22

1

2

3

4

5

6

7

8



6 - 22 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 23

Platform Control Box Wiring Diagram, S-80Deutz BF4L 2011 Models


6 - 24


6 - 23


6 - 25

Electrical Schematic, S-80GM 3.0L Models

6 - 26

1

2

3

4

5

6

7

8



6 - 26 S-80 • S-85 Part No. 111165


P2

3B

AT

RD

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

20ARD

P2

0B

AT

RD

C4

3H

RN

BK

CR5

NO

GR

CB3

RD

TB41

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

HO

UR

ME

TE

R

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TB35

TS2

AUX

PUMP

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

TB21

TS51

TB27

RD

TS1

TS52

TB33

RD

C1

34

-E.H

.

WH

-21

GR

/WH

FB

C3

3S

TR

BK

EN

GIN

E

STA

RT

EN

GIN

E

STA

RT

GE

NE

RA

TO

R

FU

EL

SE

LE

CT

FU

EL

SE

LE

CT

GA

S

GA

S

LP

LP

ON

AU

XIL

IAR

Y

PO

WE

R

AU

XIL

IAR

Y

PO

WE

R

C4

5G

EN

GR

/WH

TS47

P24FS WH

TS54

HIG

HR

PM

TS4

BRN

RD

OR/BK

WH

BK

L5

TB39

C3

9L

PB

L/R

D

HIG

H(F

S)

LO

WR

PM

TIL

TA

LA

RM

RD

WH

BK

H2HM

+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C2

-1

C2

-7

C1

-9C

35

ES

PD

BK

/RD

TB23

TB24

TB46D7

-

+

12V DC

B1

AUX

FAN

CR17

NO

15A

TB20

CB1

RD

B1

BA

TT

ER

Y

3 1 2

FU

NC

.E

NA

BL

E

C6

-16

C6

-23

C6

-34

C6

-33

C6

-28

C6

-27

C6

-24

C5

-12

G1

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

RD

RD/BK

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RG

R/B

K

15A

CB2

C2

8T

TA

RD

/BK

WH

TB28

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

C4

6H

RN

GR

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C7

P-1

P3

HORN

RD

P2

3B

AT

WH

WH

TB23

D2

C7

P-2

L4

FS1

BKC9P-1

P2

CR39

NO

GR/BK

RD

BL

GM ENGINE HARNESS

GR

/BK

PU

/BK

BK

DK

BL

RD

/BL

PU

YE

RD

YE

/BK

WH

/BL

LT

BL

FUEL

PUMP

+

C3

5R

PM

BK

/RD

C3

9L

PB

L/R

D

C3

8E

SL

BL

/RD

P2

3B

AT

SA

RD

C3

3S

TR

BK

C2

7A

UX

RD

C4

1R

PM

OR

/BK

C2

1IG

NW

H

C8

-5

C8

-12

C8

-11

C8

-6

C8

-4

C8

-3

C8

-8

C8

-1

M4

C8

-2

C8

-7

C8

-9

C5

-18

C5

-10

C5

-13

C5

-19

C5

-5

C5

-6

C5

-2

C5

-11

RGND.

REGULATOR1

U18

BAT.

2

WH-E.H.

STARTER

M3

TS3

TS53

D10

D11

CR2

NO D8

G1 G3 G2

C2

6T

SR

GR

/BK

C2

5P

SR

BL

/BK

ALT

ER

NA

TO

R

HY

DR

AU

LIC

CO

OL

ING

FA

N(O

PT

ION

)

HY

DR

UA

LIC

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H(O

PT

ION

)

GM

EN

GIN

E

HA

RN

ES

S

STA

RT

BA

TT

ER

Y

VO

LT

ME

TE

R(O

PT

ION

)

WA

TE

RT

EM

PE

RA

TU

RE

SE

ND

ER

(OP

TIO

N)

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

TIO

N)

D42

D43

EN

GIN

ES

PE

ED

TB24A


ADD D40 ONLY IF UNIT HAS L4 AND L48.

ANSI/CSA (DOMESTIC MACHINE) ADD L48.

3

CE AND LOAD WEIGHT OPTION.

5

6

4

ROCKER STEER OPTION ONLY.

NOTES:

BRN

BL/WH

RD

BR

N

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 27


PR

IMA

RY

BO

OM

RE

TR

AC

T

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WNP

LA

TF

OR

ML

EV

EL

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

RIG

HTP

LA

TF

OR

MR

OTA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

LE

FT

TS7

TS57

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

WH

H4

H3



3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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



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

NC

CR27 CE

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

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

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

CR8

NC

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

CR30

NO

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 28


6 - 27


6 - 29

Ground Control Box Wiring Diagram, S-80GM 3.0L Models

6 - 30

1

2

3

4

5

6

7

8



6 - 30 S-80 • S-85 Part No. 111165






26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.



30 E.D.C. REVERSE WH C1B-4 WH C5-21

31 E.D.C. FORWARD WH/BK C5-20 WH/BK C1B-5



45 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12

60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4


BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

GR/BK C2B-6

TB24AD


BK C1B-7 33 BK-S.P.

HOUR METER

EN

GIN

E

C5

WIRING

HARNESS:

TO BASE

CONTROL BOX

CONNECTIONS

WH/BK-5A

WH-4A

WH-23AB

BK-C23-5

ENGINE START

GLOW PLUG

STEER RT/AXLE EXT

ENGINE RPM

LIMIT SWITCH #1

L.P.

ENGINE RPM

BRN-GND STUD

12

VD

CT

O

PL

AT

FO

RM

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

GR C2B-5

CR5

RD CR38#30

BK/WH C6-29

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

HIGH/LOW

RPM

D14

D13

OR/BK-15A


OR/BK C2B-3

OR C6-10

D42

BL/BK C6-37

BK/RD CR3#30

BK/WH C5-22

OR C6-40

OR/BK C5-2

RD C6-31

41

46

40

BL/BK C1B-11

BK/RD C1B-9

BK/WH C1B-8

39

37

35

34

BK/RD-9A

BRN

GROUND STUD

BK-33

RD-1A

WH-21A

WH C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

PLATFORM

ROTATE

CB1

ENGINE

CB2

CONTROLS

TS52

ENGINE

START

TS59

PLATFORM

LEVEL

TS62

TURNTABLE

ROTATE

-

+

TS63

BOOM EXTEND/

RETRACT

TS61

BOOM

UP/DOWN

PRIMARY BOOM UP




BOOM EXTEND

BOOM RETRACT

EXTEND/RETRACT F.C.


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



KEY SWITCH PWR/PWR TO PLAT.

OIL COOLER FAN

FUSED 12V DC

IGNITION POWER

PRIMARY BOOM DOWN


AUXILIARY PUMP

SBD/DESCENT ALARM

BRAKE

CD AB

WT/RD C5-23

BK C5-5

BK C23-4

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3

OR C4B-2

21

WH/RD C1B-6

RD CR39#86&C1B-1

WH C7B-2

24 RD CR2#30

WH/RD C6-32

RD27

32

BK CR5#30

RD C5-1923

22

GR C6-17

GR/BK C6-18

OR C6-14

OR/BK C6-15

OR/RD CR38#87A

RD CR38#86

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 C6-3

WH C6-4

WH/BK C6-5

RD C6-1

3

5

4

2

1

GR/BK C5-14

WH S.P.

RD-S.P.-CB3

RD-S.P.

D7

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.

BL/BK C5-16

D2

NC

P1

EMERGENCY

STOP

NC

TS51

AUXILIARY

PUMP

OIL PRESSURE

G2G1

VOLT METER

G3

WATER TEMPERATURE

GR

OU

ND

ST

UD

G6

CB3

OIL COOLER/

OPTION

BRN (GND)

H1

RD-B2-S.P.

RD-B1-20C

RD-24AA

868686

RD-B2-H1

CR39 #30

RD-B1-H1 RD-B1-S.P.

CR38

86

24A

WH-S.P.-D2

42

D34


RD CR17#30

RD/BK C6-19

RD C6-30

RD C5-6

33A

R2

OR/RD C6-11

38

BL/BK C6-20

OR/RD CR29#86

CHECK ENGINE LED


CR23

CR5

CR2

TS61

CB1

TS62

L2

G6

CB2

DRIVE LIGHT RELAY (OPTIONAL)




HORN RELAY


HOUR METER


LABEL

TS51

KS1

TS54

TS59

TS57

TS52

P1




FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH

AUXILIARY POWER TOGGLE SWITCH


KEY SWITCH

DESCRIPTION

G1

G2

G3



WATER TEMP. GAUGE (OPTIONAL)

CR17

CR29

CR38

CR39





IGNITION/START MODULEU1

TS53 LP/GAS SELECT TOGGLE SWITCH

R2 TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS

CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A

CR8 BOOM FUNCTION CUTOUT

CR3 HIGH IDLE CUTOUT RELAY


AXLE DUMP VALVE

HORN

START RELAY

LIMIT SWITCH #2

LIMIT SWITCH POWER

RD-1B

RD-S.P.-CB1

D52 GND STUD

D8

WH CR17 #86

RD-B1-20D

RD-B1-H1

WH C5-3 & C5-11

OR/RD CR8#87A

BK/WH C6-38

CR8#86+

D15

GND STUD

D57

RD/BK CR8#30

86 86

CR29 CR39

86

CR8

86

CR17

RD/BK 2B

RD-24B

BL/RD C4B-1

WH-C6-34

RD-24AD

OR/RD 42C

RD CR2#30

OR/RD 16B

OR/RD 16C

OR C6-33

WH-21B

RD C6-27

BL/RD C6-13

RD-27D

BK 7B

RD C6-23 C2-6 134 RD-H6 RD-KSI-SPKEY SWITCH POWER

KEY SWITCH POWER

L2

CHECK ENG. LED

24

3

B1

B

1

-

+

WH-23A

BK-22A

KSI

KEY SWITCH

RD-134A

TS53

LP/GAS

BL/RD-39A

D11

D42

WH-C5-11

BL/RD TS53

RD C6-24 134ABL/RD C5-13

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 31

Platform Control Box Wiring Diagram, S-80GM 3.0L Models


CR27

WH-TS7WH-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

BL

/RD

C2

P-1

GR

/WH

JIB

CA

BL

E

WH

C7

P-2

BK

C7

P-1

JC3

DRIVE

AND STEER

P2

EMERGENCY

STOP

TS3

FUEL SELECTTS4

HIGH/LOW

RPM

TS2

ENGINE

START

L1

TS1

AUXILIARY PUMP

TS14

DRIVE

SPEED

TS7

PLATFORM

ROTATE

TS9

PLATFORM

LEVEL

P3

HORN

JC2

PRIMARY BOOM

UP/DOWN AND

TURNTABLE

ROTATE

JC1

BOOM

EXTEND/

RETRACT

GND STUD

H1

TILT

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 DC BATTERY

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

C9JIB

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-1

1

DL

ITE

GR

/BK

C2

P-6

C4

0L

S1

OR

C2

P-2

TS

3-C

39

LP

BL

/RD

C2

P-1

C3

6S

TC

CB

LC

1P

-10

P3

-C4

3H

RN

GR

C2

P-5

BK

J1

-2

CR26

AXLE CUTOUT

+

TS15

DRIVE

ENABLE

19/18 CONTROL CABLE

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

D10

D12

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-1

1

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

U13

ALC-500

D2


RD

/BK

H1

RD LS CABLE Y

Y

RD-H1

RD-P2

+

L4

BK LS CABLE CIP-12

RD

C2

P-6

GN

/BK

L4

OPT

GN

/BK

C3

P-1

0

RD

/BK

L4

8

GN

/BK

H1

(D3

9)

L48

+

TS48/TS49

RD WL1

RD WL2

TS15


BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATEJC2

CR26

U13

JC1

TILT ALARM

ALC500

AXLE CUTOUT RELAY

BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACT

COMPONENT INDEX

TS2

TS9

TS15

TS3

P3

TS1

TS14

L1

P2

DRIVE ENABLE LED


FUEL SELECT TOGGLE SWITCH (FORD)

HORN SWITCH




TS47 GENERATOR TOGGLE SWITCH ( OPTION )

TS4

TS7

HIGH RPM TOGGLE SWITCH


DRIVE SPEED LOW/HIGH TOGGLE SWITCH



H1

TS49

TS48 WORK LIGHT RELAY (OPTION)

DRIVE LIGHT RELAY (OPTION)





L48 TILT ALARM LED

D40

D39

TS2

GR

/WH

C2

P-7

DETAIL B:

GENERATOR OPTION


6 - 32


6 - 31


6 - 33

Electrical Schematic, S-80Perkins 804-33 Models

6 - 34

1

2

3

4

5

6

7

8



6 - 34 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 35


PR

IMA

RY

BO

OM

RE

TR

AC

T

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WNP

LA

TF

OR

ML

EV

EL

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

RIG

HTP

LA

TF

OR

MR

OTA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

LE

FT

TS7

TS57

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

WH

H4

H3



3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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



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

NC

CR27 CE

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

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

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

CR8

NC

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

2C

29

-2C

29

-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

CR30

NO

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 36


6 - 35


6 - 37

Ground Control Box Wiring Diagram, S-80Perkins 804-33 Models

6 - 38

1

2

3

4

5

6

7

8



6 - 38 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 39

Platform Control Box Wiring Diagram, S-80Perkins 804-33 Models


6 - 40


6 - 39


6 - 41

Electrical Schematic, S-80Ford LRG-425 EFI

6 - 42

1

2

3

4

5

6

7

8



6 - 42 S-80 • S-85 Part No. 111165


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 43



6 - 44


6 - 43


6 - 45

Ground Control Box Wiring Diagram, S-80Ford LRG-425 EFI

6 - 46

1

2

3

4

5

6

7

8



6 - 46 S-80 • S-85 Part No. 111165


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 47

Platform Control Box Wiring Diagram, S-80Ford LRG-425 EFI


6 - 48


6 - 47


6 - 49


6 - 50

1

2

3

4

5

6

7

8



6 - 50 S-80 • S-85 Part No. 111165

1

2

3

4

5

6

7

8



P1

34

RD

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

RD

P2

0B

AT

RD

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

20A

RD

TB41

GE

NE

RA

TO

R

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

IN/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TB35

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

STARTERAUX

PUMP

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

TB21

CR2

NO

8

7

6

5

10

9

TS51

TB27

RD

TS1

TS52

1

2

TB33

3

RD

IGN./START

MODULE

WH

-21

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RD

OR/BK

OIL

TE

MP

ER

AT

UR

EA

ND

OIL

PR

ES

SU

RE

LE

D

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

ST

PB

L/R

D

S2

NC

S1

NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

PR2

NO

BK

/WH

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TIL

TA

LA

RM

RD

WH

BK

BK

H2HM

+

_

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

-

+

12 V

DC

B1

D22

AUX

FAN

CR17

NO

TB20

CB1

15A

RD

B1

BA

TT

ER

Y

3 1 2

FU

NC

.E

NA

BL

E

PU

LL

IN

HO

LD

A

WH

RD

BK

CB

D6

CR1CR1

NO

FUSE

70A

HO

LD

PU

LL

INW

H

BK

21

RD

3

MODULE

TIME DELAY

-COM

+AUX

S-613

+BAT

MOM N.O.

BRN

WH

RD

RP

MS

OL

EN

OID

CR28

NO

C6

-16

C6

-23

C6

-34

C6

-33

C5

-3 C5

-2

C6

-28

C6

-27

C5

-15

C5

-5

R3

3S

TR

BK

C2

1IG

NW

H

TB33AG

LO

WP

LU

GR

EL

AY

GL

OW

PL

UG

GL

OW

PL

UG

FU

EL

VA

LV

E

C5

-22

C6

-13

4R

D

C5

-12

C5

-18

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

C3

3S

TR

BK

C5

-7

C5

-11

BL/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RG

R/B

K

CB2

15A

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

P3

HORN

RD

P2

3B

AT

WH

AU

XIL

IAR

Y

PO

WE

R

AU

XIL

IAR

Y

PO

WE

R

EN

GIN

E

STA

RT

EN

GIN

E

STA

RT

GL

OW

PL

UG

GL

OW

PL

UG GE

NE

RA

TO

R

ON

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1

P2

CR39

NO

D42

EN

GIN

ER

PM

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

TIO

N)

OIL

TE

MP

ER

AT

UR

E

SE

ND

ER

(OP

TIO

N)

C2

6T

SR

GR

/BK

C2

5P

SR

BL

/BK

G3 G2

VO

LT

ME

TE

R(O

PT

ION

)

G1

TB24A

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

DR

AU

LIC

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H(O

PT

ION

)

HY

DR

AU

LIC

CO

OL

ING

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

Y

5D40

L48+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:

3 ROCKER STEER OPTION ONLY.

5 ADD D40 ONLY IF UNIT HAS L4 AND L48.


2 C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.

6CE Option, See 6 - 98

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 51


PR

IMA

RY

BO

OM

RE

TR

AC

T

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

WH

BRN

TS7

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

TS8

TS58

WH

H4

H3



3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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



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

JIB

VA

LV

ES

JIB

VA

LV

ES

P23 RD

NC

CR27 CE

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

C4

P-7

C1

9JS

VG

R/W

H

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C19JSV GR/WH

DR

IVE

ED

CF

OR

WA

RD

NC

CR13

CR13

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK

NOHC

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

D41

AX

LE

EX

TE

ND

/RE

TR

AC

TS

EL

EC

T

C6

0A

XO

R/R

D

C2

P-4

AX

LE

DU

MP

VA

LV

E

NC

CR8

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

CR30

NO

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 NC

CR38

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 52


6 - 51


6 - 53


6 - 54

1

2

3

4

5

6

7

8



6 - 54 S-80 • S-85 Part No. 111165






26 OIL TEMP SENDER GR/BK C5-14 GR/BK-S.P.



30 E.D.C. REV WH C1B-4 WH C5-21

31 E.D.C. FWD WH/BK C5-20 WH/BK C1B-5



45 GEN. OPTION GR/WH C2B-7 GR/WH C5-12

60 AXLE EXT/RET SELECT OR/RD C6-39 OR/RD C2B-4


CHECK ENGINE LED


CR23

CR3

CR5

CR8

CR2

TS61

CB1

TS62

L2

G6

CB2

CB3

DRIVE LIGHT RELAY OPTION

HIGH IDLE CUTOUT RELAY




CIRCUIT BREAKER, OIL COOLER/OPTION, 15A

HORN RELAY

BOOM FUNCTION CUTOUT RELAY


HOUR METER


LABEL

TS51

KS1

TS56

TS54

TS59

TS57

TS58

TS52

P1

GLOW PLUG TOGGLE SWITCH


JIB BOOM UP/DOWN TOGGLE SWITCH



FUNCTION ENABLE TOGGLE SWITCH


RED EMERGENCY STOP BUTTON

KEY SWITCH

DESCRIPTION

G1

G2

G3



OIL TEMPERATURE GAUGE (OPTIONAL)

CR17

CR29

CR38

CR39





R2 5 OHM RESISTOR

U1 IGNITION/START MODULE

CR28 TROMBETTA PULL IN RELAY

86

87

30

85

BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

GR/BK C2B-6

TB24AD


BK C1B-7 BK ISM#333 BK-S.P.

HOUR METER

EN

GIN

E

C5

WIRING

HARNESS:

TO BASE

CONTROL BOX

CONNECTIONS

WH/BK-5A

WH-4A

WH-23AB

BK-C23-5

ENGINE START

GLOW PLUG

STEER RT/AXLE EXT

ENGINE RPM

LIMIT SWITCH #1

L.P.

ENGINE RPM

BRN-GND STUD

12

VD

CT

O

PL

AT

FO

RM

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

KEY PWR.WH-23B

7

GR C2B-5

CR5

RD 24B

10

WH-CR2#86

CR2

ENG. FAULT

KEY BYPASS

IGN./FUEL ON9

8

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

HIGH/LOW

RPM

D14

D42

D13

OR/BK-15A

RD-27B

BRN GND

OR/BK-41B

BK-33B

4 AUX. ON

BATTERY6

5 GROUND

START RELAY

TACHOMETER

START INPUT3

1

2


OR/BK C2B-3

OR C6-10

BL/BK C6-37

BK/RD CR3#30

BK/WH C5-22

OR C6-40

OR/BK C5-2 OR/BK ISM#2

RD C6-31

41

46

40

BL/BK C1B-11

BK/RD C1B-9

BK/WH C1B-8

39

37

35

34

BK/RD-9A

BRN

GROUND STUD

BK-33

RD-1A

WH-21A

WH C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

PLATFORM

ROTATE

CB1

ENGINE

TS52

ENGINE

START

TS59

PLATFORM

LEVEL

TS62

TURNTABLE

ROTATE

-

+

TS63

BOOM EXTEND/

RETRACT

TS61

BOOM

UP/DOWN

PRIMARY BOOM UP




BOOM EXTEND

BOOM RETRACT

EXTEND/RETRACT FLOW CONTROL


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



KEYSWITCH PWR/PWR TO PLAT

OIL COOLER FAN

FUSED 12V DC

IGNITION POWER

PRIMARY BOOM DOWN


AUXILIARY PUMP

SBD/DESCENT ALARM

BRAKE

CD AB

WT/RD C5-23

BK C23-4

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3

OR C4B-2

21

WH/RD C1B-6

RD C5-6

WH C7B-2

24 RD CR2#30

WH/RD C6-32

RD ISM#427

32

BK CR5#30

23

22

GR C6-17

GR/BK C6-18

OR C6-14

OR/BK C6-15

OR/RD CR38#87A

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

CR39#30

BK C6-7

BK/WH C6-8

BK/RD C6-9

11

10

7

8

9

RD/WH C6-3

WH C6-4

WH/BK C6-5

RD C6-1 RD CR38#86

BK/WH C6-38

3

5

4

2

1

GR/BK C5-14

WH S.P.

RD-S.P.-CB3

RD-S.P.

D6

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.

BL/BK C5-16

D2

NC

P1

EMERGENCY

STOP

NC

TS51

AUXILIARY

PUMP

OIL PRESSURE

G2G1

VOLT METER

G3

OIL TEMPERATURE

BL/RD L2

GR

OU

ND

ST

UD

G6

U1IGNITION/

START

MODULE

CB3

OIL COOLER/

OPTION

BRN-CR19#85

H1

RD-B2-S.P.

RD-B1-20C

RD-24AA

868686

RD-B2-H1

RD-B1-H1 RD-B1-S.P.

CR3

86

RD-CR28#30

RD-CR39#87&C1B1

24A

WH-S.P.-D2

BK-33AA

42

D34


RD CR17#30

RD/BK C6-19

RD C6-30

33A BK ISM#1BK-CR28#86BK C5-5D51

R2

OR/RD C6-11

38

BK/WH-S.P.

BL/BK C6-20

OR/RD CR29#86


AXLE DUMP VALVE

HORN

START RELAY

LIMIT SWITCH #2

LIMIT SWITCH POWER

BK/RD C5-18

BK/WH-34A

BK/RD-35B

RD-S.P.-CB1

D52 GND STUD

D8D7

WH CR17 #86

CB2

CONTROLSBK-33AB

BR

N

OR

/RD

-16

C

BK

/WH

C6

-29

RD

-1B

RD

C6

-27

RD

-27

D

RD

-24

C

BK C5-7

RD-B1-20D

RD-B1-H1

OR/RD CR8#87A

CR8#86+

D15

GND STUD

D57

D42

RD/BK CR8#30

86

86

CR29

CR39

86

86

CR8

CR38

86

CR17

RD/BK 2B

BL/RD C4B-1

WH-C6-34

RD-24AD

OR/RD 42C

OR/RD 16B

OR C6-33

WH-21B

BL/RD C6-13

BK 7B

86

CR28

3

1

BL/WH C1-12

RD H6

BK-22D2

BK C7B-1

RD-TS52

GR//BK H6

RD-TS51

BRN

8

12

5

6

7

4

P134PWR RD-134B

H6

C32

CONNECTOR

PLUG

RD C6-23 C2-6 134 RD-H6 RD-KSI-SP

TS56

GLOW PLUG

L2

CHECK ENG. LED

-

+

WH-23A

BK-22A

RD C23-6

KS1

KEY SWITCH

1

2

3

4

B

B1

RD-134A

RD-C23-7

-

L45

PLATFORM

OVERLOAD

LED

+

GR/BK-H6

PLATFORM OVERLOAD LEDL45

GR/BK-C3B-10

GR/BK-L45

RD C6-24 134A

WH ISM#7

KEY SWITCH POWER

KEY SWITCH POWER BL/RD ISM #10

WH C5-3 & C5-11

TS58

JIB

BOOM


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 55


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


HORN SWITCH



ENGINE START SWITCH

TS47 GENERATOR TOGGLE SWITCH (OPTION)

TS4

TS7

TS8

HIGH RPM SWITCH



LOW/HIGH SWITCHDRIVE SPEED TOGGLE



CR13

CR26

H1

TS48

TS49

WORK LIGHT TOGGLE SWITCH (OPTION)

DRIVE LIGHT TOGGLE SWITCH (OPTION)

GLOW PLUG OPTIONTS6




CR27

WH-TS7WH-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

CR26

AXLE CUTOUT

P2

EMERGENCY

STOP

TS4

HIGH/LOW

RPMTS2

ENGINE

START

L1

TS1

AUXILIARY

PUMP

TS14

DRIVE

SPEED

TS7

PLATFORM

ROTATE

TS9

PLATFORM

LEVEL

P3

JC2

PRIMARY BOOM

UP/DOWN AND

TURNTABLE

ROTATE

JC1

BOOM

EXTEND/

RETRACT

BK

/WH

C1

P-8

JC3

DRIVE

GND STUD

H1

TILT

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 DC

BATTERY

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-1

1

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

+

TS15

DRIVE

ENABLE

19/18 CONTROL CABLE

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

TS6

GLOW 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-1

1

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

U13

ALC-500

D2


RD

/BK

H1

RD LS CABLERD-H1

RD-P2

+

L4

BK LS CABLE CIP-12

RD

C2

P-6

GN

/BK

L4



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


L48 TILT ALARM LED

D40

D39

TS2

GR

/WH

C2

P-7

DETAIL B: GENERATOR OPTION

TS8

JIB BOOM

JIB

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7

RD/BK JIB CABLEGND

CR13

CUTOUT

JIB

GR/WH C4P-7

GR/WH TS7


6 - 56


6 - 55


6 - 57


6 - 58

1

2

3

4

5

6

7

8



6 - 58 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 59



6 - 60


6 - 59


6 - 61


6 - 62

1

2

3

4

5

6

7

8



6 - 62 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 63



6 - 64


6 - 63


6 - 65


6 - 66

1

2

3

4

5

6

7

8



6 - 66 S-80 • S-85 Part No. 111165


P2

3B

AT

RD

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

20ARD

P2

0B

AT

RD

C4

3H

RN

BK

CR5

NO

GR

CB3

RD

TB41

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

HO

UR

ME

TE

R

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TB35

TS2

AUX

PUMP

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

TB21

TS51

TB27

RD

TS1

TS52

TB33

RD

C1

34

-E.H

.

WH

-21

GR

/WH

FB

C3

3S

TR

BK

EN

GIN

E

STA

RT

EN

GIN

E

STA

RT

GE

NE

RA

TO

R

FU

EL

SE

LE

CT

FU

EL

SE

LE

CT

GA

S

GA

S

LP

LP

ON

AU

XIL

IAR

Y

PO

WE

R

AU

XIL

IAR

Y

PO

WE

R

C4

5G

EN

GR

/WH

TS47

P24FS WH

TS54

HIG

HR

PM

TS4

BRN

RD

OR/BK

WH

BK

L5

TB39

C3

9L

PB

L/R

D

HIG

H(F

S)

LO

WR

PM

TIL

TA

LA

RM

RD

WH

BK

H2HM

+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C2

-1

C2

-7

C1

-9C

35

ES

PD

BK

/RD

TB23

TB24

TB46D7

-

+

12V DC

B1

AUX

FAN

CR17

NO

15A

TB20

CB1

RD

B1

BA

TT

ER

Y

3 1 2

FU

NC

.E

NA

BL

E

C6

-16

C6

-23

C6

-34

C6

-33

C6

-28

C6

-27

C6

-24

C5

-12

G1

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

RD

RD/BK

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RG

R/B

K

15A

CB2

C2

8T

TA

RD

/BK

WH

TB28

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

C4

6H

RN

GR

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C7

P-1

P3

HORN

RD

P2

3B

AT

WH

WH

TB23

D2

C7

P-2

L4

FS1

BKC9P-1

P2

CR39

NO

GR/BK

RD

BL

GM ENGINE HARNESS

GR

/BK

PU

/BK

BK

DK

BL

RD

/BL

PU

YE

RD

YE

/BK

WH

/BL

LT

BL

FUEL

PUMP

+

C3

5R

PM

BK

/RD

C3

9L

PB

L/R

D

C3

8E

SL

BL

/RD

P2

3B

AT

SA

RD

C3

3S

TR

BK

C2

7A

UX

RD

C4

1R

PM

OR

/BK

C2

1IG

NW

H

C8

-5

C8

-12

C8

-11

C8

-6

C8

-4

C8

-3

C8

-8

C8

-1

M4

C8

-2

C8

-7

C8

-9

C5

-18

C5

-10

C5

-13

C5

-19

C5

-5

C5

-6

C5

-2

C5

-11

RGND.

REGULATOR1

U18

BAT.

2

WH-E.H.

STARTER

M3

TS3

TS53

D10

D11

CR2

NO D8

G1 G3 G2

C2

6T

SR

GR

/BK

C2

5P

SR

BL

/BK

ALT

ER

NA

TO

R

HY

DR

AU

LIC

CO

OL

ING

FA

N(O

PT

ION

)

HY

DR

UA

LIC

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H(O

PT

ION

)

GM

EN

GIN

E

HA

RN

ES

S

STA

RT

BA

TT

ER

Y

VO

LT

ME

TE

R(O

PT

ION

)

WA

TE

RT

EM

PE

RA

TU

RE

SE

ND

ER

(OP

TIO

N)

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

TIO

N)

D42

D43

EN

GIN

ES

PE

ED

TB24A


ADD D40 ONLY IF UNIT HAS L4 AND L48.

ANSI/CSA (DOMESTIC MACHINE) ADD L48.

3

CE AND LOAD WEIGHT OPTION.

5

6

4

ROCKER STEER OPTION ONLY.

NOTES:

BRN

BL/WH

RD

BR

N

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 67


PR

IMA

RY

BO

OM

RE

TR

AC

T

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

P46 RD

C41RPM OR/BK

WH

BRN

TS7

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

BO

OM

EX

TE

ND

/RE

TR

AC

T

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

T

BO

OM

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

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

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

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

C1

PB

UR

D

PR

IMA

RY

BO

OM

EX

TE

ND

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

ER

AT

ION

AL

DR

IVE

/RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

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

DR

IVE

/RO

TA

TE

SP

EE

D

LIM

ITS

WIT

CH

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

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

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

TS8

TS58

WH

H4

H3



3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

1413

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



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

JIB

VA

LV

ES

JIB

VA

LV

ES

P23 RD

NC

CR27 CE

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

C4

P-7

C1

9JS

VG

R/W

H

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C19JSV GR/WH

DR

IVE

ED

CF

OR

WA

RD

NC

CR13

CR13

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK

NOHC

LS3

NC

2AO

NOHC

2AS

NC

1RO

NOHC

1RS

TS16

RE

TR

AC

T

EX

TE

ND

AX

LE

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NC

CR26

D37

D38

D35 D36

RE

TR

AC

T

EX

TE

ND

AX

LE

D41

AX

LE

EX

TE

ND

/RE

TR

AC

TS

EL

EC

T

C6

0A

XO

R/R

D

C2

P-4

AX

LE

DU

MP

VA

LV

E

NC

CR8

D34

D15

TB16

S3

NC

CR29

NC

AX

LE

NO

TE

XT

EN

DE

DP

RE

SS

UR

ES

WIT

CH

OP

EN

WH

EN

AX

LE

FU

LLY

EX

TE

ND

ED

AX

LE

EX

TE

ND

RE

LA

Y

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

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

ER

AT

ION

AL

DR

IVE

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

CR30

NO

C27AUX + FE RDL

EF

T

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 NC

CR38

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

3

PR

IMA

RY

BO

OM

EX

TE

ND

CU

TO

UT

RE

LA

Y

PR

IMA

RY

BO

OM

UP

CU

TO

UT

RE

LA

Y


6 - 68


6 - 67


6 - 69


6 - 70

1

2

3

4

5

6

7

8



6 - 70 S-80 • S-85 Part No. 111165






26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.



30 E.D.C. REVERSE WH C1B-4 WH C5-21

31 E.D.C. FORWARD WH/BK C5-20 WH/BK C1B-5



45 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12

60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4


BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

GR/BK C2B-6

TB24AD


BK C1B-7 33 BK-S.P.

HOUR METER

EN

GIN

E

C5

WIRING

HARNESS:

TO BASE

CONTROL BOX

CONNECTIONS

WH/BK-5A

WH-4A

WH-23AB

BK-C23-5

ENGINE START

GLOW PLUG

STEER RT/AXLE EXT

ENGINE RPM

LIMIT SWITCH #1

L.P.

ENGINE RPM

BRN-GND STUD

12

VD

CT

O

PL

AT

FO

RM

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B

1

GR C2B-5

CR5

RD CR38#30

BK/WH C6-29

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

HIGH/LOW

RPM

D14

D13

OR/BK-15A


OR/BK C2B-3

OR C6-10

D42

BL/BK C6-37

BK/RD CR3#30

BK/WH C5-22

OR C6-40

OR/BK C5-2

RD C6-31

41

46

40

BL/BK C1B-11

BK/RD C1B-9

BK/WH C1B-8

39

37

35

34

BK/RD-9A

BRN

GROUND STUD

BK-33

RD-1A

WH-21A

WH C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

PLATFORM

ROTATE

CB1

ENGINE

CB2

CONTROLS

TS52

ENGINE

START

TS59

PLATFORM

LEVEL

TS62

TURNTABLE

ROTATE

-

+

TS63

BOOM EXTEND/

RETRACT

TS61

BOOM

UP/DOWN

PRIMARY BOOM UP




BOOM EXTEND

BOOM RETRACT

EXTEND/RETRACT F.C.


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



KEY SWITCH PWR/PWR TO PLAT.

OIL COOLER FAN

FUSED 12V DC

IGNITION POWER

PRIMARY BOOM DOWN


AUXILIARY PUMP

SBD/DESCENT ALARM

BRAKE

CD AB

WT/RD C5-23

BK C5-5

BK C23-4

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3

OR C4B-2

21

WH/RD C1B-6

RD CR39#86&C1B-1

WH C7B-2

24 RD CR2#30

WH/RD C6-32

RD27

32

BK CR5#30

RD C5-1923

22

GR C6-17

GR/BK C6-18

OR C6-14

OR/BK C6-15

OR/RD CR38#87A

RD CR38#86

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 C6-3

WH C6-4

WH/BK C6-5

RD C6-1

3

5

4

2

1

GR/BK C5-14

WH S.P.

RD-S.P.-CB3

RD-S.P.

D7

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.

BL/BK C5-16

D2

NC

P1

EMERGENCY

STOP

NC

TS51

AUXILIARY

PUMP

OIL PRESSURE

G2G1

VOLT METER

G3

WATER TEMPERATURE

GR

OU

ND

ST

UD

G6

CB3

OIL COOLER/

OPTION

BRN (GND)

H1

RD-B2-S.P.

RD-B1-20C

RD-24AA

868686

RD-B2-H1

CR39 #30

RD-B1-H1 RD-B1-S.P.

CR38

86

24A

WH-S.P.-D2

42

D34


RD CR17#30

RD/BK C6-19

RD C6-30

RD C5-6

33A

R2

OR/RD C6-11

38

BL/BK C6-20

OR/RD CR29#86

CHECK ENGINE LED


CR23

CR5

CR2

TS61

CB1

TS62

L2

G6

CB2

DRIVE LIGHT RELAY (OPTIONAL)




HORN RELAY


HOUR METER


LABEL

TS51

KS1

TS54

TS59

TS57

TS58

TS52

P1





FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH

AUXILIARY POWER TOGGLE SWITCH


KEY SWITCH

DESCRIPTION

G1

G2

G3



WATER TEMP. GAUGE (OPTIONAL)

CR17

CR29

CR38

CR39





IGNITION/START MODULEU1

TS53 LP/GAS SELECT TOGGLE SWITCH

R2 TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS

CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A

CR8 BOOM FUNCTION CUTOUT

CR3 HIGH IDLE CUTOUT RELAY


AXLE DUMP VALVE

HORN

START RELAY

LIMIT SWITCH #2

LIMIT SWITCH POWER

RD-1B

RD-S.P.-CB1

D52 GND STUD

D8

WH CR17 #86

RD-B1-20D

RD-B1-H1

WH C5-3 & C5-11

OR/RD CR8#87A

BK/WH C6-38

CR8#86+

D15

GND STUD

D57

RD/BK CR8#30

86 86

CR29 CR39

86

CR8

86

CR17

RD/BK 2B

RD-24B

BL/RD C4B-1

WH-C6-34

RD-24AD

OR/RD 42C

RD CR2#30

OR/RD 16B

OR/RD 16C

OR C6-33

WH-21B

RD C6-27

BL/RD C6-13

RD-27D

BK 7B

RD C6-23 C2-6 134 RD-H6 RD-KSI-SPKEY SWITCH POWER

KEY SWITCH POWER

L2

CHECK ENG. LED

24

3

B1

B

1

-

+

WH-23A

BK-22A

KSI

KEY SWITCH

RD-134A

TS53

LP/GAS

BL/RD-39A

D11

D42

WH-C5-11

BL/RD TS53

RD C6-24 134ABL/RD C5-13

TS58

JIB

BOOM

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 71



CR27

WH-TS7WH-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

BL

/RD

C2

P-1

GR

/WH

JIB

CA

BL

E

WH

C7

P-2

BK

C7

P-1

JC3

DRIVE

AND STEER

P2

EMERGENCY

STOP

TS3

FUEL SELECTTS4

HIGH/LOW

RPM

TS2

ENGINE

START

L1

TS1

AUXILIARY PUMPTS14

DRIVE

SPEED

TS8

JIB BOOM

TS7

PLATFORM

ROTATE

TS9

PLATFORM

LEVEL

P3

HORN

JC2

PRIMARY BOOM

UP/DOWN AND

TURNTABLE

ROTATE

JC1

BOOM

EXTEND/

RETRACT

GND STUD

H1

TILT

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 DC BATTERY

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

C9JIB

P2

-P2

3S

WB

AT

WH

C7

P-2

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7

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

RD/BK JIB CABLE

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-1

1

DL

ITE

GR

/BK

C2

P-6

C4

0L

S1

OR

C2

P-2

TS

3-C

39

LP

BL

/RD

C2

P-1

C3

6S

TC

CB

LC

1P

-10

P3

-C4

3H

RN

GR

C2

P-5

BK

J1

-2

CR26

AXLE CUTOUT

+

TS15

DRIVE

ENABLE

19/18 CONTROL CABLE

GND

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

D10

D12

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

CR13

JIB BOOM

CUTOUT

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-1

1

BK

P2

BL

/WH

J1

-6

GR/WH C4P-7

WH

C9

-2

BK

J3

-3

BL

TS

16

TS

16

-C6

1A

XB

L/B

KC

3P

11

CR13 BRN

RD

LS

18

Y

Y GR/WH TS7

U13

ALC-500

D2


RD

/BK

H1

RD LS CABLE Y

Y

RD-H1

RD-P2

+

L4

BK LS CABLE CIP-12

RD

C2

P-6

GN

/BK

L4

OPT

GN

/BK

C3

P-1

0

RD

/BK

L4

8

GN

/BK

H1

(D3

9)

L48

+

TS48/TS49

RD WL1

RD WL2

TS15


BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATEJC2

CR13

CR26

U13

JC1

TILT ALARM

ALC500

JIB BOOM CUTOUT RELAY

AXLE CUTOUT RELAY

BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACT

COMPONENT INDEX

TS2

TS9

TS15

TS8

TS3

P3

TS1

TS14

L1

P2

DRIVE ENABLE LED



FUEL SELECT TOGGLE SWITCH (FORD)

HORN SWITCH




TS47 GENERATOR TOGGLE SWITCH ( OPTION )

TS4

TS7

HIGH RPM TOGGLE SWITCH


DRIVE SPEED LOW/HIGH TOGGLE SWITCH



H1

TS49

TS48 WORK LIGHT RELAY (OPTION)

DRIVE LIGHT RELAY (OPTION)





L48 TILT ALARM LED

D40

D39

TS2

GR

/WH

C2

P-7

DETAIL B:

GENERATOR OPTION


6 - 72


6 - 71


6 - 73


6 - 74

1

2

3

4

5

6

7

8



6 - 74 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 75



6 - 76


6 - 75


6 - 77


6 - 78

1

2

3

4

5

6

7

8



6 - 78 S-80 • S-85 Part No. 111165



1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 79



6 - 80


6 - 79


6 - 81


6 - 82

1

2

3

4

5

6

7

8



6 - 82 S-80 • S-85 Part No. 111165


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 83



6 - 84


6 - 83


6 - 85


6 - 86

1

2

3

4

5

6

7

8



6 - 86 S-80 • S-85 Part No. 111165


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 87



6 - 88


6 - 87


6 - 89

Connector Pin Legend - Sheet 1

6 - 90

1

2

3

4

5

6

7

8



6 - 90 S-80 • S-85 Part No. 111165


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

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 91


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

11

91

6

81


6 - 92


6 - 91


6 - 93

Dual Battery Option

6 - 94

1

2

3

4

5

6

7

8



6 - 94 S-80 • S-85 Part No. 111165

Dual Battery Option

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

Y

SINGLE BATTERY (STANDARD)

CB2

15A

WH

RDRD

PLAT

GRD

KS1 TB22

P1 RD

+

-

RD

P2

0B

AT

RD

C1

07

AF

WH

C4

1R

PM

OR

/BK

CB3

20A

RD

12 V

DC

12 V

DC

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

-

+

BATTERY

SEPARATOR

B1B2

D22

TB20

CB1

15A

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



Part No. 111165 S-80 • S-85 6 - 95

Belt Drive Generator Option

120VAC / 60HZ

LINE BK

NEUTRAL WH

GND GR

GND BR

P20BAT

TG3

TG1

TG4

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

TG1

TG4

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

Y

F

-

+

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- 220V

15A- 120V

30A

A B

BATTERY+

PLUG

CR1

BA

BAFIELDGR2

TG

120 VAC / 60 HZ with Regulator

220 VAC / 50 HZ with Regulator

-

+


6 - 96

Belt Drive Generator Option

6 - 95


6 - 97

CE Option

6 - 98

1

2

3

4

5

6

7

8



6 - 98 S-80 • S-85 Part No. 111165


CE Option

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

B

3

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

LOAD

SENSE

MODULE

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

TS15

L1WH


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

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

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-1

1

NC

CR26

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

P26ESTP 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

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 99

Platform Level Cutout, CTE Option


6 - 100

Platform Level Cutout, CTE Option

6 - 99


6 - 101

12 kW Hydraulic Generator Wiring Diagram

6 - 102

1

2

3

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5

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7

8



6 - 102 S-80 • S-85 Part No. 111165

12 kW Hydraulic Generator Wiring Diagram

1. Turning on the Generator supplies current

to the high idle relay through the diode

switching the engine to high RPM. In addition

the diode between TB45 and TB29 supplies

power to the motor stroke valve switching

the motors to high speed/low torque mode.

2. The SX controller is turned ON supplying

power to bypass valve and the change over

relay. The EDC valve is switched over to the

output of the SX controller.

12

5

WH

8

10

11

9

7

6

WH

COLOR

3

4

2

WH/BK

PIN#

1

CKT#

WH/BK

COLOR

WH

OR/RD

RD/WH

BL/RD

BK/RDBR

WH/RDBR

RD

RD/BK

GR/WHGR/WH

GR/BKGR/BK

GRBR

BR

WH/BK

WH

BR

GND

C22PWR

V150HG

C45GEN

GND

C31EDC-(A)

C30EDC+(A)

GND

GND

C31EDC-

C30EDC+

GND

Harness

Inside

Enclosure

DR

IVE

ED

C-

DR

IVE

ED

C+

B C

U4

AD

C5

-21

C5

-20

C1

B-5

C1

B-4

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C1P-5 C1P-4 C2P-7

C2

B-7

C4

5G

EN

GR

/ WH

TB45

TS47

P25FS-RD

P24FS-WH

TS4

TB35

C3

5R

PM

BK

/RD

C1

B-9

C1P-9

RP

MH

I

GE

NE

RA

TO

RO

N

D12

RP

ML

O

FOOTSWITCH

2 4

6

81 3

5 7

RS232RxD

A1 BATTERY +

A2 SENSOR POWER +5 VDC

A3 BATTERY-

B1 VALVE 0 FWD COIL

B2 VALVE 1 NC

B3 DIGITAL OUTPUT BYPASS/OMRON

C1 TxD

C2 RxD

C3 /BOOT

D1 ANALOG 0 JOYSTICK

D2 ANALOG 1 NC

D3 DIG IN 3 NC

E1 NOT USED

E2 NOT USED

E3 NOT USED

F1 DIG IN 0

F2 DIG IN 1 GENERATOR ON

F3 DIG IN 2

RS232TxD

CR

4P

HIG

HID

LE

RE

LA

Y

C4

5G

EN

GR

/ WHV151HG GR

V150HG GR/BK

1k ohms124 ohms

124 ohms

APBPC

P26FS-BK

TB29

21

3

C1

B-3

C1P-3

C2

9M

SR

D/W

H

BY

PA

SS

PC

OIL

MO

TO

RS

TR

OK

E

VA

LV

E

SX Controller

OMRON

RELAY

TB22

C5

-18

C5

-24

C5

-1

C5

-12

8 N.C.

2 COM

1 N.O.

3 GND5 SW INPUT

TIME DELAY

MODULE 4S

TB24

16

15

ALC-500

20

3. When the AC generator is turned OFF the

SX module will ramp the output to the EDC to

threshold preventing cavitation to the hydraulic

motor powering the generator. When threshold

is reached the bypass valve is turned OFF.

L1

L2

L3N

RED

ORANGE

BLACK

GREEN

GREEN

BLACK

WHITE

RED

8 GA 4 CONDUCTOR

208 VAC

OUTLET

L1 L2 L3

NEUTRAL BUSS BAR

12.5 KW HYDRAULIC GENERATOR

NEMA 4 CONTROL BOX

50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI

BRASS

SILVER

120 VAC GFI

GREEN 12GA

BLACK 12GA

XY

Z

8 GA 5 CONDUCTOR

20 AMP CIRCUIT

BREAKERGROUND

STUD ON

PANEL

1 2

3

N

5 4

6

BLACK 12GA

12 GA 3 CONDUCTOR

ENCLOSURE

SILVER

GREEN

110 VAC

GFI

BRASS

BLACK

GREEN

WHITE

12 GA 3 CONDUCTOR

1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 103

12 kW Hydraulic Generator Option

21CC

PUMP

DRIVE

FUNCTION

MANIFOLD

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

31

B

A

13

SWV

HYDRAULIC GENERATOR

280 psi

G2 G1

OIL

DIVERTER

MANIFOLD

PMP B CLR PMP A

MTR B MTR A

G2

G1

CY

CW

CX

CV0.031

CU

Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.


6 - 104

12 kW Hydraulic Generator Option

6 - 103


6 - 105

Hydraulic Schematic, 2WD Models

6 - 106

1

2

3

4

5

6

7

8



6 - 106 S-80 • S-85 Part No. 111165


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

PUMP2189

TEST

A

B

TEST310 psi

21.4 bar

51 psi

3.5 bar

T2

CP

2 SPEED

RETURN

FILTER

25 psi

1.7 bar

102 psi

7 bar

BRAKE

OC1 LS TESTOC2

T1

PRESS

PR2

PLATFORM

ROTATE

V2

PR2

PR1

0.030 in

0.076 mm

0.070 in

1.77 mm

25 psi

1.7 bar

T2

PR1

30 psi

2 bar

30 psi

2 bar

TANK

SW2

V1

SW1

2500 psi

172 bar

V2

T3

S1

RET

0.035 in

0.89 mmV1 J1

J2

JIB BOOM

(S-85 Models)TURNTABLE

ROTATE

1200 psi

82.7 bar

ST2ST1

PTEST

AUX

EXTACCUM

2800 psi

193 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

1.7 gpm

6.4 L/ minM

PS

3.5 gpm

13.2 L/min

JIB SELECT

MANIFOLD

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

65 psi

4.5 bar

A

F 5:1 3500 PSI

B

B

B A A

C

C

D

D

6 8 3 1

HYDRAULIC ROTARY COUPLER

2 954 10

AXLE SELECT

MANIFOLD

FLB

FLR

V2 PILOT

FAR

RAR

FAE

RAE

AXLE EXTEND

CYLINDERS

FRONT REAR

2A 2D 2B136A8A8B6B 9A 9B2C

TE

54 10

STEER

CYLINDERS

TIE ROD

CYLINDER

RIGHT

LEFT

C C

C C C

C C C C

C

FRB

FRR

1000 psi

68.9 barTEST

V1

OSCILLATE VALVE

850 psi

58.6 bar

OSCILLATE CYLINDERS

LEFT RIGHT

A

B

OUT

IN

TEST

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

BA

BB

BD

BE

BC

BGBH

BI

BF

GG

HH

NN

VV

XXWW

LL

MM

II

JJ

KK

J

K

L

PQ

NO

OO

W

M

S

Z

V

U

Y

T

R

X

AA

PP

RRQQSS

TT

UU

CC

DD

BB

I

G

C


1

2

3

4

5

6

7

8



Part No. 111165 S-80 • S-85 6 - 107

1

2

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4

5

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7

8



REAR

RIGHT

REAR

LEFT

RESERVOIR

M1

CDL

T

M2

FRONT

LEFT

M3

50%

2 gpm

7.6 L/min

2 gpm

7.6 L/min

2 gpm

7.6 L/min

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

2 954 710

BRAKE/2 SPEED

MANIFOLD

DRIVE PUMP

E

3625 psi

250 bar

3 psi

0.2 bar

3 psi

0.2 bar

FUNCTION

PUMP2189

TEST

A

B

TEST310 psi

21.4 bar

51 psi

3.5 bar

T2

CP

2 SPEED

RETURN

FILTER

25 psi

1.7 bar

850 psi

58.6 bar

102 psi

7 bar

BRAKE

OC1 LS TESTOC2

T1

PRESS

DRIVE MANIFOLD

PL2PL1

PR2

PLATFORM

ROTATE

SLAVE

MASTER

V2

PR2

PR1

0.030 in

0.076 mm

25 psi

1.7 bar

T2

PR1

30 psi

2 bar

30 psi

2 bar

30 psi

2 bar

P2

2100 psi

145 bar

P1

TANK

SW2

V1

SW1

2500 psi

172 bar

V2

T3

S1

RET

0.035 in

0.89 mmV1 J1

J2

JIB BOOM

(S-85 Models)TURNTABLE

ROTATE

1200 psi

82.7 bar

ST2ST1

PTEST

AUX

EXTACCUM

2800 psi

193 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

1.7 gpm

6.4 L/ minM

PS

3.5 gpm

13.2 L/min

AXLE SELECT

MANIFOLD

JIB SELECT

MANIFOLD

HIGH

PRESSURE

FILTER

EXTEND

7 GPM (REGEN)

FUNCTION

MANIFOLD

FLB

FLR

V1 V2 PILOT

FAE

FAR

RAR

RAE

AXLE EXTEND

CYLINDERSOSCILLATE VALVE

OSCILLATE CYLINDERS

ACCUMULATOR

FRONT REAR

TEST

450 psi

22 bar

AXLE EXTEND

PRESSURE SWITCH

2A 2D2B138A6A6B8B 9A 9B2C 7

0.6 gpm

2.27 L/min

0.6 gpm

2.27 L/min

0.1 gpm

0.38 L/min

0.3 gpm

1.1 L/min

AUXILIARY

PUMP

TE

54 10

MEDIUM

PRESSURE

FILTER

PLATFORM LEVEL

CYLINDERS

PRIMARY LIFT

CYLINDER

DUMP

MANIFOLD

B

A

IN

OUTSTEERING

CYLINDERS

65 psi

4.5 bar

TIEROD

CYLINDER

LEFT RIGHT

LEFT

RIGHT

A

F 5:1 3500 PSI

B

B

B A A

C C

F F

EE

C

C

D

D

C C C C

C C

C C CC

FRB

FRR

A

B

DE

F

H

EE

FF

BA

BB

BD

BE

BC

BJ

BKBT

BV

BS

BU

BW

BR

BN BP

BQ

BO

BM

BL

GG

HH

NN

VV

XXWW

LL

MM

II

JJ

KK

J

K

L

PQ

NO

OO

W

M

S

Z

V

U

Y

T

R

X

AA

PP

RRQQSS

TT

UU

CC

DD

BB

I

G

C

OIL COOLER

OPTION



6 - 108


6 - 107

February 2012 - cigpower.com.t manual/service111165.pdf · February 2012 S-80 • S-85 Part No....

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Transcript of February 2012 - cigpower.com.t manual/service111165.pdf · February 2012 S-80 • S-85 Part No....