genie s80 s85
description
Transcript of genie s80 s85
S-80 • S-85 Part No. 77832
February 2012
ii
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 3738 to 5380) ... 111165
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) ................ 122985
Introduction
Copyright © 2011 Terex Coporation
77832 Rev D February 2012Fourth Edition, Fourth 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.
February 2012
Part No. 77832 S-80 • S-85
Revision History
Revision Date Section Procedure / Schematic Page / Description
D 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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S-80 • S-85 Part No. 77832
February 2012
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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. 77832 S-80 • S-85 v
Serial Number Legend
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
S-80 • S-85 Part No. 77832
February 2012
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 perform
maintenance 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, lifting
equipment 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. 77832 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.
S-80 • S-85 Part No. 77832
February 2012
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
Deutz F4L-913 Engine ........................................................................................... 2 - 5
Perkins 704-30 Engine Specifications .................................................................... 2 - 6
Machine Torque Specifications .............................................................................. 2 - 7
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 8
SAE and Metric Fastener Torque Charts ................................................................ 2 - 9
Section 3 Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
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TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................. 3 - 7
A-2 Perform Function Tests ................................................................................ 3 - 7
A-3 Perform Engine Maintenance ....................................................................... 3 - 8
A-4 Check the Hydraulic Filter Condition Indicators ............................................ 3 - 9
A-5 Test the Oscillate Axle ............................................................................... 3 - 10
A-6 Test the Extendable Axles ......................................................................... 3 - 10
A-7 Perform 30 Day Service ............................................................................. 3 - 11
A-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 12
A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-11 Perform Engine Maintenance ..................................................................... 3 - 14
A-12 Perform Engine Maintenance - Deutz Models ............................................. 3 - 15
A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15
A-14 Perform Engine Maintenance - GM and Perkins Models ............................. 3 - 17
Checklist B Procedures
B-1 Inspect the Battery(s) ................................................................................. 3 - 18
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19
B-3 Test the Key Switch ................................................................................... 3 - 21
B-4 Check the Exhaust System ....................................................................... 3 - 21
B-5 Inspect the Engine Air Filter ....................................................................... 3 - 22
B-6 Check the Oil Cooler and Cooler Fins - Deutz Models ................................ 3 - 23
B-7 Confirm the Proper Brake Configuration...................................................... 3 - 24
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TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 25
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 26
B-10 Check and Adjust the Engine RPM ............................................................ 3 - 27
B-11 Perform Engine Maintenance ..................................................................... 3 - 29
B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 30
B-13 Test the Ground Control Override ............................................................... 3 - 30
B-14 Test the Platform Self-leveling ................................................................... 3 - 31
B-15 Test the Engine Idle Select Operation ........................................................ 3 - 31
B-16 Test the Fuel Select Operation - GM Models.............................................. 3 - 32
B-17 Test the Drive Enable System ................................................................... 3 - 33
B-18 Test the Drive Brakes ................................................................................ 3 - 34
B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 35
B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 35
B-21 Test the Alarm Package (if equipped) ........................................................ 3 - 36
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 37
B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 38
B-24 Perform Engine Maintenance - GM Models ................................................ 3 - 39
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 40
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 41
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Part No. 77832 S-80 • S-85
Section 3 Scheduled Maintenance Procedures, continued
C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 41
C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 44
C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 44
C-6 Perform Engine Maintenance - GM Models ................................................ 3 - 46
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 47
D-2 Check the Extendable Axle Wear Pads ...................................................... 3 - 48
D-3 Check the Free-wheel Configuration ........................................................... 3 - 49
D-4 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 50
D-5 Inspect for Turntable Bearing Wear ............................................................ 3 - 51
D-6 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 53
D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 54
D-8 Replace the Drive Hub Oil .......................................................................... 3 - 55
D-9 Perform Engine Maintenance - Deutz Models ............................................. 3 - 57
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 58
E-2 Perform Engine Maintenance - Perkins Models .......................................... 3 - 60
E-3 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 60
E-4 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 62
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
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TABLE OF CONTENTS
Section 4 Repair Procedures, continued
2-3 Platform Rotator ......................................................................................... 4 - 10
2-4 Platform Overload System ......................................................................... 4 - 13
Jib Boom Components, S-85
3-1 Jib Boom.................................................................................................... 4 - 16
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 17
Boom Components
4-1 Cable Track ................................................................................................ 4 - 18
4-2 Boom ......................................................................................................... 4 - 21
4-3 Boom Lift Cylinder ...................................................................................... 4 - 24
4-4 Boom Extension Cylinders ......................................................................... 4 - 26
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 28
Turntable Covers
5-1 Turntable Covers ........................................................................................ 4 - 29
Engines
6-1 RPM Adjustment ........................................................................................ 4 - 30
6-2 Flex Plate................................................................................................... 4 - 30
6-3 Engine Fault Codes - GM Models ............................................................... 4 - 34
Ground Controls
7-1 Control Relays ............................................................................................ 4 - 35
7-2 Power Relay ............................................................................................... 4 - 36
7-3 Terminal Strip ............................................................................................. 4 - 37
Hydraulic Pumps
8-1 Function Pump ........................................................................................... 4 - 38
8-2 Drive Pump ................................................................................................ 4 - 39
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Section 4 Repair Procedures, continued
Manifolds
9-1 Function Manifold Components - View 1 .................................................... 4 - 41
9-2 Function Manifold Components - View 2 .................................................... 4 - 45
9-3 Valve Adjustments - Function Manifold ...................................................... 4 - 47
9-4 Turntable Rotation Manifold Components ................................................... 4 - 49
9-5 Brake/Two-speed Manifold Components .................................................... 4 - 50
9-6 Jib Boom Select Manifold Components, S-85 ............................................ 4 - 51
9-7 Axle Select Manifold Components .............................................................. 4 - 53
9-8 2WD Traction Manifold Components .......................................................... 4 - 55
9-9 4WD Traction Manifold Components .......................................................... 4 - 57
9-10 Valve Adjustments - Traction Manifold ....................................................... 4 - 59
9-11 Valve Coils ................................................................................................. 4 - 60
Fuel and Hydraulic Tanks
10-1 Fuel Tank ................................................................................................... 4 - 62
10-2 Hydraulic Tank ........................................................................................... 4 - 63
Turntable Rotation Components
11-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 65
2WD Steer Axle Components
12-1 Yoke and Hub ............................................................................................ 4 - 68
12-2 Steer Cylinder ............................................................................................ 4 - 69
12-3 Tie Rod Cylinder ......................................................................................... 4 - 70
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Section 4 Repair Procedures, continued
4WD Steer Axle Components
13-1 Yoke and Drive Hub ................................................................................... 4 - 72
13-2 Drive Motor ................................................................................................ 4 - 73
13-3 Drive Hub ................................................................................................... 4 - 74
13-4 Steer Cylinders........................................................................................... 4 - 74
13-5 Tie Rod Cylinders ....................................................................................... 4 - 75
Non-steer Axle Components
14-1 Drive Motor ................................................................................................ 4 - 76
14-2 Drive Hub ................................................................................................... 4 - 76
Oscillating Axle Components
15-1 Oscillate Axle Cylinders ............................................................................. 4 - 77
15-2 Oscillate Directional Valve ......................................................................... 4 - 78
Extendable Axle Components
16-1 Extendable Axles ....................................................................................... 4 - 80
16-2 Axle Extension Cylinder ............................................................................. 4 - 82
Section 5 Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes ........................................................................................................... 5 - 2
Fault Code Chart .................................................................................................... 5 - 3
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
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February 2012
Part No. 77832 S-80 • S-85
Section 6 Schematics, continued
Connector Pin Legend ............................................................................................ 6 - 6
GM 3.0L Engine Wiring Harness ............................................................................ 6 - 7
Electrical Schematic, S-80Deutz F4L 913 Models (before serial number 3577) ................. located at end of manual
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577) .............................................. 6 - 10
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577) .............................................. 6 - 11
Electrical Schematic, S-80Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 14
Electrical Schematic, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 18
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 22
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 23
Ground Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 26
Platform Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 27
Electrical Schematic, S-80GM 3.0L Models (before serial number 3577) .......................... located at end of manual
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577) ....................................................... 6 - 30
TABLE OF CONTENTS
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February 2012
Section 6 Schematics, continued
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577) ....................................................... 6 - 31
Electrical Schematic, S-80GM 3.0L Models (after serial number 3576) .......................................................... 6 - 34
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576) .......................................................... 6 - 38
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576) .......................................................... 6 - 39
Electrical Schematic, S-80Perkins 704-30 Models (before serial number 3577) ................ located at end of manual
Ground Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577) ............................................. 6 - 42
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577) ............................................. 6 - 43
Electrical Schematic, S-80Perkins 704-30 Models (after serial number 3576) ................................................ 6 - 46
Ground Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576) ................................................ 6 - 50
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576) ................................................ 6 - 51
Electrical Schematic, S-85Deutz F4L 913 Models (before serial number 3577) ................. located at end of manual
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577) .............................................. 6 - 54
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577) .............................................. 6 - 55
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Part No. 77832 S-80 • S-85
TABLE OF CONTENTS
Section 6 Schematics, continued
Electrical Schematic, S-85Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 58
Electrical Schematic, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 62
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 66
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576) ................................................ 6 - 67
Ground Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 70
Platform Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576) ................................................ 6 - 71
Electrical Schematic, S-85GM 3.0L Models (before serial number 3577) .......................... located at end of manual
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577) ....................................................... 6 - 74
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577) ....................................................... 6 - 75
Electrical Schematic, S-85GM 3.0L Models (after serial number 3576) .......................................................... 6 - 78
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576) .......................................................... 6 - 82
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576) .......................................................... 6 - 83
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TABLE OF CONTENTS
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Section 6 Schematics, continued
Electrical Schematic, S-85Perkins 704-30 Models (before serial number 3577) ................ located at end of manual
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577) ............................................. 6 - 86
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577) ............................................. 6 - 77
Electrical Schematic, S-85Perkins 704-30 Models (before serial number 3577) ............................................. 6 - 90
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576) ................................................ 6 - 94
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576) ................................................ 6 - 95
Dual Battery Option ............................................................................................. 6 - 97
Hydraulic Schematic, 2WD Models ...................................................................... 6 - 99
Hydraulic Schematic, 4WD Models .....................................................................6 - 101
Part No. 77832 S-80 • S-85 2 - 1
Section 2 • SpecificationsFebruary 2012
Specifications
Performance Specifications
Drive speed, maximum
Stowed position 3.3 mph5.3 km/h
40 ft/8.2 sec12.2 m/8.2 sec
Raised or extended position 0.68 mph1.1 km/h
40 ft/43 sec12.2 m/43 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°boom fully stowed 80 to 84 seconds
Turntable rotate, 360°boom raised or extended 210 to 240 seconds
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 aresubject to change without notice.
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-lbs569.4 Nm
Lug nut torque, lubricated 320 ft-lbs434 Nm
Fluid capacities
Fuel tank 33 gallons124.9 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 32 fl oz0.95 liters
Drive hubs 61 fl oz1.8 liters
Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5
For operational specifications, refer to theOperator's Manual.
S-80 • S-85 Part No. 778322 - 2
Section 2 • Specifications February 2012
Drive pump
Type: bi-directional variable displacement piston pump
Flow rate @ 2300 rpm 30.3 gpm114.7 L/min
Drive pressure, maximum 4200 psi290 bar
Charge pump
Type: gerotor
Displacement 0.85 cu in13.9 cc
Flow rate @ 2300 rpm 8 gpm30.3 L/min
Charge pressure @ 2300 rpm 320 psiNeutral position 22 bar
Function pump
Type: two-section tandem gear pump
Displacement - Pump 1 (inner) 1.4 cu in22.9 cc
Flow rate @ 2300 rpm 12.7 gpm48 L/min
Displacement - Pump 2 (outer) 0.24 cu in4 cc
Flow rate @ 2300 rpm 2.25 gpm8.5 L/min
Auxiliary pump
Type: fixed displacement gear pump
Displacement - static 0.151 cu in2.47 cc
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
SPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalentISO viscosity 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 have a minimum viscosity indexrating greater than 140. They should provide excellentantiwear, oxidation, corrosion inhibition, sealconditioning, and foam and aeration suppressionproperties.
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
Note: Use Chevron Aviation A hydraulic oil when inambient temperatures consistently below0°F / -17°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. 77832 S-80 • S-85 2 - 3
Section 2 • SpecificationsFebruary 2012
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
Brakes
Brake release pressure 310 psi21.4 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
Manifold ComponentSpecifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 14 ft-lbs / 18.9 Nm
SAE No. 6 23 ft-lbs / 31.2 Nm
SAE No. 8 36 ft-lbs / 48.8 Nm
SAE No. 10 62 ft-lbs / 84.1 Nm
SAE No. 12 84 ft-lbs / 113.9 Nm
Valve coil resistance specifications
Proportional solenoid valve 4 to 6Ω(schematic items K, W and CC)
2 position 3 way solenoid valve 5.5 to 7Ω(schematic items D, R, X, TT and UU)
3 position 4 way solenoid valve 5 to 7Ω(schematic items A, E, N and S)
2 position 3 way solenoid valve 5.5 to 7Ω(schematic items KK, MM, VV and WW)
2 position 3 way solenoid valve 3.5 to 5Ω(schematic item G)
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
S-80 • S-85 Part No. 778322 - 4
Section 2 • Specifications February 2012
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 rpm386.1 Hz
High idle 2300 rpm538.2 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
Size 13 x 613/16 x 93/8 inches33 x 17.3 x 23.8 cm
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 inches1.01 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. 77832 S-80 • S-85 2 - 5
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Injection system
Injection pump make IMSA
Injection pump pressure 8702 psi600 bar
Injector opening pressure 3626 psi250 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Batteries
Type 12V DC
Group 31
Size 13 x 613/16 x 93/8 inches33 x 17.3 x 23.8 cm
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
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
Number of cylinders 4
Bore and stroke 4.02 x 4.92 inches102.1 x 125 mm
Horsepower 76 @ 2300 rpm57 kW @ 2300 rpm
Firing order 1 - 3 - 4 - 2
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 rpm385.7 Hz
High idle - no load 2300 rpm570.4 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
Oil viscosity requirements
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.
S-80 • S-85 Part No. 778322 - 6
Section 2 • Specifications February 2012
SPECIFICATIONS
Perkins 704-30 Engine
Displacement 183 cu in3 liters
Number of cylinders 4
Bore and stroke 3.82 x 3.94 inches97 x 100 mm
Horsepower 61 @ 2300 rpm45 kW @ 2300 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 17.5:1
Compression pressure 300 to 500 psi20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must bewithin 50 psi / 3.45 bar of highest cylinder
Low idle 1600 rpm246.7 Hz
High idle 2500 rpm385.4 Hz
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.014 in0.35 mm
Exhaust 0.014 in0.35 mm
Lubrication system
Oil pressure 41 psi(at 2300 rpm) 2.8 bar
Oil capacity 7.4 quarts(including filter) 7 liters
Oil viscosity requirements
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.
Injection system
Injection pump make Zexel PFR-KX
Injection pump pressure 2755 psi190 bar
Injector opening pressure 3626 psi250 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Engine coolant
Capacity 11.5 quarts10.9 liters
Batteries
Type 12V DC
Group 31
Size 13 x 613/16 x 93/8 inches33 x 17.3 x 23.8 cm
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator 65A, 12V DC
Fan belt deflection 3/8 in10 mm
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Part No. 77832 S-80 • S-85 2 - 7
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Machine Torque Specifications
Platform rotator
1-8 center bolt, Gr 5, dry 640 ft-lbs867 Nm
3/8 -16 bolts, Gr 8, lubricated 35 ft-lbs**(use blue thread locking compound) 57 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm
Rotate drive hub mounting bolts, dry 110 ft-lbs149 Nm
Rotate drive hub mounting bolts, lubricated 80 ft-lbs108 Nm
Backlash plate mounting bolts, dry 280 ft-lbs 379 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 247 ft-lbs335 Nm
Drive hub mounting bolts, lubricated 185 ft-lbs**(use blue thread locking compound) 251 Nm
Drive motor mounting bolts, dry 110 ft-lbs149 Nm
Drive motor mounting bolts, lubricated 80 ft-lbs108 Nm
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
S-80 • S-85 Part No. 778322 - 8
Section 2 • Specifications February 2012
Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 14 ft-lbs / 18.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 48.8 Nm
-10 62 ft-lbs / 84.1 Nm
-12 84 ft-lbs / 113.9 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 250 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 15 ft-lbs / 20.3 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 100 ft-lbs / 135.6 Nm
-12 135 ft-lbs / 183 Nm
-16 200 ft-lbs / 271 Nm
-20 250 ft-lbs / 334 Nm
-24 305 ft-lbs / 414 Nm
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.
The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield 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.
SPECIFICATIONS
Seal-Lok® Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 Nm
-6 30 ft-lbs / 40 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 80 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Part No. 77832 S-80 • S-85 2 - 9
Section 2 • SpecificationsFebruary 2012
SPECIFICATIONS
Size(mm)
in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in- lbs N m in- lbs Nm5 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 N m ft -lbs N m ft -lbs N m ft -lbs N m ft -lbs N m ft -lbs N m ft- lbs N m 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 4.6DRYLUBED
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 8.8DRY
SIZE THREAD
in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m20 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
f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m18 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 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
5/16
3/8
7/16
1/2
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
LUBED
1/4
LUBED DRY LUBED DRY
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
10.9 12.98.84.6
S-80 • S-85 Part No. 778322 - 10
Section 2 • Specifications February 2012
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Part No. 77832 S-80 • S-85 3 - 1
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall be
completed 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 a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Unless otherwise specified, perform each
procedure with the machine in the followingconfiguration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom betweenthe circle-end (yellow arrow) wheels
• Turntable secured with the turntablerotation lock pin
• Key switch in the off position with thekey removed
• Wheels chocked
• All external AC power supply disconnectedfrom the machine
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
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 potentially hazardoussituation which, if not avoided,may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
3 - 2 S-80 • S-85 Part No. 77832
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. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
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Part No. 77832 S-80 • S-85 3 - 5
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Instructions• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) forthe type of inspection to be
performed.
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. After
repair, place a check in the “R” box.
LegendY = yes, acceptable
N = no, remove from service
R = repaired
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Maintenance Inspection Report
Checklist B Y N R
B-1 Battery(s)
B-2 Electrical wiring
B-3 Key switch
B-4 Exhaust system
B-5 Engine air filter
B-6 Oil cooler and fins-Deutz models
B-7 Brake configuration
B-8 Tires, wheels andlug nut torque
B-9 Drive hub maintenance
B-10 Engine RPM
B-11 Engine maintenance
B-12 Oscillate directionalControl
B-13 Ground controloverride
B-14 Platform self-leveling
B-15 Engine idle select
B-16 Fuel select operation
B-17 Drive enable system
B-18 Drive brakes
B-19 Drive speed-stowed
B-20 Drive speed-raisedor extended
B-21 Alarm package
B-22 Fuel and hydraulic tankventing systems
B-23 Hydraulic oil analysis
Perform every 400 hours:
B-24 Engine maintenance -GM models
Checklist A Y N R
A-1 Pre-operationinspection
A-2 Function tests
A-3 Engine maintenance
A-4 Filter condition indicator
A-5 Oscillate axle
A-6 Extendable axles
Perform after 40 hours:
A-7 30 day service
Perform after 50 hours:
A-8 Engine maintenance -Deutz models
Perform every 100 hours:
A-9 Inspect filter/separator -Diesel models
A-10 Grease rotationbearing
A-11 Engine maintenance
Perform after 125 hours:
A-12 Engine maintenance -Deutz models
Perform after 150 hours:
A-13 Replace drive hub oil
Perform every 200 hours:
A-14 Engine maintenance -
GM and Perkinsmodels
Comments
3 - 6 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist C Y N R
C-1 Engine maintenance -Deutz and Perkinsmodels
C-2 Grease platform
overload (if equipped)
C-3 Test the platform
overload (if equipped)
C-4 Air filter element
C-5 Replace filter/separator -
Deutz and Perkinsmodels
Perform every 800 hours:
C-6 Engine maintenance -GM models
Checklist D Y N R
D-1 Boom wear pads
D-2 Axle wear pads
D-3 Free-wheel
configuration
D-4 Turntable rotation
bearing bolts
D-5 Turntable bearing wear
D-6 Engine maintenance -
Deutz and Perkinsmodels
D-7 Replace hydraulic filters
D-8 Drive hub oil
Perform every 1500 hours:
D-9 Engine maintenance -
Deutz models
MAINTENANCE INSPECTION REPORT
Checklist E Y N R
E-1 Hydraulic oil
E-2 Engine maintenance - Perkins models
E-3 Grease axle bearings,2WD models
Perform every 3000 hours:
E-4 Engine maintenance -Deutz and Perkinsmodels
Instructions• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) forthe type of inspection to beperformed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Six Month or 500 hourInspection: A+B+C
Annual or 1000 hourInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure iscompleted.
• Use the step-by-step procedures in
this section to learn how to performthese inspections.
• If any inspection receives an “N”, tag
and remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.
LegendY = yes, acceptable
N = no, remove from service
R = repaired
Comments
Part No. 77832 S-80 • S-85 3 - 7
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Checklist A Procedures
A-1Perform Pre-operationInspectionCompleting 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 Operator's Manual on your machine.
A-2Perform Function TestsCompleting 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 Operator's Manual on your machine.
3 - 8 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-3Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
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 theGM 3.0L Operator Handbook(GM part number 36100007) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
GM 3.0L Operator HandbookGenie part number 101095
Perkins 704-30 Operator HandbookGenie part number 101840
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 77832 S-80 • S-85 3 - 9
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST A PROCEDURES
A-4Check the Hydraulic FilterCondition IndicatorsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
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
3 - 10 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
A-6Test the Extendable AxlesNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Note: Tip-over hazard. Do not raise or extend theboom unless both axles are fully extended. If theaxle extension system is not operating correctly,the stability of the machine 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 horizontal andthen stop. The boom should not raise above thelimit switch unless both axles are 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.
A-5Test the Oscillate Axle
Note: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
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.
Note: Tip-over hazard. Failure to perform thisprocedure on a firm, level surface will compromisethe stability of the machine and could result in themachine tipping over.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
3 Drive the left steer tire up onto a 6 inch / 15 cmblock or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
4 Drive both steer tires up onto a6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firmcontact with the ground.
Note: If the chassis does not remain level duringthe test, refer to Repair Procedure 15-2, How to SetUp the Directional Valve Linkage.
CHECKLIST A PROCEDURES
Part No. 77832 S-80 • S-85 3 - 11
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
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.
A-7Perform 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-3 Perform Engine Maintenance -All Models
• A-10 Grease the Turntable Bearing andRotate Gear
• B-8 Inspect the Tires, Wheels andLug Nut Torque
• B-9 Check the Drive Hub Oil Level andFastener Torque
• D-4 Check the Turnable Rotation BearingBolts
• D-7 Replace the Hydraulic Filter Elements
CHECKLIST A PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
A-9Inspect the Fuel Filter/WaterSeparator - Deutz and PerkinsModels
Note: Genie specifications require that thisprocedure be performed every 100 hours ormonthly, whichever comes 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-8Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed after 50 hours of operation.
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 forcommissioning new and overhauled engines andadditional engine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341).
Deutz 913 Operator HandbookGenie part number 62446
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST A PROCEDURES
Part No. 77832 S-80 • S-85 3 - 13
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST A PROCEDURES
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 Separator Element,for instructions on how to prime the fuel filter/waterseparator.
6 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
d
c
e
b
a A-10Grease the Turntable RotationBearing and Rotate Gear
Note: Genie specifications require that thisprocedure be performed every 100 hours ofoperation. Perform this procedure more often ifdusty 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.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
3 - 14 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-11Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 100 hours.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theGM 3.0L Operator Handbook(GM part number 36100007) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
GM 3.0L Operator HandbookGenie part number 101095
Perkins 704-30 Operator HandbookGenie part number 101840
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 77832 S-80 • S-85 3 - 15
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
A-12Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed every 125 hours ofoperation.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341).
Deutz 913 Operator HandbookGenie part number 62446
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
A-13Replace the Drive Hub Oil
Note: Manufacturer specifications require that thisone-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 first 150 hoursmay 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 drive hub plugs
a
CHECKLIST A PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
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 Repeat this procedure for each drive hub.
Turntable Rotate Drive Hub:
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.
4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.
Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.
5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.
a motorb drive hubc drive hub mounting bolts
6 Install the drive hub assembly onto 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 11-1, How to Adjust theTurntable Rotation Gear Backlash.
b
a
c
Part No. 77832 S-80 • S-85 3 - 17
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
A-14Perform Engine Maintenance -GM and Perkins Models
Note: Engine specifications require that thisprocedure be performed every 200 hours.
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 theGM 3.0L Operator Handbook(GM part number 36100007) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
GM 3.0L Operator HandbookGenie part number 101095
Perkins 704-30 Operator HandbookGenie part number 101840
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST A PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
Checklist B Procedures
B-1Inspect the Battery(s)
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes 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.
Part No. 77832 S-80 • S-85 3 - 19
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:
• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a 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
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.
Electrocution/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.
3 - 20 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
13 Inspect for a liberal coating of dielectric greasein the following location:
• All wire harness connectors toplatform control box
14 Remove the engine tray retaining fastener fromthe engine tray anchor hole at the pivot end ofthe engine tray.
15 Swing the engine tray in towards the machine.
16 Install the engine tray retaining fasteners.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
4 Install the bolt that was just removed into theanchor hole to secure the engine tray frommoving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Engine wiring harness
• Battery area wiring
6 Open the turntable cover at the ground controlsside of the machine.
7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Inside of the ground control box
• Hydraulic manifold wiring
• Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric greasein the following locations:
• All wire harness connectors toground control box
9 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.
10 Inspect the turntable area for burnt, chafed andpinched cables.
11 Lower the secondary boom to the stowedposition and turn the engine off.
12 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Cable track on the boom
• Cables on the boom and jib boom
• Jib boom/platform rotate manifold
• Inside of the platform control box
Part No. 77832 S-80 • S-85 3 - 21
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-3Test the Key SwitchNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes 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
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.
Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.
Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-5Inspect the Engine Air Filter
Note: Genie requires that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.
Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.
a clampb canister end capc dust discharge valve
a
b
c
2 Be sure that all nuts and bolts are tight.
3 Inspect all welds for cracks.
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.
Part No. 77832 S-80 • S-85 3 - 23
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
2 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.
3 Remove the filter element.
5 Clean the inside of the canister and the end capwith a damp cloth.
6 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.
7 Install the filter element.
8 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
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-7Confirm the ProperBrake Configuration
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.
1 Check each drive hub disconnect cap to be sureit is in the engaged position.
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
Part No. 77832 S-80 • S-85 3 - 25
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-8Inspect the Tires, Wheelsand Lug Nut Torque
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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 2Specifications.
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
CHECKLIST B PROCEDURES
3 - 26 S-80 • S-85 Part No. 77832
Section 3 • Scheduled Maintenance Procedures February 2012
B-9Check the Drive Hub Oil Leveland Fastener Torque
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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 theplugs are located one on top and the other at 90degrees.
a drive hub plugs
2 Remove the plug located at 90 degrees andcheck the oil level.
Result: The oil level should be even with thebottom of the side plug hole.
3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole. Refer to Section 2,Specifications.
4 Apply pipe thread sealant to the plug(s) andinstall the plug(s) in the drive hub.
5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
Turntable Rotate Drive Hub
1 Remove the plug located on the side of the huband check the oil level.
Result: The oil level should be even with thebottom of the plug hole.
a plugb drive hub
2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole. Refer toSection 2, Specifications.
3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.
a
b
a
CHECKLIST B PROCEDURES
Part No. 77832 S-80 • S-85 3 - 27
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-10Check and Adjust theEngine RPM
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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 yourlocal GM dealer.
Deutz 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.
Deutz enginea 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.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
8 Adjust the secondary adjustment screw until thelow idle is 1300 rpm. Tighten the locknut.
9 Install the secondary idle adjustment screw capand tighten. Do not over tighten.
10 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) positionand check the rpm.Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustmentstep 11.
11 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts whenactivating high idle.
Perkins models
12 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.
Skip to step 14 if the low idle rpm is correct.
13 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
14 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 15.
15 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.
Part No. 77832 S-80 • S-85 3 - 29
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-11Perform Engine Maintenance
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR theGM 3.0L Operator Handbook(GM part number 36100007) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
GM 3.0L Operator HandbookGenie part number 101095
Perkins 704-30 Operator HandbookGenie part number 101840
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-13Test the Ground ControlOverrideNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes 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.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boomfunction through a partial cycle.
Result: All boom functions should operate.
Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.
B-12Check the Oscillate DirectionalValve Linkage
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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
Part No. 77832 S-80 • S-85 3 - 31
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-15Test the Engine Idle SelectOperationNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.
Low idle (turtle symbol) allows the operator tocontrol individual boom functions only.
High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.
Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This setting activates high idleonly when the foot switch is pressed down.
1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Start the engine from the ground controls.
4 Move and hold the function enable toggle switchin the high idle (rabbit symbol) position.
Result: The engine rpm should change to highidle.
B-14Test the Platform Self-levelingNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.
1 Start the engine from the ground controls.
2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.
3 Raise and lower the boom through a full cycle.
Result: The platform should remain level atall times to within ±5 degrees.
Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-16Test the Fuel Select Operation -GM Models
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can 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.
6 Turn the key switch to platform controls.
7 At the platform controls, move the engine idleselect toggle switch to high idle (rabbit symbol).Do not press down the foot switch.
Result: The engine rpm should change to highidle.
8 Move the engine idle select toggle switch to lowidle (turtle symbol).
Result: The engine rpm should change to lowidle.
9 Move the engine idle select toggle switch to footswitch activated high idle (rabbit and foot switchsymbol).
Result: The engine rpm should not change tohigh idle.
10 Press down the foot switch.
Result: The engine rpm should change to highidle.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-17Test the Drive Enable SystemNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes 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.
1 Start the engine from the platform controls.
2 Press down the foot switch.
3 Rotate the turntable until the boom moves pastone of the the non-steer wheels.
Result: The drive enable indicator light shouldturn on and remain on while theboom is anywhere in the rangeshown.
4 Slowly move the drive controlhandle off center.
Result: The drive function should not operate.
4 Release the foot switch and shut the engine offby pushing the red Emergency Stop button in tothe off position.
5 Move the fuel select toggle switch to LPG.
6 Start the engine and allow it to run at low idle.
7 Press down the foot switch to allow the engineto run at high idle.
Result: The engine should start promptly andoperate smoothly in low and high idle.
Note: The engine may hesitate momentarily andthen continue to run on the selected fuel if the fuelsource is switched while the engine is running.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
B-18Test the Drive Brakes
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.
Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-7, Confirm the 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.
2 Start the engine from the platform controls.
3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.
4 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.
5 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.
Note: The brakes must be able to hold the machineon any slope it is able to climb.
5 Rotate the turntable until the boom moves pastthe other non-steer wheel.
Result: The drive enableindicator light should come onand remain on while the boomis anywhere in the 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.
Blue
Yellow
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-20Test the Drive Speed -Raised or Extended PositionNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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.
2 Start the engine from the platform controls.
3 Extend the axles.
4 Move the engine idle select toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).
5 Press down the foot switch and raise the boomabove 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 PositionNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
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.
Note: Perform this procedure with the boom in thestowed position.
1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the start and finish lines.
4 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
5 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
8 Continue at full speed and note the time whenthe machine reference point crosses the finishline.
9 Press down the foot switch and lower the boomto the stowed position.
10 Extend the boom 3 feet / 90 cm.
11 Choose a point on the machine (i.e., contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.
12 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
13 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
B-21Test the Alarm Package(if equipped)Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
The alarm package includes:
• Travel alarm
• Descent 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.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-22Inspect the Fuel and HydraulicTank Cap Venting Systems
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first. Perform thisprocedure more often if dusty conditions exist.
Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.Procced to step 4.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.
note: When checking for positive tank cap venting,air should pass freely through the cap.
3 Turn the key switch to platform controls.
Result: The flashing beacons should be onand flashing.
4 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.
Result: The descent alarm should sound whenthe controller is held down.
5 Press down the foot switch. Move the drivecontroller off center, hold for a moment 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.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
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
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, 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.
Part No. 77832 S-80 • S-85 3 - 39
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
B-24Perform Engine Maintenance -GM Models
Note: GM engine specifications require that thisprocedure be performed every 400 hours.
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 theGM 3.0L Operator Handbook(GM part number 36100007).
GM 3.0L Operator HandbookGenie part number 101095
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST B PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
C-1Perform Engine Maintenance -Deutz and Perkins Models
Note: Engine specifications require that thisprocedure be performed every 500 hours.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
Perkins 704-30 Operator HandbookGenie part number 101840
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Checklist C Procedures
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST C PROCEDURES
C-2Grease the Platform OverloadMechanism (if equipped)
Note: Genie specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first. Perform thisprocedure more often if dusty conditions exist.
Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.
1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.
2 Thoroughly pump grease into each greasefitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
C-3Test the Platform OverloadSystem (if equipped)
Note: Genie specifications require that thisprocedure be performed every 500 hours or 6months, 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.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.
Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.
Result: The platform overload indicator 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.Illustration 1
Part No. 77832 S-80 • S-85 3 - 43
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
8 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
9 Turn the key switch to ground control.
10 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
11 Activate the auxiliary power toggle switch.
Note: The engine will turn off when the auxiliarypower is activated.
12 Using auxiliary power, test all machine functionsfrom the ground controls.
Result: All ground control functions shouldoperate.
13 Using a suitable lifting device, lift the additionaltest weight from the platform.
Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.
Note: There may be an 2 second delay before theoverload indicator lights and alarm turn off.
14 Start the engine and test all machine functionsfrom the ground controls.
Result: All ground control functions shouldoperate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate.
Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).
17 Using a suitable lifting device, remove theremaining test weights from the platform.
CHECKLIST C PROCEDURES
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CHECKLIST C PROCEDURES
C-4Replace the Engine Air FilterElement - Deutz and Perkinsmodels
Note: Engine specifications require that thisprocedure be performed every 500 hours or semi-annually, whichever comes first.
Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.
2 Remove the filter element.
3 Use a damp cloth to wipe the filter sealingsurface and the inside of the outlet tube. Makesure that all contaminant is removed before thefilter is inserted.
4 Check new filter element gasket for damagebefore installing.
5 Install the new filter element.
6 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
C-5Replace the Fuel Filter/WaterSeparator - Diesel Models
Note: Genie specifications require that thisprocedure be performed every 500 hours orannually, 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.
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 engine side turntable cover and locatethe fuel filter/water separator.
Note: The fuel filter/water separator is located nearthe hydraulic pump.
2 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separatorhead.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
8 Apply a thin layer of oil onto the element gasket.Install the filter/bowl assembly onto the filterhead. Tighten the drain plug and vent plug.
Component damage hazard. Thedrain plug and vent plug can bedamaged if they 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
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CHECKLIST C PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
C-6Perform Engine Maintenance -GM Models
Note: Engine specifications require that thisprocedure be performed every 800 hours.
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 theGM 3.0L Operator Handbook(GM part number 36100007).
GM 3.0L Operator HandbookGenie part number 101095
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST C PROCEDURES
Part No. 77832 S-80 • S-85 3 - 47
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
Checklist D Procedures
D-1Check the Boom Wear Pads
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.
Note: If the wear pads are still within specification,refer to Repair Procedure 4-2, How to Shim theBoom.
1 Start the engine from the ground controls.
2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear 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 inner boom tubes.
Boom wear pad specifications
Boom one wearpad specifications Minimum
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 two wearpad specifications Minimum
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 three wearpad specifications Minimum
Top and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm
b ca
a boom number 1b boom number 2c boom number 3
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
3 Extend and retract the axles through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the axletubes.
Note: Always maintain squareness between theouter and inner axle tubes.
Axle wearpad specifications Minimum
Top, bottom and side wear pads 1/2 inch(both end of axle) 12.7 mm
Extendable inner axle wearpad specifications Minimum
Top, bottom and side wear pads 1/2 inch(both end of axle) 12.7 m
D-2Check the Extendable AxleWear Pads
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
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 16-1, 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 16-1, 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 16-1, How to Remove an Inner Axle.
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Section 3 • Scheduled Maintenance ProceduresFebruary 2012
D-3Check the Free-wheelConfiguration
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
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
CHECKLIST D PROCEDURES
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CHECKLIST D PROCEDURES
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 valv
a
d
c
b
D-4Check the Turntable RotationBearing Bolts
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.
1 Start the engine from the platform controls andextend the axles.
2 Turn the key switch to ground controls.
3 Raise the boom and place a safety chock 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 the Genie Parts department.
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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
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.
Note:Perform this procedure with the machine on afirm, level surface and the boom in the stowedposition.
3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.
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.
CHECKLIST D PROCEDURES
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CHECKLIST D PROCEDURES
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.
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.
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.
a
b
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Part No. 77832 S-80 • S-85 3 - 53
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
D-6Perform Engine Maintenance -Deutz and Perkins Models
Note: Genie specifications require that thisprocedure be performed every 1000 hours.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
Perkins 704-30 Operator HandbookGenie part number 101840
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
D-7Replace the Hydraulic FilterElements
Note: Genie specifications requires that thisprocedure be performed every 1000 hours orannually, whichever come first. Perform thisprocedure more often if dusty conditions exist.
Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.
Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.
Note: Perform this procedure with the engine off.
Hydraulic return filter
1 Open the ground controls side turntable coverand locate the hydraulic return filter mounted onthe hydraulic tank.
2 Place a suitable container under the hydraulictank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.
5 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the installation procedure.
6 Use a permanent ink marker to write the dateand number of hours from the hour meter 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.
Part No. 77832 S-80 • S-85 3 - 55
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
D-8Replace the Drive Hub Oil
Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly 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.
a drive hub plugs
a
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.
15 Start the engine from the ground controls.
16 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
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 Repeat this procedure for each drive hub.
Turntable Rotate Drive Hub:
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.
4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.
Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.
5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.
a motorb drive hubc drive hub mounting bolts
6 Install the drive hub assembly onto 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 11-1, How to Adjust theTurntable Rotation Gear Backlash.
b
a
c
Part No. 77832 S-80 • S-85 3 - 57
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
D-9Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed every 1500 hours ofoperation.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341).
Deutz 913 Operator HandbookGenie part number 62446
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST D PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
E-1Test or Replace theHydraulic Oil
Note: Genie specifications require that thisprocedure be performed every 2000 hours or everytwo 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: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Remove the fuel tank. Refer to Repair Procedure10-1, How to Remove the Fuel Tank.
2 Close the two hydraulic shutoff 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.
3 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.
4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.
5 Disconnect and plug the T-fitting located at thereturn filter with the two hoses connected to it.Cap the fitting on the return filter housing.
6 Disconnect and plug the supply hose for theauxiliary power unit. Cap the fitting on thehydraulic tank.
open closed
Checklist E Procedures
Part No. 77832 S-80 • S-85 3 - 59
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
CHECKLIST E PROCEDURES
7 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.
8 Support the hydraulic tank with two 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 Procedure8-2, 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.
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST E PROCEDURES
E-2Perform Engine Maintenance -Perkins Models
Note: Engine specifications require that thisprocedure be performed every 2000 hours.
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 thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Perkins 704-30 Operator HandbookGenie part number 101840
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.
E-3Grease the Steer Axle WheelBearings - 2WD Models
Note: Genie specifications require that thisprocedure be performed every 2000 hours or everytwo years, whichever comes 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-steer wheels. Center a lifting jackunder the steer axle.
3 Raise the machine approximately6 inches / 15 cm. Place blocks under the drivechassis for support.
4 Remove the lug nuts. Remove the tire and wheelassembly.
Part No. 77832 S-80 • S-85 3 - 61
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
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 up
and down movement.
Skip to step 10 if there is no movement.
6 Remove the dust cap from the hub and removethe cotter pin from the castle nut.
Note: Always replace the cotter pin with a new onewhen removing the castle nut or when checking thetorque of the castle nut.
7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearings.
8 Fully loosen the castle nut, then torque thecastle nut to 8 ft-lbs / 11 Nm.
9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.
Result: If there is side to side or up and down
movement, proceed to step 10 to replace thewheel bearings with new ones.
Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.
Result: If there is no side to side or up and down
movement, grease the wheel bearings.
10 Remove the castle nut.
Note: Always replace the cotter pin with a new onewhen removing the castle nut or when checking thetorque of the castle nut.
11 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.
12 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove theinner bearing.
13 Pack both bearings with clean, fresh grease.
14 Place the large inner bearing into the rear of thehub.
15 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.
16 Slide the hub onto the yoke spindle.
Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.
17 Place the outer bearing into the hub.
18 Install the washer and castle nut.
19 Torque the castle nut to 35 ft-lbs / 47 Nmto seat the bearings.
20 Loosen the castle nut, then torque the castle nutto 8 ft-lbs / 11 Nm.
CHECKLIST E PROCEDURES
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Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST E PROCEDURES
21 Install a new cotter pin. Bend the cotter pin tolock it in place.
Note: Always replace the cotter pin with a new onewhen removing the castle nut or when checking thetorque of the castle nut.
22 Install the dust cap.
23 Install the tire and wheel assembly. Torque thewheel lug nuts. 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.
E-4Perform Engine Maintenance -Deutz and Perkins Models
Note: Engine specifications require that thisprocedure be performed every 3000 hours.
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 theDeutz 913 Operator Handbook(Deutz part number 0297 7341) OR thePerkins 704-30 Operator Handbook(Perkins part number TPD 1336E).
Deutz 913 Operator HandbookGenie part number 62446
Perkins 704-30 Operator HandbookGenie part number 101840
Part No. 77832 S-80 • S-85 3 - 63
Section 3 • Scheduled Maintenance ProceduresFebruary 2012
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST E PROCEDURES
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Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 1
February 2012
Repair Procedures
About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.
Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
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.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Repairs Start:Read, understand and obey the safety 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.
Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
• Machine parked on a flat, level surface
• Boom in the stowed position
• Turntable rotated with the boom betweenthe non-steering wheels
• Turntable secured with the turntablerotation lock pin
• Key switch in the off position with thekey removed
• Wheels chocked
• All external AC power supply disconnectedfrom the machine
Section 4 • Repair Procedures
4 - 2 S-80 • S-85 Part No. 77832
February 2012
The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.
Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.
a ALC-500 circuit boardb drive/steer joystick controllerc boom extend/retract
joystick controllerd boom up/down and turntable rotate
left/right joystick controller
1-1ALC-500 Circuit Board
Note: When the ALC-500 circuit board is replaced,the joystick controllers will need to be calibrated.See 1-2, How to Calibrate a Joystick.
How to Remove the ALC-500Circuit Board1 Push in the Emergency Stop button to the off
position at both the ground and platformcontrols.
2 Remove the platform control box lid retainingfasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted tothe inside of the platform control box.
Electrocution/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
Section 4 • Repair Procedures
Part No. 77832 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.
1-2Joysticks
How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.
Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.
Note: Perform this procedure with the engine off.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 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,pause for a moment, then move the joystick fullstroke in the opposite direction. Hold for 5seconds and return the joystick to the neutralposition.
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.
PLATFORM CONTROLS
Section 4 • Repair Procedures
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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: Perform this procedure with the boom in thestowed position.
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.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
Section 4 • Repair Procedures
Part No. 77832 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 80 to 84 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. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 6 times.
Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
Section 4 • Repair Procedures
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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 10%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.
Section 4 • Repair Procedures
Part No. 77832 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.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 8 times.
Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
9 Select a boom function joystick to set thethreshold.
10 Slowly move the joystick off center in eitherdirection just until the function begins to move.
11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.
Result: The alarm should sound indicating asuccessful calibration.
12 Repeat steps 9 through 11 for each boomjoystick controlled machine function (boom up/down, boom extend/retract and turntable rotate).
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Note: Do not operate any machine function duringthe 10 second waiting time.
14 Cycle the red Emergency Stop button off, thenback on.
PLATFORM CONTROLS
Section 4 • Repair Procedures
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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.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.
5 Tag and disconnect the foot switch wiring fromthe foot switch. Remove the cable from theback of the platform.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
6 Remove the platform control box mountingfasteners. Lower the control box and set itaside.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
Note: If your machine is equipped with an airline toplatform option, the airline must be disconnectedfrom the platform before removal.
7 Support and secure the platform to anappropriate lifting device.
8 Remove the platform mounting fasteners andremove the platform from the machine.
Crushing hazard. The platformcould become unstable and fallwhen it is removed from themachine if not properly supported.
Section 4 • Repair Procedures
Part No. 77832 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 no air in theclosed loop.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 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.
Section 4 • Repair Procedures
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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.
PLATFORM COMPONENTS
2-3Platform Rotator
The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.
How to Remove thePlatform Rotator
Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Remove the platform. See 2-1,How to Remove the Platform.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 11
February 2012
PLATFORM COMPONENTS
2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the rotator.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
3 S-85: Support the jib boom leveling arms andthe platform mounting weldment with anappropriate lifting device. Do not apply anylifting pressure.
4 Remove the mounting bolts from the platformmounting weldment. Remove the center boltand slide the platform mounting weldment off ofthe platform rotator.
Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if not properlysupported when removed from themachine.
5 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.
S-80:
6 Support the rod end of the platform levelingslave cylinder. Protect the cylinder rod fromdamage.
7 Remove the pivot pin retaining fasteners fromboth the slave cylinder rod-end pivot pin andthe rotator pivot pin.
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.
Section 4 • Repair Procedures
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a
d c b
PLATFORM COMPONENTS
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.
Before serial number 3571:
2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a container tocollect any drainage. Secure the container tothe boom.
3 Open the top bleed valve on the rotator, but donot remove it.
a top bleed valveb bottom bleed valvec containerd clear hose
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 bleedvalve. Close the bleed valve.
Crushing hazard. Keep clear of theplatform during rotation.
5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.
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 bleedvalve. Close the bleed valve.
Crushing hazard. Keep clear of theplatform during rotation.
7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.
After serial number 3570:
2 Place a suitable container underneath theplatform rotator.
3 Open the top bleed screw on the rotator, but donot remove it.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Section 4 • Repair Procedures
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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.
4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.
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.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.
Crushing hazard. Keep clear 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.
Section 4 • Repair Procedures
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5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.
Result: The overload indicator lights 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.
6 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds. Proceed to step7.
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.
PLATFORM COMPONENTS
7 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.
Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
8 Add an additional 10 lb / 4.5 kg test weight tothe platform.
Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.
Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.
9 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 15
February 2012
10 Turn the key switch to ground control.
11 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
12 Using a suitable lifting device, lift the test weightoff the platform floor.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.
Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.
13 Test all machine functions from the groundcontrols.
Result: All ground control functions shouldoperate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate normally.
PLATFORM COMPONENTS
Section 4 • Repair Procedures
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Jib Boom Components, S-85
3-1Jib Boom
How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
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.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Attach a lifting strap from an overhead crane tothe jib boom assembly.
7 Place blocks under the platform 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.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 17
February 2012
JIB BOOM COMPONENTS, S-85
3-2Jib Boom Lift Cylinder
How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.
Note: Do not rest the entire weight of the boom onthe blocks.
2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.
4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.
5 Attach a lifting strap from an overhead crane tothe lug at the rod end of the jib boom liftcylinder.
6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.
Crushing hazard. The jib boom liftcylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.
Section 4 • Repair Procedures
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4-1Cable Track
The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable track isnecessary when performing major repairs thatinvolve removing the boom.
How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. 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 controlbox.
3 Loosen the squeeze connector and remove thefoot switch cable from the control box.
4 Disconnect the wire connectors from the bottomof the platform control box.
Note: When installing the wire connectors to thebottom of the platform control box, match the colorof the connectors to those on the control box to besure they are installed in the correct location.
5 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side.
Boom Components
6 S-80: Tag, disconnect and plug the hydraulichoses from the counterbalance valve manifoldlocated on the platform rotator. Cap the fittingson the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling slave cylinder at theunion and connect the hoses from the cylindertogether using a connector.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
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.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 19
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BOOM COMPONENTS
10 Tag, disconnect and plug the wiring from the jibboom/platform rotate select manifold.
11 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
All models:
12 From the ground controls, raise the boom to ahorizontal position.
13 Remove the fasteners from the drive speed limitswitch bracket (LS1RS) mounted on the side ofthe boom at the platform end of the boom. Donot remove the limit switch from the bracket.
14 Remove the cotter pin from the upper cabletrack at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
15 Remove the cable track guide fasteners fromthe cable track guides at the platform end of theboom. Remove the cable track guides from theboom.
16 Remove the cable clamp from the pivot end ofthe boom.
17 Place blocks between the upper and 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.
Section 4 • Repair Procedures
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How to Repair the Cable TrackNote: Component damage hazard. The boom cabletrack can be damaged if it is twisted.
Note: A cable track repair kit is available throughthe Genie Service Parts Department, part no.77896. The kit includes a 4-link section of cabletrack.
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 ifthey are 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 bedamaged if they are kinked orpinched.
7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.
8 Install the rollers onto the new section of cabletrack.
9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.
BOOM COMPONENTS
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 21
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, Boom WearPad Specifications
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 PrimaryBoom
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
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.
Section 4 • Repair Procedures
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5 Raise the boom to a horizontal position highenough that the boom lift cylinder rod end canclear the boom lift cylinder mounting boss.
6 Remove the turntable end cover.
7 Remove the pin retaining fasteners from themaster cylinder rod-end pivot pin.
8 Place a rod through the pin and twist to removethe pin. Lower the rod end of the mastercylinder.
9 Remove the fasteners from the boom angle limitswitches (LS2RO and LS2RS) mounted to theinside of both turntable riser side plates at thepivot end of the boom. Do not disconnect thewiring.
10 Remove the fasteners from the boom extendlimit switch (LS1RO) mounted next to the boomextension cylinder at the pivot end of the boom.Do not disconnect the wiring.
11 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
12 Attach an overhead 5 ton / 5000 kg crane to thecenter point of the boom.
13 Attach a similar lifting device to the boom liftcylinder for support.
14 Place support blocks under the boom liftcylinder, across the turntable.
15 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.
Crushing hazard. The boom liftcylinder could fall if not properlysupported.
16 Lower the rod end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.
17 Remove the pin retaining fastener from theboom pivot pin.
18 Use a soft metal drift to remove the boom pivotpin. Carefully remove the boom from themachine.
Crushing hazard. The boom couldbecome unbalanced and fall if notproperly supported by the overheadcrane.
BOOM COMPONENTS
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 23
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: Pay careful attention to the location andquantity of shims used with 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 whenremoved from the number 2 boomtube if not properly supported.
Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.
Section 4 • Repair Procedures
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11 Remove the external snap rings from theextension cylinder pivot pin at the platform endof the number 3 boom tube. Use a soft metaldrift to remove the pin.
12 Support and slide the extension cylinder out ofthe pivot end of the number 3 boom tube. Placethe extension cylinder on blocks for support.
Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe number 3 boom tube if notproperly supported.
Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.
4-3Boom Lift Cylinder
How to Remove the BoomLift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
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.
BOOM COMPONENTS
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 25
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 thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin, and lower the liftcylinder onto the blocks. Protect the cylinderrod from damage.
Crushing hazard. The boom liftcylinder could become unbalancedand fall when it is disconnectedfrom the machine if not properlysupported.
8 Remove the mounting fasteners from thebarrel-end cylinder pivot pin retaining plates.
9 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform and remove it from the machine.
Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported.
Component damage hazard. Thecables and hydraulic hoses can bedamaged if the lift cylinder ispulled across them.
Section 4 • Repair Procedures
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4-4Boom Extension Cylinders
The extension cylinder consists of two cylindersthat are fastened together. The first cylinderextends and retracts the number 2 boom tube. Thesecond cylinder extends and retracts the number 3boom tube. The extension cylinders are equippedwith counterbalance valves to prevent movementin the event of a hydraulic line failure.
How to Remove theBoom Extension Cylinders
This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
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.
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 / 1.83 m.
5 Remove the external snap rings from theextension cylinder pivot pin at the platform end.Use a soft metal drift to remove the pin.
6 Remove the turntable end cover.
7 Support the rod end of the master cylinder witha lifting device.
8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Place a rodthrough the pin and twist to remove the pin.
Note: Use the platform level toggle switch withauxiliary power to relieve pressure on the mastercylinder barrel-end pivot pin.
9 Lay the master cylinder down. Protect thecylinder rod from damage.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 27
February 2012
10 Remove the external snap rings from theextension cylinder pivot pin at the pivot end ofthe boom. Use a soft metal drift to remove thepin through the access holes in the turntableriser.
11 Using auxiliary power, move the boomextend/retract toggle switch in the extenddirection and extend the extension cylinder outthe pivot end of the boom approximately1 foot / 30 cm.
12 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
13 Attach a lifting strap from an overhead crane tothe end of the extension cylinder and lift slightlyto relieve the pressure on the trunnion pins.
14 Remove the trunnion pin access covers fromboth sides of the number 1 boom tube at thepivot end of the boom.
BOOM COMPONENTS
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 boom, retract boomfully after installing all the pins. Install the two top¼-20 bolts through the access holes located midsection of the primary boom. Extend the boom andreplace the two lower ¼-20 bolts in the number 3boom tube.
Section 4 • Repair Procedures
4 - 28 S-80 • S-85 Part No. 77832
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.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin.
5 Place a rod through the barel-end pivot pin andtwist to remove the pin.
6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.
7 Remove the pin retaining fastener from therod-end pivot pin.
8 Place a rod through the rod-end pivot pin andtwist to remove the pin.
9 Remove the master cylinder from the machine.
Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properlysupported by the lifting devicewhen removed from the machine.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 29
February 2012
5-1Turntable Covers
How to Remove aTurntable Cover1 Raise the turntable cover. Support and secure
the open cover with an overhead crane orforklift. Do not lift the cover.
Crushing hazard. Due to its heavyweight, do not attempt to supportthe cover by hand.
Component damage hazard.Protect the cover from damage byusing carpet or padding on thecrane or forklift forks.
2 Remove the upper retaining clip from the gasstrut.
3 Gently pry the strut pivot socket off of the ballstud and lower the strut. Protect the strutcylinder rod from damage.
Crushing hazard. The cover couldfall if not properly supported whenthe strut is removed.
Note: Mark the location of the hinge supportbracket on the bulkhead to ensure proper coveralignment during installation.
Turntable Covers
4 Remove the cover hinge bolts that fasten thehinge support bracket to the bulkhead.
5 Carefully lift and remove the cover fromthe machine.
Bodily injury hazard. Safety decalsare essential to safe machineoperation. Failure to replace allsafety and instructional decalscould create a situation resulting indeath or serious injury. If aturntable cover must be replaced,be sure that all appropriate safetyand instructional decals areapplied to the new cover.
Crushing hazard. The turntablecover could become unbalancedand fall if not properly supportedand secured to an appropriatelifting device.
Note: Alignment adjustments may be necessarywhen a new cover is installed.
Section 4 • Repair Procedures
4 - 30 S-80 • S-85 Part No. 77832
February 2012
6-1RPM Adjustment
Refer to Maintenance Procedure B-10,Check and Adjust the Engine RPM.
Engines
a b c d e
f
6-2Flex 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 3/16 inch / 4.8 mm gap - Diesel Models
5/32 inch / 3.8 mm gap - GM Models
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 31
February 2012
ENGINES
7 Slide the engine mounting plate towards thepump as far as it will go.
8 Support the drive pump assembly with anappropriate lifting device.
9 Remove all of the engine bell housing fasteners.
10 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard. Hosescan be damaged if they are kinkedor pinched.
11 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
Perkins models:
1 Remove the fuel filter/water separator mountingfasteners.
2 Remove the fuel filter/water separator and lay itto the side. Do not disconnect the hoses.
3 Support the drive pump assembly with anappropriate lifting device.
4 Remove all of the engine bell housing fasteners.
5 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard. Hosescan be damaged if they are kinkedor pinched.
6 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
How to Remove the Flex PlateDeutz models:
1 Remove the tailpipe bracket mounting fastenersfrom the engine bell housing.
2 Support the drive pump assembly with anappropriate lifting device.
3 Remove all of the engine bell housing fasteners.
4 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
5 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
GM models:
1 Remove the muffler clamp at the exhaust pipe.
2 Remove the muffler bracket to bell housingfasteners. Remove the muffler and bracketassembly.
3 Disconnect the electrical connector for thecrankshaft position sensor located at thebottom of the bell housing.
4 Support the engine with a suitable lifting device.Do not lift it.
5 Remove the engine plate to vibration isolatorfasteners.
6 Remove the engine mounting plate to bellhousing fasteners.
Component damage hazard. Theengine could fall and thecrankshaft position sensor canbecome damaged if the engine isnot properly supported when thefasteners are removed.
Section 4 • Repair Procedures
4 - 32 S-80 • S-85 Part No. 77832
February 2012
ENGINES
How to Install the Flex Plate1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
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.
Deutz models
Perkins models
1
2
3
4 5
6
1
2 3
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.
a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 3/16 inch / 4.8 mm gap - Diesel Models
5/32 inch / 3.8 mm gap - GM Models
4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.
a b c d e
f
1
2
3
4 5
6 1
2
34
5
GM models
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 33
February 2012
Perkins models
10
6 1
8
4
11
7 5
92
12
3
C
C C
C
C
C
C
CC
C
C
C
6 1
9
5
7
32
8
4
A A
B
B
B
B
B
B
B
ENGINES
5 Install the pump and bell housing assembly.
Gm and Deutz models: Torque the bell housingmounting bolts in sequence to 37 ft-lbs / 50 Nm.
Perkins models: Torque the bell housingmounting bolts in sequence to19 ft-lbs / 25.7.
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.
10
6 1
8
4
11
7 5
92
12
3
GM models
Deutz models
Section 4 • Repair Procedures
4 - 34 S-80 • S-85 Part No. 77832
February 2012
ENGINES
6-3Engine Fault Codes -GM Models
How to Retrieve Engine FaultCodesGM models:
When 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 is requiredto retrieve fault codes stored within the ECM.Contact Genie Service Department for assistancein retrieving fault codes.
Note: If the check engine light is on and the engineis stopped, tag the machine and remove fromservice. Contact service personnel immediately.
Note: If the check engine light is on and the engineis still running, contact service personnel within 24hours.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 35
February 2012
Ground Controls
7-1Control Relays
Relays used for single function switching are singlepole double throw (SPDT) relays.
How to Test a Single Pole DoubleThrow Relay
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Tag and disconnect all the wiring from the relayto be tested.
2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.
Test Desired result
terminal 85 to 86 with resistor 75 to 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
Section 4 • Repair Procedures
4 - 36 S-80 • S-85 Part No. 77832
February 2012
GROUND CONTROLS
7-2Power Relay
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
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(large post)
b
a
ba
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 37
February 2012
GROUND CONTROLS
7-3Terminal 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.
Section 4 • Repair Procedures
4 - 38 S-80 • S-85 Part No. 77832
February 2012
2 Tag, disconnect and plug the hydraulic hosesfrom the function pump. Cap the fittings on thepump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the pump mounting fasteners.Carefully remove the pump.
Component damage hazard.Be sure to open the two hydraulictank valves (if equipped) andprime the pump after installing thepump. See 8-2, How to Prime thePump.
Hydraulic Pumps
8-1Function Pump
How to Remove the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 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 withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
open closed
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 39
February 2012
HYDRAULIC PUMPS
8-2Drive Pump
The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.
How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Disconnect the wire harness at the electronicdisplacement controller (EDC), located on thedrive pump.
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 withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
open closed
Section 4 • Repair Procedures
4 - 40 S-80 • S-85 Part No. 77832
February 2012
3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.
5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.
6 Remove the drive pump assembly from themachine.
Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.
Note: Before installing the pump, verify properpump coupler spacing. See 6-2, 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 models: Close the valve on the LPG tank,then disconnect the hose from the tank. Movethe fuel select toggle switch to the LPGposition.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 / 20.68 bar.
4 GM models: Connect the LPG hose to the LPGtank 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
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 41
February 2012
Manifolds
9-1Function 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 extend .................................... 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 retract ..................................... 50-55 ft-lbs / 68-75 Nm
8 Check valve ....................................... H ........... Differential sensing circuit,turntable rotate left/right ...................... 8-10 ft-lbs / 10-15 Nm
9 Differential sensing valve .................. I ............ Boom extend/retract circuit(prevents overflowingthe proportional valve) ..................... 30-35 ft-lbs / 41-47 Nm
10 Differential sensing valve .................. J ............ Turntable rotate left/right circuit(prevents overflowingthe proportional valve) ..................... 30-35 ft-lbs / 41-47 Nm
11 Proportional solenoid valve .............. K ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
12 Check valve ....................................... L ........... Differential sensing circuit,platform level down ............................. 8-10 ft-lbs / 10-15 Nm
13 Check valve ....................................... M .......... Differential sensing circuit,platform level up .................................. 8-10 ft-lbs / 10-15 Nm
14 Solenoid valve, 3 position 4 way ....... N ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm
15 Differential sensing valve .................. O ........... Boom up/down circuit(prevents overflowingthe proportional valve) ..................... 30-35 ft-lbs / 41-47 Nm
16 Counterbalance valve ....................... P ........... Platform level down circuit ............... 35-40 ft-lbs / 47-54 Nm
17 Counterbalance valve ....................... Q ........... Platform level up circuit .................... 35-40 ft-lbs / 47-54 Nm
18 Solenoid valve, 2 position 3 way ...... R ........... Boom down ....................................... 33-37 ft-lbs / 45-50 Nm
19 Solenoid valve, 3 position 4 way ...... S ........... Steer left/right andaxle extend/retract ............................ 35-40 ft-lbs / 47-54 Nm
20 Relief valve, 2900 psi / 200 bar ........ T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page.
Section 4 • Repair Procedures
4 - 42 S-80 • S-85 Part No. 77832
February 2012
MANIFOLDS
A B C
D
E
G
K
L
M
P
R
S
Q
O
N
J
I
H
F
TUVWX
AA
CC
DD
EE
GG
FF
BB
Z
Y
1 2 3
202123 2224
25
26
27
28
29
30
31
32
33
4
5
6
7
10
8
9
11
12
13
14
16
15
17
18
19
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 43
February 2012
MANIFOLDS
Function Manifold Components - View 1, continued
Index SchematicNo. Description Item Function Torque
21 Check valve ....................................... U ........... Blocks flow from auxiliary pumpto function pump ............................... 30-35 ft-lbs / 41-47 Nm
22 Priority flow regulator valve,3.5 gpm / 13.2 L/min .......................... V ........... Steer circuit ....................................... 30-35 ft-lbs / 41-47 Nm
23 Proportional solenoid valve .............. W .......... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
24 Solenoid valve, 2 position 3 way ...... X ........... Boom up ........................................... 33-37 ft-lbs / 45-50 Nm
25 Check valve ....................................... Y ........... Blocks flow from function pumpto auxiliary pump .............................. 30-35 ft-lbs / 41-47 Nm
26 Check valve ....................................... Z ........... Hydraulic oil cooler bypass .............. 30-35 ft-lbs / 41-47 Nm
27 Check valve ....................................... AA ......... Boom up/down circuit ......................... 8-10 ft-lbs / 10-15 Nm
28 Needle valve ..................................... AB ......... Platform level circuit ......................... 30-35 ft-lbs / 41-47 Nm
29 Proportional solenoid valve .............. AC ........ Turntable rotate circuit ...................... 20-30 ft-lbs / 27-47 Nm
30 Differential sensing valve .................. AD ........ Meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
31 Check valve ....................................... AE ......... Differential sensing circuit,boom extend/retract ............................ 8-10 ft-lbs / 10-15 Nm
32 Flow regulator valve,0.1 gpm / 0.37 L/min .......................... AF ......... Bleeds off differential
sensing valves to tank ...................... 20-25 ft-lbs / 27-34 Nm
33 Flow regulator valve,0.6 gpm / 2.27 L/min .......................... AG ........ Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm
Section 4 • Repair Procedures
4 - 44 S-80 • S-85 Part No. 77832
February 2012
MANIFOLDS
A B C
D
E
G
K
L
M
P
R
S
Q
O
N
J
I
H
F
TUVWX
AA
CC
DD
EE
GG
FF
BB
Z
Y
1 2 3
202123 2224
25
26
27
28
29
30
31
32
33
4
5
6
7
10
8
9
11
12
13
14
16
15
17
18
19
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 45
February 2012
9-2Function Manifold Components - View 2
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index SchematicNo. Description Item Function Torque
1 Check valve, 30 psi / 2 bar ................ AH ........ Platform rotate circuit(prevents hydraulic hosesfrom 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.......................................................................... Operates axle extend light ............... 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
Section 4 • Repair Procedures
4 - 46 S-80 • S-85 Part No. 77832
February 2012
MANIFOLDS
AH
AI
AL
AJ
AK
AMANAO
AY
79 8
1
2
4
3
5
6
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 47
February 2012
MANIFOLDS
9-3Valve Adjustments -Function Manifold
How to Adjust the SystemRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom retract toggle switch with theboom fully retracted. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item T) on thefunction manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 to confirm relief valvepressure.
How to Adjust the Boom DownRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom down toggle switch with theboom fully lowered. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item OO) onthe function manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 and confirm reliefvalve pressure.
Section 4 • Repair Procedures
4 - 48 S-80 • S-85 Part No. 77832
February 2012
How to Adjust the Boom ExtendRelief ValveNote: Perform this procedure with the boom in thestowed position.
1 Connect a 0 to 3000 psi / 0 to 200 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom extend toggle switch with theboom fully extended. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item F) on thefunction manifold.
5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.
Tip-over hazard. Do not adjustthe relief valves higher thanspecified.
6 Repeat steps 2 through 5 to confirm relief valvepressure.
MANIFOLDS
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 49
February 2012
MANIFOLDS
9-4Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control sideof the machine.
Index SchematicNo. Description Item Function Torque
1 Shuttle valve, 2 position 3 way ......... PP ......... Turntable rotation brake release ........ 8-10 ft-lbs / 10-15 Nm
2 Counterbalance valve ....................... QQ ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
3 Counterbalance valve ....................... RR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
1 2 3
PP
RR
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February 2012
9-5Brake/Two-Speed Manifold Components
The brake/two-speed manifold is mounted on the engine tray.
Index SchematicNo. Description Item Function Torque
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
UU
SS
21 3
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 51
February 2012
MANIFOLDS
9-6Jib Boom Select Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ...... 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
Section 4 • Repair Procedures
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February 2012
MANIFOLDS
VV WW
XX
1 2 3
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 53
February 2012
MANIFOLDS
9-7Axle Select Manifold Components
The axle select manifold is mounted next to the drive manifold at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Directional valve, pilot operated2 position 3 way ................................ FA ......... Directs flow from steer cylinders
to axle extend circuit ......................... 30-35 ft-lbs / 41-47 Nm
2 Pressure reducing valve,1000 psi / 69 bar ............................... FB ......... Limits pressure to tie rod cylinder
during axle extension ....................... 30-35 ft-lbs / 41-47 Nm
3 Directional valve, pilot operated2 position 3 way ................................ FC ......... Directs flow from steer cylinders
to axle retract circuit .......................... 30-35 ft-lbs / 41-47 Nm
4 Directional valve, pilot operated2 position 2 way ................................ FD ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
5 Directional valve, pilot operated2 position 2 way ................................ FE ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
Section 4 • Repair Procedures
4 - 54 S-80 • S-85 Part No. 77832
February 2012
MANIFOLDS
FA FB FC
FD
FE
4
5
1 32
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 55
February 2012
MANIFOLDS
9-82WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar ......... 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
Section 4 • Repair Procedures
4 - 56 S-80 • S-85 Part No. 77832
February 2012
MANIFOLDS
BF
BG
BH
BI
1 2
3
4
5
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 57
February 2012
MANIFOLDS
9-94WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index SchematicNo. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar ......... 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
Section 4 • Repair Procedures
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February 2012
MANIFOLDS
STEER END
NON-STEER END
14
13
12
11
10
8
9
7 6 5
4
3
21
BJ
BK
BL
BM
BN
BO
BP
BQ
BS
BRBT
BU
BV
BW
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 59
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MANIFOLDS
9-10Valve 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.
Section 4 • Repair Procedures
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9-11Valve Coils
How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Tag and disconnect the wiring from the coil to betested.
2 Test the coil resistance.
Result: The resistance should be withinspecification, plus or minus 30%.
Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.
Valve coil resistance specifications
Proportional solenoid valve 4 to 6Ω(schematic items K, W and CC)
2 position 3 way solenoid valve 5.5 to 7Ω(schematic items D, R, X, TT and UU)
3 position 4 way solenoid valve 5 to 7Ω(schematic items A, E, N and S)
2 position 3 way solenoid valve 5.5 to 7Ω(schematic items KK, MM, VV and WW)
2 position 3 way solenoid valve 3.5 to 5Ω(schematic items G)
How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Test the coil for resistance. Refer to, How toTest a Coil.
MANIFOLDS
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 61
February 2012
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.
a multimeterb 9V DC batteryc 10Ω resistord coil
Note: Dotted lines in illustration indicate areversed connection as specified instep 6
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read 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.
5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.
6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.
Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.
MANIFOLDS
9V
BATTERY
10
RESISTOR
�
AMMETERCOIL
+
-
+
-
d
a
b
b
c
c
Section 4 • Repair Procedures
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Fuel and Hydraulic Tanks
10-1Fuel Tank
How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
1 Turn the manual fuel shutoff valve to theclosed position (if equipped).
2 Remove the fuel filler cap from the tank.
3 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer tocapacity specifications.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
Note: Be sure to only use a hand operated pumpsuitable for use with gasoline and diesel fuel.
4 Tag, disconnect, drain and plug the supply andreturn fuel hoses. Cap the fittings on the fueltank.
5 Remove the fuel tank retaining fasteners.
6 Remove the fuel tank from the machine.
Component damage hazard.The fuel tank is plastic and maybecome damaged if allowed to fall.
Component damage hazard.When installing the plastic fueltank, do not overtighten theretaining fasteners.
Note; Clean the fuel tank and inspect for damagebefore installing it onto the machine.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 63
February 2012
FUEL AND HYDRAULIC TANKS
10-2Hydraulic Tank
The primary functions of the hydraulic tank are tocool, clean and de-aerate the hydraulic fluid duringoperation. The tank utilizes internal suctionstrainers for the pump supply hoses and has anexternal return filter equipped with a filter conditionindicator.
How to Remove theHydraulic Tank
Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Lower and retract the boom to the stowedposition.
2 Remove the fuel tank. See 10-1, How toRemove the 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.
18 Clean up any oil that may have spilled.
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
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 65
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 bolt threads.Torque theback lash pivot plate mounting bolts tospecification. Refer to Section 2, MachineTorque Specifications.
7 Install the brake and then the motor onto thedrive hub. Apply removable thread lockingcompound to bolt threads.Torque the motor/brake mounting bolts to specification. Refer toSection 2, Machine Torque Specifications.
8 Adjust turntable rotation gear backlash.See 11-1, How to Adjust the Turntable RotationGear Backlash.
11-1Turntable 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. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Secure the turntable from rotating with theturntable rotation lock pin.
2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
3 Loosen the backlash pivot plate and adjustmentbolts.
Turntable Rotation Components
unlocked locked
a b c
Section 4 • Repair Procedures
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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.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
3 Remove the hydraulic tube that connects fromthe counterbalance manifold to the brake. Capthe fittings on the brake and manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the motor/brake mounting fasteners.Carefully remove the motor from the brake.
a motorb drive hub with brakec drive hub mounting bolts
5 Clean up any oil that may have spilled.
b
a
c
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 67
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.
1 Secure the turntable from rotating with theturntable rotation lock pin.
Note: The turntable rotation lock pin is located nextto the boom rest pad.
2 Loosen the backlash pivot plate mountingfasteners.
a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts
3 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation gear into the turntable bearing ringgear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.
6 Turn the adjustment bolt 1/2 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.
8 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.
TURNTABLE ROTATION COMPONENTS
a b c
Section 4 • Repair Procedures
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2WD Steer Axle Components
12-1Yoke and Hub
How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from both
the steering cylinder and the tie rod cylinderpivot pins. Use a soft metal drift to remove thepins.
2 Loosen the wheel lug nuts. Do not removethem.
3 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.
4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
5 Remove the lug nuts. Remove the tire andwheel assembly.
6 Remove the pin retaining fasteners from theyoke pivot pins.
7 Support and secure the yoke and hub assemblyto a lifting jack.
8 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.
9 Remove the yoke and hub assembly from themachine.
Crushing hazard. The yoke andhub assembly may becomeunbalanced and fall if not properlysupported and secured to thelifting jack when it is removed fromthe machine.
How to Remove the Huband Bearings1 Loosen the wheel lug nuts. Do not remove them.
2 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.
3 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
4 Remove the lug nuts. Remove the tire andwheel assembly.
5 Remove the dust cap, cotter pin and castle nut.
Note: Always replace the cotter pin with a new onewhen installing the castle nut.
6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove the rearbearing.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 69
February 2012
2WD STEER AXLE COMPONENTS
How to Install the Huband BearingsNote: When replacing a wheel bearing, both theinner and outer bearings including the pressed-inraces must be replaced.
1 Be sure that both bearings are packed withclean, fresh grease.
2 Place the large inner bearing into the rear of thehub.
3 Press the bearing seal evenly into the hub untilit 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 35 ft-lbs / 47 Nm toseat the bearings.
8 Fully loosen the castle nut, then re-tighten to8 ft-lbs / 11 Nm. Install a new cotter pin.
9 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts. Refer toSection 2, Specifications.
12-2Steer 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.
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 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.
3 Remove the steer cylinder from the machine.
Section 4 • Repair Procedures
4 - 70 S-80 • S-85 Part No. 77832
February 2012
2WD STEER AXLE COMPONENTS
12-3Tie 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.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Support and secure the tie rod cylinder to alifting jack.
3 Remove the pin retaining fasteners from eachtie rod cylinder pivot pin.
4 Remove the pivot pin from each end of the tierod cylinder.
5 Remove the tie rod cylinder from the machine.
Crushing hazard. The tie rodcylinder may become unbalancedand fall if not properly supportedand secured to the lifting jackwhen it is removed from themachine.
How to Perform the Toe-inAdjustmentNote: Perform this procedure on a firm, levelsurface. Block the non-steer tires and be sure thatthe machine is in the stowed position.
1 Straighten the steer wheels.
2 Measure the steer tires, front to front and backto back, using a measuring fixture.
3 Center a lifting jack of ample capacity under thesteer axle and raise the machine until the steertires are off the ground.
4 Loosen the jam nut on the adjustable endof the tie rod cylinder.
5 Remove the pin retaining fasteners from theadjustable end of the tie rod cylinder. Removethe pivot pin.
6 Slide the tie rod cylinder off of the yoke andadjust it by turning the end.
Note: One half turn on the adjustable end equalsapproximately 1/
8 inch / 3.2 mm change in the front
and rear measurements.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 71
February 2012
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 recheck thefront and back measurements (step 2).If further adjustment is needed, repeatsteps 3 through 8.
Toe-in specification 0 ± 1/8 inch / 6.35 mm
2WD STEER AXLE COMPONENTS
Section 4 • Repair Procedures
4 - 72 S-80 • S-85 Part No. 77832
February 2012
6 Remove the lug nuts. Remove the tire andwheel assembly.
7 Remove the hydraulic hose clamp retainingfastener from the top of the yoke pivot pin.
8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the drive huband remove the drive motor from the machine.
10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.
11 Support and secure the yoke and drive hubassembly to a lifting jack.
12 Use a slide hammer to remove the upper yokepivot pin. Use a soft metal drift to drive thelower yoke pivot pin down and out.
Crushing hazard. The yoke anddrive hub assembly could becomeunbalanced and fall when the yokepivot pins are removed if notproperly supported and secured tothe lifting jack.
13 Place the yoke and drive hub assembly on a flatsurface with the drive hub facing down.
14 Remove the drive hub mounting fasteners thatattach the drive hub to the yoke. Remove theyoke from the drive hub. Refer toSection 2, Specifications.
Note: Replace the thrust washer when installing theyoke and drive hub assembly onto the axle.
4WD Steer Axle Components
13-1Yoke 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.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Loosen the wheel lug nuts. Do not remove them.
4 Block the non-steer wheels, and center a liftingjack of ample capacity under the steer axle.
5 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 73
February 2012
3 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the drive motor mounting fasteners.
5 Slide the drive motor shaft out of the drive hub,and remove the drive motor from the machine.Refer to Section 2, Specifications.
13-2Drive Motor
How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSauer dealer.
Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Extend the axles.
2 Remove the drive motor access covers fromboth sides of the inner axle.
4WD STEER AXLE COMPONENTS
Section 4 • Repair Procedures
4 - 74 S-80 • S-85 Part No. 77832
February 2012
4WD STEER AXLE COMPONENTS
13-4Steer 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.
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 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Remove the hose bracket mounting fastener onthe steer cylinder barrel-end pivot pin.
3 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.
4 Remove the steer cylinder from the machine.
13-3Drive 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 13-2, How toRemove a Drive Motor.
2 Loosen the wheel lug nuts. Do not remove them.
3 Center a lifting jack of ample capacity under thenon-steer axle.
4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
5 Remove the wheel lug nuts, then the tire andwheel assembly.
6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.
7 Remove the drive hub mounting fasteners thatattach the drive hub to the axle. Remove thedrive hub.
Crushing hazard. The drivehub could become unbalancedand fall if not properly supportedand secured to the lifting jackwhen removed from the machine.
Note: Do not re-use the drive hub mountingfasteners. Genie specifications require the use ofnew fasteners.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 75
February 2012
13-5Tie Rod Cylinder
How to Remove theTie Rod CylinderThis procedure is the same as the 2WD procedure.See 12-3, How to Remove the Tie Rod Cylinder.
4WD STEER AXLE COMPONENTS
How to Perform the Toe-inAdjustmentThis procedure is the same as the 2WD procedure.See to 12-3, How to Perfrom the Toe-inAdjustment.
Section 4 • Repair Procedures
4 - 76 S-80 • S-85 Part No. 77832
February 2012
Non-steer Axle Components
14-1Drive Motor
How to Remove a Drive MotorThis procedure is the same as the steer axleprocedure. See 13-2, How to Remove a DriveMotor.
14-2Drive Hub
How to Remove a Drive HubThis procedure is the same as the steer axleprocedure. See 13-3, How to Remove a Drive Hub.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 77
February 2012
Oscillating Axle Components
15-1Oscillate Axle Cylinders
The oscillating axle cylinders extend and retractbetween the drive chassis and the axle to maintaina level chassis while driving over uneven terrain.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic hose failure.
How to Remove an Oscillate AxleCylinderNote: Perform this procedure on firm, level surfacewith the boom in the stowed position.
Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation. Referto Section 2, Hydraulic Hose and Fitting TorqueSpecifications.
1 Rotate the turntable until the boom is betweenthe steer tires.
2 Remove the fasteners from the drive chassiscover at the steer end. Remove the cover.
3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.
5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.
6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.
7 Remove the cylinder from the machine.
Crushing hazard. The oscillatecylinder could become unbalancedand fall if not properly attached tothe overhead crane whenremoved from the machine.
Section 4 • Repair Procedures
4 - 78 S-80 • S-85 Part No. 77832
February 2012
OSCILLATING AXLE COMPONENTS
15-2Oscillate 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 should be between 800 / 55 barand 900 psi / 65 bar.
Result: Pressure is less than 800 psi / 55 bar ormore than 900 psi / 65 bar. Repeat thisprocedure beginning with step 5.
12 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.
13 Install the cover on the non-steer end of thedrive chassis.
a
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 79
February 2012
How to Set Up the DirectionalValve LinkageNote: Perform this procedure on a firm, levelsurface.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the surfacethe machine is on is completely level.
Tip-over hazard. Failure to performthis procedure on a firm, levelsurface will compromise thestability of the machine and couldresult in the machine tipping over.
3 Check the tire pressure in all four tires and addair if needed to meet specification.
4 Remove the drive chassis cover from thenon-steer end of the machine.
5 Disconnect the linkage clevis yoke from theaxle.
6 Place a "bubble type" level on the turntablerotate bearing plate at the non-steer end. Checkto be sure the drive chassis is completely level.
7 To level the drive chassis, start the engine andpush up or pull down on the linkage adjustmentrod until the machine is completely level.
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 GenieService Department.
OSCILLATING AXLE COMPONENTS
Section 4 • Repair Procedures
4 - 80 S-80 • S-85 Part No. 77832
February 2012
16-1Extendable 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,Axle wear pad specifications
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
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 81
February 2012
EXTENDABLE AXLE COMPONENTS
How to Remove an Inner AxleNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.
Steer end:
1 Extend the axles.
2 Remove the drive chassis cover.
3 2WD models: Remove the yoke and hubassembly. Refer to 12-1, How to Remove theYoke and Hub.
4WD models: Remove the yoke and drive hub.Refer to 13-1, How to Remove the Yoke andDrive Hub 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 location andnumber of shims used when removing the wearpads.
11 Carefully remove the inner axle from the outeraxle.
Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.
Non-steer end:
12 Loosen the wheel lug nuts. Do not remove them.
13 Block the steer tires and center a lifting jackunder the outer axle.
14 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.
15 Remove the lug nuts. Remove the tire and wheelassembly.
16 Remove the drive motor covers from both sidesof the inner axle.
Section 4 • Repair Procedures
4 - 82 S-80 • S-85 Part No. 77832
February 2012
17 Tag, disconnect and plug the hydraulic hoses atthe drive motor. Cap the fittings on the drivemotor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
18 Place blocks under the axle extension cylinderfor support.
19 Remove the external snap rings from the axleextension cylinder pivot pin of the inner axle tobe removed. Use a soft metal drift to removethe pin.
20 Attach a strap from a lifting device through theinner axle close to the drive hub for support.
21 Remove all wear pads from the outer axle.
Note: Pay careful attention to the location andnumber of shims used when removing the wearpads.
22 Carefully remove the inner axle from the outeraxle.
Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.
Component damage hazard. Hosescan be damaged if they are kinkedor pinched.
EXTENDABLE AXLE COMPONENTS
16-2Axle Extension Cylinder
How to Remove the AxleExtension CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note:Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.
1 Extend the axles.
2 Remove the drive chassis cover.
Steer end:
3 Remove the engine side yoke and hub.
2WD models: Remove the yoke and hubassembly. Refer to 12-1, How to Remove theYoke and Hub.
4WD models: Remove the yoke and drive hub.Refer to 13-1, How to Remove the Yoke andDrive Hub Assembly.
4 Remove the access cover at the end of theinner axle.
Section 4 • Repair Procedures
Part No. 77832 S-80 • S-85 4 - 83
February 2012
EXTENDABLE AXLE COMPONENTS
5 Tag, disconnect and plug the axle extendcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
6 Place blocks under the axle extension cylinderfor support.
7 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
8 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
Non-steer end:
9 Remove the drie motor access covers from bothsides of the axle.
10 Remove the drive motor. Refer to 13-2, How toRemove a Drive Motor.
11 Remove the drive hub. Refer to 13-3, How toRemove a Drive Hub.
12 Tag, disconnect and plug the axle extendcylinder hydraulic hoses from RAE and RAR portson the axle select manifold. Cap the fittings onthe manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
13 Place blocks under the axle extension cylinderfor support.
14 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.
15 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.
Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.
Section 4 • Repair Procedures
4 - 84 S-80 • S-85 Part No. 77832
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Section 5 • Fault Codes
Part No. 77832 S-80 • S-85 5 - 1
February 2012
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Genie S-80and Genie S-85 Operator’s Manual on yourmachine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropiate flow chart thoroughly.
Attempting shortcuts may produce hazardousconditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Note: Perform all troubleshooting on a firm levelsurface.
Note: Two persons may be required to safelyperform some troubleshooting procedures.
Fault Codes
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in thefollowing configuration:
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between the circle-end wheels (yellow arrow)
• Turntable secured with the turntable rotation lock pin
• Key switch in the off position with the key removed
• Welder disconnected from the machine (if equipped with the weld cable to platform option)
• Wheels chocked
• All external AC power supply disconnected from the machine
Section 5 • Fault Codes
5 - 2 S-80 • S-85 Part No. 77832
February 2012
FAULT CODES
Fault Code Chart -Control System
How to Retrieve Control SystemFault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine off,the key switch turned to platform controls and thered Emergency Stop button pulled out to the onposition at both the ground and platform controls.
1 Open the platform control box lid.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.
3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
Note: When the red LED is flashing the code, theyellow LED will be on solid.
4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
Note: When the yellow LED is flashing the code,the red LED will be on solid.
5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.
Section 5 • Fault Codes
Part No. 77832 S-80 • S-85 5 - 3
February 2012
Fault Code Chart
Continued on next page
Error Source Error Type ID Name ID Name
Condition Solution 11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
21 Boom 1 Joystick (primary boom up/ down)
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
22 Boom 1 directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
23 Boom 1 flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
31 Boom 2 Joystick (secondary boom up/down or primary boom extend/retract)
18 Just calibrated Initiate 1 second beep of alarm.
Self-clearing. (transient)
32 Boom 2 directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
Section 5 • Fault Codes
5 - 4 S-80 • S-85 Part No. 77832
February 2012
FAULT CODE CHART
Error Source Error Type ID Name ID Name
Condition Solution
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
33 Boom 2 flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
41 Turntable rotate joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
42 Turntable rotate directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
43 Turntable rotate flow control valve
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
44 Drive enable override switches 21 Fault
Enable override direction is frozen at neutral.
Power up controller with problem corrected.
Section 5 • Fault Codes
Part No. 77832 S-80 • S-85 5 - 5
February 2012
FAULT CODE CHART
Error Source Error Type ID Name ID Name
Condition Solution 11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
51 Drive joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
12 15
Value too high Value too low
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Calibrate valve thresholds.
53 Drive flow valve (EDC)
18 Just calibrated
Normal function except threshold for one or both directions is zero.
Self-clearing. (transient)
54 Drive brake valve
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
55 High speed drive motor Valve
21 Fault
Motor speed frozen in the low state. Alarm sounds indicating fault.
Power up controller with problem corrected.
11 12 15 16
Value at 5V Value too high Value too low Value at 0V
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
17 Not calibrated Joystick speed and direction frozen at zero and neutral.
Calibrate joystick.
61 Steer joystick
18 Just calibrated Initiate 1-second beep of alarm.
Self-clearing. (transient)
62 Steer directional valves
21 Fault
Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.
Power up controller with problem corrected.
Section 5 • Fault Codes
5 - 6 S-80 • S-85 Part No. 77832
February 2012
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February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 6 - 1
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions printed in theGenie S-80 and Genie S-85 Operator's Manualon your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.
Electrical Schematics
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Hydraulic Schematics
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
February 2012Section 6 • Schematics
6 - 2 S-80 • S-85 Part No. 77832
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
February 2012 Section 6 • Schematics
Part No. 77832 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. 77832
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February 2012Section 6 • Schematics
Connector Pin Legend
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 778326
Connector Pin Legend
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
WH/RD
10
12
11
C34SA
C35ESPD
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
6C134PWRGR/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
C7
RD
RD
RD
RD
BRN
BRN
P24BAT-FEH37
C21IGN-FEH16A
C30EDC+
C31EDC-
C32BRK
C29MS
C34SA
P23BATSA
22
24
23
20
21
19
C24TSPS
C35RPM
16
18
17
15
14
P24BAT-FEH37B
C39LP-FEH67410
C38ESL-FEH65813
12
11
FE361N8
9
7
C107AF
C41RPM
R33STR5
6
4
2
3
1
CKT #PIN
#
BL/WH
BL/RD
BL/RD
BK/WH
RD/WH
WH/RD
WH/BK
WH
WH/BK
WH
WH/RD
RD/WH
RD
BK/WH
WH/RD
RD/WH
WH
WH/BK
BK/RD
BL/RD
WHWH
OR
WH
DEUTZ
ENGINE
OR/BKOR/BK
BK
WH
BK
WH
C5-GBOX
FORD
ENGINE
OR/BK
BK
WH
ENGINE
PERKINS
C5-ENGINE HARNESS
MARK NUMBER ON CABLE 3
RD
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
OR/BK
WH
3.0L GM
ENGINE
BL/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
GR/WH GR/WH GR/WH
C132PLI
C46BBR
C46BBR RD
GR
BK/RD
XX
2
3
1
4
COLOR
GRN
BK
WH
C9 FS DT04-4P
CHASSIC
LINE
NEUTRAL
CKT # PIN #
N/C
ACDC
R16PBR BK/WH
C8PBR BK/WH
C26TSR
C25PSR
C35RPM-FEH306
BL/BK BL/BK
BK/RD
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
RD (YEL)
C38LPG BL/RD
FE242/R33STR DGR BK
R38LPG BRN
BL/BK BL/BK
GR/BK GR/BKGR/BK GR/BK
C45GEN
P24BAT-FEH37
C21IGN-FEH16A
C12DRE
C31EDC
C32BRK
C29MS
C34SA
P23BATSA
22
24
23
20
21
19
C24TSPS
C35RPMVLV
16
18
17
15
14
P24BAT-FEH37B
C39LP-FEH67410
C38ESL-FEH65813
12
11
FE361N8
9
7
C107AF (C21)
C41RPM
R33STR5
6
4
2
3
1
CKT #PIN
#
PK/LGR
YEL/BK
BL/RD
BK/WH
RD/WH
WH/RD
WH/BK
WH
WH/BK
WH
WH/RD
RD/WH
YEL (18)
BK/WH
WH/RD
RD/WH
WH
WH/BK
BK/RD
BL/RD
WHRD/LGR
OR
WH
DEUTZ
ENGINE
OR/BKOR/BK
BK
WH
BK
WH
FORD
ENGINE
OR/BK
BK
WH
ENGINE
PERKINS
RD
WH/RD
RD/WH
WH/BK
WH
WH
BK
OR/BK
WH
3.0L GM
ENGINE
BL/RD
BK/RD
GR/WH GR/WH GR/WH
BK/RD
RD
C26TSR
C25PSR
C35RPM-FEH306
BL/BK BL/BK
TAN/LBL
YEL (12)
C38LPG BL/RD
FE242 (R33STR) DGR BK
R38LPG (C27AUX) BRN
BL/BK BL/BK
GR/BK GR/BKGR/BK GR/BK
BRN
BL/RD
RD
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 7
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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#
10
06
LT.
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/BLUE1
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#
10
02
RE
D/B
LA
CK
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
Section 6 • SchematicsFebruary 2012
GM 3.0L Engine Wiring Harness
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783210
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577)
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER BL/BK C5-16 BL/BK-S.P
26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-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, 20A
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
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
R2
R3
10 OHM RESISTOR
5 OHM RESISTOR
U1 IGNITION/START MODULE
CR28 TROMBETTA PULL IN RELAY
86
87
30
85
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 BK ISM#333 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AB
BK-22D
ENGINE START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
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
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
RD-27B
RD-CR1#30
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
D7
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
GROUND STUD
BRN
BK-33A
RD-1A
WH-21A
WH C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEYS WITCH PWR/PWR TO PLAT.
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEYS WITCH PWR/PWR TO PLAT.
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21WH C5-3&C5-11
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24 RD CR2#30
WH/RD C6-32
RD ISM#427
32
BK CR5#30
RD ISM#723
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.D6
BK-S.P.
RD-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
NON
O
KS1
P1EMERGENCY STOP
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
OIL TEMPERATURE
BL/RD L5
GROUND
STUD
BL C3B-10
G6HOUR METER
U1IGNITION/START
MODULE
CB3OIL COOLER/
OPTIONs, 20A
BRN-CR19#85
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
868686
RD-B2-H1
RD-ISM #6
RD-B1-H1 RD-B1-S.P.
CR3
86
RD-CR28#30
BL/RD ISM#10
23A
24A
RD-S.P.-L2
BL/RD C5-15
BK-33AA
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR17#30
D29
D30
RD/BK C6-19
RD C6-24
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
RD C6-38
L2CHECK ENGINE LED
-
+RD 23-A
TS56GLOW PLUG
BK/WH-34A
BK/RD-35B
RD-S.P.-CB1
D52 GND STUD
D8
WH CR17#86
CB2CONTROLS, 15A
BK-33AB
BK C5-7
RD-B1-20D
RD-B1-H1
CR19 R3
BRN(GND)
BRN-G6
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 11
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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 NC
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
JC3DRIVE/STEER
CR26AXLE CUTOUT
JC1
EXTEND/
RETRACT
BOOM
TS7
ROTATE
PLATFORM
JC2UP/DOWN
AND TURNTABLE
ROTATE
BOOM
P2EMERGENCY STOP
TS4HIGH/LOW
RPMTS2
ENGINE START
L1
TS1AUXILIARY PUMP
TS14DRIVE
SPEED
TS9PLATFORM
LEVEL
P3HORN
GR
/WH
C2
P-7
BK
/WH
C1
P-8
GND STUD
H1TILT ALARM
RD
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
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
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE ENABLE
19/18 CONTROL CABLE
TS48WORK LIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
D2
D12
D1
TS6GLOW PLUG
OPTION
OPT.
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 STUDJ1 J2
J3
WH
J1
-5
BL
J1
-4
BR
N+
L40
TS16
EXTEND/
RETRACT
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
H1
RD
WL
1
RD
WL
2
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
U13
CR26
JC2
TILT ALARM
ALC500
AXLE CUT-OUT RELAY
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
U13ALC-500
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)
CR40
See CE Lift/Drive Option
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-80Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783214
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-80Deutz F4L 913 Models (after serial number 3576)
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.
6
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 15
Electrical Schematic, S-80Deutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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 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 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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-80Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Electrical Schematic, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783218
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
P1
34
RD
HO
RN
RE
LA
Y
LE
VE
LS
EN
SO
R
HO
RN
20ARD
P2
0B
AT
RD
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
NO
GR
CB3
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
N/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 POWER
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
IGNITION/
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
DAU
XIL
IAR
Y
PO
WE
R
AU
XIL
IAR
Y
PO
WE
R
EN
GIN
E
STA
RT
GL
OW
PL
UG GE
NE
RA
TO
R
ON
GL
OW
PL
UG
EN
GIN
E
STA
RT
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/RD
CR3
TB23
TB24
TB46
D8
D7
-
+
12V DC
B1
D22
AUX
FAN
CR17
NO
15A
TB20
CB1
RD
B1
BA
TT
ER
Y
3 1 2
FU
NC
TIO
NE
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-COM
+AUX
S-613
+BAT
MOM N.O. TIME DELAY
BRN
WH
RDFAN BELT
BREAK
SWITCH
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
G.P
.F
UE
LV
ALV
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
15A
CB2
C2
8T
TA
RD
/BK
7
WH
GR
/BK
H6 L48 TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
U33
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
LS18
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
L4
FS1
BKC9P-1
P2
CR39
NO
D42
EN
GIN
ES
PE
ED
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
STA
RT
BA
TT
ER
Y
D39
5D40
+
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 .
LOAD
SENSE
MODULE
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 19
Electrical Schematic, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783222
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A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576)
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 23
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576)
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2
3
4
5
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N M L K J I H G F E D C B A
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
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE 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
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783226
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
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
U33
IGNITION/START MODULE
PLATFORM OVERLOAD 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
H6U33
PLATFORM
OVERLOAD
MODULE
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 27
Platform Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE 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
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783230
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577)
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 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-2 RD/BK C6-28
29 2WD/4WD RD/WH C5-24 RD/WH C1B-3
30 E.D.C. REVERSE WH C1B-4 WH C5-21
31 E.D.C. FORWARD 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 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 33 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AD
BK-22D
ENGINE START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
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 24B
WH C5-11
CR2
BK-C6-16
OR-14A
GR-17A
GR/BK-18A
GR/WH C4B-7
RD-B1-20A
RD-24AA
BK-22B
ALL BRN WIRES
BK/RD-35A
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
BASE TERMINATION BLOCK
OR/BK C2B-3
D7
BL/BK C6-37
BK/RD C5-18
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
GROUND STUD
BRN
BK-33A
RD-1A
WH-21A
D8
WH C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
CB2CONTROLS, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEY SWITCH PWR/PWR TO PLAT
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WH CR17#86
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24
WH/RD C6-32
27
32
BK CR5#30
23
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.
RD-S.P.
BK-S.P.
RD-S.P.-D2
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
P1EMERGENCY STOP
D2
NC
NON
O
KS1
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
WATER TEMPERATURE
GROUND
STUD
BL C3B-10
G6HOUR METER
CB3OIL COOLER/
OPTION, 20A
BRN(GND)
H1
RD-B2-S.P.
RD-B1-20C
RD-B2-H1
CR17
RD-24AD86
8686
WH-C6#34
OR-C6#33
WH-21B
RD-B1-H1 RD-B1-S.P.
23A
24A
RD-S.P.-L2
BL/RD C5-13
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR2#30
D15D29
D30
RD/BK C6-19
RD C6-24
CR29
86
33A
BK C5-5
OR/RD C6-11
38
BL/BK C6-20
OR/RD CR29#86
OR/RD 42C
BL/RD C4B-1
BL/RD C6-13
AXLE DUMP VALVE
HORN
START RELAY
LIMIT SWITCH #2
LIMIT SWITCH POWER
RD C5-19
-
+RD-23A
TS53FUEL SELECT
D11
BL/RD-39A
BL/RD-S.P.BL/RD-C5-10BL/RD-C2B-1
L2CHECK ENGINE LED
OR C6-10
RD C5-6
RD CR17#30 RD-S.P.
GND STUD
RD CR23#30
D57
CR19
R3
R2
WH/RD-6A
BRN(GND)
BRN-G6
RD-B1-20D
RD-B1-H1
86
CR8
RD/BK CR8#30
OR/RD CR8#87A
CR8#86+
BK 7B
OR/RD 16B
RD/BK 2B
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR5
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY (OPTIONAL)
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
COOLANT TEMPERATURE GAUGE (OPTIONAL)
CR17
CR29
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
IGNITION/START MODULEU1
TS53 LP/GAS SELECT TOGGLE SWITCH
R2 TURNTABLE ROTATE LIMITING RESISTOR, 10 OHMS
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
R3 TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS (APU)
CR19 TURNTABLE ROTATE LIMITING RELAY
CR8 BOOM FUNCTION CUTOUT
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 31
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577)
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 NC
BL
/RD
C2
P-1
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
TS4RPMHIGH/LOW
JC3DRIVE/STEER
JC1
EXTEND/
RETRACT
BOOM
TS1AUXILIARY PUMP
See CE Lift/Dirve Option
TS9
LEVEL
PLATFORMP2
EMERGENCY
STOP
TS3FUEL SELECT
TS2ENGINE START
L1
TS14DRIVE
SPEED
TS7PLATFORM
ROTATE
P3HORN
JC2TURNTABLE
ROTATE AND
BOOM
UP/DOWN
GR
/WH
C2
P-7
GROUND STUD
H1TILT ALARM
RD
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
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
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
CR26AXLE CUTOUT
+
TS15DRIVE ENABLE
19/18 CONTROL CABLE
TS48WORK LIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
D12
D10
D1
OPT.
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
TS16
EXTEND/
RETRACT
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
H1
RD
WL
1
RD
WL
2
COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
U13
JC2
TILT ALARM
PLATFORM CONTROLS CIRCUIT BOARD (ALC500)
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
TS2
TS9
TS15
TS3
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
U13ALC-500
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)
CR40
D2
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-80GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783234
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-80GM 3.0L Models (after serial number 3576)
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
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 35
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Electrical Schematic, S-80GM 3.0L Models (after serial number 3576)
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-80GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783238
1
2
3
4
5
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7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576)
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 WATER 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. REVERSE WH C1B-4 WH C5-21
31 E.D.C. FORWARD 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 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
BRN GND
CR23
10 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AD
DRIVE LIGHT OPTION RELAY
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
BASE TERMINATION BLOCK
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
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
PRIMARY BOOM FLOW CONTROL
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH 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 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
OR/RD C6-22OR/RD C4B-4
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
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR5
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY (OPTIONAL)
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
WATER TEMP. GAUGE (OPTIONAL)
CR17
CR29
CR38
CR39
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
EXTEND FUNCTION CUTOUT RELAY
AUXILIARY PUMP RELAY
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
CR25 AXLE RET L/O 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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 39
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N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576)
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
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
CE MODELS (SEE DETAIL A)
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
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
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
PLATFORM LEVEL TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH (FORD)
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH ( OPTION )
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
DRIVE SPEED LOW/HIGH TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS49
TS48 WORK LIGHT RELAY (OPTION)
DRIVE LIGHT RELAY (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
L4 PLATFORM OVERLOAD LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L48 TILT ALARM LED
D40
D39
TS2
GR
/WH
C2
P-7
DETAIL B:
GENERATOR OPTION
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783242
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577)
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER BL/BK C5-16 BL/BK-S.P
26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-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
86
87
30
85
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 BK ISM#333 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AB
BK-22D
ENGIEN START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
ENGINE RPM
LIMIT SWITCH #1
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 POWERWH-23B
7
GR C2B-5
CR5
TB33AB
RD 24B
10
CR1
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
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
BK/WH-34A
RD-27B
RD-CR1#30
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
D7
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-33A
RD-1A
WH-21A
WH C2B-2
BK/RD-S.P.
BK/WH-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
CB2CONTROLS, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEY SWITCH PWR/PWR TO PLAT
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WH CR17#86
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21WH C5-3&C5-11
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24 RD CR2#30
WH/RD C6-32
RD ISM#427
32
BK CR5#30
RD ISM#723
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.D6
BK-S.P.
RD-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
NON
O
KS1
P1EMERGENCY
STOP
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
COOLANT TEMPERATURE
BL/RD L5
GROUND
STUD
BL C3B-10
G6HOUR METER
U1IGNITION/START
MODULE
CB3OIL COOLER/
OPTION, 20A
BRN-CR19#85
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
86868686
RD-B2-H1
RD-ISM #6
RD-B1-H1 RD-B1-S.P.
CR3
86
+
-
L28
LED
GLOW PLUG
BL/RD ISM#10
23A
24A
RD-S.P.-L2
BL/RD C5-15
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR17#30
D29
D30
RD/BK C6-19
RD C6-24
33ABK C5-5D51
R2
OR/RD C6-11
38
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 CR1#86
RD C6-38
L2LEDCHECK ENGINE
-
+RD 23-A
BK/RD-35B
RD-S.P.-CB1
D52 GND STUD
D8
RD-B1-20D
RD-B1-H1
CR19 R3
BRN(GND)
BRN-G6
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR3
CR5
CR1
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY OPTION
HIGH IDLE CUTOUT RELAY
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
IGNITION / START RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
COOLANT TEMPERATURE GAUGE (OPTIONAL)
L28 GLOW PLUG LED
CR17
CR29
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
U1 IGNITION/START MODULE
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
R3
R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS (APU)
CR19 TURNTABLE ROTATE LIMITING RELAY
CR8 BOOM FUNCTION CUTOUT
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 43
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2
3
4
5
6
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N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577)
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 NC
P2EMERGENCY STOP
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
TS4
RPM
HIGH/LOW
JC3DRIVE/STEER
CR26AXLE CUTOUT
JC1
EXTEND/
RETRACT
BOOM
TS7
ROTATE
PLATFORM
JC2
UP/DOWN AND
TURNTABLE
ROTATE
BOOM
TS2ENGINE START
L1
TS1AUXILIARY PUMP
TS14DRIVE
SPEED
TS9PLATFORM
LEVEL
P3HORN
GR
/WH
C2
P-7
GND STUD
H1TILT ALARM
RD
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
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
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE ENABLE
BK
/WH
C1
P-8
+
L24GLOW PLUG LED
19/18 CONTROL CABLE
TS48WORKLIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
D12
D1
OPT.
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 STUDJ1 J2
J3
WH
J1
-5
BL
J1
-4
BR
N
+
L40
TS16
EXTEND/
RETRACT
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
H1
RD
WL
1
RD
WL
2
BR
N-G
ND
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
U13
JC2
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
L24
P2
DRIVE ENABLE LED
GLOW PLUG LED
PLATFORM LEVEL TOGGLE SWITCH
HORN BUTTON
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
U13ALC-500
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)
CR40
See CE Lift/Dirve Option
D2
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-80Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783246
1
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5
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A B C D E F G H I J K L M N
Electrical Schematic, S-80Perkins 704-30 Models (after serial number 3576)
P1
34
RD
HO
RN
RE
LA
Y
LE
VE
LS
EN
SO
R
HO
RN
20ARD
P2
0B
AT
RD
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
NO
GR
CB3
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
N/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
CR1
NO
BK
-R1
-E.H
.
TB21
CR2
NO
8
7
6
5
10
9
TS51
TB27
RD
TS1
TS52
1
2
TB33
3
RD
IGNITION/
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
WA
TE
RT
EM
PE
RA
TU
RE
AN
D
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
WA
TE
RT
EM
PE
RA
TU
RE
SW
ITC
H
TB34
C3
4S
AB
K/W
H
GL
OW
PL
UG
CR4
NO CR4
CR3
NO
BK
/RD
-R4
-E.H
.
BK
/WH
RP
MS
OL
EN
OID
RP
MR
EL
AY
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TIL
TA
LA
RM
W
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
6
47 3
1
5
-
+
12V DC
B1
D22
AUX
FAN
CR17
NO
15A
TB20
CB1
RD
B1
BA
TT
ER
Y
3 1 2
L24
L28
FU
NC
.E
NA
BL
E
PU
LL
IN
HO
LD
A
WH
RD
BK
CBW
H
BK
FL2
FUSE
LINK
D6
C6
-16
C6
-23
C6
-34
C6
-33
C5
-3 C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-13
4R
D
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
C5
-11
BL/RD
RD
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
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
C7
B-1
C2
P-5
C1
P-2
H1
C7
P-1
P3
HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1
P2
CR39
NO
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
TIO
N)
WA
TE
RT
EM
PE
RA
TU
RE
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
TB33A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
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
STA
RT
BA
TT
ER
Y
5D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
3
5
NOTES:
ROCKER STEER OPTION ONLY.
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
C5
-18
C5
-19
L48
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 47
1
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N M L K J I H G F E D C B A
Electrical Schematic, S-80Perkins 704-30 Models (after serial number 3576)
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-80Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783250
1
2
3
4
5
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8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576)
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 WATER 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
CR1
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
IGNITION/START RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
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
AXLE EXTEND LED RELAY
EXTEND FUNCTION CUTOUT RELAY
AUXILIARY PUMP RELAY
R2 5 OHM RESISTOR
U1 IGNITION/START MODULE
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
CR2CR1
TB33AB
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
D13
D42
OR/BK-15A
RD-27B
RD-CR1#30
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
D42
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
RD C5-6
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
RD ISM#427
32
BK CR5#30
23
22
GR C6-17
OR/RD CR38#87A
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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
WATER TEMPERATURE
BL/RD L2
GR
OU
ND
ST
UD
G6
U1IGNITION/
START
MODULE
CB3
OIL COOLER/
OPTION
BRN(GND)
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
86868686
RD-B2-H1
CR39 #30
RD-B1-H1 RD-B1-S.P.
CR3
86
24A
WH-S.P.-D2
BK CR1 #86
42
D34
OR/RD C6-22OR/RD C4B-4
RD CR17#30
RD/BK C6-19
RD C6-30 / RD C5-19
33ABK 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
CONTROLS
RD-B1-20D
RD-B1-H1
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
3
1
BL/WH C1-12 P134PWR RD-134B
RD H6
BK-22D2
BK C7B-1
RD-TS52
GN/BK H6
RD-TS51
BRN
8
12
5
6
7
4 GN/BK-C3B-10
H6
RD C6-23 C2-6 134 RD-H6 RD-KSI-SP
L28
GLOW PLUG
LED
L2
CHECK ENG. LED
-
+
WH-23A
BK-22A
RD C23-6
KS1
KEY SWITCH
B
1
2
3
4
B1
RD-134A
RD-C23-7
-
-
L45
PLATFORM
OVERLOAD
LED
+
+
GR/BK-H6
PLATFORM OVERLOAD LED
GLOW PLUG LED
L45
L28
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
+
-
BR
N
OR
/RD
-16
C
BK
/WH
C6
-29
RD
-1B
RD
C6
-27
RD
-27
D
RD
-24
C
86
CR39
86
CR38
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 51
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576)
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
U13
JC1
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE 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)
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
BK
RDRD
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
L24
GLOW
PLUG LED
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
LS18
7
6
5
4
3
2
1
4
2
1
3
5
6
7
4
2
1
3
5
6
7
BR
NJ1
-10
BR
N-G
ND
+-
+-
+-
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
L24
PLATFORM OVERLOAD LED
GLOW PLUG LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
GN
/BK
C3
P-1
0
RD
/BK
L4
8
OPT.
GN
/BK
H1
(D3
9)
L48
+
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
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-80Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783254
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577)
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER BL/BK C5-16 BL/BK-S.P
26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-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
TS58
LABEL
TS51
KS1
TS56
TS54
TS59
TS57
TS52
P1
JIB BOOM UP/DOWN TOGGLE SWITCH
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
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
R2
R3
10 OHM RESISTOR
5 OHM RESISTOR
U1 IGNITION/START MODULE
CR28 TROMBETTA PULL IN RELAY
86
87
30
85
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 BK ISM#333 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AB
BK-22D
ENGINE START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
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
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
RD-27B
RD-CR1#30
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
D7
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
GROUND STUD
BRN
BK-33A
RD-1A
WH-21A
WH C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS58JIB BOOM
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEYS WITCH PWR/PWR TO PLAT.
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEYS WITCH PWR/PWR TO PLAT.
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21WH C5-3&C5-11
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24 RD CR2#30
WH/RD C6-32
RD ISM#427
32
BK CR5#30
RD ISM#723
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.D6
BK-S.P.
RD-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
NON
O
KS1
P1EMERGENCY STOP
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
OIL TEMPERATURE
BL/RD L5
GROUND
STUD
BL-10A
D28
BL C3B-10
G6HOUR METER
U1IGNITION/START
MODULE
CB3OIL COOLER/
OPTION, 20A
BRN-CR19#85
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
868686
RD-B2-H1
RD-ISM #6
RD-B1-H1 RD-B1-S.P.
CR3
86
RD-CR28#30
BL/RD ISM#10
23A
24A
RD-S.P.-L2
BL/RD C5-15
BK-33AA
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR17#30
D29
D30
RD/BK C6-19
RD C6-24
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
RD C6-38
L2CHECK ENGINE LED
-
+RD 23-A
TS56GLOW PLUG
BK/WH-34A
BK/RD-35B
RD-S.P.-CB1
D52 GND STUD
D8
WH CR17#86
CB2CONTROLS, 15A
BK-33AB
BK C5-7
RD-B1-20D
RD-B1-H1
CR19 R3
BRN(GND)
BRN-G6
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 55
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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 NC
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
JC3DRIVE/STEER
CR26AXLE CUTOUT
JC1
EXTEND/
RETRACT
BOOM
TS7
ROTATE
PLATFORM
JC2UP/DOWN
AND TURNTABLE
ROTATE
BOOM
P2EMERGENCY STOP
TS4HIGH/LOW
RPMTS2
ENGINE START
L1
TS1AUXILIARY PUMP
TS14DRIVE
SPEED
TS8JIB BOOM
TS9PLATFORM
LEVEL
P3HORN
GR
/WH
C2
P-7
BK
/WH
C1
P-8
GND STUD
H1TILT ALARM
RD
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
TS
8-J
DA
LA
RM
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
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
RED+BLK 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
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE ENABLE
19/18 CONTROL CABLE
GND
TS48WORK LIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
BL
C3
P-1
0
D27
D2
D12
D1
TS6GLOW PLUG
OPTION
OPT.
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
CR13JIB
CUTOUT
TS16
EXTEND/
RETRACT
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
-6GR/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
H1
RD
WL
1
RD
WL
2
Y
Y
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
CR13
U13
JC2
TILT ALARM
ALC500
JIB BOOM CUTOUT RELAY (S-85 MODELS)
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
TS8
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
GR/WH TS7
U13ALC-500
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)
CR40
See CE Lift/Drive Option
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-85Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783258
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-85Deutz F4L 913 Models (after serial number 3576)
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.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
2 C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
6
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 59
Electrical Schematic, S-85Deutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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
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
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-85Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Electrical Schematic, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783262
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
P1
34
RD
HO
RN
RE
LA
Y
LE
VE
LS
EN
SO
R
HO
RN
20ARD
P2
0B
AT
RD
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
NO
GR
CB3
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
N/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 POWER
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
IGNITION/
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
DAU
XIL
IAR
Y
PO
WE
R
AU
XIL
IAR
Y
PO
WE
R
EN
GIN
E
STA
RT
GL
OW
PL
UG GE
NE
RA
TO
R
ON
GL
OW
PL
UG
EN
GIN
E
STA
RT
C1
-7
C1
-8
C2
-7
C1
-9C
35
ES
PD
BK
/RD
CR3
TB23
TB24
TB46
D8
D7
-
+
12V DC
B1
D22
AUX
FAN
CR17
NO
15A
TB20
CB1
RD
B1
BA
TT
ER
Y
3 1 2
FU
NC
TIO
NE
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-COM
+AUX
S-613
+BAT
MOM N.O. TIME DELAY
BRN
WH
RDFAN BELT
BREAK
SWITCH
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
G.P
.F
UE
LV
ALV
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
15A
CB2
C2
8T
TA
RD
/BK
7
WH
GR
/BK
H6 L48 TB28
12 8
C32-8
C1
B-2
C2
B-5
TB134
RDRD
PLAT
GRD
BK
KS1 TB22
P1 RD
U33
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
LS18
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
L4
FS1
BKC9P-1
P2
CR39
NO
D42
EN
GIN
ES
PE
ED
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
STA
RT
BA
TT
ER
Y
D39
5D40
+
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 .
LOAD
SENSE
MODULE
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 63
Electrical Schematic, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
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
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
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783266
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576)
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
CR8
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
BOOM FUNCTION CUTOUT RELAY
IGNITION POWER RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS56
TS54
TS59
TS57
TS58
TS52
P1
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN 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
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 67
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
U13
JC1
JIB BOOM CUTOUT RELAY
AXLE CUTOUT RELAY
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
TS8
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
CR13
CR26
H1
TS48
TS49
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM
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
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
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85Deutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Platform Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783270
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
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
U33
IGNITION/START MODULE
PLATFORM OVERLOAD 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
H6U33
PLATFORM
OVERLOAD
MODULE
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
TS58
JIB
BOOM
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 71
Platform Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
U13
JC1
JIB BOOM CUTOUT RELAY
AXLE CUTOUT RELAY
TILT ALARM
ALC500
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
TS8
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
CR13
CR26
H1
TS48
TS49
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
GLOW PLUG OPTIONTS6
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM
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
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
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85, CE ModelsDeutz F4L 913 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783274
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577)
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 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-2 RD/BK C6-28
29 2WD/4WD RD/WH C5-24 RD/WH C1B-3
30 E.D.C. REVERSE WH C1B-4 WH C5-21
31 E.D.C. FORWARD 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 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 33 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AD
BK-22D
ENGINE START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
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 24B
WH C5-11
CR2
BK-C6-16
OR-14A
GR-17A
GR/BK-18A
GR/WH C4B-7
RD-B1-20A
RD-24AA
BK-22B
ALL BRN WIRES
BK/RD-35A
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
BASE TERMINATION BLOCK
OR/BK C2B-3
D7
BL/BK C6-37
BK/RD C5-18
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
GROUND STUD
BRN
BK-33A
RD-1A
WH-21A
D8
WH C2B-2
BK/RD-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
CB2CONTROLS, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS58JIB BOOM
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEY SWITCH PWR/PWR TO PLAT
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WH CR17#86
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24
WH/RD C6-32
27
32
BK CR5#30
23
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.
RD-S.P.
BK-S.P.
RD-S.P.-D2
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
P1EMERGENCY STOP
D2
NC
NON
O
KS1
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
COOLANT TEMPERATURE
GROUND
STUD
BL-10A
D28
BL C3B-10
G6HOUR METER
CB3OIL COOLER/
OPTION, 20A
BRN(GND)
H1
RD-B2-S.P.
RD-B1-20C
RD-B2-H1
CR17
RD-24AD86
8686
WH-C6#34
OR-C6#33
WH-21B
RD-B1-H1 RD-B1-S.P.
23A
24A
RD-S.P.-L2
BL/RD C5-13
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR2#30
D15D29
D30
RD/BK C6-19
RD C6-24
CR29
86
33A
BK C5-5
OR/RD C6-11
38
BL/BK C6-20
OR/RD CR29#86
OR/RD 42C
BL/RD C4B-1
BL/RD C6-13
AXLE DUMP VALVE
HORN
START RELAY
LIMIT SWITCH #2
LIMIT SWITCH POWER
RD C5-19
-
+RD-23A
TS53LP/GAS
SEL SWD11
BL/RD-39A
BL/RD-S.P.BL/RD-C5-10BL/RD-C2B-1
L2CHECK ENGINE LED
OR C6-10
RD C5-6
RD CR17#30 RD-S.P.
GND STUD
RD CR23#30
D57
CR19
R3
R2
WH/RD-6A
BRN(GND)
BRN-G6
RD-B1-20D
RD-B1-H1
86
CR8
RD/BK CR8#30
OR/RD CR8#87A
CR8#86+
BK 7B
OR/RD 16B
RD/BK 2B
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR5
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY (OPTIONAL)
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
TS58
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
WATER TEMP. GAUGE (OPTIONAL)
CR17
CR29
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
IGNITION/START MODULEU1
TS53 LP/GAS SELECT TOGGLE SWITCH
R2 TURNTABLE ROTATE LIMITING RESISTOR, 10 OHMS
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
R3 TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS (APU)
CR19 TURNTABLE ROTATE LIMITING RELAY
CR8 BOOM FUNCTION CUTOUT
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 75
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577)
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 NC
BL
/RD
C2
P-1
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
TS4RPMHIGH/LOW
JC3DRIVE/STEER
JC1
EXTEND/
RETRACT
BOOM
TS1AUXILIARY PUMP
See CE Lift/Dirve Option
TS9
LEVEL
PLATFORMP2
EMERGENCY
STOP
TS3FUEL SELECT
TS2ENGINE START
L1
TS14DRIVE
SPEED
TS8JIB BOOM
TS7PLATFORM
ROTATE
P3HORN
JC2TURNTABLE
ROTATE AND
BOOM
UP/DOWN
GR
/WH
C2
P-7
GROUND STUD
H1TILT ALARM
RD
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
TS
8-J
DA
LA
RM
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
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
RED+BLK 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
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
CR26AXLE CUTOUT
+
TS15DRIVE ENABLE
19/18 CONTROL CABLE
GND
TS48WORK LIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
BL
C3
P-1
0
D27
D12
D10
D1
OPT.
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
CR13
CUTOUT
JIB BOOMTS16
EXTEND/
RETRACT
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
H1
RD
WL
1
RD
WL
2
Y
Y
COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
CR13
U13
JC2
TILT ALARM
PLATFORM CONTROLS CIRCUIT BOARD (ALC500)
JIB CUTOUT RELAY
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
TS2
TS9
TS15
TS8
TS3
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH SWITCHDRIVE SPEED TOGGLE
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
GR/WH TS7
U13ALC-500
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)
CR40
D2
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-85GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783278
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Electrical Schematic, S-85GM 3.0L Models (after serial number 3576)
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
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 79
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Electrical Schematic, S-85GM 3.0L Models (after serial number 3576)
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
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
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-85GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783282
1
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A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576)
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 WATER 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. REVERSE WH C1B-4 WH C5-21
31 E.D.C. FORWARD 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 GENERATOR OPTION GR/WH C2B-7 GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT OR/RD C6-39 OR/RD C2B-4
12 DRIVE ENABLE BL/WH C6-12 BL/WH C3B-12
BRN GND
CR23
10 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AD
DRIVE LIGHT OPTION RELAY
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
BASE TERMINATION BLOCK
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
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
PRIMARY BOOM FLOW CONTROL
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH 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 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
OR/RD C6-22OR/RD C4B-4
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
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR5
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY (OPTIONAL)
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS58
TS52
P1
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
WATER TEMP. GAUGE (OPTIONAL)
CR17
CR29
CR38
CR39
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
EXTEND FUNCTION CUTOUT RELAY
AUXILIARY PUMP RELAY
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
CR25 AXLE RET L/O 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
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 83
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N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576)
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
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
CE MODELS (SEE DETAIL A)
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
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
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
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH (FORD)
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH ( OPTION )
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
DRIVE SPEED LOW/HIGH TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS49
TS48 WORK LIGHT RELAY (OPTION)
DRIVE LIGHT RELAY (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
L4 PLATFORM OVERLOAD LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
L48 TILT ALARM LED
D40
D39
TS2
GR
/WH
C2
P-7
DETAIL B:
GENERATOR OPTION
DETAIL A
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85GM 3.0L Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783286
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A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577)
CIRCUIT DESCRIPTION FROM TO
61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21
19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.
25 OIL PRESSEURE SENDER BL/BK C5-16 BL/BK-S.P
26 WATER TEMP SENDER GR/BK C5-14 GR/BK-S.P.
28 TILT ALARM RD/BK C1B-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
86
87
30
85
BRN GND
CR23
15 AMP FUSE
RD C4B-11
RD C4B-12
GR/BK C2B-6
TB24AB
DRIVE LIGHT OPTION RELAY
BK C1B-7 BK ISM#333 BK-S.P.
EN
GIN
E
C5
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH/BK-5A
WH-4A
WH-23AB
BK-22D
ENGIEN START
GLOW PLUG
STEER RIGHT/AXLE EXTEND
ENGINE RPM
LIMIT SWITCH #1
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 POWERWH-23B
7
GR C2B-5
CR5
TB33AB
RD 24B
10
CR1
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
TS54HIGH/LOW
RPM
D14
D13
OR/BK-15A
BK/WH-34A
RD-27B
RD-CR1#30
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
D7
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-33A
RD-1A
WH-21A
WH C2B-2
BK/RD-S.P.
BK/WH-S.P.
BK/WH-8A
RD/WH-3A
RD/BK-2A
BK-7A
BK-22A
RD-27A
TS57PLATFORM
ROTATE
CB1ENGINE, 15A
CB2CONTROLS, 15A
TS52ENGINE START
TS59PLATFORM
LEVEL
TS58JIB BOOM
TS62TURNTABLE
ROTATE
-
+
TS63BOOM EXTEND/
RETRACT
TS61BOOM
UP/DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
TURNTABLE ROTATE F.C.
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
PLATFORM ROTATE RIGHT
PLATFORM ROTATE LEFT
KEY SWITCH PWR/PWR TO PLAT
OIL COOLER FAN
FUSED 12V DC
IGNITION POWER
PRIMARY BOOM DOWN
12V DC BATTERY SUPPLY
KEY SWITCH PWR/PWR TO PLAT
AUXILIARY PUMP
SBD/DESCENT ALARM
BRAKE
CD AB
WH CR17#86
WT/RD C5-23
RD
WH C7B-2
BK C7B-1
GR C4B-5
GR/BK C4B-6
OR/BK C4B-3
OR C4B-2
21WH C5-3&C5-11
WH/RD C1B-6
RD C6-27&C1B-1
RD C6-23
24 RD CR2#30
WH/RD C6-32
RD ISM#427
32
BK CR5#30
RD ISM#723
22
GR C6-17
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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.D6
BK-S.P.
RD-S.P.
GR-S.P.
GR/BK-S.P.
OR-S.P.
OR/BK-S.P.
RD-23A
WH/RD-S.P.
BK/RD-S.P.
BL 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
NON
O
KS1
P1EMERGENCY
STOP
NC
NON
O
STA
CK
ED
CO
NTA
CT
S
TS51AUXILIARY PUMP
OIL PRESSURE
G2G1
VOLT METER
G3
COOLANT TEMPERATURE
BL/RD L5
GROUND
STUD
BL-10A
D28
BL C3B-10
G6HOUR METER
U1IGNITION/START
MODULE
CB3OIL COOLER/
OPTION, 20A
BRN-CR19#85
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
86868686
RD-B2-H1
RD-ISM #6
RD-B1-H1 RD-B1-S.P.
CR3
86
+
-
L28
LED
GLOW PLUG
BL/RD ISM#10
23A
24A
RD-S.P.-L2
BL/RD C5-15
42 D34OR/RD C6-22OR/RD C4B-4
RD C6-30
RD CR17#30
D29
D30
RD/BK C6-19
RD C6-24
33ABK C5-5D51
R2
OR/RD C6-11
38
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 CR1#86
RD C6-38
L2LEDCHECK ENGINE
-
+RD 23-A
BK/RD-35B
RD-S.P.-CB1
D52 GND STUD
D8
RD-B1-20D
RD-B1-H1
CR19 R3
BRN(GND)
BRN-G6
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
CHECK ENGINE LED
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CR23
CR3
CR5
CR1
CR2
TS61
CB1
TS62
L2
G6
CB2
DRIVE LIGHT RELAY OPTION
HIGH IDLE CUTOUT RELAY
CIRCUIT BREAKER, ENGINE, 15A
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
HORN RELAY
IGNITION POWER RELAY
IGNITION / START RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
TS58
LABEL
TS51
KS1
TS54
TS59
TS57
TS52
P1
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
ENGINE START SWITCH
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
AUXILIARY POWER TOGGLE SWITCH
EMERGENCY STOP BUTTON
KEY SWITCH
DESCRIPTION
G1
G2
G3
VOLT METER GAUGE (OPTIONAL)
OIL PRESSURE GAUGE (OPTIONAL)
WATER TEMP. GAUGE (OPTIONAL)
L28 GLOW PLUG LED
CR17
CR29
HYDRAULIC COOLER FAN RELAY
AXLE EXTEND LED RELAY
U1 IGNITION/START MODULE
CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
R3
R2 TURNTABLE ROTATE LIMITING RESISTOR 10 OHMS
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS (APU)
CR19 TURNTABLE ROTATE LIMITING RELAY
CR8 BOOM FUNCTION CUTOUT
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 87
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N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577)
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 NC
P2EMERGENCY STOP
GR
/WH
JIB
CA
BL
E
WH
C7
P-2
BK
C7
P-1
TS47
OPTION
GENERATOR
TS4
RPM
HIGH/LOW
JC3DRIVE/STEER
CR26AXLE CUTOUT
JC1
EXTEND/
RETRACT
BOOM
TS7
ROTATE
PLATFORM
JC2
UP/DOWN AND
TURNTABLE
ROTATE
BOOM
TS2ENGINE START
L1
TS1AUXILIARY PUMP
TS14DRIVE
SPEED
TS8JIB BOOM
TS9PLATFORM
LEVEL
P3HORN
GR
/WH
C2
P-7
GND STUD
H1TILT ALARM
RD
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
TS
8-J
DA
LA
RM
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
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
RED+BLK 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
C4
0L
S1
OR
C2
P-2
C3
6S
TC
CB
LC
1P
-10
P3
-C4
3H
RN
GR
C2
P-5
BK
J1
-2
+
TS15DRIVE ENABLE
BK
/WH
C1
P-8
+
L24GLOW PLUG LED
19/18 CONTROL CABLE
GND
TS48WORKLIGHT
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
BL
C3
P-1
0
D27
D12
D1
OPT.
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 STUDJ1 J2
J3
WH
J1
-5
BL
J1
-4
BR
N
+
L40
CR13JIBBOOM
CUTOUTTS16
EXTEND/
RETRACT
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
H1
RD
WL
1
RD
WL
2
Y
Y
BR
N-G
ND
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACTJC1
CR13
U13
JC2
TILT ALARM
ALC500
JIB CUTOUT RELAY
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
TS8
P3
TS1
TS14
L1
L24
P2
DRIVE ENABLE LED
GLOW PLUG LED
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
HORN BUTTON
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
H1
TS48 WORK LIGHT TOGGLE SWITCH (OPTION)
TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH
L40 AXLE EXTENDED LED
GR/WH TS7
U13ALC-500
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)
CR40
See CE Lift/Dirve Option
D2
Section 6 • SchematicsFebruary 2012
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (before serial number 3577)
February 2012Section 6 • Schematics
Electrical Schematic, S-85Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783290
1
2
3
4
5
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8
A B C D E F G H I J K L M N
Electrical Schematic, S-85Perkins 704-30 Models (after serial number 3576)
P1
34
RD
HO
RN
RE
LA
Y
LE
VE
LS
EN
SO
R
HO
RN
20ARD
P2
0B
AT
RD
C4
3H
RN
BK
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
NO
GR
CB3
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
N/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
CR1
NO
BK
-R1
-E.H
.
TB21
CR2
NO
8
7
6
5
10
9
TS51
TB27
RD
TS1
TS52
1
2
TB33
3
RD
IGNITION/
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
WA
TE
RT
EM
PE
RA
TU
RE
AN
D
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
WA
TE
RT
EM
PE
RA
TU
RE
SW
ITC
H
TB34
C3
4S
AB
K/W
H
GL
OW
PL
UG
CR4
NO CR4
CR3
NO
BK
/RD
-R4
-E.H
.
BK
/WH
RP
MS
OL
EN
OID
RP
MR
EL
AY
RP
MR
EL
AY
HIG
H(F
S)
LO
WR
PM
TIL
TA
LA
RM
W
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
6
47 3
1
5
-
+
12V DC
B1
D22
AUX
FAN
CR17
NO
15A
TB20
CB1
RD
B1
BA
TT
ER
Y
3 1 2
L24
L28
FU
NC
.E
NA
BL
E
PU
LL
IN
HO
LD
AW
H
RD
BK
CB
WH
BK
FL2
FUSE
LINK
D6
C6
-16
C6
-23
C6
-34
C6
-33
C5
-3 C5
-2
C6
-28
C6
-27
C5
-15
C2
1IG
NW
H
C5
-22
C6
-13
4R
D
C5
-12
D14
D13
D52
D12
R2
1IG
NW
H
R11
6H
YD
OR
A C
B
C5
-11
BL/RD
RD
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
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
C7
B-1
C2
P-5
C1
P-2
H1
C7
P-1
P3
HORN
RD
P2
3B
AT
WH
WH
TB23
C7
B-2
D2
C7
P-2
FS1
BKC9P-1
P2
CR39
NO
D42
EN
GIN
ES
PE
ED
OIL
PR
ES
SU
RE
SE
ND
ER
(OP
TIO
N)
WA
TE
RT
EM
PE
RA
TU
RE
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
TB33A
C5
-5
D51
C21IGN WH C21IGN WH
C27AUX RD
C41RPM OR/BK
P46 RD
P23 RD
P25FS RD
P24FS WH
P26ESTP BK P26ESTP BK
C28TTA RD/BK
HY
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
STA
RT
BA
TT
ER
Y
5D40
+
C3
P-1
0C
13
3P
LA
BL
C3
B-1
0
3
5
NOTES:
ROCKER STEER OPTION ONLY.
ADD D40 ONLY IF UNIT HAS L4 AND L48.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
C5
-18
C5
-19
L48
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 91
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Electrical Schematic, S-85Perkins 704-30 Models (after serial number 3576)
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
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
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
Section 6 • SchematicsFebruary 2012
Electrical Schematic, S-85Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576)
February 2012Section 6 • Schematics
S-80 • S-85 Part No. 7783294
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
Ground Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576)
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 WATER 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
CR1
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
IGNITION/START RELAY
HOUR METER
TURNTABLE ROTATE TOGGLE SWITCH
LABEL
TS51
KS1
TS54
TS59
TS57
TS58
TS52
P1
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN 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
AXLE EXTEND LED RELAY
EXTEND FUNCTION CUTOUT RELAY
AUXILIARY PUMP RELAY
R2 5 OHM RESISTOR
U1 IGNITION/START MODULE
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
CR2CR1
TB33AB
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
D13
D42
OR/BK-15A
RD-27B
RD-CR1#30
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
D42
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
RD C5-6
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
RD ISM#427
32
BK CR5#30
23
22
GR C6-17
OR/RD CR38#87A
GR/BK C6-18
OR C6-14
OR/BK C6-15
20
18
17
16
15
14
WH/RD C3B-6
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
RD/WH C3B-3
WH/BK C3B-5
WH C3B-4
RD C3B-1
RD/BK C3B-2&C6-2
6WH/RD C6-6
BK/RD C6-9
BK C6-7
BK/WH C6-8
11
10
7
8
9
RD/WH C6-3
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
WATER TEMPERATURE
BL/RD L2
GR
OU
ND
ST
UD
G6
U1IGNITION/
START
MODULE
CB3
OIL COOLER/
OPTION
BRN(GND)
H1
RD-B2-S.P.
RD-B1-20C
RD-24AA
86868686
RD-B2-H1
CR39 #30
RD-B1-H1 RD-B1-S.P.
CR3
86
24A
WH-S.P.-D2
BK CR1 #86
42
D34
OR/RD C6-22OR/RD C4B-4
RD CR17#30
RD/BK C6-19
RD C6-30 / RD C5-19
33ABK 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
CONTROLS
RD-B1-20D
RD-B1-H1
OR/RD CR8#87A
CR8#86+
D15
GND STUD
D57
RD/BK CR8#30
86
CR29
86
CR8
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
3
1
BL/WH C1-12 P134PWR RD-134B
RD H6
BK-22D2
BK C7B-1
RD-TS52
GN/BK H6
RD-TS51
BRN
8
12
5
6
7
4 GN/BK-C3B-10
H6
RD C6-23 C2-6 134 RD-H6 RD-KSI-SP
L28
GLOW PLUG
LED
L2
CHECK ENG. LED
-
+
WH-23A
BK-22A
RD C23-6
KS1
KEY SWITCH
B
1
2
3
4
B1
RD-134A
RD-C23-7
-
-
L45
PLATFORM
OVERLOAD
LED
+
+
GR/BK-H6
PLATFORM OVERLOAD LED
GLOW PLUG LED
L45
L28
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
+
-
BR
N
OR
/RD
-16
C
BK
/WH
C6
-29
RD
-1B
RD
C6
-27
RD
-27
D
RD
-24
C
86
CR39
86
CR38
TS58
JIB
BOOM
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 95
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576)
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2
CR13
U13
JC1
TILT ALARM
ALC500
JIB BOOM CUTOUT RELAY
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
COMPONENT INDEX
TS2
TS9
TS15
TS8
P3
TS1
TS14
L1
P2
DRIVE ENABLE LED
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
HORN SWITCH
EMERGENCY STOP BUTTON
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS4
TS7
HIGH RPM SWITCH
PLATFORM ROTATE TOGGLE 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)
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
BK
RDRD
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
L24
GLOW
PLUG LED
TS1
AUXILIARY
PUMP
TS14
DRIVE
SPEED
TS8
JIB BOOM
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
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
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
GND
TS
48
-WL
2R
DC
2P
-11
TS
48
-WL
1R
DC
2P
-12
C2P-9 & 10
BL
C3
P-1
0
D12
LS18
7
6
5
4
3
2
1
4
2
1
3
5
6
7
4
2
1
3
5
6
7
BR
NJ1
-10
BR
N-G
ND
+-
+-
+-
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
CUTOUT
JIB
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
GR/WH TS7
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
L24
PLATFORM OVERLOAD LED
GLOW PLUG LED
LS18 PLATFORM OVERLOAD LIMIT SWITCH
GN
/BK
C3
P-1
0
RD
/BK
L4
8
OPT.
GN
/BK
H1
(D3
9)
L48
+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
DETAIL A
February 2012 Section 6 • Schematics
Platform Control Box Wiring Diagram, S-85Perkins 704-30 Models (after serial number 3576)
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 97
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 RDA
LT
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)
Dual Battery Option
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
February 2012 Section 6 • Schematics
Dual Battery Option
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 99
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N M L K J I H G F E D C B A
Hydraulic Schematic, 2WD Models
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
30 psi
2 bar
T2
PR1
30 psi
2 bar
30 psi
2 bar
TANK
SW2
V1
SW1
2500 psi
172 bar
V2
T3
S1
RET
0.035 in
0.89 mmV1 J1
J2
JIB BOOM
(S-85 Models)TURNTABLE
ROTATE
1200 psi
82.7 bar
ST2ST1
PTEST
AUX
EXTACCUM
2900 psi
200 bar
SECONDARY
RETRACT
4 GPM
PRIMARY
BOOM EXTENSION CYLINDER
3300 PSI3:1D
E 3:1 3500 PSI
COUNTERBALANCE VALVE
3:1
C
B
3:1
3:1
RATIO
1000 PSI
3000 PSI
2000 PSI
PRESSURE
AXLE CP LIM SW
1.7 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
YY
A
B
DE
F
H
AE
AF
FA
FB
FD
FE
FC
BGBH
BI
BF
AG
AH
AN
VV
XXWW
AL
AM
AI
AJ
AK
J
K
L
PQ
NO
AO
W
M
S
Z
V
U
Y
T
R
X
AA
PP
RRQQSS
TT
UU
AC
AD
AB
I
G
C
February 2012 Section 6 • Schematics
Hydraulic Schematic, 2WD Models
February 2012 Section 6 • Schematics
Part No. 77832 S-80 • S-85 101
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Hydraulic Schematic, 4WD Models
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
30 psi
2 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
2900 psi
200 bar
SECONDARY
RETRACT
4 GPM
PRIMARY
BOOM EXTENSION CYLINDER
3300 PSI3:1D
E 3:1 3500 PSI
COUNTERBALANCE VALVE
3:1
C
B
3:1
3:1
RATIO
1000 PSI
3000 PSI
2000 PSI
PRESSURE
AXLE CP LIM SW
1.7 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
YY
A
B
DE
F
H
AE
AF
FA
FB
FD
FE
FC
BJ
BKBT
BV
BS
BU
BW
BR
BN BP
BQ
BO
BM
BL
AG
AH
AN
VV
XXWW
AL
AM
AI
AJ
AK
J
K
L
PQ
NO
AO
W
M
S
Z
V
U
Y
T
R
X
AA
PP
RRQQSS
TT
UU
AC
AD
AB
I
G
C
OIL COOLER
OPTION
Section 6 • SchematicsFebruary 2012
Hydraulic Schematic, 4WD Models
IGNITIOIN/STARTMODULE
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
P23BATWH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
S-613
+BAT
+AUX
RD-HOLD
WH-PULL IN
TIMEDELAY
COM
-BAT
MOMN.O.
TROMBETTA
FAN BELTBREAK SWITCH
CA B
31 2
D37
D38
D41
Electrical SchematicGenie Part number 77807
Genie S-80
Deutz F4L 913 Models(before serial number 3577)
Rev B
A B C D E F G H I J K L M N O P
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
P23BAT WH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
D37
D38
D41
Rev B
Electrical SchematicGenie Part number 77807
Genie S-80
GM 3.0L Models(before serial number 3577)
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N O P
IGN./STARTMODULE
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
L4
L3
P23BAT WH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
C B A
D37
D38
D41
Rev B
Electrical SchematicGenie Part number 77807
Genie S-80
Perkins 704-30 Models(before serial number 3577)
A B C D E F G H I J K L M N O P
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
IGNITIOIN/STARTMODULE
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
P23BATWH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
S-613
+BAT
+AUX
RD-HOLD
WH-PULL IN
TIMEDELAY
COM
-BAT
MOMN.O.
TROMBETTA
FAN BELTBREAK SWITCH
CA B
31 2
D37
D38
D41
Rev B
Electrical SchematicGenie Part number 77808
Genie S-85
Deutz F4L 913 Models(before serial number 3618)
A B C D E F G H I J K L M N O P
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
P23BATWH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
D37
D38
D41
Rev B
Electrical SchematicGenie Part number 77808
Genie S-85
GM 3.0L Models(before serial number 3577)
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N O P
IGN./STARTMODULE
+H3
STARTER
FB1+
+H1
G6 G1 G2G3
FAN
H2+ +
L4
L3
P23BAT WH
P22BAT BK
BATGND BRN
C7P-2
P2BLK
WHT
FS1
C9-2
C9-1C9-3 RED
D12
TB24
BATTERYSEPARATOR
FB2+
H4 S7
U4
Y2 Y27 Y17Y16Y4Y3 Y3
21 3
C B A
D37
D38
D41
Rev B
Electrical SchematicGenie Part number 77808
Genie S-85
Perkins 704-30 Models(before serial number 3577)
A B C D E F G H I J K L M N O P
A B C D E F G H I J K L M N O P
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8