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Service Manual
Serial Number Range
S-80
S-85
S-80X
from S8008-8000 to S8013-11875
from S8508-8001 to S8513-11875
from S80X10-8500 to S80X13-11875
Part No. 122985
Rev D1
September 2015
Introduction
September 2015
Introduction
Important
Serial Number Information
Read, understand and obey the safety rules and
operating instructions in the appropriate operator's
manual on your machine before attempting any
maintenance or repair procedure.
Genie offers the following Service
Manuals for these models:
This manual provides detailed scheduled maintenance
information for the machine owner and user. It also
provides troubleshooting fault codes and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However, several
procedures require specialized skills, tools, lifting
equipment and a suitable workshop. In these instances,
we strongly recommend that maintenance and repair be
performed at an authorized Genie dealer service center.
Compliance
Title
Part No.
Genie S-80 and S-85 Service Manual
(from serial number 101 to 785) .......... 34032
Genie S-80 and S-85 Service Manual
(from serial number 786 to 965) .......... 52270
Genie S-80 and S-85 Service Manual
(from serial number 966 to 3081) ........ 72062
Genie S-80 and S-85 Service Manual
(from serial number 3082 to 3737) ...... 77832
Genie S-80 and S-85 Service Manual
(from serial number 3738 to 5380) ... 111165
Machine Classification
Group B/Type 3 as defined by ISO 16368
Genie S-80 and S-85 Service Manual
(from serial number 5381 to 7999) ... 122149
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree of
accuracy possible. However, continuous improvement of
our products is a Genie policy. Therefore, product
specifications are subject to change without notice.
Readers are encouraged to notify Genie of errors and
send in suggestions for improvement. All
communications will be carefully considered for future
printings of this and all other manuals.
Copyright © 2011 Terex Corporation
122985 Rev D February 2012
Seventh Edition, Fourth Printing
"Genie" and "S" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Contact Us:
Printed in U.S.A.
http://www.genielift.com
e-mail: [email protected]
ii
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Revision History
Revision
Date
Section
Procedure / Schematic Page / Description
D
2/2012
2 - Spec.
2-1
3 - Maint.
3-1, 3-51
4 - Repair
4-3 to 4-6, 4-18
3 - Maint.
E-4
D1
9/2015
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.
3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #.
Fault Codes_Section 5.
6-5_Section 6_Schematic Page #.
Part No. 122985
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
S-80 • S-85 • S-80X
September 2015
REVISION HISTORY, CONTINUED
Revision
Date
Section
Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.
3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #.
Fault Codes_Section 5.
6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Serial Number Legend
Model: S-80
S8008-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES503
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg
S80
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 80 ft/ 24.4 m
08 - 12345
Sequence
number
Model
Maximum platform reach : 71 ft 6 in/ 21.8 m
Gradeability: N/A
Model year
Country of manufacture: USA
This machine complies with:
Terex South Dakota
500 Oak Wood road
PO Box 1150
Watertown, SD 57201
USA
Sequence number
(stamped on chassis)
Serial label
(located under cover)
PN - 77055
Part No. 122985
S-80 • S-85 • S-80X
iii
September 2015
This page intentionally left blank.
iv
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 and Genie S-85
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
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.
Part No. 122985
S-80 • S-85 • S-80X
v
Section 1 - Safety Rules
September 2015
SAFETY RULES
Personal Safety
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Be sure that all tools and working areas
are properly maintained and ready for use.
Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area is
properly ventilated and well lit.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi
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Part No. 122985
September 2015
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1
Safety Rules
General Safety Rules .................................................................................................. v
Section 2
Rev
Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 2
Hydraulic Component Specifications ...................................................................... 2 - 3
Valve Coil Resistance Specifications ..................................................................... 2 - 4
Continental TME27 Engine Specifications ............................................................. 2 - 5
Deutz TD2011L04i Engine Specifications ............................................................... 2 - 6
Perkins 804D-33 Engine Specifications ................................................................. 2 - 7
Machine Torque Specifications .............................................................................. 2 - 8
Manifold Component Specifications ....................................................................... 2 - 8
Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 9
SAE and Metric Torque Specifications ................................................................. 2 - 10
Part No. 122985
S-80 • S-85 • S-80X
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September 2015
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1
Inspect the Manuals and Decals .................................................................. 3 - 7
A-2
Perform Pre-operation Inspection ................................................................. 3 - 8
A-3
Perform Engine Maintenance ....................................................................... 3 - 8
A-4
Perform Function Tests ................................................................................ 3 - 9
A-5
Test the Oscillate Axle ................................................................................. 3 - 9
A-6
Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10
A-7
Perform 30 Day Service ............................................................................. 3 - 10
A-8
Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 11
A-9
Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-11 Perform Engine Maintenance ..................................................................... 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 15
A-13 Perform Engine Maintenance - Perkins Models .......................................... 3 - 17
Checklist B Procedures
viii
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
S-80 • S-85 • S-80X
Part No. 122985
September 2015
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
B-5
Inspect the Engine Air Filter ....................................................................... 3 - 22
B-6
Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 23
B-7
Confirm the Proper Brake Configuration ...................................................... 3 - 24
B-8
Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 24
B-9
Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 25
B-10 Check and Adjust the Engine RPM ............................................................ 3 - 26
B-11 Perform Engine Maintenance ..................................................................... 3 - 28
B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 28
B-13 Test the Ground Control Override ............................................................... 3 - 29
B-14 Test the Platform Self-leveling ................................................................... 3 - 29
B-15 Test the Engine Idle Select Operation ........................................................ 3 - 30
B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 31
B-17 Test the Drive Enable System ................................................................... 3 - 32
B-18 Test the Drive Brakes ................................................................................ 3 - 33
B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 33
B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 34
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 35
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 36
B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 37
B-24 Inspect the Boom Extend/Retract Cables ................................................... 3 - 37
Checklist C Procedures
Part No. 122985
C-1
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 39
C-2
Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 39
C-3
Test the Platform Overload System (if equipped) ....................................... 3 - 40
C-4
Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 43
C-5
Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 43
C-6
Check the Safety Envelope Limit Switches and Angle Sensor, S-80X ....... 3 - 45
S-80 • S-85 • S-80X
ix
September 2015
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
Checklist D Procedures
A
Section 4
Rev
D-1
Check the Boom Wear Pads ...................................................................... 3 - 48
D-2
Check the Free-wheel Configuration ........................................................... 3 - 49
D-3
Check the Turntable Rotation Bearing Bolts ............................................... 3 - 50
D-4
Inspect the Turntable Bearing Wear ........................................................... 3 - 51
D-5
Perform Engine Maintenance ..................................................................... 3 - 53
D-6
Replace the Hydraulic Filter Elements ........................................................ 3 - 53
D-7
Replace the Drive Hub Oil .......................................................................... 3 - 54
D-8
Perform Engine Maintenance - Deutz Models ............................................. 3 - 56
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil ............................................................... 3 - 57
E-2
Perform Engine Maintenance - Perkins Models .......................................... 3 - 59
E-3
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 59
E-4
Remove and Replace the Boom Extend/Retract Cables ............................. 3 - 60
Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1
ALC-500 Circuit Board .................................................................................. 4 - 2
1-2
Joysticks ..................................................................................................... 4 - 3
Platform Components
x
2-1
Platform ....................................................................................................... 4 - 9
2-2
Platform Leveling Slave Cylinder ................................................................ 4 - 10
S-80 • S-85 • S-80X
Part No. 122985
September 2015
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures, continued
2-3
Platform Rotator ......................................................................................... 4 - 11
2-4
Calibrate the Platform Overload System .................................................... 4 - 13
Jib Boom Components, S-85
3-1
Jib Boom .................................................................................................... 4 - 16
3-3
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 - 25
4-5
Boom Extend/Retract Cables ..................................................................... 4 - 28
4-6
Platform Leveling Master Cylinder .............................................................. 4 - 32
Engines
5-1
RPM Adjustment ........................................................................................ 4 - 33
5-2
Flex Plate ................................................................................................... 4 - 33
Ground Controls
6-1
Control Relays ............................................................................................ 4 - 38
Hydraulic Pumps
Part No. 122985
7-1
Function Pump ........................................................................................... 4 - 39
7-2
Drive Pump ................................................................................................ 4 - 40
S-80 • S-85 • S-80X
xi
September 2015
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures, continued
Manifolds
8-1
Function Manifold Components .................................................................. 4 - 42
8-2
Valve Adjustments - Function Manifold ...................................................... 4 - 44
8-3
Brake/Two-speed Manifold Components .................................................... 4 - 46
8-4
Turntable Rotation Manifold Components ................................................... 4 - 47
8-5
Platform Rotate Manifold Components ....................................................... 4 - 48
8-6
Platform Manifold Components, S-80 ......................................................... 4 - 49
8-7
Platform Manifold Components, S-85 ......................................................... 4 - 50
8-8
2WD Traction Manifold Components .......................................................... 4 - 51
8-9
4WD Traction Manifold Components (before serial number 8581) ............... 4 - 53
8-10 4WD Traction Manifold Components (after serial number 8580) .................. 4 - 55
8-11 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 57
8-12 Valve Adjustments - Traction Manifold ....................................................... 4 - 58
8-13 Valve Coils ................................................................................................. 4 - 59
Fuel and Hydraulic Tanks
9-1
Fuel Tank ................................................................................................... 4 - 61
9-2
Hydraulic Tank ........................................................................................... 4 - 62
Turntable Rotation Components
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 64
2WD Steer Axle Components
11-1 Yoke and Hub ............................................................................................ 4 - 67
11-2 Steer Cylinder ............................................................................................ 4 - 68
xii
S-80 • S-85 • S-80X
Part No. 122985
September 2015
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures, continued
4WD Steer Axle Components
12-1 Yoke and Drive Hub ................................................................................... 4 - 69
12-2 Drive Motor ................................................................................................ 4 - 70
12-3 Drive Hub ................................................................................................... 4 - 70
12-4 Steer Cylinders ........................................................................................... 4 - 71
Non-steer Axle Components
13-1 Drive Motor ................................................................................................ 4 - 72
13-2 Drive Hub ................................................................................................... 4 - 72
Oscillating Axle Components
14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73
14-2 Oscillate Directional Valve ......................................................................... 4 - 74
Section 5
Rev
Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Engine Fault Codes - Continental Models ............................................................... 5 - 7
Section 6
Rev
Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Connector Pin Legend - View 1 .............................................................................. 6 - 6
Connector Pin Legend - View 2 .............................................................................. 6 - 7
Part No. 122985
S-80 • S-85 • S-80X
xiii
September 2015
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04i Models ......................................................................... 6 - 10
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 14
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 15
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04i Models ......................................................................... 6 - 18
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 19
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 22
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 26
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 27
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 30
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 31
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 34
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 38
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 39
xiv
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Part No. 122985
September 2015
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 42
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 43
Electrical Schematic, S-80X
Deutz TD2011L04i Models ......................................................................... 6 - 46
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Deutz TD2011L04i Models ......................................................................... 6 - 50
Ground Control Box Switch panel Wiring Diagram, S-80X,
Deutz TD2011L04i Models ......................................................................... 6 - 51
Platform Control Box Wiring Diagram, S-80X,
Deutz TD2011L04i Models ......................................................................... 6 - 54
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Deutz TD2011L04i Models ......................................................................... 6 - 55
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models ............................................................................ 6 - 58
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 62
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 63
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models ............................................................................ 6 - 66
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 67
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 70
Part No. 122985
S-80 • S-85 • S-80X
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September 2015
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 74
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 75
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 78
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 79
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 82
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 86
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 87
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 90
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 91
Electrical Schematic, S-80X,
Perkins 804D-33 Models ............................................................................ 6 - 94
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Perkins 804D-33 Models ............................................................................ 6 - 98
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Perkins 804D-33 Models ............................................................................ 6 - 99
Platform Control Box Wiring Diagram, S80X,
Perkins 804D-33 Models ........................................................................... 6 - 102
Platform Control Box Switch Panel Wiring Diagram, S80X,
Perkins 804D-33 Models ........................................................................... 6 - 103
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Part No. 122985
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TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models ....................................................................... 6 - 106
Ground Control Box Terminal Strip Wiring Diagram
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 110
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 111
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models ....................................................................... 6 - 114
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 115
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111) ............................ 6 - 118
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111) ............................ 6 - 122
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111) ............................ 6 - 123
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111) ............................ 6 - 126
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111) ............................ 6 - 127
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110) ............................... 6 - 130
Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110) ............................... 6 - 134
Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110) ............................... 6 - 135
Part No. 122985
S-80 • S-85 • S-80X
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September 2015
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued .................................................................................................
Platform Control Box Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110) ............................... 6 - 138
Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110) ............................... 6 - 139
Electrical Schematic, S-80X,
Continental TME27 Models ....................................................................... 6 - 142
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Continental TME27 Models ....................................................................... 6 - 146
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models ....................................................................... 6 - 147
Platform Control Box Wiring Diagram, S-80X,
Continental TME27 Models ....................................................................... 6 - 150
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models ....................................................................... 6 - 151
Continental TME27 Engine Harness .................................................................... 6 - 154
Platform Level Cutout, CTE Option ..................................................................... 6 - 155
Continental Options Schematic ........................................................................... 6 - 158
Deutz and Perkins Options Schematic ................................................................ 6 - 159
12 kW Hydraulic Generator Wiring Diagram ......................................................... 6 - 162
12 kW Hydraulic Generator Electrical Schematic ................................................ 6 - 163
Belt Driven Generator Option .............................................................................. 6 - 166
Relay and Fuse Panel Legend ............................................................................ 6 - 167
Hydraulic Schematic, 2WD Models ..................................................................... 6 - 170
Hydraulic Schematic, 4WD Models ..................................................................... 6 - 171
12 kW Hydraulic Generator Hydraulic Schematic ................................................ 6 - 173
xviii
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 2 • Specifications
Specifications
Machine Specifications
Fluid capacities
Rough Terrain and Non Marking Tires and Wheels
Fuel tank,
(Deutz and Perkins models)
35 gallons
132.5 liters
(Continental models)
30 gallons
113.5 liters
Tire size
Tire ply rating
Overall tire diameter
Tire pressure
Wheel diameter
Wheel width
Tire weight, new foam-filled (minimum)
18-625 FF
16
40.7 in
103.3 cm
Foam filled
24.5 in
62.2 cm
15 in
38.1 cm
622 lbs
282 kg
41/18LLx22.5
Tire ply rating
14
Tire pressure
70 psi
4.8 bar
Wheel diameter
22.5 in
57 cm
Wheel width
33.5 pounds
15.2 kg
Hydraulic tank
40 gallons
151.4 liters
Hydraulic system
(including tank)
50 gallons
189.3 liters
Turntable rotation drive hub
(single fill port)
Turntable rotation drive hub
(Dual fill ports)
Four wheel drive hubs
High Floatation Tires and Wheels
Tire size
LPG tank
Two wheel drive hubs
40 fl oz
1.2 liters
43 fl oz
1.3 liters
30.5 fl oz
0.90 liters
23 fl oz
0.68 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
14 in
35.6 cm
Lugs and Lug Nut Torque
Wheel lugs
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
569 Nm
Lug nut torque, lubricated
320 ft-lbs
434 Nm
Part No. 122985
S-80 • S-85 • S-80X
2-1
September 2015
Section 2 • Specifications
SPECIFICATIONS
Performance Specifications
Hydraulic Oil Specifications
Drive speed, maximum
Hydraulic Oil Specifications
Stowed position
RT Tires
40 ft / 7.9-8.5 sec
12.2 m / 7.9-8.5 sec
Stowed position
Flotation Tires
40 ft / 11-13 sec
12.2 m / 11-13 sec
Raised or extended position
40 ft / 40-45 sec
12.2 m / 40-45 sec
Braking distance, maximum
High range on paved surface
Gradeability
3 ft
90 cm
Refer to the Operator’s Manual
Boom function speeds, maximum
from platform controls
Hydraulic oil type
Viscosity grade
Viscosity index
Cleanliness level, minimum
Water content, maximum
25 to 35 seconds
Optional fluids
Jib boom down (S-85)
15 to 25 seconds
Biodegradable
Boom up (ANSI, CSA, AS models)
57 to 65 seconds
Boom up (CE models)
75 to 83 seconds
Fire resistant
Boom down (ANSI, CSA, AS models) 61 to 69 seconds
75 to 83 seconds
Boom extend
59 to 67 seconds
Boom retract
57 to 65 seconds
Turntable rotate, 360°
boom fully stowed
Turntable rotate, 360°
boom raised or extended
Platform rotate, 160°
200 ppm
Mineral based
Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
95 to 103 seconds
210 to 250 seconds
8 to 12 seconds
Platform level up
50 to 60 seconds
Platform level down
40 to 50 seconds
2-2
15/13
Chevron Rando HD MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Jib boom up (S-85)
Boom down (CE models)
Chevron Rando HD MV equivalent
Multi-viscosity
200
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 2 • Specifications
SPECIFICATIONS
Continued use of Chevron Aviation
A hydraulic oil when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Hydraulic Component
Specifications
Drive pump
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
below 0°F / -18°C.
Type: bi-directional variable displacement piston pump
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Flow rate @ 2300 rpm
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Drive pressure, maximum
Displacement
0 to 2.8 cu in
0 to 46 cc
0 to 30.3 gpm
0 to 114.7 L/min
3750 psi
259 bar
Charge pump
Type:
gerotor
Displacement
0.85 cu in
13.9 cc
Flow rate @ 2300 rpm
9 gpm
34.1 L/min
Charge pressure @ 2300 rpm
Neutral position
310 psi
21.4 bar
Function pump
Type:
variable displacement piston pump
Displacement
0 to 2.3 cu in
0 to 38 cc
Flow rate @ 2300 rpm
0 to 23 gpm
0 to 87 L/min
Auxiliary pump
Type:
Displacement - static
Part No. 122985
S-80 • S-85 • S-80X
fixed displacement gear pump
0.151 cu in
2.47 cc
2-3
September 2015
Section 2 • Specifications
SPECIFICATIONS
Function manifold
System relief pressure
(measured at PTEST port)
3200 psi
221 bar
Boom down relief pressure
(measured at PTEST port)
2400 psi
165 bar
Boom extend relief pressure
(measured at PTEST port)
2400 psi
165 bar
Steer/axle extend
flow regulator
3.5 gpm
13.2 L/min
Oscillate relief pressure
950 psi
65.5 bar
Drive manifold
Hot oil relief pressure
280 psi
19.3 bar
Brake release pressure
Wheel drive hubs
240 psi
16.5 bar
Drive motors
Displacement per revolution, variable
(2 speed motor)
0.9 to 2.7 cu in
14.7 to 45 cc
Hydraulic filters
High pressure filter
Beta 3 ≥ 200
High pressure filter
bypass pressure
102 psi
7 bar
Medium pressure filter
Beta 3 ≥ 200
Medium pressure filter
bypass pressure
51 psi
3.5 bar
Hydraulic tank
return filter
2-4
Valve Coil Resistance
Specifications
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / -7.8°C
that your air temperature increases or decreases
from 68°F / 20°C.
Valve coil resistance specifications
Proportional solenoid valve
(schematic items SE)
3.7 Ω
Proportional solenoid valve
(schematic items SR and SF)
4.8 Ω
2 position 3 way solenoid valve
(schematic items SJ)
4.1 Ω
2 position 3 way solenoid valve
(schematic items SK)
9Ω
3 position 4 way solenoid valve
(schematic items SI and SL)
7.2 Ω
Solenoid valve, NO, Poppet
(schematic items SP and SQ)
5.6 Ω
10 micron with
25 psi / 1.7 bar bypass
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 2 • Specifications
SPECIFICATIONS
Continental TME27 Engine
Displacement
Fuel Requirement
164 cu in
2.68 liters
4
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio
3.58 x 4.06 inches
91 x 103.2 mm
59.03 @ 2500 rpm
44 kW @ 2500 rpm
1-3-4-2
8.2:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle - computer controlled
Frequency
1600 rpm
53.33 Hz
High idle - computer controlled
Frequency
2500 rpm
83.33 Hz
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Electronic fuel pump
Fuel pressure, static
Fuel flow rate
Type
Exhaust
0.018 in
0.46 mm
12V DC
Group
31
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
Alternator output
Fan belt deflection
0.014 in
0.36 mm
0.42 gpm
1.59 L/min
Batteries
Valve clearance, warm
Intake
55 psi
3.8 bar
1
1000A
200 minutes
65A @ 13.8V DC
1 /2
inch
12 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
40-60 psi
2.8-4.1 bar
7 quarts
6.65 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Part No. 122985
S-80 • S-85 • S-80X
2-5
September 2015
Section 2 • Specifications
SPECIFICATIONS
Deutz TD2011L04i Engine
Displacement
Oil viscosity requirements
189.6 cu in
3.1 liters
4
Number of cylinders
Bore and stroke
3.7 x 4.409 inches
94 x 112 mm
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Oil temperature switch
Oil temperature switch point
284°F
140°C
Horsepower
Continuous
Net intermittent
Continuous
Net intermittent
Firing order
69.1 @ 2500 rpm
72.8 @ 2500 rpm
51.5 KW @ 2500 rpm
54.3 KW @ 2500 rpm
1-3-4-2
Oil pressure switch
Oil pressure switch point
Fuel injection system
Low idle
Frequency
1300 rpm
331.5 Hz
Injection pump make
High idle
Frequency
2350 rpm
599.3 Hz
Injector opening pressure
Compression ratio
17.5:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Governor
centrifugal mechanical
Exhaust
0.012 in
0.3 mm
0.020 in
0.5 mm
Oil capacity
(including filter)
2-6
Injection pump pressure, maximum15,000 psi/1034 bar
3046 psi
210 bar
Fuel Requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Batteries
21.8 psi
1.5 bar
12V DC
Group
31
Quantity
1
Cold cranking ampere
Reserve capacity @ 25A rate
Lubrication system
Minimum oil pressure, hot
(at 1300 rpm)
Bosch
Type
Valve clearance, cold
Intake
22 psi
1.5 bar
Alternator output
Fan belt deflection
12.8 quarts
12.1 liters
S-80 • S-85 • S-80X
1000A
200 minutes
80A @ 14V DC
3 /8
to 1/2 inch
9 to 12 mm
Part No. 122985
September 2015
Section 2 • Specifications
SPECIFICATIONS
Perkins 804D-33 Engine
Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio
Injection system
201 cu in
3.3 liters
Injection pump make
Injection pump pressure
4
3.70 x 4.72 inches
94 x 120 mm
63 @ 2600 rpm
47 KW @ 2600 rpm
1-3-4-2
22:1
300 to 500 psi
20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must be
within 50 psi / 3.45 bar of highest cylinder
Compression pressure
Low idle
Frequency
1650 rpm
335.5 Hz
High idle
Frequency
2300 rpm
467.7 Hz
Injector opening pressure
1707 to 1849 psi
117.7 to 127.5 bar
~2000 psi
~138 bar
Fuel Requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Engine coolant
Capacity
12.5 quarts
11.8 liters
Batteries
Type
Group
Quantity
Cold cranking ampere
Governor
Zexel
12V DC
31
1
1000A
mechanical all speed
Reserve capacity @ 25A rate
200 minutes
Valve clearance, cold
Alternator output
Intake
Exhaust
0.0098 in
0.25 mm
Fan belt deflection
90A, 12V DC
3/8 to 1/2 in
9 to 12 mm
0.0098 in
0.25 mm
Lubrication system
Oil pressure @ 2000 rpm
40-60 psi
2.8-4.1 bar
Oil capacity
(including filter)
10.6 quarts
10 liters
Oil viscosity requirements
Units ship with 15W-40.
Extreme operating temperatures my require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Part No. 122985
S-80 • S-85 • S-80X
2-7
September 2015
Section 2 • Specifications
SPECIFICATIONS
Machine Torque Specifications
Platform rotator
1-8 center bolt, GR 5, lubricated
3 /8
-16 bolts, GR 8
*(use blue thread locking compound)
480 ft-lbs
651 Nm
35 ft-lbs*
47 Nm*
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
Rotate drive hub mounting bolts, lubricated
Backlash plate mounting bolts, lubricated
180 ft-lbs
244 Nm
80 ft-lbs
108 Nm
Manifold Component
Specifications
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
280 ft-lbs
379 Nm
Drive motor and hubs
Drive hub mounting bolts, dry
Drive hub mounting bolts, lubricated
*(use blue thread locking compound)
210 ft-lbs
284 Nm
160 ft-lbs*
217 Nm
Drive motor mounting bolts, dry
110 ft-lbs
149 Nm
Drive motor mounting bolts, lubricated
*(use blue thread locking compound)
80 ft-lbs*
108 Nm
Drive hub oil plug, O-ring seal
13 ft-lbs
18 Nm
2-8
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 2 • Specifications
SPECIFICATIONS
Seal-Lok® fittings
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
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
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok® Fittings
(tube fitting - installed into Steel)
(hose end)
SAE Dash size
Torque
SAE Dash size
Torque
-4
15 ft-lbs / 20.3 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
30 ft-lbs / 40 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 55 Nm
-10
100 ft-lbs / 135.6 Nm
-10
60 ft-lbs / 80 Nm
-12
135 ft-lbs / 183 Nm
-12
85 ft-lbs / 115 Nm
-16
200 ft-lbs / 271 Nm
-16
110 ft-lbs / 150 Nm
-20
250 ft-lbs / 334 Nm
-20
140 ft-lbs / 190 Nm
-24
305 ft-lbs / 414 Nm
-24
180 ft-lbs / 245 Nm
Part No. 122985
S-80 • S-85 • S-80X
2-9
September 2015
Section 2 • Specifications
SPECIFICATIONS
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
5/16
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size
(mm)
5
6
7
4.6
Class 4.6
LUBED
2 - 10
Class 8.8
LUBED
DRY
10.9
DRY
Class 10.9
LUBED
12.9
DRY
Class 12.9
LUBED
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
8.8
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Scheduled maintenance inspections shall be
completed daily, quarterly, six months, annually
and every two years as specified on the
Maintenance Inspection Report. The frequency
and extent of periodic examinations and tests
may also depend on national regulations.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial machine damage.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
Repair any machine damage or malfunction
before operating machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a
period longer than three months must complete
the quarterly inspection.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
•
Machine parked on a firm, level surface
•
Boom in the stowed position
•
Turntable rotated with the boom between
the non-steer (yellow arrow) wheels
•
Turntable secured with the turntable
rotation lock pin
•
Key switch in the off position with the
key removed
•
Wheels chocked
•
All external AC power supply disconnected
from the machine
Part No. 122985
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-80 • S-85 • S-80X
3-1
Section 3 • Scheduled Maintenance Procedures
September 2015
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: The following symbols have been used in
this manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation
Report to use for each inspection. Store completed
forms as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Indicates that a warm engine will be
required to perform this procedure.
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
To account for repeated procedures, the
Scheduled Maintenance Procedures Section and
the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that dealer service is required
to perform this procedure.
Checklist
Six month or every 500 hours
Annual or every 1000 hours
Two year or every 2000 hours
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of four years or in compliance
with employer, jobsite and governmental
regulations and requirements.
3-2
S-80 • S-85 • S-80X
Part No. 122985
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Use the operator’s manual on your machine.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it is
put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be performed
by qualified service technicians, according to the
manufacturer's specifications and the requirements
listed in the responsibilities manual.
The Pre-delivery Preparation consists of completing
the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machine
from service, repair and reinspect it. After repair, place
a check in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201-6150
(605) 882-4000
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
Y
N
R
Section 3 • Scheduled Maintenance Procedures
September 2015
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3-4
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A
Serial number
A-1 Inspect the manuals
and decals
B-1 Battery(s)
Date
A-2 Pre-operation
inspection
B-3 Key switch
Hour meter
A-3 Engine maintenance
Y N R
A-4 Function tests
Checklist B
B-2 Electrical wiring
B-4 Exhaust system
B-5 Engine air filter
Machine owner
A-5 Oscillate axle
B-6 Oil cooler and finsDeutz models
Inspected by (print)
A-6 Filter condition indicator
B-7 Brake configuration
Perform after 40 hours:
A-7 30 day service
B-8 Tires, wheels and
lug nut torque
Perform after 50 hours:
B-9 Drive hub maintenance
A-8 Engine maintenance Deutz and Continental
models
B-10 Engine RPM
Inspector signature
Inspector title
Inspector company
B-11 Engine maintenance
Instructions
• Make copies of this report to use for
each inspection.
Perform every 100 hours:
B-12 Oscillate directional
Control
A-9 Inspect filter/separator Diesel models
B-13 Ground control
override
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
A-10 Grease rotation
bearing
B-14 Platform self-leveling
Perform after 150 hours:
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A-11 Engine maintenance
A
A-12 Replace Drive Hub oil
Perform every 200 hours:
A+B
Six Month or 500 hour
Inspection:
A+B+C
A-13 Engine maintenance Perkins models
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-raised
or extended
B-21 Alarm package and
descent alarm
Annual or 1000 hour
Inspection:
A+B+C+D
B-22 Fuel and hydraulic tank
venting systems
2 Year or 2000 hour
Inspection:
A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
Y N R
B-23 Hydraulic oil analysis
B-24 Inspect the Boom
Extend/Retract Cables
Comments
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 122985
S-80 • S-85 • S-80X
3-5
Section 3 • Scheduled Maintenance Procedures
September 2015
MAINTENANCE INSPECTION REPORT
Model
Checklist C
Y N R
Checklist E
Y N R
C-1 Engine maintenance
E-1 Hydraulic oil
Date
C-2 Grease platform
overload (if equipped)
E-2 Engine maintenance Perkins models
C-3 Test the platform
overload (if equipped)
Perform every 3000 hours:
Hour meter
Serial number
E-3 Engine maintenance Deutz and Perkins
models
C-4 Air filter element
Machine owner
C-5 Replace filter/separator
Deutz and Perkins
models
Inspected by (print)
Inspector signature
C-6 Safety envelope
S-80X
Inspector title
Checklist D
Perform every 10 years:
E-4 Replace the Boom
Extend/Retract Cables
Y N R
D-1 Boom wear pads
Inspector company
D-2 Free-wheel
configuration
Instructions
• Make copies of this report to use for
each inspection.
D-3 Turntable rotation
bearing bolts
D-4 Turntable bearing wear
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
D-5 Engine maintenance
D-6 Replace hydraulic filters
D-7 Drive hub oil
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
Perform every 1500 hours:
D-8 Engine maintenance Deutz models
Six Month or 500 hour
Inspection:
A+B+C
Annual or 1000 hour
Inspection:
A+B+C+D
Comments
2 Year or 2000 hour
Inspection:
A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 122985
S-80 • S-85 • S-80X
3-7
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
September 2015
PROCEDURES
A-2
Perform Pre-operation
Inspection
A-3
Perform Engine Maintenance
Genie specifications require that this procedure be
performed daily.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong
with a machine before the operator performs the
function tests. The pre-operation inspection also
serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
Engine specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
139320
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3-8
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-4
Perform Function Tests
A-5
Test the Oscillate Axle
Genie specifications require that this procedure be
performed daily.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Genie specifications require that this procedure be
performed daily.
Proper axle oscillation is essential to safe machine
operation. If the axle oscillation system is not
operating correctly, the stability of the machine is
compromised and it may tip over.
Tip-over hazard. Failure to perform
this procedure on a firm, level
surface will compromise the
stability of the machine and could
result in the machine tipping over.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a
6 inch / 15 cm block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
3 Drive the left steer tire up onto a 6 inch / 15 cm
block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
4 Drive both steer tires up onto a
6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firm
contact with the ground.
Note: If the chassis does not remain level during
the test, refer to Repair Procedure 14-2, How to Set
Up the Directional Valve Linkage.
Part No. 122985
S-80 • S-85 • S-80X
3-9
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
September 2015
PROCEDURES
A-6
Check the High Pressure
Hydraulic Filter Condition
Indicator
A-7
Perform 30 Day Service
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the
maintenance tables for continued scheduled
maintenance.
Maintaining the high pressure hydraulic filter in
good condition is essential to good system
performance and safe machine operation. The filter
condition indicator will show when the hydraulic flow
is bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
remain in the hydraulic system and cause
component damage.
1 Perform the following maintenance procedures:
•
A-10
Grease the Turntable Rotation Bearing
and Rotate Gear
•
B-8
Inspect the Tires, Wheels and
Lug Nut Torque
2 Start the engine from the ground controls.
•
B-9
3 Change the engine idle to high rpm (rabbit
symbol).
Check the Drive Hub Oil Level and
Fastener Torque
•
B-24
Inspect the Boom Extend/Retract
Cables
•
D-4
Check the Turnable Rotation Bearing
Bolts
•
D-7
Replace the Hydraulic Filter Elements
1 Open the engine side turntable cover.
4 Visually inspect the filter condition indicator.
Result: The filter condition indicator should be
operating with the plunger in the green area.
Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter should be
replaced. See D-6, Replace the Hydraulic
Filters.
3 - 10
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8
Perform Engine Maintenance Deutz and Continental Models
A-9
Inspect the Fuel Filter/Water
Separator - Diesel Models
Engine specifications require that this one-time
procedure be performed after the first 50 hours of
operation.
Genie specifications require that this procedure be
performed every 100 hours or monthly, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
perform this procedure can lead to poor engine
performance and/or hard starting, and continued
use may result in component damge. Extremely
dirty conditions may require this procedure be
performed more often.
Required maintenance procedures for
commissioning new and overhauled engines and
additional engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
139320
Continental TME27 Owner's Manual
Genie part number
111901
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
To access the engine:
Perkins Models:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 122985
1 Put on protective clothing and eye wear.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
S-80 • S-85 • S-80X
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
September 2015
PROCEDURES
4 Loosen the vent plug located on the fuel filter/
water separator head.
8 Start the engine from the ground controls and
check the fuel filter/water separator and vent
plug for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
a
d
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
a
b
c
d
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
vent plug
drain plug
filter bowl
separator head
3 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
6 Tighten the vent plug.
Note: If the fuel filter/water separator is completely
drained, you must prime the fuel filter/water
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7
4 Locate the fuel filter/water separator next to the
oil filter.
Clean up any fuel that may have spilled.
3 - 12
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
5 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
A-10
Grease the Turntable Rotation
Bearing and Rotate Gear
Note: Do not completely drain the filter.
Genie specifications require that this procedure be
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
a
b
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the platform end of
the tank side bulkhead.
a
b
fuel filter/water separator
drain valve
6 Clean up any fuel that may have spilled.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
Part No. 122985
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments
of 4 to 5 inches / 10 to 13 cm at a time and
repeat this step until the entire bearing has been
greased.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
S-80 • S-85 • S-80X
3 - 13
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
September 2015
PROCEDURES
A-11
Perform Engine Maintenance
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Engine specifications require that this procedure be
performed every 100 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Required maintenance procedures and additional
engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
139320
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
3 - 14
111901
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Install the plugs.
A-12
Replace the Drive Hub Oil
Manufacturer specifications require that this one-time
procedure be performed after the first 150 hours.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil after the initial 150 hours of
use may cause the machine to perform poorly and
continued use may cause component damage.
Drive hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the lowest
point.
5 Install the plugs into the drive hub. Torque to
Specification. Refer to Section 2,
Specifications.
6 Repeat steps 1 through 4 for the other drive hub.
7 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
Turntable rotate drive hub:
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
2 Remove both plugs and drain the oil into a suitable
container.
Note: The turntable rotation lock pin is located next
3 Drive the machine until one plug is at the top and
the other is at 90 degrees.
a
to the boom rest pad.
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyes
located near the drive motor.
a.
Part No. 122985
models with o-ring plugs
S-80 • S-85 • S-80X
3 - 15
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
September 2015
PROCEDURES
4 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device.
a
B
5 Remove the plug the drive hub. Drain the oil
from the hub into a suitable container.
c
a
B
A
b
A
d
b
Dual fill port rotator
a
motor
b
drive hub
c
drive hub mounting bolts
d
fill ports
6 Install the drive hub assembly onto the machine.
Torque the drive hub mounting bolts to
specification. Refer to Section 2, Specifications.
d
Single fill port rotator
a
motor
b
fill port
c
drive hub mounting bolts
d
drive hub
3 - 16
c
7 Fill the drive hub with oil. Refer to Section 2,
Specifications. Apply pipe thread sealant to the
plug. Install the plug.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 10-1, How to Adjust the
Turntable Rotation Gear Backlash.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
PROCEDURES
A-13
Perform Engine Maintenance Perkins Models
Engine specifications require that this procedure be
performed every 200 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 122985
S-80 • S-85 • S-80X
3 - 17
Section 3 • Scheduled Maintenance Procedures
September 2015
Checklist B Procedures
3 Be sure that the battery hold downs and cable
connections are tight.
B-1
Inspect the Battery(s)
4 Be sure that the battery separator wire
connections are tight (if equipped).
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions. A single
battery configuraton is standard. A dual battery
option is available, where one battery is used to
start the engine and the other is used to power the
control system and auxiliary power unit. The two
batteries are charged by the alternator through a
battery separator.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
5 Fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
•
Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
•
Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 8.
8 Perform an equalizing charge, OR fully charge
the battery(s) and allow the battery(s) to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 - 18
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
B-2
Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged.
Proceed to step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution/ burn hazard.
Contact with hot or live circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.
1 Open the turntable cover at the engine side of
the machine.
2 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
a
b
a
b
Part No. 122985
S-80 • S-85 • S-80X
engine tray anchor hole
engine tray retaining fastener
3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
PROCEDURES
3 Locate the engine tray anchor hole on the
turntable.
4 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
5 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
•
September 2015
13 Inspect for a liberal coating of dielectric grease
in the following location:
•
All wire harness connectors to
platform control box
14 Remove the engine tray retaining fastener from
the engine tray anchor hole at the pivot end of
the engine tray.
15 Swing the engine tray in towards the machine.
16 Install the engine tray retaining fasteners.
Engine wiring harness
6 Open the turntable cover at the ground controls
side of the machine.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
result in death or serious injury.
7 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
•
Battery area wiring
•
Inside the ground control box
•
Hydraulic manifold wiring
•
Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric grease
in the following locations:
•
All wire harness connectors to
ground control box
9 Start the engine from the ground controls and
raise the boom above the turntable covers.
10 Inspect the turntable area for burnt, chafed and
pinched cables.
11 Lower the boom to the stowed position 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, rotate, level manifold
•
Inside of the platform control box
3 - 20
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-3
Test the Key Switch
B-4
Check the Exhaust System
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause a
hazardous operating situation.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
Bodily injury hazard. Do not
inspect while the engine is running.
Remove the key to secure from
operation.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check all machine function from the platform
controls.
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no functions
should operate.
Part No. 122985
S-80 • S-85 • S-80X
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 21
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
2 Be sure that all nuts and bolts are tight.
3 Inspect all welds for cracks.
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
B-5
Inspect the Engine Air Filter Continental, Deutz and Perkins
Models
5 Swing the engine pivot plate in towards the
machine.
6 Install the bolts that were just removed into the
original holes to secure the engine pivot plate.
Crushing hazard. Failure to install
the bolts into the engine pivot plate
to secure it from moving could
result in death or serious injury.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
Note: Perform this procedure with the engine off.
1 Locate the engine air filter assembly.
2 Release the latches from the air cleaner canister
end cap. Remove the end cap.
3 Remove the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
Replace the filter if needed.
6 Install the filter element.
7 Install the air filter canister end cap and secure
the end cap latches.
Note: Be sure the discharge valve is pointing down
when the cap is instaled.
3 - 22
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-6
Check the Oil Cooler and
Cooling Fins - Deutz Models
3 Remove the fasteners from the engine side
cover, then remove the cover.
4 Inspect the oil cooler for leaks and physical
damage.
a
b
c
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating a
machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
Oil cooler:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 122985
a
b
c
oil cooler
cylinder head cooling fins
fan blower fins
5 Clean the oil cooler of debris and foreign
material.
Cooling and fan blower fins:
6 Inspect the fan blower fins for physical damage.
7 Clean the fan blower fins of debris and foreign
material.
8 Inspect the head cooling passages and fins for
physical damage or foreign material, using a
flashlight.
9 Clean the cylinder head cooling passages of
debris and foreign material.
10 Install the engine side cover.
11 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
S-80 • S-85 • S-80X
3 - 23
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
B-7
Confirm the Proper
Brake Configuration
B-8
Inspect the Tires, Wheels
and Lug Nut Torque
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
Maintaining the tires and wheels in good
condition, including proper wheel fastener torque, is
essential to safe operation and good performance.
Tire and/or wheel failure could result in a machine
tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
Bodily injury hazard. An overinflated tire can explode and could
result in death or serious injury.
disengaged position
engaged position
Tip-over hazard. Do not use
temporary flat tire repair products.
Note: The tires on some machines are foam filled
and 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 and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
4 Check the pressure in each air-filled tire. Add air
as necessary. Refer to Section 2,
Specifications.
3 - 24
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-9
Check Drive Hub Oil Level and
Fastener Torque
Genie specifications require that this procedure be
performed every 250 hours.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
Drive hubs:
1 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
4 Install the plugs into the drive hub. Torque to
Specification. Refer to Section 2,
Specifications.
5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat steps 1 through 5 for the other drive
hubs.
Turntable rotate drive hub:
Single fill port rotator:
1 Remove the plug located on the top of the hub
and check the oil level.
Result: The oil level should be visible below the
bottom of the fill port.
a
a
B
a
A
b
models with o-ring plugs
2 Remove the plug located at 90 degrees and
check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
Part No. 122985
S-80 • S-85 • S-80X
d
c
Single fill port rotator
a
motor
b
fill port
c
drive hub mounting bolts
d
drive hub
3 - 25
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
Dual fill port rotator:
2 Remove one of the plugs located on the side of
the hub and check the oil level.
B-10
Check and Adjust the
Engine RPM
Result: The oil level should be even with the
bottom of the plug hole.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
a
B
b
A
c
Continental models:
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM.
If rpm adjustment or service is required, please
contact the Genie Industries Service Department.
Deutz TD2011L04i models:
1 Connect a tachometer to the engine. Start the
engine from the ground controls and check the
rpm. Refer to Section 2, Specifications.
d
Dual fill port rotator
a
motor
b
drive hub
c
drive hub mounting bolts
d
fill ports
3 If necessary, add oil. Refer to Section 2,
Specifications.
4 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
5 Check the torque of the turntable rotate drive
hub mounting fasteners. Refer to Section 2,
Specifications.
3 - 26
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Perkins models:
1 Connect a tachometer to the engine. Start the
engine from the ground controls and check the
rpm. Refer to Section 2, Specifications.
Skip to step 3 if the low idle rpm is correct.
2 Loosen the low idle lock nut. Turn the low idle
adjustment screw clockwise to increase the rpm
or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
a
a
c
b
b
Deutz models
a
high idle adjustment
b
low idle adjustment
Skip to step 4 if the low idle rpm is correct.
2 Loosen the locknut on the low idle adjustment
screw.
f
3 Adjust the low idle adjustment screw until low
idle meets specification. Tighten the locknut.
5 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
d
Perkins models
a
solenoid boot
b
yoke lock nut
c
low idle adjustment screw
d
low idle lock nut
e
yoke
f
high idle adjustment nut
4 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustment
step 5.
e
3 Move the function enable/rpm select toggle
switch to the high idle (rabbit symbol) position.
Refer to Section 2, Specifications.
If high idle rpm is correct, disregard adjustment
step 4.
4 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
Part No. 122985
S-80 • S-85 • S-80X
3 - 27
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
B-11
Perform Engine Maintenance
Engine specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
139320
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
111901
B-12
Check the Oscillate Directional
Valve Linkage
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper axle oscillation is essential to safe machine
operation. If the oscillate directional valve linkage is
not operating correctly, the stability of the machine
is compromised and it may tip over.
1 Remove the drive chassis cover from the
non-steer end of the machine.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for
the following:
•
Lock nut is tight against yoke
•
Yoke clevis pins are installed
•
Cotter pins are installed through clevis pins
•
Linkage is properly attached to
directional valve
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 28
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-13
Test the Ground Control
Override
B-14
Test the Platform Self-leveling
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow ground
personnel to operate the machine from the ground
controls whether or not the red Emergency Stop
button at the platform controls is in the on or off
position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the red Emergency Stop button at the
platform controls to the off position.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder
located at the base of the boom.
A platform self-leveling failure creates an unsafe
working condition for platform and ground
personnel.
1 Start the engine from the ground controls.
2 Start the engine from the ground controls.
2 Hold the function enable toggle switch to either
side and adjust the platform to a level position
using the platform level toggle switch.
3 At the ground controls, operate each boom
function through a partial cycle.
3 Raise and lower the boom through a full cycle.
Result: All boom functions should operate.
Part No. 122985
Result: The platform should remain level at
all times to within ±5 degrees.
S-80 • S-85 • S-80X
3 - 29
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
5 Release the function enable button.
B-15
Test the Engine Idle Select
Operation
Result: The engine rpm should change to low
idle.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are three settings.
Low idle (turtle symbol) allows the operator to
control individual boom functions only.
Functon enable button high idle (rabbit symbol)
allows the operator to control multiple boom
functions simultaneously. This setting maintains a
consistent high idle.
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal
machine operation. This setting activates high idle
only when the foot switch is pressed down.
1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
6 Turn the key switch to platform controls.
7 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine rpm should remain at low
idle.
8 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine rpm should not change to
high idle.
9 Press down the foot switch.
Result: The engine rpm should change to high
idle.
high idle.
10 Press down the foot switch.
Result: The engine rpm should change to high
idle.
3 Start the engine from the ground controls.
4 Move and hold the function button in and move
the idle switch to the high idle (rabbit symbol)
position.
Result: The engine rpm should change to high
idle.
3 - 30
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-16
Test the Fuel Select Operation Gasoline/LPG Models
4 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button in to
the off position.
5 Move the fuel select toggle switch to LPG.
6 Start the engine and allow it to run at low idle.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made whether the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Note: The engine may hesitate momentarily and
then continue to run on the selected fuel if the fuel
source is switched while the engine is running.
Note: Perform this test after checking the gasoline
and LPG fuel levels, and warming the engine to
normal operating temperature.
1 Move the fuel select toggle switch to gasoline
and then move the engine idle select switch to
foot switch activated high idle (rabbit and foot
switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Part No. 122985
S-80 • S-85 • S-80X
3 - 31
CHECKLIST B
PROCEDURES
B-17
Test the Drive Enable System
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper drive enable system operation is
essential to safe machine operation. When the
boom is past the non-steering wheels, drive
movement is stopped and the
indicator light turns on. The drive
enable switch must be held to
either side to reactivate the drive
function and should alert the
operator that the machine may
move in the opposite direction that the drive and
steer controls are moved. An improperly functioning
drive enable system may allow the machine to be
moved into an unsafe position.
5 Rotate the turntable until the boom moves past
the other non-steer wheel.
Result: The drive enable
indicator light should come on
and remain on while the boom
is anywhere in the range shown.
6 Move and hold the drive enable toggle switch to
either side and slowly move the drive control
handle off center.
Result: The drive function should operate.
Collision hazard. Always use the
color-coded direction arrows on the
platform controls and the drive
chassis to identify the direction of
travel.
Note: When the drive enable system is in use, the
machine may drive in the opposite direction that the
drive and steer control handle is moved.
Note: Perform this procedure with the boom in the
stowed position.
1 Start the engine from the platform controls.
Blue
2 Press down the foot switch.
3 Rotate the turntable until the boom moves past
one of the the non-steer wheels.
Result: The drive enable indicator light should
turn on and remain on while the
boom is anywhere in the range
shown.
4 Slowly move the drive control
handle off center.
Result: The drive function should not operate.
Yellow
CHECKLIST B PROCEDURES
B-18
Test the Drive Brakes
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
See B-7, Confirm the Proper Brake
Configuration.
Note: Select a test area that is firm, level and free
of obstructions.
Note; Perform this procedure with the boom in the
stowed 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., contact
patch of a tire) as a visual reference for use
when crossing the test line.
4 Bring the machine to top drive speed before
reaching the test line. Release the drive
controller when your reference point on the
machine crosses the test line.
5 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
B-19
Test the Drive Speed Stowed Position
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire
proportionally controlled speed range.
Note: Select a test area that is firm, level and free
of obstructions.
Note: Perform this procedure with the boom in the
stowed position.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
when crossing the start and finish lines.
4 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
5 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Performance
Specifications.
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
B-20
Test the Drive Speed Raised or Extended Position
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Performance
Specifications.
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire
proportionally controlled speed range.
Select a test area that is firm, level and free of
obstructions.
8 Press down the foot switch and lower the boom
to the stowed position.
9 Extend the boom 3 feet / 90 cm.
10 Choose a point on the machine (i.e., contact
patch of a tire), as a visual reference for use
when crossing the start and finish lines.
11 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
2 Start the engine from the platform controls.
12 Continue at top speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Performance
Specifications.
3 Move the engine idle select toggle switch to
foot switch activated high idle (rabbit and foot
switch symbol).
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
4 Press down the foot switch and raise the boom
10° above horizontal.
5 Choose a point on the machine (i.e. contact
patch of a tire), as a visual reference for use
when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
3 - 34
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-21
Test the Alarm Package
(if equipped) and the Descent
Alarm
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The alarm package includes:
•
Travel alarm
•
Flashing beacons
Alarms and beacons are installed to alert operators
and ground personnel of machine proximity and
motion. The alarm package is installed on the
turntable rear cover. Beacons are installed on both
turntable covers.
3 Turn the key switch to platform controls.
Result: The flashing beacons should be on
and flashing.
4 Press down the foot switch. Move the boom
controller to the down position, hold for a
moment and then release it.
Result: The descent alarm should sound when
the controller is held down.
5 Press down the foot switch. Move the drive
controller off center, hold for a moment and then
release it. Move the drive controller off center in
the opposite direction, hold for a moment and
then release it.
Result: The travel alarm should sound when the
drive controller is moved off center in either
direction.
Note: The alarms and beacons will operate with the
engine running or not running.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: Both flashing beacons should be on and
flashing.
2 Move and hold the function enable button to
either side and activate the boom toggle switch
in the down position, hold for a moment and
then release it.
Result: The descent alarm should sound when
the toggle switch is held down.
Part No. 122985
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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the caps be inspected
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air passes through the hydraulic tank
cap. 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 cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
Note: Perform this procedure with the engine off.
Note: This procedure applies to diesel equipped
machines only.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Procced to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank cap venting, air
should pass freely through the cap.
3 - 36
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-23
Perform Hydraulic Oil Analysis
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and continued
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more frequently.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
B-24
Inspect the Boom
Extend/Retract Cables
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Inspecting for foreign objects, damage and/or
improper adjustment of the boom extend/retract
cables and related components on a regular basis
is essential to good machine performance and safe
machine operation. The boom extend and retract
functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
1 Raise the boom to horizontal and fully extend
the boom.
2 After the boom is fully extended, lower the boom
until the platform is at chest height. Turn the
machine off.
3 Remove the boom end cover retaining fasteners
and remove the cover.
4 Remove the retaining fasteners from the access
covers located on the side of the boom at the
platform end of the machine. Remove the
covers.
Part No. 122985
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3 - 37
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
September 2015
PROCEDURES
5 Visually inspect the cables and components
through both inspection holes for the following:
6 Install the cover at the pivot end of the boom.
7 Install the access panels on the sides of the
boom.
•
Frayed or broken wire strands
•
Kinks in the cables
•
Corrosion
•
Paint or foreign materials on the cable
•
Split or cracked cable ends
9 Turn the key switch to the platform controls.
•
Cables are on all pulleys
10 Extend the boom approximately 2 feet / 0.6 m.
•
Extend cable break limit switch arm is
centered in the pivot plate
•
Cables have equal tension
11 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
•
Cables at end of adjustment range
•
No broken or damaged pulleys
•
No unusual or excessive pulley wear
•
All fasteners in place and secure
8 Start the engine from the ground controls and
fully retract and lower the boom to the stowed
position.
Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the
number 3 boom tube begins to retract.
Note: A flashlight and inspection mirror may be
necessary to thoroughly inspect the above items.
Note: A pulley groove gauge should be used to
check the condition of the pulleys.
3 - 38
Note: If the number 2 boom tube moves more than
1
/2 inch / 13 mm before the number 3 boom tube
begins to retract, the boom extend/retract cables
need to be adjusted. See Repair Procedure 4-5,
How to Adjust the Boom Extend/Retract Cables.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
Checklist C Procedures
C-1
Perform Engine Maintenance
C-2
Grease the Platform Overload
Mechanism (if equipped)
Engine specifications require that this procedure be
performed every 500 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
139320
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
111901
Genie specifications require that this procedure be
performed every 500 hours or six months,
whichever comes first. Perform this procedure more
often if dusty conditions exist.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 122985
S-80 • S-85 • S-80X
3 - 39
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST C PROCEDURES
C-3
Test the Platform Overload
System (if equipped)
Genie specifications require that this procedure be
performed every 500 hours or six months,
whichever comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued use
of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity at
one of the locations shown.
Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
3 - 40
Illustration 1
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
6 Using a suitable lifting device, place an
additional 50 lbs / 23 kg of weight onto the
platform.
Result: The alarm should sound and the engine
should shut off. The platform overload indicator
lights should be flashing at both the ground and
platform controls.
Result: The alarm does not sound, the engine
does not shut off and the platform overload
indicator lights are not flashing. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash, the alarm sounds
and the engine shuts off.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
7 Using a suitable lifting device, remove the test
weights, restart the engine and carefully move
the test weights to each remaining location on
the platform. Refer to Illustration 1.
Result: The alarm should sound, the engine
should shut off and the platform overload
indicator lights should be flashing at both the
ground and platform controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
14 Start the engine and test all machine functions
from the ground controls.
Result: All ground control functions should
operate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System (if
equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash, the alarm sounds
and the engine shuts off.
17 Push in the red Emergency stop button at the
platform to shut off engine.
8 Test all machine functions from the platform
controls.
18 Using a suitable lifting device, remove all test
weights from the platform.
Result: All platform control functions should not
operate.
9 Turn the key switch to ground control.
10 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
19 Pull out the red Emergency stop button to the on
position at the platform controls.
20 Remove the fasteners securing the lid to the
platform controls. Using Illustration 2 as a
guide, locate the timer relay inside the platform
control box. Tag and disconnect the red wire
from terminal 5 on the timer relay.
11 Activate the auxiliary power toggle switch.
12 Using auxiliary power, test all machine functions
from the ground controls.
Timer Relay
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Orange
Wire
Terminal 5
Illustration 2
Part No. 122985
S-80 • S-85 • S-80X
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Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST C PROCEDURES
21 Using Illustration 3 as a guide, locate D31 Valve
Power LED on the ALC500 printed circuit board.
Valve Power LED
26 Using a suitable lifting device, place an
additional 50 lbs / 23 kg of weight onto the
platform.
Result: The alarm should sound and the Valve
Power LED should not light. The platform
overload indicator lights should be flashing at
both the ground and platform controls.
ALC 500 Board
27 Working from outside the platform and standing
next to the platform rotator, locate the orange
wire, which enters into the base of the platform
control box from the load sense switch and
locate the wire terminal at the end of the wire.
Tag and disconnect the connectors.
Refer to Illustration 2.
28 Using a multimeter set to read resistance
(ohms), securely install a lead from the
multimeter to the connector on the orange wire,
and securely connect the other multimeter lead
to a ground point in the control box.
Illustration 3
22 Step on the footswitch at the platform.
Result: The Valve Power LED should not
illuminate.
Result: The readout on the multimeter should
indicate zero resistance.
Result: The Valve Power LED is illuminated.
Remove the machine from service and contact
the Genie Service Department.
Result: The readout on the multimeter shows
resistance. Remove the machine from service
and contact the Genie Service Department.
23 Securely install the red wire, disconnected in
step 20, onto terminal 5 of the relay timer.
24 Step on the footswitch at the platform.
Result: The Valve Power LED should illuminate.
Result: The Valve Power LED is not illuminated.
Remove the machine from service and contact
the Genie Service Department.
25 Using a suitable lifting device, place a test
weight equal to that of the available capacity at
the center location shown in Illustration 1.
29 Using a suitable lifting device, remove all weight
from the platform. Note the result on the
multimeter.
Result: The readout on the multimeter should
indicate infinite resistance.
Result: The readout on the multimeter shows
zero resistance. Remove the machine from
service and contact the Genie Service
Department.
31 Turn off the multimeter and remove the leads
from the machine. Securely connect the wires
disconnected in step 27.
32 Close the platform control box. Install and
securely tighten the fasteners. Do not
overtighten.
3 - 42
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-4
Replace the Engine Air Filter
Element
Engine specifications require that this procedure be
performed every 500 hours or six months,
whichever comes first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor 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 cleaner
canister.
C-5
Replace the Fuel Filter/Water
Separator Element Diesel Models
Note: Genie specifications require that this
procedure be performed every 500 hours or six
months, whichever comes first.
Regular replacement of the fuel filter/water
separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
engine performance and/or hard starting, and
continued use may result in component damge.
Extremely dirty conditions may require this
procedure be performed more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
2 Remove the filter element.
3 Use a damp cloth to wipe the filter sealing
surface and the inside of the outlet tube. Make
sure that all contaminant is removed before the
filter is inserted.
4 Check new filter element gasket for damage
before installing.
Note: Perform this procedure with the engine off.
5 Install the new filter element.
Perkins Models:
6 Install the end cap on the canister and secure.
1 Put on protective clothing and eye wear.
Note: Be sure the discharge slot is pointing down.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
Part No. 122985
S-80 • S-85 • S-80X
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Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST C PROCEDURES
8 Start the engine from the ground controls and
check the fuel filter/water separator and vent
plug for leaks.
4 Loosen the vent plug located on the fuel filter/
water separator head.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
a
d
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
a
b
c
d
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
vent plug
drain plug
filter bowl
separator head
3 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
6 Tighten the vent plug.
Note: If the fuel filter/water separator is completely
drained, you must prime the fuel filter/water
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7
4 Locate the fuel filter/water separator next to the
oil filter. for leaks.
Clean up any fuel that may have spilled.
3 - 44
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
5 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
Note: Do not completely drain the filter.
C-6
Check the Safety Envelope Limit
Switches and Angle Sensor,
S-80X
Note: Genie specifications require that this
procedure be performed every 500 hours or six
months, whichever comes first.
a
b
a
b
Testing the safety envelope system regularly is
essential to safe machine operation. Continued use
of an improperly operating safety envelope could
result in the system not restricting the range of
motion. Machine stablity could be compromised
resulting in the machine tipping over.
Note: Perform this procedure with the machine on a
firm, level surface with all weight, tools and
equipment removed from the platform.
fuel filter/water separator
drain valve
Note: Start this procedure with the boom fully
retracted and in the stowed position.
6 Clean up any fuel that may have spilled.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Ground controls:
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position.
2 Start the engine from the ground controls.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
Part No. 122985
S-80 • S-85 • S-80X
3 - 45
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST C PROCEDURES
3 Turn and hold the function enable switch to the
restricted maximum platform capacity and raise
the primary boom until it is fully elevated.
a
b
7 Measuring Tape:
Measure the distance between the center of the
pivot pins as shown, 201.75 inches / 512 cm
± 2.0 inch / 5 cm.
Digital Protractor:
1000 lbs /
454 kg
500 lbs /
227 kg
Place the digital protractor on the turntable
chassis and reset the protractor to 0°. Place the
protractor on top of the primary boom. The
protractor should display 58° ± 2°.
Result: The primary boom angle is not within
specifications.Consult Genie Industries Service
Department.
a
b
restricted maximum platform
capacity
unrestricted maximum platform
capacity
Measure between
the centers of these
pivot pins
4 Extend the primary boom until it is fully
extended.
5 Lower the primary boom until it stops.
Result: The boom will automatically stop after
10 degrees.
Result: The primary boom does not stop after 10
degrees. Check limit switches LST3O and
LST3S.
6 Turn the key switch to the off position and push
in the red Emergency Stop button.
Note: The follwing step can be done using a
measuring tape or a digital protractor (Genie part
number 58377).
3 - 46
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
Platform controls:
Note: Start this procedure with the boom fully
retracted and in the stowed position.
1 Pull out the red Emergency Stop button to the
on position and start the engine.
2 Select the restricted maximum platform capacity
with the toggle switch.
a
b
1000 lbs /
454 kg
500 lbs /
227 kg
6 Move the primary boom down joystick off center
and retract the primary boom until the
unrestricted platform capacity light stops
flashing.
Result: Primary boom down should return to
normal operation.
7 Lower the primary boom 5 feet / 1.5 m and
activate primary boom extend.
Result: Primary boom extend will stop and the
unrestricated platform capacity light will start
flashing.
8 Activate primary boom extend and raise the
primary boom until the unrestricated platform
capacity light stops flashing.
Result: Primary boom extend should return to
normal operation.
9 Return the machine to the fully stowed position.
a
b
restricted maximum platform
capacity
unrestricted maximum platform
capacity
3 Raise the primary boom until it is fully elevated.
4 Extend the primary boom until it is fully
extended.
5 Lower the primary boom until it stops.
Result: The boom will automatically stop after
10 degrees and the unrestricted platform
capacity light will flash.
Result: The primary boom does not stop after 10
degrees. Calibrate the boom angle sensor. Refer
to Repair Procedure 1-2, How to Calibrate the
Boom angle Sensor.
Part No. 122985
S-80 • S-85 • S-80X
3 - 47
Section 3 • Scheduled Maintenance Procedures
September 2015
Checklist D Procedures
4 Extend and retract the boom through the entire
range of motion to check for tight spots that
may cause binding or scraping of the boom.
D-1
Check the Boom Wear Pads
Note: Always maintain squareness between the
outer and inner boom tubes.
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
Boom wear pad specifications
Boom number one
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in
component damage and unsafe operating
conditions.
5 /8
Top and side wear pads
(extension end of boom)
inch
15.9 mm
Boom number two
1/2 inch
12.7 mm
Top, bottom and side wear pads
(extension end of boom)
1 Start the engine from the ground controls.
2 Raise the end of the boom to a comfortable
working height (chest high), then extend the
boom 1 foot / 30 cm.
1 /2
Bottom wear pads
(pivot end of boom)
inch
12.7 mm
Top and side wear pads
(pivot end of boom)
5/8 inch
15.9 mm
Boom number three
1/2 inch
12.7 mm
Top, bottom and side wear pads
(pivot end of boom)
3 Measure each wear pad. Replace the wear pad
if it is less than specification. If the wear pad is
still within specification, shim as necessary to
obtain zero clearance and zero drag.
a
3 - 48
1/2 inch
12.7 mm
Bottom wear pads
(extension end of boom)
Note: If the wear pads are still within specification,
refer to Repair Procedure 4-2, How to Shim the
Boom.
a
b
c
Minimum
b
c
boom 1
boom 2
boom 3
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Manually rotate each non-steer wheel.
D-2
Check the Free-wheel
Configuration
Result: Each non-steer wheel should rotate with
minimum effort.
Genie specifications require that this procedure be
performed every 1000 hours or annually, whichever
comes first.
Proper use of the free-wheel configuration is
essential to safe machine operation. The free-wheel
configuration is used primarily for towing. A
machine configured to free-wheel without operator
knowledge could result in death or serious injury
and property damage.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the blocks.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury and
property damage.
Steer wheels: 4WD models
7 Chock the non-steer wheels to prevent the
machine from rolling.
Collision hazard. Select a work site
that is firm and level.
8 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the steer wheels.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
9 Lift the wheels off the ground and then place
blocks under the drive chassis for support.
Non-steer wheels: All models
1 Chock the steer wheels to prevent the machine
from rolling.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each steer wheel
hub.
disengaged position
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer wheels.
3 Lift the wheels off the ground and place blocks
under the drive chassis for support.
engaged position
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
Part No. 122985
S-80 • S-85 • S-80X
3 - 49
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST D PROCEDURES
11 Manually rotate each steer wheel.
D-3
Check the Turntable Rotation
Bearing Bolts
Result: Each steer wheel should rotate with
minimum effort.
12 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury and
property damage.
All models:
13 Turn the valve in a clockwise direction to be
sure it is fully closed.
Note: The free-wheel valve is located on the bottom
of the drive pump, and should always remain
closed.
Genie specifications require that this procedure be
performed every 1000 hours or annually, whichever
comes first.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Start the engine from the platform controls and
extend the axles.
2 Turn the key switch to ground controls.
3 Raise the boom and place a safety chock on the
lift cylinder rod. Carefully lower the boom onto
the lift cylinder safety chock.
Crushing hazard. Keep hands
away from cylinder and all moving
parts when lowering the boom.
b
c
a
d
a
b
c
d
3 - 50
drive pump
screwdriver
lift pump
free-wheel valve
Note: The lift cylinder safety chock is available
through Genie Service Parts.
4 Remove the center turntable cover retaining
fasteners. Remove the cover.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Confirm that each turntable mounting bolt is
torqued in sequence to specification. Refer to
Section 2, Specifications.
D-4
Inspect for Turntable Bearing
Wear
Genie specifications require that this procedure be
performed every 1000 hours or annually, whichever
comes first.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
Note: Perform this procedure with the machine on a
firm, level surface and the boom in the stowed
position.
1 Grease the turntable bearing. See A-12, Grease
the Turntable Rotation Bearing and Rotate Gear.
Bolt torque sequence
6 Install the center turntable cover and tighten the
retaining fasteners.
7 Raise the boom and remove the safety chock.
8 Lower the boom to the stowed position.
2 Torque the turntable bearing bolts to
specification. See D-4, Check the Turntable
Rotation Bearing Bolts.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
9 Confirm that each bearing mounting bolt under
the drive chassis is torqued in sequence to
specification. Refer to Section 2, Specifications.
Part No. 122985
S-80 • S-85 • S-80X
3 - 51
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST D PROCEDURES
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more than
1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch /
2.5 cm from the turntable rotation bearing.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero" position.
a
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
b
11 Lower the boom to the stowed position and turn
the machine off.
c
12 Remove the dial indicator from the machine.
d
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the
indicator.
6 Fully extend the boom and lower to a horizontal
position.
3 - 52
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-5
Perform Engine Maintenance
D-6
Replace the Hydraulic Filters
Engine specifications require that this procedure be
performed every 1000 hours.
Genie requires that this procedure be performed
every 1000 hours or annually, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
Deutz TD2011 Operation Manual
Genie part number
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
139320
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filters be replaced more often.
Note: Perform this procedure with the engine off.
Hydraulic return filter:
111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
1 Open the ground controls side turntable cover
and locate the hydraulic return filter housing on
top of the hydraulic tank.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
4 Remove the filter element from the filter
housing.
5 Install the new filter element into the filter
housing.
6 Push the filter element down to be sure the
O-ring on the element is fully seated into the
housing.
7 Rotate the filter element clockwise to lock it in
place.
Part No. 122985
S-80 • S-85 • S-80X
3 - 53
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST D PROCEDURES
8 Install the filter housing cap.
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
oil filter housing.
D-7
Replace the Drive Hub Oil
Medium and high pressure filters:
Note: The medium pressure filter is for the charge
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating
axle circuit.
10 Open the engine side turntable cover and locate
the two filters.
Note: The high pressure filter is located toward the
bulkhead with a condition indicator. The medium
pressure filter is located nearest the operator.
11 Place a suitable container under the filters.
12 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housings.
Genie specifications require that this procedure be
performed every 1000 hours or annually, whichever
comes first.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
Drive hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
13 Remove the filter element from the housings.
2 Remove both plugs and drain the oil into a
suitable container.
14 Inspect the housing seals and replace them if
necessary.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
15 Install the new medium and high pressure filter
elements into the housings and tighten them
securely.
a
16 Clean up any oil that may have spilled during the
installation procedure.
17 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
oil filter housings.
18 Start the engine from the ground controls.
19 Inspect the filter housings and related
components to be sure that there are no leaks.
a.
models with o-ring plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Install the plugs.
5 Install the plugs into the drive hub. Torque to
Specification. Refer to Section 2,
Specifications.
3 - 54
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
6 Repeat steps 1 through 4 for the other drive hub.
7 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
5 Remove the plug the drive hub. Drain the oil
from the hub into a suitable container.
Turntable rotate drive hub:
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
a
B
A
b
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyes
located near the drive motor.
4 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device.
Part No. 122985
S-80 • S-85 • S-80X
d
c
Single fill port rotator
a
motor
b
fill port
c
drive hub mounting bolts
d
drive hub
3 - 55
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST D PROCEDURES
D-8
Perform Engine Maintenance Deutz Models
a
B
A
b
c
Engine specifications require that this procedure be
performed every 1500 hours of operation.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
d
Deutz TD2011 Operation Manual
Genie part number
Dual fill port rotator
a
motor
b
drive hub
c
drive hub mounting bolts
d
fill ports
139320
To access the engine:
6 Install the drive hub assembly onto the machine.
Torque the drive hub mounting bolts to
specification. Refer to Section 2, Specifications.
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure.
7 Fill the drive hub with oil. Refer to Section 2,
Specifications. Apply pipe thread sealant to the
plug. Install the plug.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 10-1, How to Adjust the
Turntable Rotation Gear Backlash.
3 - 56
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
Checklist E Procedures
2 Models without hydraulic tank shutoff valves:
Remove the drain plug from the hydraulic tank
and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
E-1
Test or Replace the
Hydraulic Oil
Models with hydraulic tank shutoff valves:
Close the two hydraulic tank valves located at
the hydraulic tank.
Genie specifications require that this procedure be
performed every 2000 hours or every two years,
whichever comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more frequently.
Component damage hazard. The
engine must not be started with the
hydraulic tank shutoff valves in the
CLOSED position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
3 Remove the drain plug from the hydraulic tank
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the fuel tank. Refer to Repair
Procedure 9-1, How to Remove the Fuel Tank.
open
closed
and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
4 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank
shutoff valves.
5 Disconnect and plug the T-fitting located at the
return filter with the two hoses connected to it.
Cap the fitting on the return filter housing.
6 Disconnect and plug the supply hose for the
auxiliary power unit. Cap the fitting on the
hydraulic tank.
Part No. 122985
S-80 • S-85 • S-80X
3 - 57
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST E PROCEDURES
7 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
hold down straps from the hydraulic tank.
18 Open the hydraulic tank shutoff valves (if
equipped).
Component damage hazard.
Be sure to open the two hydraulic
tank shutoff valves and prime the
pump after installing the hydraulic
tank. Refer to Repair Procedure
7-2, How to Prime the Pump.
8 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an appropriate
lifting device.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank may become unbalanced and
fall if it is not properly supported
and secured to the lifting device.
10 Remove the suction strainers from the tank and
clean them using a mild solvent.
11 Rinse out the inside of the tank using a mild
solvent.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
19 Operate all machine functions through a full
cycle and check for leaks.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
17 Clean up any oil that may have spilled.
3 - 58
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-2
Perform Engine Maintenance Perkins Models
E-3
Perform Engine Maintenance Deutz and Perkins Models
Engine specifications require that this procedure be
performed every 2000 hours.
Engine specifications require that this procedure be
performed every 3000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
engine information are available in the:
Required maintenance procedures and additional
engine information are available in the:
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
Deutz TD2011 Operation Manual
Genie part number
To access the engine:
Perkins 804D-33 Operation and Maintenance Manual
Genie part number
111332
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 122985
139320
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
S-80 • S-85 • S-80X
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 59
Section 3 • Scheduled Maintenance Procedures
September 2015
CHECKLIST E PROCEDURES
E-4
Replace the Boom Extend/
Retract Cables
Genie specifications require that this procedure be
performed every 10 years.
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Replace the boom extend/retract cables. See
Repair Procedure 4-5, How to Replace the
Boom Extend/Retract Cables.
3 - 60
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
•
Machine parked on a firm, level surface
•
Boom in the stowed position
•
Turntable rotated with the boom between
the non-steering wheels
•
Turntable secured with the turntable
rotation lock pin
•
Key switch in the off position with the
key removed
•
Wheels chocked
•
All external AC power supply disconnected
from the machine
Part No. 122985
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-80 • S-85 • S-80X
4-1
Section 4 • Repair Procedures
September 2015
Platform Controls
The platform control box contains one printed
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall
Effect technology and require no adjustment. The
operating parameters of the joysticks are stored in
memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. See 1-2,
How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
a
1-1
ALC-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-500
Circuit Board
1 Push in the Emergency Stop button to the off
position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
4 Attach a grounded wrist strap to the ground
screw inside the platform control box.
c
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
b
a
b
c
ALC-500 circuit board
drive/steer joystick controller
primary boom up/down,
extend/retract and
turntable rotate right/left
joystick controller
5 Carefully disconnect the wire connectors from
the circuit board.
6 Remove the ALC-500 circuit board mounting
fasteners.
7 Carefully remove the ALC-500 circuit board from
the platform control box.
4-2
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
1-2
Joysticks
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
How to Calibrate a Joystick
Note: No machine fuction should operate while
performing the joystick calibration procedure.
The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function
will operate.
Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set.
How to Adjust the Joystick
Max-out Setting
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
The max-out setting of a joystick controls the
maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum
performance. The max-out settings on the joystick
can be changed to compensate for hydraulic pump
wear to maintain peak performance from the
machine.
3 Turn the key switch to platform control. Do not
start the engine.
Note: Perform this procedure with the boom in the
stowed position.
Note: Perform this procedure with the engine off.
1 Open the platform control box.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from the
joystick for approximately 10 seconds or until
the alarm sounds. Connect the wire harness
connector to the joystick.
6 Move the joystick full stroke in either direction
and hold for 5 seconds.
7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds.
Result: The alarm should sound indicating
successful joystick calibration.
Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
Part No. 122985
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
S-80 • S-85 • S-80X
4-3
Section 4 • Repair Procedures
September 2015
PLATFORM CONTROLS
7 Momentarily activate the drive enable toggle
switch in the right direction 4 times.
Result: There should be a pause and the alarm
should sound 4 times indicating that the
machine is in max-out calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
8 Start the engine from the platform controls and
press down the foot switch.
9 Start a timer and activate the machine function
that needs to be adjusted. Record the time it
takes for that function to complete a full cycle
(ie; boom up).
10 Compare the machine function time with the
function times listed in Section 2,
Specifications. Determine whether the function
time needs to increase or decrease.
11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle
time. Momentarily move the drive enable toggle
switch in the right direction to increase the
function speed or momentarily move the drive
enable toggle switch in the left direction to
decrease the function speed.
Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change
in 2% increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Result: The alarm does not sound. The
minimum or maximum adjustment has been
obtained. No changes can be saved.
Note: Do not operate any machine function during
the 10 second waiting time.
14 Cycle the red Emergency Stop button off, then
back on.
How to Adjust the Joystick
Ramp Rate Setting
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum
output, when moved out of the neutral position. The
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain
peak performance from the machine.
Note: Perform this procedure with the boom in the
stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4-4
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that the
machine is in ramp rate calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
13 Repeat steps 9 through 11 for each joystick
controlled machine function.
14 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Note: Do not operate any machine function during
the 10 second waiting time.
15 Cycle the red Emergency Stop button off, then
back on.
Ramp rate (factory settings)
8 Start the engine from the platform controls and
press down the foot switch.
Turntable rotate
accelerate
decelerate
3 seconds
2 second
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how
long it takes the function to reach maximum
speed. This is the ramp rate.
Boom up/down
accelerate
decelerate
3 seconds
1 second
10 Compare the function ramp rate time with the
table below and determine whether the ramp
rate time needs to increase or decrease.
11 Release the foot switch.
12 While the joystick is activated, set the ramp
rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time
or momentarily move the drive enable toggle
switch in the left direction to decrease the time.
Boom extend/retract
accelerate
decelerate
2.5 seconds
1 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed
4 seconds
0.5 second
0.75 second
1 second
1 second
1 second
4 seconds
Note: Each time the drive enable toggle switch is
momentarily moved, the time will change in 5%
increments.
Part No. 122985
S-80 • S-85 • S-80X
4-5
Section 4 • Repair Procedures
September 2015
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PLATFORM CONTROLS
How to Adjust the Joystick
Threshold Setting
10 Slowly move the joystick off center in either
direction just until the function begins to move.
The threshold setting of a joystick is the minimum
output at which a function proportional valve can
open and allow the function to operate.
11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
move the drive enable toggle switch to either
side to set the threshold.
Note: Perform this procedure with the boom in the
stowed position.
Result: The alarm should sound indicating a
successful calibration.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
12 Repeat steps 9 through 11 for each boom
joystick-controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
2 Turn the key switch to platform control. Do not
start the engine.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
3 Push in the red Emergency Stop button to the
off position at the platform controls.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Note: Do not operate any machine function during
the 10 second waiting time.
14 Cycle the red Emergency Stop button off, then
back on.
Function speeds (factory settings)
Boom up
89 to 93 seconds
Boom down
90 to 94 seconds
Result: There should be a pause and the alarm
should sound 8 times indicating that the
machine is in threshold calibration mode.
Boom extend
73 to 79 seconds
Boom retract
79 to 84 seconds
Result: The alarm does not sound. Repeat steps
3 through 7.
Turntable rotate, 360°
boom fully stowed
7 Momentarily activate the drive enable toggle
switch in the right direction 8 times.
8 Start the engine from the platform controls and
press down the foot switch.
9 Select a boom function joystick to set the
threshold.
4-6
95 to 103 seconds
Drive speeds (factory settings)
Stowed- high speed
Non-stowed
S-80 • S-85 • S-80X
7.9 to 8.5 seconds
40 to 45 seconds
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM CONTROLS
How to Calibrate the Boom
Angle Sensor
Note: Manually reduce the boom speed as it
reaches the fully elevated position.
The boom angle sensor controls the maximum
angle that the boom can attain.
9 Momentarily activate the drive enable toggle
switch to the right 1 time to set the elevated
position.
Note: Perform this procedure with the boom in the
stowed position.
1 Pull out the red Emergency Stop button to the
on position at the ground controls.
2 Turn the key switch to platform controls.
3 Move and hold the drive enable toggle switch to
the right and pull out the red Emergency Stop
button to the on position.
4 When the alarm sounds, release the drive
enable toggle switch.
Result: The alarm will sound indicating that the
angle sensor has been calibrated.
10 Release the joystick and the foot switch and
wait for 10 seconds.
Result: The alarm will sound indicating that the
settings have been saved and is leaving
calibration mode.
11 Cycle the red Emergency Stop button off, then
back on. Start the machine and return to the
stowed position.
5 Momentarily activate the drive enable toggle
switch to the right 12 times.
Result: There should be a pause and the alarm
should sound 12 times indicating that the
machine is in Angle Sensor calibration mode.
6 Start the engine from the platform controls and
press down the foot switch.
7 Momentarily activate the drive enable toggle
switch to the right 1 time to set the stowed
position.
Note: The alarm will not sound indicating the
setting.
8 Raise the primary boom to the fully elevated
position.
Part No. 122985
S-80 • S-85 • S-80X
4-7
Section 4 • Repair Procedures
September 2015
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4-8
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Platform Components
7 Support and secure the platform to an
appropriate lifting device.
2-1
Platform
How to Remove the Platform
8 Remove the platform mounting fasteners and
remove the platform from the machine.
1 Remove the cable clamp from the top of the
platform mounting weldment.
2 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side. Do
not disconnect the wiring.
Crushing hazard. The platform
could become unstable and fall
when it is removed from the
machine if not properly supported.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
5 Tag and disconnect the foot switch wiring from
the foot switch. Remove the cable from the
back of the platform.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
6 Remove the platform control box mounting
fasteners. Lower the control box and set it
aside.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
Note: If your machine is equipped with an airline to
platform option, the airline must be disconnected
from the platform before removal.
Part No. 122985
S-80 • S-85 • S-80X
4-9
Section 4 • Repair Procedures
September 2015
PLATFORM COMPONENTS
2-2
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
4 Remove the pin retaining fastener from the
slave cylinder rod-end pivot pin. Use a soft
metal drift to drive the rod-end pivot pin out.
Crushing hazard. The jib boom
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly supported.
5 Remove the external snap rings from the barrelend pivot pin.
6 Use a soft metal drift to drive the barrel-end
pivot pin out.
How to Remove the Platform
Leveling Slave Cylinder
7 Carefully pull the cylinder out of the primary
boom to access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the
closed loop.
8 Tag, disconnect and plug the hydraulic hoses
from the slave cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible.
How to Bleed the Slave Cylinder
2 Raise the primary boom slightly and place
blocks under the platform for support.
Note: Do not start the engine. Use auxiliary power
for this procedure.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
1 Raise the primary boom to a horizontal position.
Note: Do not rest the entire weight of the boom on
the blocks.
4 - 10
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
2 Tag, disconnect and plug the hydraulic hoses
from the platform rotator manifold. Cap the
fittings on the rotator.
2-3
Platform Rotator
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
How to Remove the
Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the platform. See 2-1,
How to Remove the Platform.
Part No. 122985
3 S-85: Support the jib boom leveling arms and
the platform mounting weldment with an
appropriate lifting device. Do not apply any
lifting pressure.
4 Remove the mounting bolts from the platform
mounting weldment. Remove the center bolt
and slide the platform mounting weldment off of
the platform rotator.
Crushing hazard. The platform
mounting weldment could become
unbalanced and fall if not properly
supported when removed from the
machine.
5 Support the platform rotator with an appropriate
lifting device. Do not apply any lifting pressure.
S-80:
6 Support the rod end of the platform leveling
slave cylinder. Protect the cylinder rod from
damage.
7 Remove the pivot pin retaining fasteners from
both the slave cylinder rod-end pivot pin and
the rotator pivot pin.
S-80 • S-85 • S-80X
4 - 11
Section 4 • Repair Procedures
September 2015
PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins.
Remove the platform rotator from the machine.
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator
fasteners, torque the fasteners to specifications.
Refer to Section 2, Specifications.
S-85:
9 Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
How to Bleed the Platform
Rotator
Note: This procedure will require two people. Do
not start the engine. Use auxiliary power for this
procedure.
1 Move the function enable toggle switch to either
side and activate the platform rotate toggle
switch to the right then the left through two
platform rotation cycles, then hold the switch to
the right position until the platform is fully
rotated to the right.
10 Support the jib boom leveling arms.
2 Place a suitable container underneath the
platform rotator.
11 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
3 Open the top bleed screw on the rotator, but do
not remove it.
Bodily injury hazard. The jib boom
leveling arms may fall if not
properly supported.
12 Lower the jib boom leveling arms.
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: When installing the platform rotator
fasteners, torque the fasteners to specifications.
Refer to Section 2, Specifications.
4 - 12
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
4 Move the function enable button to either side
and hold the platform rotate toggle switch to the
left position until the platform is fully rotated to
the left. Continue holding the toggle switch until
air stops coming out of the bleed screw. Close
the bleed screw.
2-4
Platform Overload System
How to Calibrate the Platform
Overload System (if equipped)
Crushing hazard. Keep clear of
the platform during rotation.
5 Open the bottom bleed screw on the rotator, but
do not remove it.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation.
7 Clean up any hydraulic oil that may have
spilled.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks.
Part No. 122985
Calibration of the platform overload system is
essential to safe machine operation. Continued
use of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.
S-80 • S-85 • S-80X
4 - 13
Section 4 • Repair Procedures
September 2015
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are
flashing at the platform and ground controls,
and the alarm is sounding. Slowly tighten the
load spring adjustment nut in a clockwise
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Result: The overload indicator lights are
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off at
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
Result: The overload indicator lights are
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure
beginning with step 6.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
4 - 14
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
PLATFORM COMPONENTS
10 Turn the key switch to ground control.
11 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
Part No. 122985
S-80 • S-85 • S-80X
4 - 15
Section 4 • Repair Procedures
September 2015
Jib Boom Components, S-85
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
3-1
Jib Boom
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Jib Boom
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the platform. See 2-1, How to Remove
the Platform.
Note: Models equipped with platform overoad
system: If the platform overload components are
disassembled and/or removed from the platform
support, the platform overload system will need to
be calibrated. See 2-4, How to Calibrate the
Platform Overload System.
2 Models equipped with platform overload
system: Tag and disconnect the electrical
connector from the platform load sense module.
3 Remove the hose and cable cover from the side
of the jib boom.
4 Remove the hose and cable clamp from the jib
boom pivot pin. Lay all hoses and cables to the
side.
6 Attach a lifting strap from an overhead crane to
the jib boom assembly.
7 Place blocks under the platform leveling
cylinder for support. Protect the cylinder rod
from damage.
8 Remove the pin retaining fastener from the
slave cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The jib boom
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly attached to the overhead
crane.
9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
10 Use a soft metal drift to remove the pin and
carefully remove the jib boom assembly from
the primary boom.
Component damage hazard.
Hoses and cables can become
damaged if they are kinked or
pinched.
4 - 16
S-80 • S-85 • S-80X
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
Part No. 122985
September 2015
Section 4 • Repair Procedures
JIB BOOM COMPONENTS, S-85
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
3-2
Jib Boom Lift Cylinder
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Jib Boom
Lift Cylinder
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Attach a lifting strap from an overhead crane to
the lug at the rod end of the jib boom lift
cylinder.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall if not properly supported
when removed from the machine.
Part No. 122985
S-80 • S-85 • S-80X
4 - 17
Section 4 • Repair Procedures
September 2015
Boom Components
4-1
Cable Track
The boom cable track guides cables and hoses
running up the boom. It can be repaired link by link
without removing the cables and hoses that run
through it. Removing the entire boom cable track is
necessary when performing major repairs that
involve removing the boom.
6 S-80: Tag, disconnect and plug the hydraulic
hoses from the counterbalance valve manifold
located on the platform rotator. Cap the fittings
on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
7 Tag, disconnect and plug the hydraulic hoses
from the platform leveling slave cylinder at the
platform manifold and cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
1 Open the platform control box.
2 Tag and disconnect the foot switch wiring from
the terminal strip inside the platform control
box.
3 Loosen the squeeze connector and remove the
foot switch cable from the control box.
8 Remove the timing link/timing link cam pin and
gently rest the timing link against the
counterweight.
4 Disconnect the wire connectors from the bottom
of the platform control box.
9 S-85:Remove the hose and cable cover from the
side of the jib boom.
Note: When installing the wire connectors to the
bottom of the platform control box, match the color
of the connectors to those on the control box to be
sure they are installed in the correct location.
10 Tag, disconnect and plug the hydraulic hoses
from the jib boom/platform rotate select
manifold. Cap the fittings on the manifold.
5 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side.
4 - 18
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
11 Tag, disconnect and plug the wiring from the jib
boom/platform rotate select manifold.
12 Tag, disconnect and plug the hydraulic hoses
from the jib boom lift cylinder. Cap the fittings
on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
All models:
13 From the ground controls, raise the boom to a
horizontal position.
18 Place blocks between the upper and lower cable
tracks and secure the upper and lower tracks
together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
when removed from the machine.
19 Attach a lifting strap from an overhead crane to
the cable track.
20 Remove the mounting fasteners that attach the
lower cable track to the boom.
21 Remove the cable track from the machine and
place it on a structure capable of supporting it.
14 Remove the fasteners from the drive speed limit
switch bracket (LS1RS) mounted on the side of
the boom at the platform end of the boom. Do
not remove the limit switch from the bracket.
15 Remove the cotter pin from the upper cable
track at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
16 Remove the cable track guide fasteners from
the cable track guides at the platform end of the
boom. Remove the cable track guides from the
boom.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
overhead crane.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Component damage hazard. The
cable track can be damaged if it is
twisted.
17 Remove the cable clamp from the pivot end of
the boom.
Part No. 122985
S-80 • S-85 • S-80X
4 - 19
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
How to Repair the Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
5 Remove the upper rollers from the replacement
section of cable track.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
Note: A cable track repair kit is available through
the Genie Industries Service Parts Department,
part no. 77896. The kit includes a 4-link section of
cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Carefully remove the snap rings from each end
of the damaged section of cable track.
3 Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
track to be replaced. Remove the rollers.
7 Connect the ends of the replacement cable
track section to the existing cable track using
the snap rings.
8 Install the rollers onto the new section of cable
track.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.
4 Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
4 - 20
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
4-2
Boom
How to Remove the Boom
TIp-over hazard. This procedure
requires the removal of the
turntable counterweight. Failure to
remove the counterweight before
removing the boom assembly will
result in the machine tipping over.
Do not remove the boom without
first removing the counterweight.
How to Shim the Boom
1 Measure each wear pad.
Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
minimum specification, perform the following
procedure. Refer to Section 3, D-1, Check the
Boom Wear Pads.
TIp-over hazard. When installing
the boom onto the machine, the
boom assembly must be first
installed prior to the installation of
the counterweight. If the
counterweight is installed before
the boom assembly, the machine
will tip over resulting in death or
serious injury.
2 Extend the boom until the wear pads are
accessible.
3 Loosen the wear pad mounting fasteners.
4 Install the new shims under the wear pad to
obtain zero clearance and zero drag.
5 Tighten the mounting fasteners.
TIp-over hazard. The turntable
counterweight is essential for
machine stability. Failure to install
the counterweight after installing
the boom assembly will
compromise machine stability
resulting in the machine tipping
over. Death or serious injury will
result.
6 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
binding or scraping.
Note: Always maintain squareness between the
outer and inner boom tubes.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Remove the jib boom. See 3-1, How to Remove
the Jib Boom.
2 Remove the cable track. See 4-1, How to
Remove the Cable Track.
Part No. 122985
S-80 • S-85 • S-80X
4 - 21
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
3 Raise the boom until the short and long link arm
to boom pivot pins are above the turntable
covers.
9 Slowly operate the overhead crane to apply
tension to the lifting straps. Do not attempt to lift
the machine with the overhead crane.
4 Place a block of wood measuring
4 x 4 x 60 inches / 10 x 10 x 152 cm under the
long link arm, across the turntable covers.
10 Locate and remove the counterweight retaining
fastener at the center of the counterweight.
Carefully lift the counterweight upwards and
remove the counterweight from the machine.
Set the counterweight on the ground. Do not
leave the counterweight suspended above the
ground.
5 Slowly lower the boom until the long link arm
contacts the wood block. Do not rest the entire
weight of the boom on the block. Turn the
machine off.
Crushing hazard. The turntable
counterweight will fall if not
properly supported by the
overhead crane resulting in death
or serious injury. Keep personnel
away from the area when
removing the counterweight.
Component damage hazard. The
turntable covers can become
damaged if the weight of the boom
is allowed to rest on the block.
6 Place wood blocks between the short link arm
and the turntable weldment for support.
7 Insert a 1.125 x 12 inches / 32 x 300 mm
eye-bolt through each hole located on the top
surface of the counterweight. Secure the eyebolts in position with flat washers and nuts.
11 Attach lifting straps from a 5 ton / 5000 kg
overhead crane to each end of the boom.
Support the boom. Do not apply any lifting
pressure.
8 Securely attach lifting straps or chains with a
minimum rating of 5 tons / 5000 kg to the lifting
points on the top of the turntable counterweight.
Attach the lifting straps or chains to a
5 ton / 5000 kg overhead crane.
12 Support and secure the rod end of the boom lift
cylinder to a second overhead crane or similar
lifting device.
Note: A spreader bar and other hardware may be
needed to safely remove the counterweight.
4 - 22
13 Remove the lift cylinder rod-end pivot pin
retaining fasteners. Use a soft metal drift to
remove the pin.
S-80 • S-85 • S-80X
Crushing hazard. The boom could
fall if not properly supported when
the lift cylinder rod-end pivot pin is
removed.
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
14 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
17 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Crushing hazard. The boom lift
cylinder could fall if not properly
supported and secured to the
lifting device.
15 Using the overhead crane, carefully lower the
boom lift cylinder and allow it to rest on the
boom rest pad. Protect the cylinder rod from
damage.
16 Remove the boom end cover retaining
fasteners and remove the cover.
18 Tag and disconnect the electrical connector for
the cable break limit switch.
19 Tag and disconnect all boom wire harness
electrical connectors located at the pivot end of
the boom.
20 Support the platform leveling master cylinder.
Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.
21 Tag, disconnect and plug the hydraulic hoses
from the bulkhead fittings at the pivot end of the
boom. Cap the bulkhead fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
22 Remove the external snap rings from both boom
pivot pins at the short and long link arms. Do
not remove the pins.
Part No. 122985
S-80 • S-85 • S-80X
4 - 23
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
23 Using the overhead crane, adjust the boom as
necessary to relieve pressure from the pivot
pins.
4-3
Boom Lift Cylinder
24 Use a soft metal drift to remove each boom
pivot pin. Carefully remove the boom assembly
from the machine and place it on a structure
capable of supporting it.
The boom lift cylinder raises and lowers the boom.
The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
Crushing hazard. The boom could
fall if not properly supported by the
overhead crane when each boom
pivot pin is removed.
How to Remove the Boom
Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Crushing hazard. The long and
short link arms may fall if not
properly supported when the
boom pivot pins are removed.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the boom to a horizontal position.
2 Attach a 5 ton / 5000 kg overhead crane to the
boom at the platform end for support. Do not lift
the boom.
3 Support and secure both ends of the boom lift
cylinder to a second overhead crane or similar
lifting device.
4 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom will
fall if not properly supported when
the primary boom rod-end pivot
pin is removed.
4 - 24
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
5 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
6 Tag, disconnect and plug the boom lift cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4-4
Boom Extension Cylinder
The boom extension cylinder is located inside the
boom assembly and incorporates cables and
pulleys that are responsible for extending the
number 3 boom tube. The primary boom extension
cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
failure.
How to Remove the Boom
Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
7 Remove the pin retaining fasteners from the
boom lift cylinder barrel-end pivot pins. Do not
remove the pins.
8 Use a slide hammer to remove the barrel-end
pivot pins.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall if not properly supported
and secured to the lifting device.
9 Move the boom lift cylinder towards the
counterweight end of the machine. Rotate the
boom lift cylinder until the barrel-end pivot pin
bores will clear the boom linkage.
10 Carefully remove the boom lift cylinder from the
machine.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall if not properly supported
and secured to the lifting device.
Part No. 122985
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
Note: Perform this procedure with the boom fully
retracted.
1 Raise the boom to a horizontal position.
S-80 • S-85 • S-80X
4 - 25
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
2 Remove the boom end cover retaining
fasteners and remove the cover.
3 Remove the access covers from both sides of
the boom at the pivot end.
4 Fully loosen the lock nuts on the extend cables.
Do not remove the nuts.
5 Loosen the retract cable nut at the platform end
of the boom. Pull the cable rod from the support
and let it hang down.
6 Remove the cable guard fasteners and remove
the cable guard.
7 Locate the retaining plates that secure the
retract cables to the inside of the number 3
boom tube.
8 Remove the cable retaining plates and pull the
retract cables off of the pulleys. Lay the cables
flat and out of the way.
9 Remove the fasteners from the retaining blocks
from the extension cylinder saddle. Remove the
blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.
10 Disconnect the wire connector to the extend
cable break limit switch.
11 Remove the retaining fasteners that secure the
extend cable mounting plates to the inside of
the number 1 boom tube.
b
a
a
b
4 - 26
cable guard
retaining block
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
13 Lift up the extend cable mounting plate and push
the extend cables towards the platform to create
slack in the cables. Rest the cable and bracket
assembly on top of the extend cylinder.
14 Locate the lower extend cable bracket on the
bottom of the number 3 boom tube.
15 Remove the lower extend cable bracket
mounting fasteners and pull back on the
bracket to release it from the number 3 boom
tube.
16 While pushing the lower extend cable bracket
towards the platform, pull the extend cable
mounting plate towards the pivot end of the
boom.
17 Secure the extend cable bracket and cables to
the cylinder to prevent them from falling off
when removing the cylinder.
a
b
a
b
c
d
c
18 Remove the external snap rings from the
extension cylinder pin at the pivot end of the
boom.
d
extend
extend
extend
extend
cable lock nuts
cable mounting plate
cable mounting plate fastener
cable bracket
12 Pull back on the extend cable mounting plate
until it clears the blocks welded to the inside of
the number 1 boom tube.
Part No. 122985
19 Use a soft metal drift to remove the pin.
20 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
S-80 • S-85 • S-80X
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 27
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
21 Attach a lifting strap from a 5 ton / 5000 kg
overhead crane to the lug at the rod end of the
boom extension cylinder.
4-5
Boom Extend/Retract Cables
22 Lift the boom extension cylinder with the crane
until it clears the cylinder saddle inside the
number 2 boom tube.
How to Adjust the Boom Extend/
Retract Cables
23 Carefully support and slide the extension
cylinder out of the boom.
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Proper adjustment of the boom extend/retract
cables and related components on a regular basis
is essential to good machine performance and safe
machine operation. The boom extend and retract
functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
Crushing hazard. The extension
cylinder could fall when removed
from the boom if not properly
supported.
Component damage hazard. Be
careful not to damage the cable
break limit switch.
Component damage hazard. Be
careful not to damage the
counterbalance valves on the
primary boom extension cylinder
when removing the cylinder from
the boom.
Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully
adjusted for proper balancing.
Note: Perform this procedure with the boom in a
horizontal position.
1 Start the engine from the Ground Controls.
2 Raise the boom to a horizontal position
3 Fully retract the boom.
4 Stop the engine.
5 Remove the boom end cover retaining
fasteners and remove the cover.
6 Inspect the threaded ends of the boom extend
cables. The threads must be clean and in good
condition with no damaged threads.
4 - 28
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
7 Locate the retract cable adjustment nut on the
bottom of the number 1 boom tube at the
platform end of the boom. Loosen the nut, but
do not remove the nut.
13 Retract and extend the boom approximately
3 feet / 1 m two times and stop during the
extension cycle. This will create slack in the
retract cables.
8 Locate the extend cable adjustment nuts on the
counterweight end of boom tube #1. Refer to
Illustration 2. Loosen the nylock nuts and jam
nuts on the cable tension equalizer bracket. Do
not remove the nuts.
Note: Be sure to not fully extend the boom. Stop
when there is approximately 3 feet / 1 m of
travel left.
9 Adjust the extend cable adjustment nut to obtain
6 3/8 inches/16.2 cm to 6 1/2 inches/16.5 cm
between the platform end of boom tube #2 and
boom tube #3. Refer to illustration 1. There
should be approximately 1/2 inch of exposed
threads on the adjustment bolts. Refer to
Illustration 2.
15 Fully extend the boom then retract the boom
approximately 12 inches / 30 cm.
Note: If the cables have been replaced, be sure the
adjustment nuts have been replaced. Do not reuse the existing nuts.
14 Repeat steps 12 and 13 two to three times.
16 At the pivot end of the boom, visually inspect
the boom extend cables for even cable droop or
sag.
Note: If the boom extend cables are uneven,
tighten the boom extend cable adjustment nut at
the pivot end of the boom for the appropriate cable.
10 Extend the boom until there is approximately 3
feet / 1 m of travel left. Do not fully extend the
boom.
11 Locate the retract cable adjustment nut on the
bottom of the number 1 boom tube at the
platform end of the boom.
12 Using a dial type torque wrench, torque the
retract cable adjustment nut to 32-36 ft lbs /
43-49 Nm using gentle and steady torque.
6.375 inches / 16.2 cm
Illustration 1
Part No. 122985
S-80 • S-85 • S-80X
4 - 29
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
17 Visually inspect the cable break limit switch arm
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate.
How to Replace the Boom
Extend/Retract Cables
Note: If the boom extend cables are adjusted
evenly, the wheel of the limit switch arm should be
centered in the notch of the pivot plate.
Note: The cable pulleys must also be replaced
when replacing the cables.
1 Remove the boom extension cylinder. See
Section 4-4, How to Remove the Boom
Extension Cylinder.
Boom extend cables:
a
2 Remove the cables from the lower boom extend
cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the boom
extend cable pulley pivot pin. Use a soft metal
drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it from the shaped end of the pin.
b
5 Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
c
Illustration 2
a
cable break limit switch
b
extend cable adjustment nut
c
extend cable pivot plate
18 Install the boom end cover at the pivot end of
the boom.
19 Fully retract and lower the boom to the stowed
position.
4 - 30
6 Route the new boom extend cables through the
boom extend pulley bracket.
7 Install the new boom extend cable pulley, pivot
pin and snap rings.
Note: Be sure the boom extend cables are routed
through the grooves of the pulley and the upper
wear pad on the extension cylinder.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
BOOM COMPONENTS
8 Install the boom extend cable clevis pins and
rue rings to the pivot plate near the cable break
limit switch.
18 At the platform end of the boom, install the
retract cables, clevis pins and rue rings to the
adjustment plate.
9 Install the boom extend cables to the lower
extend cable bracket that mounts to the number
3 boom tube.
19 Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
Boom retract cables:
20 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
10 Remove the rue rings and clevis pins from the
boom retract cables at the platform end of the
boom.
21 Install the boom extension cylinder assembly
into the boom.
11 Attach the cable pulling tool or a rope to one of
the boom retract cables at the pivot end of the
boom.
Note: Before lowering the extension cylinder into
the saddles of the number 1 boom tube, wrap the
boom retract cables around the pulleys.
Note: A cable pulling tool is available through
Genie Service Parts Department (Genie part no.
94510)
22 Adjust the boom extend/retract cables.
See Section 4-5, How to Adjust the Boom
Extend/Retract Cables.
12 At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
13 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
14 Securely attach the rope to the same end of the
new boom retract cable.
15 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
16 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
17 Repeat steps 14 through 19 for the other boom
retract cable.
Part No. 122985
S-80 • S-85 • S-80X
4 - 31
Section 4 • Repair Procedures
September 2015
BOOM COMPONENTS
4 Remove the pin retaining fastener from the
master cylinder barrel-end pivot pin.
4-6
Platform Leveling
Master Cylinder
5 Place a rod through the barel-end pivot pin and
twist to remove the pin.
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed loop hydraulic
circuit that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the pivot end of the boom.
How to Remove the Platform
Leveling Master Cylinder
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible.
6 Attach a lifting strap from an overhead crane to
the lug on the rod end of the master cylinder.
7 Remove the pin retaining fastener from the
rod-end pivot pin.
8 Place a rod through the rod-end pivot pin and
twist to remove the pin.
9 Remove the master cylinder from the machine.
2 Remove the turntable end cover to access the
master cylinder.
3 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Crushing hazard. The master
cylinder could become unbalanced
and fall if it is not properly
supported by the lifting device
when removed from the machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 32
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Engines
5-1
RPM Adjustment
5-2
Flex Plate
Refer to Maintenance Procedure B-10,
Check and Adjust the Engine RPM.
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.
Type "B" flex plates combines the pump coupler,
as part of the flex plate, which is installed onto the
engine flywheel.
Type "B"
(flexplate with
coupler combined)
Part No. 122985
S-80 • S-85 • S-80X
4 - 33
Section 4 • Repair Procedures
September 2015
ENGINES
How to Remove the Flex Plate
Deutz model:
Note: Perform this procedure with the engine off
and cool to the touch.
5 Tag and disconnect the wiring from the bell
housing.
1 Open the engine side turntable cover.
6 Remove the U-bolt from the exhaust flex pipe at
the muffler.
2 Tag and disconnect the battery cables from the
battery(s).
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
3 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
Burn hazard. Hot engine parts can
cause severe burns.
7 Remove the muffler bracket retaining fasteners
from bell housing. Remove the muffler and
bracket assembly from the engine.
8 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing engine fasteners.
9 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched
a
10 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
b
a
b
engine tray anchor hole
engine tray retaining fastener
4 Tag and disconnect the wiring plug at the
electronic displacement controller (EDC),
located on the drive pump.
4 - 34
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
ENGINES
Perkins model:
11 Tag and disconnect the wiring from the bell
housing.
12 Remove the exhaust pipe clamp at the muffler.
Burn hazard. Hot engine parts can
cause severe burns.
13 Remove the muffler mounting bracket fasteners.
Remove the muffler and bracket assembly from
the engine.
14 Remove the hose clamps from the air cleaner
elbow and the engine intake manifold.
15 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
assembly from the engine.
16 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing to engine fasteners.
21 Remove the relay housing from the muffler
mount. Do not disconnect the relays.
22 Disconnect and remove the ECM from the
muffler mount.
23 Close the shutoff valve on the Liquid Petroleum
Gas (LPG) tank by turning it clockwise
(if equipped).
24 Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
25 Remove the muffler mount.
26 Support the drive pump with an appropriate
lifting device. Remove all of pump plate
mounting fasteners.
27 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
Continental model:
17 Tag and disconnect the wire harness from the
oxygen sensor.
28 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine flywheel.
18 Remove the exhaust pipe heat shield fasteners
from the top of the muffler.
Burn Hazard. Hot engine parts can
cause severe burns.
19 Remove the muffler retainer bracket fasteners.
20 Remove the muffler fasteners securing the
muffler to the exhaust manifold. Remove the
muffler from the bracket.
Part No. 122985
S-80 • S-85 • S-80X
4 - 35
Section 4 • Repair Procedures
September 2015
ENGINES
How to Install the Flex Plate
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump. Apply
Loctite® removable thread sealant to the
mounting screws.
Note: Torque the flex plate mounting bolts in two
stages.
Continental model: Torque the flex plate
mounting bolts in sequence to
20.8 ft-lbs / 28 Nm.
Deutz model: Torque the flex plate mounting
bolts in sequence to 28 ft-lbs / 38 Nm.
Perkins model:
Torque the flex plate mounting bolts in
sequence to 46.7 ft-lbs / 63.3 Nm.
2 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine.
3 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
Apply Loctite® removable thread sealant to the
pump retaining fasteners. Torque the pump
retaining fasteners to 57 ft-lbs / 77 Nm.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
5 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump
end plate for your engine.
6 Install the pump and pump mounting plate
assembly onto the engine. Apply Loctite®
removable thread sealant to the mounting
screws.
Perkins model:
Torque the pump mounting plate fasteners in
sequence to 28 ft-lbs / 38 Nm.
Deutz model:
Torque the pump mounting plate fasteners in
sequence to 46.7 ft-lbs / 63.3 Nm.
Continental model:
Torque the pump mounting plate fasteners in
sequence to 23 ft-lbs / 31.2 Nm.
4 Install the pump onto the pump mounting plate.
Component damage hazard.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 - 36
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
ENGINES
6
1
1
8
10
3
6
4
3
11
12
5
4
5
7
2
2
Perkins 804C-33
Pump Mounting Plate
Perkins, Deutz and Continental
Flex Plate
6
6
1
4
3
11
1
8
10
8
10
9
12
4
3
11
12
5
7
5
7
2
2
9
9
Continental Pump Mounting Plate
Deutz BF4L-2011
Pump Mounting Plate
Part No. 122985
S-80 • S-85 • S-80X
4 - 37
Section 4 • Repair Procedures
September 2015
Ground Controls
6-1
Control Relays
Relays used for single function switching are single
pole double throw (SPDT) relays.
How to Test a Single Pole Double
Throw Relay
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
1 Tag and disconnect all the wiring from the relay
to be tested.
terminal no. 87a - N.C.
terminal no. 85 - coil negative (-)
terminal no. 30 - common
terminal no. 86 - coil positive (+)
terminal no. 87 - N.O.
Control Relay Schematic
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test
terminal 85 to 86 with resistor
terminal 87 to 87a and 30
terminal 87a to 30
Desired result
75 to 85Ω
no continuity
(infinite Ω)
continuity
(zero Ω)
3 Connect 12V DC to terminal 85 and a ground
wire to terminal 86, then test the following
terminal combinations.
Test
terminal 87 to 87a and 30
terminal 87 to 30
4 - 38
Desired result
no continuity
(infinite Ω)
continuity
(zero Ω)
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Hydraulic Pumps
2 Tag, disconnect and plug the hydraulic hoses
from the function pump. Cap the fittings on the
pump.
7-1
Function Pump
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Function
Pump
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
3 Remove the pump mounting fasteners.
Carefully remove the pump.
1 Close the two hydraulic tank valves located at
the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open
Part No. 122985
Component damage hazard.
Be sure to open the two hydraulic
tank valves (if equipped) and
prime the pump after installing the
pump. See 7-2, How to Prime the
Pump.
closed
S-80 • S-85 • S-80X
4 - 39
Section 4 • Repair Procedures
September 2015
HYDRAULIC PUMPS
2 Close the two hydraulic tank valves located at
the hydraulic tank.
7-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local
authorized service center.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
open
closed
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Disconnect the wire harness at the electronic
displacement controller (EDC), located on the
drive pump.
4 - 40
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
HYDRAULIC PUMPS
3 Tag, disconnect and plug the hydraulic hoses
from the drive and function pumps. Cap the
fittings on the pumps.
How to Prime the Pump
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves (if equipped) are in the
open position before priming the
pump. The engine must not be
started with the hydraulic tank
shutoff valves in the closed
position or component damage will
occur.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
fasteners.
1 Connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
2 Continental models: If equipped, close the
valve on the LPG tank, then disconnect the
hose from the tank. Move the fuel select toggle
switch to the LPG position.
Deutz and Perkins models: Disconnect the
engine wiring harness from the fuel solenoid at
the injector pump.
6 Remove the drive pump assembly from the
machine.
Component damage hazard.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Note: Before installing the pump, verify proper
pump coupler spacing. See 5-2, Flex Plate.
3 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
pressure reaches 300 psi / 20.7 bar.
4 Continental models: If equipped, connect the
LPG hose to the LPG tank and open the valve
on the tank.
Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
5 Start the engine from the ground controls and
check for hydraulic leaks.
Part No. 122985
S-80 • S-85 • S-80X
4 - 41
Section 4 • Repair Procedures
September 2015
Manifolds
8-1
Function Manifold Components
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index
No.
Description
1
Solenoid valve, 2 position 3 way ...... SJ ......... Boom up ........................................... 50-55 ft-lbs / 68-75 Nm
Schematic
Item
Function
Torque
2
Solenoid valve, 2 position 3 way ...... SK ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
3
Solenoid valve, NO, Poppet .............. SP ......... Extend ............................................... 33-37 ft-lbs / 45-50 Nm
4
Solenoid valve, NO, Poppet .............. SQ ........ Retract .............................................. 33-37 ft-lbs / 45-50 Nm
5
Proportional valve ............................. SR ........ Extend proportional .......................... 20-25 ft-lbs / 27-34 Nm
6
Differential sensing valve .................. SS ......... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
7
Proportional valve ............................. SF ......... Boom up/down proportional ............. 33-37 ft-lbs / 45-50 Nm
8
Solenoid valve, 3 position, 4 way ..... SL ......... Steering directional .......................... 20-25 ft-lbs / 27-34 Nm
9
Proportional valve ............................. SE ......... Swing proportional ........................... 20-25 ft-lbs / 27-34 Nm
10
Solenoid valve, 3 position, 4 way ..... SI .......... Swing directional .............................. 26-30 ft-lbs / 35-41 Nm
11
Flow regulator valve .......................... SD ........ Oscillate flow control ........................ 20-25 ft-lbs / 27-34 Nm
12
Relief valve, 2400 psi / 165 bar ........ SN ........ Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm
13
Relief valve, 2400 psi / 165 bar ........ SO ........ Boom extend relief ........................... 20-25 ft-lbs / 27-34 Nm
14
Check valve, 30 psi / 2.1 bar ............. ST ......... Return check valve ........................... 30-35 ft-lbs / 41-47 Nm
15
Differential sensing valve .................. SH ........ Primary lift ......................................... 30-35 ft-lbs / 41-47 Nm
16
Check valve ....................................... SA ......... Back flow / check function pump ...... 30-35 ft-lbs / 41-47 Nm
17
Relief valve, 3200 psi / 221 bar ........ SB ......... System relief ..................................... 20-25 ft-lbs / 27-34 Nm
18
Pressure reducing valve ................... SC ........ Oscillate pressure control ................. 30-35 ft-lbs / 41-47 Nm
19
Differential sensing valve .................. SG ........ Differential sensing/turntable rotate . 30-35 ft-lbs / 41-47 Nm
20
Flow regulator valve .......................... SM ........ Steering flow control ......................... 20-25 ft-lbs / 27-34 Nm
4 - 42
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
SJ
SK
SP
20
19
18
17
16
15
SQ
SM
SC
SR
SB
SS
4
5
6
SH
SE
12
3
SA
SL
13
2
SG
SF
14
1
ST
SI
7
8
9
10
SO
SN
SD
Part No. 122985
S-80 • S-85 • S-80X
11
4 - 43
Section 4 • Repair Procedures
September 2015
MANIFOLDS
How to Adjust the Boom Down
Relief Valve
8-2
Valve Adjustments Function Manifold
Note: Perform this procedure with the boom in the
stowed position.
How to Adjust the System
Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the diagnostic nipple located next to
the auxiliary pump.
Note: Perform this procedure with the boom in the
stowed position.
2 Start the engine from the ground controls.
Note: Auxiliary power will be used to perform this
procedure. Do not start the engine.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the diagnostic nipple (PTEST) located
next to the auxiliary pump.
2 Simultaneously activate and hold the auxiliary
power toggle switch and the primary boom
retract toggle switch with the primary boom fully
retracted. Observe the pressure reading on the
pressure gauge. Refer to Section 2,
Specifications.
3 Locate the system relief valve on the function
manifold (item SB). Use a wrench to hold the
relief valve and remove the cap using an allen
wrench.
4 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counter clockwise to
reduce the pressure. Install the relief valve cap.
3 Hold the function enable/rpm select toggle
switch to the high idle position and activate and
hold the boom down toggle switch with the
boom fully lowered. Observe the pressure
reading on the pressure gauge. Refer to
Section 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item SN) on
the function manifold.
5 Adjust the internal hex socket. Turn it clockwise
to increase pressure or counterclockwise to
decrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
6 Repeat steps 2 through 5 and confirm relief
valve pressure.
Component damage hazard. Do
not adjust the relief valve higher
than specified.
5 Repeat step 2 to confirm relief valve pressure.
6 Remove the pressure gauge.
4 - 44
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
How to Adjust the Boom Extend
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 3000 psi / 0 to 200 bar pressure
gauge to the diagnostic nipple (PTEST port) on the
function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high idle position and activate and
hold the boom extend toggle switch with the
boom fully extended. Observe the pressure
reading on the pressure gauge. Refer to
Section 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item SO) on
the function manifold.
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
Part No. 122985
S-80 • S-85 • S-80X
4 - 45
Section 4 • Repair Procedures
September 2015
MANIFOLDS
8-3
Brake/Two-Speed Manifold Components
The brake/two speed manifold is mounted inside the drive chassis.
Index
Schematic
No.
Description
Item
Function
Torque
1
Solenoid valve, 2 position 3 way .... BA ........... Brake release .................................... 20-25 ft-lbs / 27-34 Nm
2
Solenoid valve, 2 position 3 way .... BC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
3
Check valve .................................... BB ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
4
Orifice, 0.025 inch / 0.63 mm ......... BD ........... Turntable rotation brake release
1
BA
4
3
2
BC
BD
BB
4 - 46
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side
of the machine.
Index
No.
Description
Schematic
Item
1
Counterbalance valve, 1000 psi ....... RA ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
2
Counterbalance valve, 1000 psi ....... RB ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
3
Shuttle valve, 2 position 3 way ......... RD ........ Turntable rotation brake release ........ 8-10 ft-lbs / 10-15 Nm
4
Orifice, 0.030 inch / 0.8 mm ............... RC ........ Brake release circuit
Function
2
1
RA
Torque
RB
RD
4
Part No. 122985
RC
S-80 • S-85 • S-80X
3
4 - 47
Section 4 • Repair Procedures
September 2015
MANIFOLDS
8-5
Platform Rotate Manifold Components
The platform rotate manifold is mounted on the platform rotator.
Index
No.
Description
Schematic
Item
Function
Torque
1
Counterbalance valve, 3300 psi ........ PA ......... Platform rotate right .......................... 37-44 ft-lbs / 50-60 Nm
2
Counterbalance valve, 3300 psi ........ PB ......... Platform rotate left ............................. 37-44 ft-lbs / 50-60 Nm
2
1
PB
PA
4 - 48
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-6
Platform Manifold Components, S-80
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 3 position 4 way ...... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm
2
Solenoid valve, 3 position 4 way ...... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm
3
Counterbalance valve, 3500 psi ....... EC ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm
4
Counterbalance valve, 3500 psi ....... ED ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm
5
Needle valve ..................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm
6
Pressure comp., flow control valve ... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm
Function
Torque
EF
EB
6
EE
EC
ED
5
1
2
3
4
EA
Part No. 122985
S-80 • S-85 • S-80X
4 - 49
Section 4 • Repair Procedures
September 2015
MANIFOLDS
8-7
Platform Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 3 position 4 way ....... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm
2
Solenoid valve, 3 position 4 way ....... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm
3
Solenoid valve, 3 position 4 way ....... EH ........ Jib Up/Down ...................................... 30-35 ft-lbs / 41-47 Nm
4
Counterbalance valve, 3500 psi ........ EC ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm
5
Counterbalance valve, 3500 psi ........ ED ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm
Function
Torque
6
Needle valve ...................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm
7
Pressure comp., flow control valve .... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm
8
Pressure comp., flow control valve .... EG ........ Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm
EH
EF
EB
8
6
2
3
EG
EC
7
1
EE
ED
4
5
EA
4 - 50
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-8
2WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index
No.
Description
1
Relief Valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2
Flow Divider / Combiner Valve ......... DB ........ Controls flow to drive motors in
.......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
3
Check Valve ...................................... DC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4
Check Valve ...................................... DD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5
Shuttle Valve, 3 position 3 way ......... DF ......... Controls flow to drive motors in
.......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm
6
Orifice Plug, 0.070 inch / 1.8 mm ...... DA ........ Equalizes flow across flow divider/
.......................................................................... combiner valve BY
Part No. 122985
Schematic
Item
Function
S-80 • S-85 • S-80X
Torque
4 - 51
Section 4 • Repair Procedures
September 2015
MANIFOLDS
1
DE
DB
DC
DD
DF
DA
4 - 52
S-80 • S-85 • S-80X
2
3
4
5
6
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-9
4WD Traction Manifold Components (before serial number 8581)
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index
No.
Description
1
Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
2
Flow divider/combiner valve ............. DB ........ Controls flow to non-steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3
Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
4
Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
5
Flow divider/combiner valve ............. CK ........ Controls flow to flow
divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6
Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
7
Orifice, 0.040 inch / 1 mm .................. DL ......... Equalizes pressure on both sides
of flow divider/combiner valve 5
8
Orifice, 0.040 inch / 1 mm .................. DA ........ Equalizes pressure on both sides
of flow divider/combiner valve 2
9
Orifice, 0.040 inch / 1 mm .................. DN ........ Equalizes pressure on both sides
of flow divider/combiner valve 13
10
Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
11
Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
12
Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13
Flow divider/combiner valve ............. DM ........ Controls flow to steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14
Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
Part No. 122985
Schematic
Item
Function
S-80 • S-85 • S-80X
Torque
4 - 53
Section 4 • Repair Procedures
September 2015
MANIFOLDS
DE
DB
DF
14
13
DP
DC
DM
DK
DD
12
11
10
1
2
3
4
5
6
DJ
DH
DG
DN
9
4 - 54
DL
DA
8
7
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-10
4WD Traction Manifold Components (after serial number 8580)
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index
No.
Description
1
Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
2
Flow divider/combiner valve ............. DB ........ Controls flow to non-steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3
Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
4
Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
5
Flow divider/combiner valve ............. CK ........ Controls flow to flow
divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6
Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
7
Orifice, 0.040 inch / 1 mm .................. DL ......... Equalizes pressure on both sides
of flow divider/combiner valve 5
8
Orifice, 0.040 inch / 1 mm .................. DA ........ Equalizes pressure on both sides
of flow divider/combiner valve 2
9
Orifice, 0.040 inch / 1 mm .................. DN ........ Equalizes pressure on both sides
of flow divider/combiner valve 13
10
Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
11
Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
12
Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13
Flow divider/combiner valve ............. DM ........ Controls flow to steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14
Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
Part No. 122985
Schematic
Item
Function
S-80 • S-85 • S-80X
Torque
4 - 55
Section 4 • Repair Procedures
September 2015
MANIFOLDS
DE
DB
DF
14
13
DC
DP
DD
DM
DK
12
11
10
1
2
3
4
5
6
DJ
DH
DG
DN
9
4 - 56
DL
DA
8
7
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-11
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
No.
Description
1
Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2
Orifice disc, 0.031 inch / 0.8 mm .... CV ........... Delays shift to drive
3
Solenoid valve ............................... CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4
Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5
Pressure switch .............................. CZ ........... Power to relay .............................................. 16 ft-lbs / 22 Nm
6
Connector ........................................ --- ............ For pressure switch ..................................... 11 ft-lbs / 15 Nm
7
Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
7
Schematic
Item
Function
Torque
CY
CU
CV
CW
CX
6
5
1
2
3
4
CZ
Part No. 122985
S-80 • S-85 • S-80X
4 - 57
Section 4 • Repair Procedures
September 2015
MANIFOLDS
4 Start the engine from the platform controls and
drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
8-12
Valve Adjustments Traction Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the
traction manifold) is necessary to return hot oil
from the closed loop drive circuit to the hydraulic
tank for cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap (item BJ). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
6 Repeat steps 4 and 5 until a pressure
differential (between the charge pump reading
and the hot oil shuttle relief valve) of
40 psi / 14.5 bar is obtained.
Note: The following procedure will require two
people.
1 Open the engine side turntable cover and
connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2 Start the engine from the platform controls and
allow the engine to run at low idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 40 bar pressure gauge to the
diagnostic nipple located on the traction
manifold.
4 - 58
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
MANIFOLDS
8-13
Valve Coils
Valve Coil Resistance
Specifications
How to Test a Coil
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite resistance
indicates the coil has failed.
Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / -7.8°C
that your air temperature increases or decreases
from 68°F / 20°C.
Proportional solenoid valve
(schematic items K and W)
4.8 Ω
2 position 3 way solenoid valve
(schematic items D, R, X, TT and UU)
6.3 Ω
2 position 3 way solenoid valve
(schematic items G)
3.3 Ω
3 position 4 way solenoid valve
(schematic items A, E, N and S)
6.3 Ω
2 position 3 way solenoid valve
(schematic items AK, AM, VV and WW)
6.3 Ω
2 position 3 way solenoid valve
(schematic item G)
3.3 Ω
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 122985
S-80 • S-85 • S-80X
4 - 59
Section 4 • Repair Procedures
September 2015
MANIFOLDS
How to Test a Coil Diode
a
AMMETER
COIL
d
-
b
+
c
10 W
RESISTOR
c
9V
BATTERY
b
+
Genie incorporates spike suppressing diodes in all
of its directional valve coils except proportional
valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following the
interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.
-
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
a
b
c
d
multimeter
9V DC battery
10Ω resistor
coil
1 Test the coil for resistance. Refer to, How to
Test a Coil.
Note: Dotted lines in illustration indicate a reversed
connection as specified in step 6.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
4 Connect the negative lead to the other terminal
on the coil.
Note: The battery should read 9V DC or more
when measured across the terminals.
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC
current, should be capable of reading up to 800
mA.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
4 - 60
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Fuel and Hydraulic Tanks
9-1
Fuel Tank
4 Tag, disconnect, drain and plug the supply and
return fuel hoses. Cap the fittings on the fuel
tank.
How to Remove the Fuel Tank
5 Remove the fuel tank retaining fasteners.
Explosion and fire hazard. Engine
fuels are combustible. Remove the
fuel tank in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
6 Remove the fuel tank from the machine.
Component damage hazard.
The fuel tank is plastic and may
become damaged if allowed to fall.
Component damage hazard.
When installing the plastic fuel
tank, do not overtighten the
retaining fasteners.
Note: Clean the fuel tank and inspect for damage
before installing it onto the machine.
1 Turn the manual fuel shutoff valve to the
closed position (if equipped).
2 Remove the fuel filler cap from the tank.
3 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
capacity specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand operated pump
suitable for use with gasoline and diesel fuel.
Part No. 122985
S-80 • S-85 • S-80X
4 - 61
Section 4 • Repair Procedures
September 2015
FUEL AND HYDRAULIC TANKS
2 Close the two hydraulic tank valves located at
the hydraulic tank (if equipped).
9-2
Hydraulic Tank
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the CLOSED position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
The primary functions of the hydraulic tank are to
cool, clean and de-aerate the hydraulic fluid during
operation. The tank utilizes internal suction
strainers for the pump supply hoses and has an
external return filter equipped with a filter condition
indicator.
How to Remove the
Hydraulic Tank
Component damage hazard.
The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the fuel tank. See 9-1, How to Remove
the Fuel Tank.
open
closed
3 Remove the drain plug from the hydraulic tank
and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
4 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank.
5 Tag and disconnect and plug the hose from the
return filter. Cap the fitting on the return filter
housing.
6 Tag and disconnect and plug the supply hose
for the auxiliary power unit. Cap the fitting on
the hydraulic tank.
4 - 62
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
FUEL AND HYDRAULIC TANKS
7 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
hold down straps from the hydraulic tank.
17 Clean up any oil that may have spilled.
18 Open the hydraulic tank shutoff valves
(if equipped).
8 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
Component damage hazard.
Be sure to open the two hydraulic
tank shutoff valves (if equipped)
and prime the pump after installing
the hydraulic tank.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
and secured to the overhead
crane.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
10 Remove the suction strainers from the tank and
clean them using a mild solvent.
11 Rinse out the inside of the tank using a mild
solvent.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
Part No. 122985
S-80 • S-85 • S-80X
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Section 4 • Repair Procedures
September 2015
Turntable Rotation Components
10-1
Turntable Rotation Drive Hub
Assembly
How to Remove the Turntable
Rotation Drive Hub Assembly
B
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
A
a
b
1 Secure the turntable from rotating with the
turntable rotation lock pin.
c
a
b
c
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
5 Remove the backlash pivot plate mounting
bolts. Carefully remove the drive hub assembly
from the machine.
unlocked
Crushing hazard. The turntable
rotation drive hub assembly could
become unbalanced and fall when
it is removed from the machine if
not properly supported.
locked
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Loosen the backlash pivot plate and adjustment
bolts.
4 Attach a suitable lifting device to the lifting eyes
on the drive hub assembly.
4 - 64
When installing the drive hub assembly:
6 Install the drive hub. Apply removable thread
locking compound to fastener threads.Torque
the backlash pivot plate mounting fasteners to
specification. Refer to Section 2, Machine
Torque Specifications.
7 Install the brake and then the motor onto the
drive hub. Apply removable thread locking
compound to fastener threads.Torque the
motor/brake mounting fasteners to
specification. Refer to Section 2, Machine
Torque Specifications.
8 Adjust turntable rotation gear backlash.
See 10-1, How to Adjust the Turntable Rotation
Gear Backlash.
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable
Rotation Hydraulic Motor
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
a
B
A
1 Secure the turntable from rotating with the
turntable rotation lock pin.
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
c
a
b
c
b
motor
drive hub mounting bolts
drive hub with brake
3 Remove the hydraulic tube that connects from
the counterbalance manifold to the brake. Cap
the fittings on the brake and manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 Remove the motor/brake mounting fasteners.
Carefully remove the motor from the brake.
5 Clean up any oil that may have spilled.
Part No. 122985
S-80 • S-85 • S-80X
4 - 65
Section 4 • Repair Procedures
September 2015
TURNTABLE ROTATION COMPONENTS
How to Adjust the Turntable
Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor pinion gear and the turntable bearing
ring gear.
Note: Perform this procedure with the boom
between the non-steer end tires and with the
machine on a firm and level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Loosen the backlash pivot plate mounting
fasteners.
B
A
3 Push the backlash pivot plate towards the
turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt one half turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Then torque the mounting fasteners on the
backlash pivot plate. Refer to Section 2,
Specifications.
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
a
b
c
a
b
c
4 - 66
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
2WD Steer Axle Components
11-1
Yoke and Hub
How to Remove the Hub
and Bearings
1 Loosen the wheel lug nuts. Do not remove
them.
How to Remove the Yoke
and Hub
1 Remove the pin retaining fasteners from both
the steering cylinder and the tie rod cylinder
pivot pins. Use a soft metal drift to remove the
pins.
2 Block the non-steer wheels and center a lifting
jack of ample capacity under the steer axle.
3 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
2 Loosen the wheel lug nuts. Do not remove
them.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
3 Block the non-steer wheels and center a lifting
jack of ample capacity under the steer axle.
5 Remove the dust cap, cotter pin and castle nut.
4 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
6 Remove the pin retaining fasteners from the
yoke pivot pins.
Note: Always replace the cotter pin with a new one
when installing the castle nut.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
7 Support and secure the yoke and hub assembly
to a lifting jack.
8 Use a slide hammer to remove the upper yoke
pivot pin, then use a soft metal drift to drive the
lower yoke pivot pin down and out.
9 Remove the yoke and hub assembly from the
machine.
Crushing hazard. The yoke and
hub assembly may become
unbalanced and fall if not properly
supported and secured to the
lifting jack when it is removed from
the machine.
Part No. 122985
S-80 • S-85 • S-80X
4 - 67
Section 4 • Repair Procedures
September 2015
2WD STEER AXLE COMPONENTS
How to Install the Hub and
Bearings, 2WD Models
11-2
Steer Cylinder
Note: When replacing a wheel bearing, both the
inner and outer bearings including the pressed-in
races must be replaced.
How to Remove a
Steer Cylinder
1 Be sure that both bearings are packed
with clean, fresh grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub
until it is flush.
4 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
5 Place the outer bearing into the hub.
6 Install the washer and castle nut.
There are two identical steer cylinders that
work in parallel. They are part of the same
hydraulic circuit, but move in opposite directions.
The tie rod cylinder maintains equal movement of
the tires.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearing.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
8 Loosen the castle nut one turn, and then torque
to 35 ft-lbs / 47 Nm.
9 Install a new cotter pin. Bend the cotter pin
to secure the castle nut.
Note: Always use a new cotter pin when installing
a castle nut.
2 Remove the pin retaining fasteners from the
steer cylinder pivot pins. Remove the pivot pin
from each end of the steer cylinder.
3 Remove the steer cylinder from the machine.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
4 - 68
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
4WD Steer Axle Components
6 Remove the lug nuts. Remove the tire and
wheel assembly.
12-1
Yoke and Drive Hub
7 Remove the hydraulic hose clamp retaining
fastener from the top of the yoke pivot pin.
How to Remove the Yoke
and Drive Hub Assembly
8 Remove the drive motor mounting fasteners.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the pin retaining fasteners from both
the steer cylinder and the tie rod cylinder pivot
pins. Remove the pins.
9 Slide the drive motor shaft out of the drive hub
and remove the drive motor from the machine.
10 Remove the pin retaining fasteners from the
upper and lower yoke pivot pins.
11 Support and secure the yoke and drive hub
assembly to a lifting jack.
12 Use a slide hammer to remove the upper yoke
pivot pin. Use a soft metal drift to drive the
lower yoke pivot pin down and out.
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
drive motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Loosen the wheel lug nuts. Do not remove
them.
4 Block the non-steer wheels, and center a lifting
jack of ample capacity under the steer axle.
Crushing hazard. The yoke and
drive hub assembly could become
unbalanced and fall when the yoke
pivot pins are removed if not
properly supported and secured to
the lifting jack.
13 Place the yoke and drive hub assembly on a flat
surface with the drive hub facing down.
14 Remove the drive hub mounting fasteners that
attach the drive hub to the yoke. Remove the
yoke from the drive hub. Refer to
Section 2, Specifications.
Note: Replace the thrust washer when installing
the yoke and drive hub assembly onto the axle.
5 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
Part No. 122985
S-80 • S-85 • S-80X
4 - 69
Section 4 • Repair Procedures
September 2015
4WD STEER AXLE COMPONENTS
3 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
drive motor.
12-2
Drive Motor
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
How to Remove a Drive Motor
Component damage hazard.
Repairs to the motor should only
be performed by an authorized
Sauer dealer.
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
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.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Extend the axles.
2 Remove the drive motor access covers from
both sides of the inner axle.
4 - 70
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
4WD STEER AXLE COMPONENTS
12-3
Drive Hub
12-4
Steer Cylinders
How to Remove a Drive Hub
How to Remove a Steer Cylinder
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
There are two identical steer cylinders that
work in parallel. They are part of the same
hydraulic circuit, but move in opposite directions.
The tie rod cylinder maintains equal movement of
the tires.
1 Remove the drive motor. See 12-2, How to
Remove a Drive Motor.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Center a lifting jack of ample capacity under the
non-steer axle.
4 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Tag, disconnect and plug the hydraulic hoses
from the steer cylinder. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5 Remove the wheel lug nuts, then the tire and
wheel assembly.
6 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
lifting jack.
7 Remove the drive hub mounting fasteners that
attach the drive hub to the axle. Remove the
drive hub.
Crushing hazard. The drive
hub could become unbalanced
and fall if not properly supported
and secured to the lifting jack
when removed from the machine.
2 Remove the hose bracket mounting fastener on
the steer cylinder barrel-end pivot pin.
3 Remove the pin retaining fasteners from the
steer cylinder pivot pins. Remove the pivot pin
from each end of the steer cylinder.
4 Remove the steer cylinder from the machine.
Note: Do not re-use the drive hub mounting
fasteners. Genie specifications require the use of
new fasteners.
Part No. 122985
S-80 • S-85 • S-80X
4 - 71
Section 4 • Repair Procedures
September 2015
Non-steer Axle Components
13-1
Drive Motor
13-2
Drive Hub
How to Remove a Drive Motor
How to Remove a Drive Hub
This procedure is the same as the steer axle
procedure. See 12-2, How to Remove a Drive
Motor.
This procedure is the same as the steer axle
procedure. See 12-3, How to Remove a Drive Hub.
4 - 72
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
Oscillating Axle Components
3 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
14-1
Oscillate Axle Cylinders
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
The oscillating axle cylinders extend and retract
between the drive chassis and the axle to maintain
a level chassis while driving over uneven terrain.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic hose failure.
How to Remove an Oscillate Axle
Cylinder
Note: Perform this procedure on firm, level surface
with the boom in the stowed position.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
4 Remove the pin retaining fasteners from the
rod-end pivot pin. Use a soft metal drift to
remove the pin.
5 Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
6 Remove the pin retaining fasteners from the
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
7 Remove the cylinder from the machine.
1 Rotate the turntable until the boom is between
the steer tires.
2 Remove the fasteners from the drive chassis
cover at the steer end. Remove the cover.
Part No. 122985
S-80 • S-85 • S-80X
Crushing hazard. The oscillate
cylinder could become unbalanced
and fall if not properly attached to
the overhead crane when
removed from the machine.
4 - 73
Section 4 • Repair Procedures
September 2015
OSCILLATING AXLE COMPONENTS
4 Start the engine from the ground control.
14-2
Oscillate Directional Valve
5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge. Refer to Section 2,
Specifications.
How to Adjust the Oscillate
Relief Valve Pressure
6 Turn the engine off.
1 Connect a 0 to 2000 psi / 0 to 150 bar pressure
gauge to the diagnostic nipple located on the
function manifold.
2 Remove the drive chassis cover from the nonsteer end of the machine.
3 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis. Refer to illustration 1.
7 Locate the relief valve on the function manifold
(item SC).
8 Loosen the jam nut on the relief valve.
9 Turn the valve clockwise to increase the
pressure or counterclockwise to decrease the
pressure.
Tip-over hazard. Do not adjust the
relief valve higher than specified.
10 Tighten the jam nut.
11 Repeat steps 4 through 10 to confirm the
oscillate relief valve pressure.
Note: The oscillate pressure required is while the
oscillate cylinders are in motion. Do not dead head
the cylinders to either side.
a
12 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
13 Install the cover on the non-steer end of the
drive chassis.
b
c
a
b
c
4 - 74
oscillate valve
clevis yoke
drive chassis
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 4 • Repair Procedures
OSCILLATING AXLE COMPONENTS
How to Set Up the Directional
Valve Linkage
8 Verify that the ground and drive chassis are
completely level.
Note: Perform this procedure on a firm, level
surface.
9 Loosen the jamb nuts and adjust the length of
the rod by turning the clevis yoke until the
clevis yoke can be pinned to the axle.
1 Lower the boom to the stowed position.
10 Install the cotter pin and tighten the jamb nuts.
2 Use a "bubble type" level to be sure the surface
the machine is on is completely level.
11 Measure the gap between the drive chassis and
the non-steer axle on both sides (from the inside
of the drive chassis).
Tip-over hazard. Failure to
perform this procedure on a firm,
level surface will compromise the
stability of the machine and could
result in the machine tipping over.
3 Check the tire pressure in all four tires and add
air if needed to meet specification.
Result: The measurements should be equal.
Note: The gap on both sides should be between
0.150 inch / 0.381 cm and 0.170 inch / 0.432 cm.
12 Add or remove shims between the oscillation
stop bar and the drive chassis to achieve the
proper gap.
4 Remove the drive chassis cover from the
non-steer end of the machine.
5 Disconnect the linkage clevis yoke from the
axle.
6 Place a "bubble type" level on the turntable
rotate bearing plate at the non-steer end.
Confirm whether the drive chassis is completely
level.
7 If the drive chassis is not level, start the engine
and push up or pull down on the linkage
adjustment rod until the machine is completely
level.
Part No. 122985
S-80 • S-85 • S-80X
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Section 4 • Repair Procedures
September 2015
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S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the 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.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 122985
S-80 • S-85 • S-80X
5-1
Section 5 • Fault Codes
September 2015
FAULT CODES
Fault Codes - Control System
How to Retrieve Control
System Fault Codes
Note: At least one fault code is present when the
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine
off, the key switch turned to platform controls
and both red Emergency Stop button pulled out
to the on position at both the ground and
platform controls.
1 Open the platform control box lid.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform
control box. Do not touch the circuit board.
3 Determine the error source: The red LED
indidates the error source and will flash two
separate codes. The first code will indicate
the first digit of the two digit code, flashing
once per second. It will then pause for 1.5
seconds and flash the second digit once per
0.5 second.
Note: When the red LED is flashing the code, the
yellow LED will be on solid.
4 Determine the error type: The yellow LED
indidates the error type and will flash two
separate codes. The first code will indicate
the first digit of the two digit code, flashing
once per second. It will then pause for 1.5
seconds and flash 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
pages to aid in troubleshooting the machine
by pinpointing the area or component
affected.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit
board components. If the circuit
board does need to be handled,
maintain firm contact with a
metal part of the machine that is
grounded at all times when
handling the printed circuit board
OR use a grounded wrist strap.
5-2
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 5 • Fault Codes
FAULT CODES
Error Source
Error Type
Condition
Solution
ID
Name
ID
Name
21
Primary
Up / Down
Joystick
11
12
15
16
17
Value at 5V
Value too high
Value too low
Value at 0V
Not calibrated
Function is
inoperative.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
Calibrate joystick.
22
Primary
Up / Down
Directional
Valves
21
Fault
Valve is operating
outside of limits.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
correted.
23
Primary
Up / Down
Flow Valve
12
15
Value too high
Value too low
17
Not calibrated
Valve is operating
outside of limits.
Alarm sounds
indicating a fault.
Normal function
except threshold
for one or both
directions is zero.
Cycle power off,
then on after
problem has been
corrected.
Calibrate valve
threshold.
Reduced speed
function.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
Calibrate angle sensor.
24
Angle sensor
11
12
15
16
17
31
Value at 5V
Value too high
Value too low
Value at 0V
Not calibrated
Invalid setup
26
Angle sensor
cross check
(S-80X)
19
Out of range
Continued on next page
Part No. 122985
S-80 • S-85 • S-80X
5-3
Section 5 • Fault Codes
September 2015
FAULT CODES
Error Source
Error Type
Condition
Solution
ID
Name
ID
Name
31
Primary
Ext. / Ret.
Joystick
11
12
15
16
17
Value at 5V
Value too high
Value too low
Value at 0V
Not calibrated
Function is
inoperative.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
Calibrate joystick.
32
Primary
Ext. / Ret.
Directional
Valves
21
Fault
Valve is operating
outside of limits.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
correted.
33
Primary
Ext. / Ret.
Flow
Valve
12
15
Value too high
Value too low
17
Not calibrated
Valve is operating
outside of limits.
Alarm sounds
indicating a fault.
Normal function
except threshold
for one or both
directions is zero.
Cycle power off,
then on after
problem has been
corrected.
Calibrate valve
threshold.
Limited speed
and direction
frozen at zero
and neutral.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
34
Ext. Ret.
Limit Switch
Cross Check
31
Invalid setup
41
Turntable
Rotate
Joystick
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
5-4
S-80 • S-85 • S-80X
Calibrate joystick.
Part No. 122985
September 2015
Section 5 • Fault Codes
FAULT CODES
Error Source
Error Type
Condition
Solution
ID
Name
ID
Name
42
Turntable
Rotate
Directional
Valves
21
Fault
Limited direction.
Frozen at zero
and neutral.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
43
Turntable
Rotate
Flow Valve
12
15
Value too high
Value too low
Cycle power off,
then on after
problem has been
correted.
17
Not calibrated
Limited speed
and direction.
Frozen at zero
and neutral.
Alarm sounds
indicating a fault.
Normal function
except threshold
for one or both
directions is zero.
Calibrate valve
threshold.
44
Drive Enable
Override
Switch
21
Fault
Drive enable
override direction
is frozen at
neutral.
Cycle power off,
then on after
problem has been
corrected.
51
Drive Joystick
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 a fault.
Cylcle power off,
then on after
problem has been
corrected.
17
Not calibrated
Calibrate joystick.
Continued on next page
Part No. 122985
S-80 • S-85 • S-80X
5-5
Section 5 • Fault Codes
September 2015
FAULT CODES
Error Source
Error Type
ID
Name
ID
Name
53
Drive Flow
Valve (EDC)
12
15
Value too high
Value too low
Frozen at zero
and neutral.
17
Not calibrated
Condition
Solution
Limited speed
and direction.
problem has been
corrected.
Alarm sounds
indicating a fault.
Normal function
except threshold
for one or both
directions is zero.
Cycle power off,
then on after
Calibrate valve
threshold.
54
Drive Brake
Valve
21
Fault
Drive frozen
at zero and
neutral.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
correted.
55
High Drive
Motor Speed
Valve
21
Fault
Motor speed
in the low state.
Alarm sounds
indicating a fault.
Cycle power off,
then on after
problem has been
corrected.
61
Steer Joystick
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 a fault.
Cylcle power off,
then on after
problem has been
corrected.
17
Not calibrated
21
Fault
62
5-6
Steer
Directional
Valve
Calibrate joystick.
Limited speed
and direction.
Frozen at zero
and neutral.
Alarm sounds
indicating a fault.
S-80 • S-85 • S-80X
Cycle power off,
then on after
problem has been
corrected.
Part No. 122985
September 2015
Section 5 • Fault Codes
FAULT CODES
Continental Engine Models
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
How to Retrieve Continental
Engine Fault Codes
Note: Before the fault codes are displayed, the
check engine light will blink a code 1654 three
times. After the fault codes, the check engine
light will blink a code 1654 three times again
indicating the end of the stored codes.
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest
efficiency while at the same time keeping
exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code
in memory that relates to the appropriate sensor
and will turn on the Check Engine Light.
Note: Perform this procedure with the key switch
in the off position.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of
the ground control box.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
4 Move and hold the run/test toggle switch to
the test position.
Note: If any fault codes are present, the ECM will
blink a three or four digit code three times for
each code stored in memory. It will blink the first
digit of a three digit code, pause, blink the
second digit, pause, blink the third digit, then
pause and possibly a fourth digit. For example:
the check engine light blinks 5 consecutive
times, blinks 3 times and then 1 time. That would
indicate code 531.
Note: Once a fault code has been retrieved and
the repair has been completed, the ECM
memory must be reset to clear the fault code
from the ECM. See How to Clear Engine Fault
Codes from the ECM.
How to Clear Engine Fault
Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and
locate the battery.
2 Disconnect the negative battery cable from
the battery for a minimum of 5 minutes.
Result: The check engine light should turn on.
The check engine light should begin to blink.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
Part No. 122985
S-80 • S-85 • S-80X
5-7
Section 5 • Fault Codes
September 2015
IAT
BP
118
117
116
217
ECT Voltage High
ECT Voltage Low
ECT higher than expected 1
ECT higher than expected 2
113
112
111
127
IAT Voltage High
IAT Voltage Low
IAT higher than expected 1
IAT higher than expected 2
Low Rev Limit
Power Derate 2
Power Derate 1
Y Y
107 MAP Voltage Low
ECT/
CHT
Adaptive Learn KC*
Code Fault Name
108 MAP Pressure High
Adaptive Learn
System
MAP
Shutdown
FAULT CODES
Y Y
Fault Conditions
MAP pressure > 16 psi and TPS < 10%
and RPM > 1800
To Unlatch, MAP pressure must be < 10 psi
MAP voltage < 0.05 vdc and TPS > 2%
and RPM < 7000
To Unlatch, MAP voltage must be > 0.5 vdc
Y
Y
Y Y Y
ECT voltage > 4.95 vdc
ECT voltage < 0.05 vdc
ECT > 210° F and RPM > 600
ECT > 230° F and RPM > 600
Y
Y
Y
IAT voltage > 4.95 vdc
IAT voltage < 0.05 vdc
IAT > 200° F and RPM > 1000
IAT > 210° F and RPM > 1000
Y
Y
Y
2229 BP Pressure High
129 BP Pressure Low
Y Y
Y Y
BP pressure > 16 psi
BP pressure < 8.3 psi
Battery
Voltage
563 Voltage High
562 Voltage Low
Y Y
Y Y
Voltage > 18 vdc
Voltage < 9.5 vdc and RPM > 1500
5V
External
643 5VE1 High Voltage
642 5VE1 Low Voltage
Y
Y
5VE1 > 5.4 vdc
5VE1 < 4.6 vdc
TPS
123
122
223
222
221
121
2112
2111
2135
TPS1 High Voltage
TPS1 Low Voltage
TPS2 High Voltage
TPS2 Low Voltage
TPS1 > than TPS2
TPS1 < than TPS2
Unable to reach > TPS
Unable to reach < TPS
TPS1/2 simultaneous
voltages out of range
Y
Y
Y
Y
Y
Y
Y
Y
Y
TPS1 voltage > 4.8 vdc
TPS1 voltage < 0.2 vdc
TPS2 voltage > 4.8 vdc
TPS2 voltage < 0.2 vdc
(TPS1 percent - TPS2 percent) > 20%
(TPS1 percent - TPS2 percent) < -20%
(target TPS - actual TPS) > 20%
(target TPS - actual TPS) < -20%
Uses same parameters as individual
TPS1/2 voltage fault detection above
* Adaptive Learn Key Cycle
5-8
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 5 • Fault Codes
219 Max Govern Speed Override
1111 Rev Fuel Limit
1112 Spark Rev Limit
Y
Oil
Pressure
524 Oil Pressure Low
Y
Adaptive
Learn
171 AL High Gasoline Bank 1
Engine
Speed
Oil pressure pulled-up input with a
threshold voltage of 2.5 vdc and
RPM > 500 and run-time > 30 s
AL_BM > 30% and RPM between 0-9999
and MAP between 0-99 psi
AL_BM < -30% and RPM between 0-9999
and MAP between 0-99 psi
AL_BM > 30% and RPM between 0-9999
and MAP between 0-99 psi
AL_BM < -30% and RPM between 0-9999
and MAP between 0-99 psi
1161 AL High LPG
1162 AL Low LPG
1155 CL High Gasoline Bank 1
CL_BM > 40% and RPM between 0-9999
and MAP between 0-99 psi
CL_BM <-40% and RPM between 0-9999
and MAP between 0-99 psi
CL_BM > 35% and RPM between 0-9999
and MAP between 0-99 psi
CL_BM < -35% and RPM between 0-9999
and MAP between 0-99 psi
1156 CL Low Gasoline Bank 1
1151 CL High LPG
1152 CL Low LPG
Catalyst
Monitor
Fault Conditions
Y FPP1 voltage > 4.8 vdc
Y FPP1 voltage < 0.2 vdc
RPM > 3400
RPM > 3600
RPM > 3800
172 AL Low Gasoline Bank 1
Closed
Loop
Low Rev Limit
Power Derate 2
Power Derate 1
Adaptive Learn KC*
Code Fault Name
2122 FPP1 High Voltage
2123 FPP1 Low Voltage
Adaptive Learn
System
FPP
Shutdown
FAULT CODES
420 Gasoline Cat Monitor
Y
Y
1165 LPG Cat Monitor
Y
Y
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
EGO2 RMS > 0.005 phi and EGO2
RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
* Adaptive Learn Key Cycle
Continued on next page
Part No. 122985
S-80 • S-85 • S-80X
5-9
Section 5 • Fault Codes
September 2015
Injectors
261 Injector Loop Open or
Low-Side Short to Ground
262 Injector Coil Shorted
Power
Relay
Control
Coil
686 Relay Control Ground Short
685 Relay Coil Short
687 Relay Coil Short to Pwr
Tach
Output
2618 Tach Output Ground Short
2619 Tach Output Short to Pwr
EPR
1171 EPR Delivery Pressure
> than expected
1172 EPR Delivery Pressure
< than expected
1173 EPR Comm Lost
1174 EPR Voltage Supply High
1175 EPR Voltage Supply Low
1176 EPR Internal Actuator
fault detection
1177 EPR Internal Circuitry
fault detection
1178 EPR Internal Comm
fault detection
Diagnostics
LPG
Low Rev Limit
Power Derate 2
Power Derate 1
Adaptive Learn KC*
Adaptive Learn
System
Code Fault Name
EGO
134 EGO Open/Lazy Pre-cat 1
Sensors 154 EGO Open/Lazy Post-cat 1
Shutdown
FAULT CODES
Y Y
Y Y
Fault Conditions
EGO cold persistently > 120 seconds
EGO cold persistently > 120 seconds
Injector off-state low-side < 4 vdc
and battery voltage > 9 vdc
Injector on-state low-side > 4 vdc
and battery voltage < 16 vdc
Y Y Y
Y Y Y
Does not turn on MIL
Does not turn on MIL
Y
Y
MJ actual-commanded press > 4 in. H20
Y
Y
MJ actual-commanded press < 4 in. H20
Y
Y
Y
Y
Y
Y
Y
Y
No MJ packets received within 500 ms
Y
Y
Y
Y
* Adaptive Learn Key Cycle
5 - 10
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 5 • Fault Codes
336 Crank Sync Noise
16
Internal
606
Processor 1612
Diagnostics 1613
1614
1615
1616
601
604
J1939
Network
1625
1626
1627
1628
Y Y
Y Y
Y Y
Never Crank Synced
at Start
COP Failure
RTI 1 Loss
RTI 2 Loss
RTI 3 Loss
A/D Loss
Invalid Interrupt
Flash Checksum Invalid
RAM Failure
Y
Y
Y
Y
Y
Y
Y
Y
Low Rev Limit
Power Derate 2
Power Derate 1
Adaptive Learn KC*
Adaptive Learn
System
Code Fault Name
Cam
342 Cam Loss
Crank
337 Crank Loss
Sensors
341 Cam Sync Noise
Shutdown
FAULT CODES
Fault Conditions
No cam pulse in 4 cycles and RPM > 1000
Cam pulses without crank activity
> 6 cam pulses
Number of invalid cam re-syncs = 1
within a time window of <= 700 ms
Number of invalid crank re-syncs = 1
within a time window of <= 800 ms
Cranking revs without sync < 4 revs
and RPM > 90 rpm
Y
Y
Y
Y
Y
Y
Y
Y
Shutdown Request
CAN Tx Failure
CAN Rx Failure
Number of shutdown requests >= 1
TX error counter > 100
Rx error counter > 100
Address conflict counter > 5
CAN Address Conflict Failure
* Adaptive Learn Key Cycle
Part No. 122985
S-80 • S-85 • S-80X
5 - 11
Section 5 • Fault Codes
September 2015
This page intentionally left blank.
5 - 12
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 122985
S-80 • S-85 • S-80X
6-1
Section 6 • Schematics
September 2015
Electrical Symbols Legend
FS1
BLK
BLK
P3
WHT
Quick disconnect
terminal
N.O.H.C
Coil
solenoid or relay
N.C.H.O
Limit switch
Horn button
normally open
P1
KS1
TB21
WHT #21
Foot switch
LS3
PLATFORM
OTS2
N.O.
GROUND
T-circuits connect
at terminal
H1
Horn or alarm
Key switch
Oil temperature
switch
normally open
T-circuits
connect
Emergency Stop
button normally
closed
FAN
FB
PR1
CTS1
N.O.
Flashing beacon
Power relay
Coolant temperature
switch
normally open
Connection
no terminal
G1
TS2
START
ENGINE
Gauge
Aux
Pump
Auxiliary pump
OPS1
N.C.
Circuits crossing
no connection
510
HM
Diode
Hydraulic oil
cooling fan
Toggle switch SPDT
Oil pressure switch
normally closed
Resistor with
ohm value
Hour meter
TS6
+
PLATFORM LEVEL
-
LED
25A
AUX MAIN
Fuse
with amperage
Battery separator
Tilt sensor
Toggle switch DPDT
A
CR4
N.O.
Control relay contact
normally open
B
C
HOLD
F1
Gauge sending unit
PULL IN
Battery
UP
DOWN
L3
Fuel or RPM
solenoid
CB1
15A
Circuit breaker
with amperage
6-2
Starting aid:
glow plug or
flame ignitor
Coil
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 6 • Schematics
Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
.035"
(0.89 mm)
Filter with
bypass valve
relief setting
Solenoid operated
proportional valve
Orifice with size
Shut off valve
Solenoid operated 3 position,
4 way, directional valve
2 position, 3 way, shuttle valve
Pump
fixed displacement
Priority
flow regulator valve
Check valve
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump
bi-directional,
variable displacement
Solenoid operated 2 position,
3 way, directional valve
Relief valve
with pressure setting
3000 psi
(206.8 bar)
3:1
o
Brake
Motor
bi-directional
Directional valve
(mechanically activated)
Counterbalance valve
with pressure and pilot ratio
Pilot operated 3 position,
3 way, shuttle valve
Motor
2-speed,
bi-directional
E
Pump prime mover
(engine or motor)
2 position, 2 way
solenoid valve
50%
50%
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Differential
sensing valve
Part No. 122985
S-80 • S-85 • S-80X
6-3
Section 6 • Schematics
September 2015
This page intentionally left blank.
6-4
S-80 • S-85 • S-80X
Part No. 122985
Section 6 • Schematics
September 2015
Connector Pin Legend - View 1
6-5
6-6
Section 6 • Schematics
September 2015
Connector Pin Legend - View 1
A
B
C
C1 DT06-12SA
1
2
COLOR
RD
RD/BK
RD/WH
WH
WH/BK
WH/RD
BK
BK/WH
BK/RD
BL
BL/BK
BL/WH
BL/WH
CIRCUIT #
C27AUX
C28TTA
C29MS
C30EDC+
C31EDCC32BRK
C33STR
C34SA
C35RPM
C36STC
C37STCC
C132PLI1
C177LS
D
E
F
G
C1
GRAY
(CE MODEL)
(S-80X MODEL)
C2 DT06-12SB
4
5
CIRCUIT #
C39LP
C40LS
C41RPM
C42LS
C46HRN
P134PWR
C45GEN
C123PBS
P109ANG
SNSR GND
PLUG
PLUG
I
J
C3 DT06-12SC
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
12
COLOR
RD
RD/BK
RD/WH
WH
WH/BK
WH/RD
BK
BK/WH
BK/RD
BL
BL/BK
BL/WH
BL/WH
CIRCUIT #
C1PBU
C2PBD
C3PBF
C4TRL
C5TRR
C6TRF
C7PBE
C8PBR
C9PERF
C132PLI2
C59CNK
C133PLA
P109LS
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
12
C6
FUNCTION MANIFOLD
C3
GREEN
(CE MODEL)
(CE MODEL)
(S-80X MODEL)
C4 DT06-12SD
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
C2
BLACK
COLOR
BL/RD
OR
OR/BK
OR/RD
GR
GR/BK
GR/WH
RD/OR
OR/GR
LT BR
-
CIRCUIT #
C13DRE
C14PLU
C15PLD
V155PCE
C17PRL
C18PRR
C43JU
C44JD
C49DLITE
SPARE
PLUG
PLUG
K
L
M
N
C5
ENGINE
3
COLOR
BL/RD
OR
OR/BK
OR/RD
GR
GR/BK
GR/WH
GR/RD
OR/WH
LT BR
-
H
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
6
7
8
C4
BROWN
DEUTZ
2011L04i
CONTINENTAL
TME27
PERKINS
804
PIN# CIRCUIT # COLOR CIRCUIT # COLOR CIRCUIT # COLOR
PIN# CIRCUIT #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
C1PBU
C2PBD
C3PBF
C4TRL
C5TRR
C6TRF
C7PBE
C8PBR
C9PERF
COLOR
RD
RD/BK
RD/WH
WH
WH/BK
WH/RD
BK
BK/WH
BK/RD
C59CNK
P210PWR
C13DRE
BL/BK
BK
BL/RD
(S-80X MODEL)
C109LS
GR/WH
(S-80X MODEL)
C177LS
C42LS
P134PWR(A)
P134PWR(B)
P134PWR(C)
BL/RD
OR/RD
RD
RD
RD
C28TTA
RD/BK
C211LO
C118LSR
BL/BK
OR
C123PBS
SNSR GND
P109ANG
C36STC
C37STCC
C212LO
C45GEN
C40LS
RD/BK
BR
GR/WH
BL
BL/BK
GR/BK
GR/WH
OR
(S-80X MODEL)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
P24PWR
C41RPM
C21IGN
RD
OR/BK
WH
P24PWR
C41RPM
C21IGN
RD
OR/BK
WH
C33STR BK
C27AUX RD
C46HRN GR
C33STR
C27AUX
C46HRN
BK
RD
GR
R21IGN
R21IGN
WH(14)
P23PWR
C41RPM
C33STR
C27AUX
C46HRN
C127TSW
C35RPM
C39LP
WH(14) R21IGN
C24TSPS WH
C24TSPS WH
C35RPM BK/RD
V155PCE OR/RD
C31EDC- WH/BK
C30EDC+ WH
C34SA
BK/WH
C32BRK WH/RD
C29MS RD/WH
C35RPM
V155PCE
C31EDCC30EDC+
C34SA
C32BRK
C29MS
BK/RD
OR/RD
WH/BK
WH
BK/WH
WH/RD
RD/WH
WH
OR/BK
BK
RD
GR
GR
BK/RD
BL/RD
WH(14)
C108ESL
BL/WH
P24PWR
RD
R24PWR
RD
V155PCE OR/RD
C31EDC- WH/BK
C30EDC+ WH
C32BRK
C29MS
WH/RD
RD/WH
(S-80X MODEL)
C7
C9
(S-80X MODEL)
12V POWER TO PLAT
FOOTSWITCH
C7 DTP06-4S
C9 FS DT04-4P
COLOR CIRCUIT # PIN #
COLOR CKT #
BK
WH
BR
BK
WH
RD
P22PWR
P23PWR
BATGND
PLUG
1
2
3
4
P26ESTP
P24FS
P25FS
PLUG
PIN #
1
2
3
4
ES0507C
6-6
S-80 • S-85 • S-80X
Part No. 122985
September 2015
Section 6 • Schematics
Connector Pin Legend - View 2
N
M
L
K
J
I
ALC500
POWER/VALVE INPUT
CIRCUIT #
GND
P24FS
P26ESTP
P24FS
COLOR
BR
WH
BK
WH
J3
ALC500
INPUT
C
DEUTZ 2011LO4i
ENGINE PLUG
CIRCUIT #
R23PWR
C21RET
C38RET
C38FP
R33STR
C41RPM
R21IGN
C35RPM
C108ESL
C127TSW
C39LP
C26TSR
PIN# CIRCUIT #
1
C41RPM
2
C107AF
C26TSR
3
C24TS
4
5
C25PSR
6
C24PS
R21IGN
7
8
GND
9
10
COLOR
WH
WH
BL
BL/WH
BK(14)
OR/BK
WH
BK/RD
BL/WH
GN
BL/RD
WH/RD
C14
GRAY
B
A
1
COLOR
OR/BK
WH
WH/RD
WH
WH/BK
WH
WH(14)
BR
-
J144
2
(GAUGE OPTION)
3
1
PLATFORM MANIFOLD
S-80X MODEL
WIRE
J8
1
GR/WH
WH
BL
GR/WH
BL/RD
BR
GR
6
CIRCUIT #
P109LS
C184PL
NC
NC
C169LED2
P109LS
C177LS
SNSR GND
NC
C169LED1
5
PIN#
1
2
3
4
5
6
7
8
9
10
10
J2
20
J22
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
DT04-12PA
CIRCUIT #
GND
GND
C18PRR
C17PRL
C43JU
C44JD
C14PLU
C15PLD
GND
GND
GND
GND
COLOR
BR
BR
GR/BK
GR
GR
GR/BK
OR
OR/BK
BR
BR
BR
BR
5
J22
6
7
8
1
11
COLOR
OR
RD/BK
BL/RD
OR/RD
OR/BK
RD
RD/BK
RD/WH
WH
WH/BK
WH/RD
BK
BK/WH
BK/RD
WH
WH/BK
BL
BL/BK
WH/RD
RD/WH
D
4
10
CIRCUIT #
C40LS
C123PBS
C13DRE
C42LS
C41RPM
C1PBU
C2PBD
C3PBF
C4TRL
C5TRR
C6TRF
C7PBE
C8PBR
C9PERF
C30EDC+
C31EDCC36STC
C37STCC
C32BRK
C29MS
E
J1
ALC500
OUTPUT
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
F
8
COLOR
WH/RD
RD/WH
WH/BK
WH/RD
BL/WH
BL/WH
BL/BK
RD/WH
GR/WH
BR
OR
BR
OR
BR
RD/BK
BL/RD
9
CIRCUIT #
C165TRS
C164PES
C163PLS
C160JPL
C159STC
C144DER
C143DEL
C29MS
P109ANG
SNSR GND
P162JPW2
JSGND2
P162JPW1
JSGND1
C28TTA
C13DRE(A)
16
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
G
CONTINENTAL TME27
ENGINE PLUG
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
2 1
4 3
PIN#
1
2
3
4
H
ES0507C
Part No. 122985
S-80 • S-85 • S-80X
6-7
September 2015
Section 6 • Schematics
Connector Pin Legend - View 2
6-7
6-8
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04i Models
6-9
6 - 10
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04i Models
A
B
C
D
E
F
G
H
I
J
K
P2
FS1
C9P-1
BK
C28TTA RD/BK
P26ESTP BK
P26ESTP BK
LOW
P22PWR BK
+
H1
-
V155PCE OR/RD
TS4
ENGINE
RPM
HIGH
C7-1
D12
L48
C4-4
C1-9
C1-8
C1-7
C1-1
C7-2
C1-2
C3-12
C2-5
TB132
1
D64
C35RPM BK/RD
U16
NO
LOW
TIMER 30
RD
TB33
D67
D2
P134PWR RD
C41RPM OR/BK
C27AUX + FE RD
C27AUX RD
D13
TB155
TB35
TB27
TB23
D68
D4
TB34
WH
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
RD
GR/BK
GBOX
GROUND
TS54
ENG.
RPM
P4
FUNC. ENABLE
HIGH
TB28
C34SA BK/WH
8
C32
TS56
GLOW
PLUG
C33STR BK
12
TS52
ENGINE
START
C27AUX RD
TB133
WH
7
AUXILIARY
PUMP
TB20
TS51
P23PWR WH
6
C28TTA RD/BK
5
C46HRN GR
1
3
4
PLAT
GND
C133PLS GR/BK
TB22
3
B
4
TS6
GLOW
PLUG
4
KS1
3
P24FS WH
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
D40
TB134
RD
2
B1
RD
C132PLI BL/WH
P134PWR RD
P1
RD
C1-12
C2-6
CB2
15AMP
P24FS WH
P25FS RD
P25FS RD
BK
P24FS WH
P3
HORN
TB46
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING WH
C24TSPS WH
C5-11
V155PCE OR/RD
CB7
15A
Y74
HOLD
ES0504D
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM CONTROL RELAY
RPM SOLENOID
RPM MODULE
GLOW PLUG
TIME DELAY
30 SECONDS
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
S-80 • S-85 • S-80X
BR
-COM MOM N.O.
S-613
S1
NO
S2
NC
B
IND
WH
RD
PULL IN
M2
+BAT
+AUX
J144-4
J144-6
J144-8
REGULATOR
R34SA BK/WH
J144-7
M3
H2
CR15
NO
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
RD
WH
PR1
NO
PR2
BK
FB
SW4
NO
NO
C
RD
B1
TB21
+
HM
-
CR3
NO
CR2
CR39A
NO
D51
FB
-
START BATTERY
CONTROL BATTERY
6 - 10
A
STA
M1
8
P134PWR RD
7
C28TTA RD/BK
BAT-
R46HRN GR
BAT+
+
J144-1
12 VDC
C116HYD WH
EXCT
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
P134FB RD
J144-2
C41RPM OR/BK
AUX MAIN
D22
F20
20A
F22
60A
CR1
NO
6
B2
C5-19
B1BAT RD
F7
20A
-
L2
R21ING WH
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12 VDC
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
BL/RD
F17
20A
5
N
C9P-3
RD
2
M
C28TTA RD/BK
P26ESTP BK
1
L
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
LED BL/RD
9
6
7
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
P134PWR RD
C3PBF RD/WH
C8PBR BK/WH
C9PER BK/RD
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
SNSR-GND BR
C123PBS RD/BK
C6-7
C6-8
C6-9
C6-11
J114
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C6-31
C118LS OR
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
C37STCC BL/BK
C36STC BL
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C1PUB RD
C2PBD RD/BK
C3PBF RD/WH
C129DA RD/BK
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C30EDC WH
C31EDC WH/BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
4 3 2 1
RD
RD
BR
BK
WH
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
GROUND
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 11
S-80 • S-85 • S-80X
10
15
8
C144DER BL/WH
RIGHT
16
LEFT
C143DEL BL/BK
4
5
13
14
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C17PRL GR
PLAT. ROTATE
4 3 2 1
3
C4-5
CCW
CW
24
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
23
NO
14 13
NO
U4
7
22
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
P24FS WH
P26ESTP BK
J22-11
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-12
14
LSB2S
NC
21
14
21
NC
13
NO
22
13
NO
24 23
NO
NO
4 3 2 1
3
6
4 3 2 1
2
TB118
14
14
CR34
TB37
TB36
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
TB42
TB13
5
TB3
TB14
TB44
CR34
13
NO
24 23
NO
13
TB5
4
R14
10W
TB4
TB1
TB7
TB8
TB17
TS62
TB30
TB31
TB29
J1
J1
J1
J1
TB40
TB32
TS61
TS63
TB59
TS59
TS58
TS57
TB15
TB43
TB18
CCW
CW
J22-7
J22-9
J22-10
Y20
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y19
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y72 Y73
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
7.5W
C27AUX RD
J2
J2
Y70 Y71
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04I Models
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04i Models
6 - 11
6 - 12
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04I Models
6 - 13
6 - 14
6 - 14
8
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A(D)
BK-GND
BL-GND
GR-GND
5
BR GND
6
ES504D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C5-3
WH L2(-)
U1
C7B
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
12V TO PLAT
1
2
3
4
5
6
7
8
9
10
H
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
WH-TB23B
CABLE
RESTRAINT
BK-C32-5
G
BASE TERMINATION BLOCK
CR23
BR-GND STUD
RD-TB20A
F
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
TB21C
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
F19
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
1
RD U16-2
E
WH/12 C7B-2
DRIVE LIGHT OPTION RELAY
RD-TB20B
D
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-9
BR GND2
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
JIB BOOM DOWN S-85
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
(UNUSED)
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
C
OR/RD C6-22
OR/BK C5-2
OR C6-40
3
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
RD DL2
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
(UNUSED)
B
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
A
OR/RD C5-19
RD C6-23
RD C6-24
BK GND1
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
WH DL1
155
134A
134
133
132
118
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
OR/BK ISM #2
41
40
39
37
36
BK/RD TS54-1(D13)
35
BK/WH U16-5
34
BK/WH TS56-3
BK ISM-3
BK TS52-3
33
WH/RD-TRAVEL ALARM 32
31
30
29
28
RD TS51-4
27
RD ISM #4
D6
24
WH ISM #7
WH KS1-1(D2)
23
BK/12 KS1-3
BK C32-4
22
WH HM(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
WH/BK C4B-9
C
D
OR/RD TS62-5(D68)
OR & WH-BEACONS
RD C32-1
RD KS1-2
GR/BK C32-8
BL/WH C32-3
OR CR34 #86
BL/BK L46(+)
A
C32
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK- TB133C
BR-GND
RD - TB134C
BL/WH-TB132C
BK-TB22C
10 AMP FUSE
BK/WH TB34C
5
6
7
8
12
1
3
4
5
3
7
BK/WH C5-22
4
RD TB23A
2
2
1
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models
I
J
K
C1B
LABEL
L
FUNCTIONS
ENGINE
C6
C5
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
M
GROUND STUD
3 1 2
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
IGNITION START MODULE
U16
GLOW PLUG TIME DELAY RELAY
NOTE: DASHED LINES INDICATE OPTIONS
U16
HARNESS TO
SWITCH PANEL
N
Part No. 122985
1
2
TS62
6
3
5
2
4
1
L46
4
2
CB2
4
5
TS61
6
2
1
1
1
2
3
P4
3
2
1
5
4
2
3
TS51
4
3
6
NO
D64
1
BR-L46(-)
RD-TB20D
S-80 • S-85 • S-80X
BR-GND STUD
GR/BK-TB18D
BL/BK-TB59D
TO GROUND
CONTROL BOX
CONNECTIONS
C
BR-HM(-)
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34#85
E
D68
6
1
3
-
F
3
1
2
TS56
G6
G
TS57
1
2
TS63
3
3
+
H
3
B
B1
4
WH-TB21D
BK-TB22D
RD-TB134D
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
I
3
1 D13
TS58
2
D2
1
2
KS1
R16
OR-TB118D
RD/WH-TB3D
J
TS59
3
TS54
R14(A)
R14
RD/WH-TS61-1
BR-HM(-)
K
L2
NC
NC
2A
2B
E-STOP
1B
CR34
1A
P1
87
L
+
M
+
N
87A
85
86
30
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models
B
A
1
2
3
4
5
6
7
8
ES0504D
6 - 15
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04I Models
6 - 15
6 - 16
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Deutz TD2011L04I Models
6 - 17
6 - 18
1
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS GR/WH C3P-12
L47-C59CNK BL/BK C3P-11
J22
ES0505D
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
OPTION
12V
BATTERY
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
TS3-C39LP BL/RD C2P-1
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C177LS BL/RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
4
BK P2
1
WH L1
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
RD C2P-6
Part No. 122985
S-80 • S-85 • S-80X
6 - 18
6
1
2
OPTION
C9
H1
6
J1
C7P
+
J22-1,2,9,10,11 AND 12
D40
J2
2
9
3
RD LS18
3
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
11
J8
J7
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
BR BATGND
(GROUND STUD)
CR27
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
CR30
8
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
BL/RD J1-16
TS15
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
GR/BK C4P-8 / J22-6
GR C4P-7 / J22-5
BR GND STUD
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
L47
D12
JC3
JC7
TS2
TS6
3
6
+
1
6
1
L1
4
TS9
TS8
TS1
TS14
TS7
+
NO
P3
NC
L48
P2
RD
5
BK
RD
RD
ES0504D
6
COMPONENT INDEX
H1
TILT ALARM
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS14
DRIVE SPEED TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS15
DRIVE ENABLE TOGGLE SWITCH
L47
LED - CABLE TENSION
U13
ALC500 JOYSTICK CONTROLLER CARD
L48
LED - TILT ALARM
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 19
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models
6 - 19
6 - 20
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111)
6 - 21
6 - 22
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
C132PLI BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
LS18A
1
FS1
P2
LS18
C9P-1
BK
V155PCE OR/RD
LOW
HIGH
9
2 SEC.
NO
30A
5
2
U34
U35
C4-10
PBOX
GROUND
8
C4-10
C4-4
C1-9
C1-8
C1-7
C1-1
C7-2
C1-2
C3-12
PBOX
GROUND
9
NO
10A
3
D12
8
2 SEC.
RD
U16
NO
TB33
-
TB23
C41RPM OR/BK
C27AUX + FE RD
C27AUX RD
TB155
TB35
TB27
TB46
L45
P134PWR RD
D4
D13
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
GR/BK
RD
+
D67
D68
TB34
D2
H6
C35RPM BK/RD
HIGH
30 SEC
LOW
C34SA BK/WH
TS54
ENG.
RPM
P4
FUNC. ENABLE
D64
TB28
WH
GBOX
GROUND
TS56
GLOW
PLUG
C33STR BK
8
12
AUXILIARY
PUMP
TB133
WH
7
P23PWR WH
U33
TS51
C28TTA RD/BK
6
TB20
TS52
ENGINE
START
C27AUX RD
5
C46HRN GR
1
4
PLAT
GND
C133PLS GR/BK
3
3
1
TB22
B
4
2
3
TB132
TS4
ENGINE
RPM
4
KS1
3
5
+
H1
L4
D39
D40
TB134
RD
2
TS6
GLOW
PLUG
P26ESTP BK
R14
4.7KW
C2-5
B1
RD
P22PWR BK
C132PLI BL/WH
P134PWR RD
P1
RD
R26ESTP BK
P3
HORN
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
C7-1
C1-12
C2-6
CB2
15AMP
P24FS WH
RD
2
P25FS RD
P25FS RD
BK
D88
PBOX
GROUND
C9P-3
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING(A) WH
C24TSPS WH
C5-19
C5-11
V155PCE OR/RD
CB7
15A
Y74
HOLD
ES0504A
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM CONTROL RELAY
RPM SOLENOID
RPM MODULE
GLOW PLUG
TIME DELAY
30 SECONDS
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
START BATTERY
S-80 • S-85 • S-80X
BR
-COM MOM N.O.
S-613
S1
NO
S2
NC
B
WH
RD
PULL IN
M2
+BAT
+AUX
J144-4
J144-6
J144-8
M3
IND
R34SA BK/WH
J144-7
FB
H2
CR15
NO
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
FB
REGULATOR
RD
WH
D51
SW4
NO
NO
BK
-
B1
PR1
NO
PR2
+
G6
-
CR3
NO
CR2
CR39A
NO
C
RD
-
CONTROL BATTERY
6 - 22
A
STA
M1
8
P134PWR RD
7
C28TTA RD/BK
BAT-
R46HRN GR
BAT+
+
J144-1
12V DC
C116HYD WH
EXCT
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
J144-2
P134FB RD
D22
C41RPM OR/BK
AUX MAIN
6
F20
20A
F22
60A
CR1
NO
F7
20A
B2
TB21
R21ING WH
B1BAT RD
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12V DC
L2
BL/RD
F17
20A
5
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
9
10
15
8
6
7
16
C144DER BL/WH
RIGHT
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C8PBR BK/WH
C9PER BK/RD
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
C118LS OR
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
C17PRL GR
PLAT. ROTATE
SNSR-GND BR
C123PBS RD/BK
C6-31
C6-9
C6-8
C6-7
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
3
C6-11
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
BR
BK
WH
RD
4 3 2 1
3
C4-5
CCW
CW
C29MS RD/WH
C32BRK WH/RD
C130TA WH/RD
C31EDC WH/BK
C30EDC WH
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C129DA RD/BK
C3PBF RD/WH
C2PBD RD/BK
C1PUB RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
14
LED BL/RD
LEFT
C143DEL BL/BK
14
4
5
13
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
P24FS WH
P26ESTP BK
J22-11
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-12
4 3 2 1
2
6
4 3 2 1
RD
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
GROUND
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 23
S-80 • S-85 • S-80X
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
7
22
14
22
LSB2S
NC
21
14
22
21
NC
13
NO
NO
TB37
TB36
13
NO
24 23
NO
NC
HO
21
14
TB5
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
13
NO
24 23
NO
13
CR34
TB13
5
TB3
TB118
TB14
TB44
CR34
TB4
TB1
4
R14
10W
TB42
TB40
TB32
TB7
TB8
TB17
TB30
TB31
TB29
J1
J1
J1
J1
TS62
TS61
TS63
TB59
TS59
TS58
TS57
TB15
TB43
TB18
CCW
CW
J22-7
J22-9
J22-10
Y20
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y19
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y72 Y73
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
5W
C27AUX RD
J2
J2
Y70 Y71
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
J114
U4
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04i Models (before serial number 8111)
6 - 23
6 - 24
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (before serial number 8111)
6 - 25
6 - 26
8
6 - 26
BR GND
7
ES0504A
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
I
C7B
16/24 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C4-10
WH L2(-)
2
1
12V TO PLAT
U1
WH-TB23B
3
H
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
BR-GND STUD
CABLE
RESTRAINT
BK-C32-5
G
1
2
3
4
5
6
7
8
9
10
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
F
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
RD-TB20A
E
RD U16-2
RD-TB20B
H6
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
PLATFORM LOAD ALARM
PLATFORM LOAD INPUT
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
S-85
JIB BOOM DOWN
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
UNUSED
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
UNUSED
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
D
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
A
OR/RD C5-19
RD C6-23
RD C6-24
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
C
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
5
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
5
6
7
8
12
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
B
155
134A
WH-BEACON (LEFT)
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34 #86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
OR/BK ISM #2
40
39
37
36
BK/RD TS54-1(D13)
35
34
BK/WH U16-5
BK/WH TS56-3
BK ISM #3
BK TS52-3
33
WH/RD-TRAVEL ALARM 32
31
30
29
28
RD TS51-4
27
RD ISM #4
D6
24
WH KS1-1(D2)
23
WH ISM #7
BK/12 KS1-3
BK C32-4
22
WH G6(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34 #30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
C
U33
4
D
OR/RD TS62-5(D68)
OR-BEACON (RIGHT)
RD L45(+)
BK/WH TB34C
RD DL2
BK GND1
BR GND2
WH DL1
WH/BK C4B-9
RD-H6(+)
BL/WH-TB132C
BK-TB22C
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (D)
BK-GND
BL-GND
GR-GND
5
3
U16
1
3
4
3
CR23
2
RD TB23A
C32
1
2
1
BK/WH C5-22
6
DRIVE LIGHT RELAY
(OPTION)
F19
TB21C
10 AMP
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)
J
K
C1B
L
LABEL
M
FUNCTIONS
ENGINE
C6
C5
H6
PLATFORM OVERLOAD ALARM
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
GROUND STUD
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
U16
IGNITION START MODULE
TIME DELAY, GLOW PLUG, 30 SECONDS
U33
LOAD SENSE MODULE
HARNESS TO
SWITCH PANEL
N
3
Part No. 122985
2
TS62
6
3
5
2
4
1
L46
4
1
2
1
CB2
4
5
TS61
6
2
1
1
2
3
P4
D64
4
5
6
NO
3
L45
TS51
4
3
2
3
1
2
1
BR-L46(-)
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-G6(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
GR-TB17D
WH-TB4D
WH/BK-TB5D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
OR-TB14D
GR/BK-TB44D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34 #85
E
D68
6
TS63
3
3
-
F
1
1
2
3
D13
TS56
G6
G
TS57
1
1
TS58
2
B
3
+
H
2
3
TS54
D2
B1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
I
3
2B
2A
1
2
KS1
R16
J
TS59
NC
NC
R14(A)
RD-TS61-2
RD/WH-TB3D
OR-TB118D
RD/WH-TS61-1
K
L2
1B
1A
P1
CR34
R14
BR-G6(-)
L
+
M
+
N
+
87
87A
85
86
30
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)
B
A
1
2
3
4
5
6
7
8
ES0504A
6 - 27
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (before serial number 8111)
6 - 27
6 - 28
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (before serial number 8111)
6 - 29
6 - 30
7
CR27
8
RD LS18 CABLE
WH TS14
WH TS7
R20
BR BATGND
(GROUND STUD)
ES0504A
RD-E-STOP
P134PWR RD
P134PWR RD
RD-H1+
C4P(BR)
C3P(GN)
C2P(BK)
C1P(GY)
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
CR30
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
R26ESTP BK C9P-1
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
LS18-C132PLI2 BK C3P-10
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C2P-10
J1-P109ANG GR/WH C2P-9
P3-C46HRN GR C2P-5
TS47 C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
C3-10
C4-10
BATGND J3-1
U35
LS18-C132PLI1 BK C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
F.S.
P26ESTP BK E-STOP
BR GND
BK P2
WH L1
WH C9P-2
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
1
5
JC3-5 C159STC BL/WH
1
GR/BK C3P-12
12V BATT
H1
Part No. 122985
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
OPT.
LS18
C9
J22
C7P
+
S-80 • S-85 • S-80X
6 - 30
RD C2P-6
D40
BATGND C7P-3
5
1
U34
J2
2
BRN
GND STUD
6
GR/BK L4
RD LS18
4
J3
COM
NO
2
3
5
3
11
J1
9
COM
NO
2
3
3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)
1
C1P-2 C28TTA RD/BK
D39
J22-1, 2, 9, 10, 11 & 12
D88
C132PLI BK C3P-12
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFROM BOX
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
WH C9P-2
BL/RD J1-16
BL/BK J1-7
RD C1P-1
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD/WH J1-8
GR/BK C4P-8/J22-6
GR C4P-7/J22-5
BR GND STUD
GR/BK H1 (D39)
BL/BK C3P-11
GR C4P-5/J22-4
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
TS15
1
D12
L4
JC3
3
JC7
TS6
+
TS2
6
L47
L1
+
1
4
1
TS9
TS1
TS8
TS7
TS14
5
L48
+
NO
6
NC
P3
P2
RD
BK
RD
RD
6
RD
ES0504A
COMPONENT INDEX
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
LS18
PLATFORM OVERLOAD LIMIT SWITCH
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
P2
EMERGENCY STOP BUTTON
TS14
DRIVE SPEED TOGGLE SWITCH
H1
J22
TILT ALARM
PLATFORM MANIFOLD
P3
HORN BUTTON
TS15
DRIVE ENABLE TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
R20
TS1
RESISTOR - 4700W
AUXILIARY TOGGLE SWITCH
U13
U34
ALC500 JOYSTICK CONTROLLER CARD
TIME DELAY RELAY - 2 SECONDS, 10A
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS2
ENGINE START TOGGLE SWITCH
U35
TIME DELAY RELAY - 2 SECONDS, 30A
L1
LED - DRIVE ENABLE
RPM SELECT TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTIONS
1
L4
LED - PLATFORM OVERLOAD
TS4
TS6
L47
LED - CABLE TENSION
TS7
PLATFORM ROTATE TOGGLE SWITCH
L48
LED - TILT ALARM
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
7
8
ROCKER / STEER OPTION
Part No. 122985
S-80 • S-85 • S-80X
6 - 31
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (before serial number 8111)
6 - 31
6 - 32
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 33
6 - 34
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
D89
C28TTA RD/BK
P26ESTP BK
P24FS WH
LS18A
1
FS1
P2
LS18
C9P-1
BK
PBOX
GROUND
2 SEC.
NO
D12
8
C3-10
C4-4
C1-9
C1-8
PBOX
GROUND
C7-2
C1-2
C3-12
C2-5
C1-7
U35
30A
C1-1
D40
C132PLI2 BK
9
V155PCE OR/RD
HIGH
LOW
5
HIGH
RD
U16
NO
TB33
-
P134PWR RD
2
5
TB23
2 SEC.
C27AUX + FE RD
9
NO
3
C27AUX RD
8
TB155
TB35
TB27
C41RPM OR/BK
D4
U34
10A
D13
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
GR/BK
RD
+
D67
D68
TB34
D2
H6
LOW
TIMER 30
C35RPM BK/RD
TS54
ENG.
RPM
P4
FUNC. ENABLE
D64
TB28
WH
GBOX
GROUND
C34SA BK/WH
8
12
TS56
GLOW
PLUG
C33STR BK
TB133
WH
7
AUXILIARY
PUMP
U33
TS51
P23PWR WH
6
TB20
TS52
ENGINE
START
C27AUX RD
5
C28TTA RD/BK
C133PLA GR/BK
4
PLAT
GND
C46HRN GR
1
3
1
TB22
3
B
4
2
+
H1
L4
D39
3
TB132
TS4
ENGINE
RPM
P26ESTP BK
R14
4.7KW
P3
HORN
TS6
GLOW
PLUG
4
KS1
3
R26ESTP BK
TB134
RD
2
B1
RD
P22PWR BK
C132PLI BL/WH
P134PWR RD
P1
RD
P24FS WH
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
C7-1
C1-12
C2-6
CB2
15AMP
P25FS RD
P24FS WH
RD
2
C9P-3
P25FS RD
BK
D88
TB46
L45
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING(A) WH
C24TSPS WH
C5-19
C5-11
V155PCE OR/RD
CB7
15A
Y74
HOLD
ES0504D
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM CONTROL RELAY
RPM SOLENOID
RPM MODULE
GLOW PLUG
TIME DELAY
30 SECONDS
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
S-80 • S-85 • S-80X
BR
-COM MOM N.O.
S-613
S1
NO
S2
NC
B
IND
WH
RD
PULL IN
M2
+BAT
+AUX
J144-4
J144-6
J144-8
M3
REGULATOR
R34SA BK/WH
J144-7
FB
H2
CR15
NO
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
PR1
NO
PR2
BK
-
B1
RD
WH
RD
-
FB
SW4
NO
NO
C
+
G6
-
CR3
NO
CR2
CR39A
NO
D51
M1
START BATTERY
6 - 34
A
STA
CONTROL BATTERY
8
P134PWR RD
7
C28TTA RD/BK
BAT-
R46HRN GR
BAT+
+
J144-1
12V DC
C116HYD WH
EXCT
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
J144-2
P134FB RD
D22
C41RPM OR/BK
AUX MAIN
6
F20
20A
F22
60A
CR1
NO
F7
20A
B2
TB21
R21ING WH
B1BAT RD
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12V DC
L2
BL/RD
F17
20A
5
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
LED BL/RD
7
2
4
1
3
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
P134PWR RD
C9PER BK/RD
C8PBR BK/WH
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
SNSR-GND BR
C123PBS RD/BK
C6-7
C6-8
C6-9
C6-11
J114
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C6-31
C118LS OR
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PUB RD
C2PBD RD/BK
C3PBF RD/WH
C129DA RD/BK
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C30EDC WH
C31EDC WH/BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
4 3 2 1
RD
RD
BR
BK
WH
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
GROUND
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 35
S-80 • S-85 • S-80X
9
6
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
P134PWR RD
C59CNK BL/BK
C14PLU OR
4 3 2 1
3
6
4 3 2 1
10
15
8
C144DER BL/WH
RIGHT
16
LEFT
C143DEL BL/BK
4
5
13
14
1
3
1
2
11
12
GND BR
2
4
P24FS WH
P24FS WH
3
C4-2
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
C17PRL GR
PLAT. ROTATE
U4
23
NO
14 13
NO
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
24
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
3
C3-11
C4-3
C4-8
C4-7
C4-6
C4-5
CCW
CW
7
LSB2S
22 NC
21
14
21
NC
13
NO
22
14
14
CR34
4 3 2 1
5
2
TB118
13
NO
24 23
NO
NO
P26ESTP BK
J22-11
14
TB9
TB37
TB36
TB42
TB13
1
D29
D30
L46
R14(A)
5W
13
NO
24 23
NO
13
CR34
TB4
TB5
4
R14
10W
TB6
TB2
TB15
TB1
TB7
TB8
TB17
TS62
TB30
TB31
TB29
TB40
TB32
TS61
TS63
TB59
TS59
TB3
TB14
TB44
UP
PLATFORM
DOWN LEVEL
DOWN
UP
CCW
J22-7
J22-12
J22-2
S-85
(OPTION)
CW
J22-8
J22-9
J22-5
J22-3
J22-10
Y20
J22-6
Y19
J22-1
TB134A
P134PWR RD
J1
J1
J1
J1
Y72 Y73
TB43
TB18
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-4
R16
7.5W
C27AUX RD
J2
J2
2
TS7
PLATFORM
ROTATE
Y70 Y71
TS58
TS57
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 35
6 - 36
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 37
6 - 38
6 - 38
3
U34
C
6
U16
ES0504D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
U1
H
12V TO PLAT
WH-U34 #9
WH L2(-)
1
2
3
4
5
6
7
8
9
10
C7B
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
WH-TB23B
CABLE
RESTRAINT
BASE TERMINATION BLOCK
3
1
2
G
BK-C32-5
BR-GND STUD
RD-TB20A
F
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
E
WH C5-1
RD-TB20B
H6
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
PLATFORM LOAD ALARM
PLATFORM LOAD INPUT
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
S-85
JIB BOOM DOWN
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
(UNUSED)
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
D
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
5
6
7
8
12
A
OR/RD C5-19
RD C6-23
RD C6-24
U33
RD-H6(+)
BL/WH-TB132C
BK-TB22C
C
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
BR GND2
BK GND1
RD DL2
WH DL1
WH/BK C4B-9
1
3
4
C32
B
155
RD U34-2
134A
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34 #86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
OR/BK ISM #2
40
39
37
36
BK/RD TS54-1(D13)
35
34
BK/WH U16-5
BK/WH TS56-3
BK TS52-3
BK ISM #3
33
32
WH/RD-TRAVEL ALARM
31
30
29
28
RD TS51-4
27
RD ISM #4 D6
24
WH KS1-1(D2)
23
WH ISM #7
BK/12 KS1-3
BK C32-4
22
WH G6(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34 #30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
D
OR/RD TS62-5(D68)
OR & WH-BEACONS
RD L45(+)
BK C3B-10
CR23
TB21C
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (D)
BK-GND
BL-GND
GR-GND
3
5
BR GND
RD TB134C (A)
F19
10 AMP FUSE
4
BK/WH TB34C
BR GND
2
WH ISM-#9
DRIVE LIGHT OPTION RELAY
5
9
7
WH C5-3
3
RD TB23A
8
1
5
8
BK/WH C5-22
2
2
1
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)
I
J
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
K
C1B
L
LABEL
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
U1
IGNITION START MODULE
U16
GLOW PLUG TIME DELAY
U33
LOAD SENSE MODULE
U34
LOAD SENSE TIME DELAY
M
FUNCTIONS
ENGINE
C6
C5
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
GROUND STUD
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
H6
PLATFORM OVERLOAD ALARM
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
HARNESS TO
SWITCH PANEL
N
3
TS62
Part No. 122985
6
3
5
2
4
1
L46
4
1
3
2
1
CB2
4
5
TS61
6
2
1
1
2
3
P4
D64
-
3
4
5
6
NO
L45
TS51
4
3
2
3
1
2
1
BR-L46(-)
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-G6(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34 #85
E
D68
6
TS63
3
TS56
G6
F
2
1
2
3
D13
B
3
+
G
TS57
1
2
1
TS58
2
TS54
D2
B1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
H
1
2B
2A
1
2
KS1
R16
OR-TB118D
RD/WH-TB3D
I
3
NC
NC
R14(A)
R14
RD/WH-TS61-1
BR-G6(-)
J
TS59
L2
1B
3
86
CR34
85
30
1A
P1
87
K
+
L
+
M
+
N
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)
B
A
1
2
3
4
5
6
7
8
ES0504D
6 - 39
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 39
6 - 40
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 41
6 - 42
RD LS18 CABLE
8
RD-E-STOP
P134PWR RD
CR30
R20
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
4700W
R26ESTP BK C9P-1
J22
CR27
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
BR BATGND
(GROUND STUD)
P134PWR RD
RD-H1+
P26ESTP BK E-STOP
BR GND
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
ES0504D
12V
BATTERY
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C132PLI2 BK C3P-10
D39
BK P2
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
C132PLI1 BL/WH C1P-12
D88
5
U35
J1 C28TTA RD/BK
4
WH L1
1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
GR/BK C3P-12
GR/BK L4
RD C2P-6
RD LS18
Part No. 122985
S-80 • S-85 • S-80X
6 - 42
1
C1P-2 C28TTA RD/BK
BATGND J3-1
OPTION
C9
H1
6
6
1
LS18
C7P
+
J22-1,2,9,10,11 AND 12
D40
J1
1
2
1
3
COM
NO
2
3
5
3
J2
2
9
11
J8
J7
J3
U13 - JOYSTICK
CONTROL CARD
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)
1
BATGND C7P-3
GROUND
D89
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
BL/RD J1-16
TS15
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
GR/BK C4P-8 / J22-6
GR C4P-7 / J22-5
BR GND STUD
GR/BK H1 (D39)
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
L4
D12
JC3
JC7
+
TS2
3
TS6
6
L47
+
1
6
1
L1
4
TS9
TS8
TS1
TS14
TS7
+
NO
P3
NC
P2
L48
RD
5
BK
RD
RD
ES0504D
6
COMPONENT INDEX
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
TS7
PLATFORM ROTATE TOGGLE SWITCH
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
H1
TILT ALARM
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS14
DRIVE SPEED TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS15
DRIVE ENABLE TOGGLE SWITCH
L1
LED - DRIVE ENABLE
U13
ALC500 JOYSTICK CONTROLLER CARD
L4
LED - PLATFORM OVERLOAD
U35
TIME DELAY RELAY
L47
LED - CABLE TENSION
L48
LED - TILT ALARM
LS18
PLATFORM OVERLOAD LIMIT SWITCH
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
R20
TS1
RESISTOR - 4700W
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 43
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Deutz TD2011L04I Models (after serial number 8110)
6 - 43
6 - 44
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Deutz TD2011L04I Models
6 - 45
6 - 46
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Deutz TD2011L04I Models
A
B
C
D
E
F
G
H
I
J
K
P26ESTP BK
1
P2
C9P-3
P25FS RD
P24FS WH
V155PCE OR/RD
C1-9
B1BAT RD
D2
P134PWR RD
C41RPM OR/BK
C27AUX + FE RD
C27AUX RD
TB155
TB35
GR/BK
TB46
P210PWR BK
D68
D4
TB34
TB23
GROUND
D67
D13
TB33
TB27
LOW RPM
D64
C35RPM BK/RD
500 LB (A & B)
P4
TS54
FUNCTION
ENGINE
ENABLE
RPM
HIGH RPM
TB28
TS56
GLOW
PLUG
C34SA BK/WH
C32
C33STR BK
8
TS52
ENGINE
START
C27AUX RD
TB133
12
TS51
AUXILIARY
PUMP
7
LOW RPM
HIGH RPM
(FS)
C1-8
C1-1
1000 LB (A)
P23PWR WH
6
C28TTA RD/BK
GRD
TB20
4
OFF
ZONE B
C7-2
C1-2
1
5
P26ESTP BK
D12
ZONE A
3
4
PLAT
C46HRN GR
3
1
TB22
3
C28TTA RD/BK
P26ESTP BK
TS4
ENGINE
RPM
D101
4
KS1
B
P24FS WH
TS6
GLOW
PLUG
TS2
ENGINE
START
L48
C2-5
TB132
2
B1
TS1
AUXILIARY
PUMP
C1-7
P22PWR BK
P134PWR RD
15 AMP
C28TTA RD/BK
H1
D40
TB134
P1
C9P-2
+
-
D6
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21IGN WH
C24TSPS WH
30
85
CR2
87
+
HM
-
85
NO
CR15
86
CR4
85
R34SA BK/WH
V155PCE OR/RD
87
C24TSPS WH
C
85
CB20
10A
86
30
PR2
PR1
NO
M3
M2
BK
H2
30
NO
87
WH
RD
FB
SW4
NO
CR39A
R21IGN WH
A
NO
R27AUX RD
85
86
R33STR BK
86
R46HRN GR
C116HYD WH
CR5
87
C28TTA RD/BK
30
NO
CR1
86
S2
S1
NC
NO
M4
Y74
REGULATOR
IND
B
HOUR METER
PRESSURE COMP VALVE
(FUNCTION ENABLE)
POWER RELAY
RPM RELAY
RPM SOLENOID
FUEL PUMP
GLOW PLUG
RELAY
GLOW PLUG
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
IGNITION POWER
RELAY
FUEL SOLENOID
AUXILIARY PUMP
RELAY
AUXILIARY PUMP
POWER RELAY
Part No. 122985
AUXILIARY PUMP
IGNITION / START
RELAY
POWER RELAY
STARTER MOTOR
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
S-80 • S-85 • S-80X
OIL COOLER
TEMPERATURE SWITCH
(OPTION)
OIL COOLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
6 - 46
CONTROL BATTERY
8
HYD
FAN
FB
-
85
87
D51
STA
B1
87
86
BAT
-
7
-
CR17
R116HYD OR
+
P134FB RD
BAT
+
P134FB RD
EXCT
12V DC
C41RPM OR/BK
ALTERNATOR
NO
P134PWR RD
AUX. MAIN
30
D22
NO
CR3
TB21
NO
F22
60A
30
6
B2
C5-19
B1BAT RD
20A
+
C5-11
R21IGN WH
BAT2 APU RD
12V DC
C5-18
B1BAT RD
20A
C5-22
C5-15
P24PWR RD
F7
START RELAY
TACHOMETER
START INPUT
AUXILIARY
IGN / START
GROUND
MODULE
BATTERY
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
BL/RD
F17
5
N
P25FS RD
C7-1
C2-6
CB2
P3
HORN
M
P24FS WH
FS1
C9P-1
2
L
ES504D
L2
H1 RD/BK
C29MS RD/WH
9
10
2
4
1
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C3-6
C3-5
C3-4
C3-9
C3-8
C3-7
C3-12
C2-3
GR/WH
C1-12
D23
BL/RD
CW
GND BR
C123PBS RD/BK
SNSR-GND BR
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
CCW
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
C177LS BL/RD
P109LS GR/WH
RETRACT
UP
DOWN
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C37STCC BL/BK
C36STC BL
C6-33
C6-34
C6-35
C6-22
C6-40
C6-23
C6-25
C6-13
C123PBS RD/BK
SNSR-GND BR
BL/RD
C6-5
C6-6
C6-7
C6-8
C6-9
C6-31
C6-3
C6-2
C6-1
C6-12
C211PLO BL/BK
S212PLO GR/BK
GR/WH
C6-4
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6-16
C6-38
C6-30
C6-21
P134PWR RD
P210PWR BK
C118LS OR
C5-21
C5-20
C6-37
C6-36
C5-23
C5-24
OR
BR
YL
RD
OR
WH
BK
WH
BR
RD
BK
WH
BR
RD
BK
WH
BR
RD
RD
BK
BL
6
BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C37STCC BL/BK
C31EDC WH/BK
C30EDC WH
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
BL
BR
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
14
4
3
9
11
10
14
13
12
5
1
7
C3-1
C3-2
C3-3
C1-4
C1-5
C1-11
C1-10
C1-6
C1-3
14
13
NO
NO
13
NO
5
13
14
15
8
7
16
6
LED BL/RD
C144DER BL/WH
RIGHT
5
10
8
6
2
6
7
8
15
16
18
17
19
20
C6-24
WH
RD
RD
BL
BR
BK
BK/WH
BL
BR
BK
BK/WH
BK
WH
BR
RD
NC
BR
BK
WH
BR
BK
Y23
Y24
Y13
Y26
Y25
7
22
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DESCENT ALARM
LOOSE CABLE LED’S
LSB2S
LOOSE CABLE
LIMIT SWITCH
MOTOR STROKE
BRAKE RELEASE
STEER CW
STEER CCW
DRIVE EDC REVERSE
DRIVE EDC FORWARD
GROUND
CR34 - PRIMARY BOOM
SPEED REDUCTION RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
LST3O - BOOM UP/DOWN
GROUND BOX - ZONE A
OPERATION AND SPEED
REDUCTION LIMIT SWITCH
LSB1EO - BOOM EXTEND
CAPACITY OPERATIONAL
LIMIT SWITCH
LSB1ES - BOOM EXTEND
CAPACITY SAFETY
LIMIT SWITCH
LST3S - BOOM ANGLE
STOWED
GROUND BOX - ZONE A
SAFETY LIMIT SWITCH
PRIMARY BOOM
EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CCW
TURNTABLE ROTATE
CW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO
BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O
ANGLE STOWED
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CCW
6 - 47
S-80 • S-85 • S-80X
Part No. 122985
LEFT
C143DEL BL/BK
C209LED BL
C208LED GR
SNSR BR
ZONE SELECT
P109TS GR/WH
C184PL WH
3
1
2
11
1
12
GND BR
4
2
P24FS WH
3
J114
C6-11
13
NO
14
13
NO
14
14
13
NO
NO
U4
1
NC
13
NO
14
5
6
C129DA RD/BK
14
21
24
2 1
1
2
3
4
1
3
4
2
22
23
NO
BK
Y15
NC
NC
21
22
21
22
21
22
23
24
NC
Y22
1
2
3
4
J134
1
2
3
4
TB9
23
24
GR
6
J133
3
BL
2
1
2
3
4
NO
TB7
2
1
J133
2
5
21
13
NO
14
13
H4
TB118
4
1
TB8
D29
Y21
Y12
Y6
Y5
Y3
Y4
Y2
Y27
P24FS WH
P26ESTP BK
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
C43JU GR
DOWN
C44JD GR/BK
C17PRL GR
C18PRR GR/BK
CW
CCW
TB3
TB4
TB1
TB37
TB36
TB44
CR68
CR34
4
CR53
R14
10W
TB5
TB18
R14(A)
5W
CR52
L46
TB42
TB13
TB30
TB31
TB32
TB29
TS62
TURNTABLE
ROTATE
TS63
PRI. BOOM
EXT. / RET.
TS61
PRI. BOOM
UP / DOWN
C27AUX RD
3
C3-11
C4-2
TB134A
P210PWR BK
2
J1
J1
J1
D24
C59CNK BL/BK
C4-3
C4-7
C4-8
C4-5
C4-6
TB59
TS59
P162JPW2-OR
CR69
TB2
TB15
TB17
UP
DOWN
J22-11
J22-12
J22-9
J22-10
J22-2
J22-1
P134PWR RD
P134PWR RD
P162JPW1-OR
2
5
TB14
TB43
D30
CW
CCW
J22-7
J22-8
J22-5
J22-6
J22-4
J22-3
Y20
Y19
Y70
R16
7.5W
TS57
PLATFORM
ROTATE
J2
J2
Y71
C159STC-BL/WH
2
C164PES-RD/WH
J8
3
C165TRS-WH/RD
3
J8
CR30
J1
JSGND1-BR
1
J25
JSGND2-BR
1
J127
NO
JOYSTICK CONTROL CARD
J3
C160JPL-WH/RD
4
4
TS9
PLATFORM
LEVEL
TS7
PLATFORM
ROTATE
LIFT / DRIVE
(OPTION)
C159STC-BL/WH
5
C163PLS-WH/BK
6
L50
L51
6
JC3
DRIVE / STEER
5
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
L47
TS14
DRIVE
SELECT
L1
TS15
DRIVE
ENABLE
TS75
ZONE SELECT
NC
1
ZONE B
ZONE A
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Deutz TD2011L04I Models
GND BR
C28TTA RD/BK
P24FS WH
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80X,
Deutz TD2011L04I Models
6 - 47
6 - 48
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Deutz TD2011L04I Models
6 - 49
6 - 50
8
6 - 50
7
U16
ES0504D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
I
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C5-3
WH L2(-)
U1
C7B
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
12V TO PLAT
1
2
3
4
5
6
7
8
9
10
H
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
3
WH-TB23B
CABLE
RESTRAINT
BK-C32-5
BR-GND STUD
TB21C
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
G
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
RD U16-2
RD-TB20A
F
WH/12 C7B-2
DRIVE LIGHT OPTION RELAY
RD-TB20B
1
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-18
E
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
(UNUSED)
(UNUSED)
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR (OPTION)
(UNUSED)
(UNUSED)
LIMIT SWITCH - LST20
RPM / TACH SIGNAL
LIMIT SWITCH - LSB1RO
(UNUSED)
STEER CCW
STEER CW
ENGINE RPM
GLOW PLUG
ENGINE START
BRAKE RELEASE
REVERSE / EDCFORWARD / EDC+
DRIVE SPEED
PLATFORM LEVEL ALARM
AUXILIARY POWER
12V POWER
POWER TO PLATFORM
KEYSWITCH PWR TO PLATFORM
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
D
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
A
OR/RD C5-19
RD C6-23
RD C6-24
BR GND2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
BK GND1
155
134A
134
133
132
118
59
46
45
D29
TB2C-DESC. ALARM 44
43
42
OR/BK ISM#2
41
40
39
37
36
35
BK/RD TS54-1(D13)
BK/WH TS56-3
34
BK/WH U16-5
33
BK TS52-3
BK ISM#3
32
31
30
29
28
RD TS51-4
D6
27
RD ISM#4
24
WH KS1-1(D2)
23
WH ISM#7
BK C32-4
BK/12 KS1-3
22
WH HM(+)
21
RD/12 CB2-2
20
18
GR/BK TS57-1
17
GR TS57-3
OR/BK TS59-3
15
OR TS59-1
14
13
BK/RD R14(A)
9
BK/WH TS63-3
8
BK CR69-87A
7
6
WH/RD R14(A)
5
WH/BK TS62-1
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TB44C
2
RD/BK CR68-87A
D30
1
RD TS61-4
RD DL2
C6-30 C211LO BL/BK
C
C
D
OR/RD TS62-5(D68)
OR-BEACON (RIGHT) WH-BEACON (LEFT)
RD C32-1
KS1-2
GR/BK C32-8
BL/WH C32-3
OR CR34#86
BL/BK L46(+)
WH DL1
C6-38 C212LO GR/BK
WH/BK C4B-9
TB2D R2PBD RD/BK
CR69
CR23
TB7D R7PBE BK
5
CR68
B
GND BR
CR53
4
CR52
RD/BK
3
TS61-6 C2PBD RD/BK
BK
F19
C32
10 AMP FUSE
TS63-1 C7PBE BK
BK/WH TB34C
BK-C7B-1
WH-TS51-5
RD-TS56-2
GN/BK-TB133C
BR-GND
RD - TB134C
BL/WH-TB132C
BK-TB22C
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A(C)
BK-GND
BL-GND
GR-GND
5
BR GND STUD
5
6
7
8
12
1
3
4
2
3
BK/WH C5-22
RD TB23A
6
2
1
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Deutz TD2011L04I Models
J
K
L
C1B
LABEL
M
FUNCTIONS
ENGINE
C6
C5
N
GROUND STUD
1 2
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
CR52
CR53
PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL
PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL
CR68
PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY
CR69
PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
R14
FUNCTION ENABLE TOGGLE SWITCH
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
TS51
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
IGNITION START MODULE
U16
GLOW PLUG TIME DELAY RELAY
HARNESS TO
SWITCH PANEL
Part No. 122985
1
D13
TS62
6
3
5
2
1
L46
4
1
4
5
6
2
CB2
TS61
2
1
1
3
1
2
3
4
4
5
6
NO
D101
NO
3
P4
TS51
4
D64 3
2
1
2
3
1
S-80 • S-85 • S-80X
GN/BK-TB18D
BL/BK-TB59D
BR-GND STUD
TO GROUND
CONTROL BOX
CONNECTIONS
C
BR-HM(-)
RD-TB20D
RD-P1-2
D
WH-C32-6
RD-TB27D
RD-TS61-2
WH-KS1-1
D4
OR/RD-TB155D
WH/BK-TB5D
WH/RD-R14(A)
WH-TB4D
GN-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-CR52-30
BK-CR53-30
RD-R16
BK/WH-TB8D
BK/RD-TB9D
BK C6-12
OR-TB14D
OR/BK-TB15D
WH-ISM#10
BK-TB33D
RD-C32-7
E
D68
4
3
6
TS63
3
TS56
TS52
BL/WH-TB34D
WH-TB23D
RD-CB2-1
BK/RD-TB35D
WH-TS51-2
BR-CR34#85
BR-L46(-)
F
2
1
-
G6
G
TS57
1
2
2
B
3
H
3
3
TS54
D2
B1
+
I
3
2B
2A
1
4
J
TS59
NC
NC
2
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
K
L2
1B
KS1
R16
OR-TB118D
RD/WH-TB3D
L
1A
R14(A)
R14
M
P1
CR34
86
BR-HM(-)
RD/WH-TS61-1
N
85
30
87
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Deutz TD2011L04I Models
B
A
1
2
3
4
5
6
7
8
ES0504D
6 - 51
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Deutz TD2011L04I Models
6 - 51
6 - 52
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram, S-80X,
Deutz TD2011L04I Models
6 - 53
6 - 54
BK P2
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS GR/WH C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C177LS BL/RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J22
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
WH L1
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
J1 C28TTA RD/BK
FOOT
SWITCH
ES0504D
12V
BATTERY
WH C9P-2
JC3-5 C159STC BL/WH
CAN HI
CAN LOW
L51(-) C169LED1 GR
L50(-) C169LED2 GR
TS75-1 P109TS GR/WH
C3P-12 P109LS BL/WH
C1P-12 C177LS BL/WH
TS75-2 C184PL WH
TS75-3 SNSR BR
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
Part No. 122985
S-80 • S-85 • S-80X
6 - 54
RD C2P-6
4
BR BATGND
(GROUND STUD)
CR27
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
CR30
8
OPTION
C9
H1
6
1
OPTION
C7P
+
J22-1,2,9,10,11 AND 12
D40
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
6
1
11
J8
J7
J1
1
2
1
3
RD LS18
3
J2
2
9
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80X,
Deutz TD2011L04I Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Deutz TD2011L04I Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
GR J8-5
BR J8-8
GR/WH J8-6
WH J8-2
GR J8-10
TS15
BL/RD J1-16
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
BR GND STUD
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
L47
D12
JC3
JC7
TS2
3
TS6
6
+
1
6
1
L1
4
TS9
TS1
TS7
P3
+
+
TS14
+
NO
L48
L51
TS75
NC
P2
L50
RD
BK
RD
BK
5
BK
RD
ES0504D
6
COMPONENT INDEX
H1
TILT ALARM
TS6
GLOW PLUG TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS7
PLATFORM ROTATE TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS14
DRIVE SPEED TOGGLE SWITCH
L47
LED - CABLE TENSION
TS15
DRIVE ENABLE TOGGLE SWITCH
L48
LED - TILT ALARM
TS75
ZONE SELECT TOGGLE SWITCH (OPTION)
L50
LED - ZONE B, 500 LB CAPACITY
U13
ALC500 JOYSTICK CONTROLLER CARD
L51
LED - ZONE A, 1000 LB CAPACITY
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 55
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Deutz TD2011L04I Models
6 - 55
6 - 56
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 57
6 - 58
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
A
B
C
D
E
F
G
H
I
J
K
P2
FS1
C9P-1
BK
C28TTA RD/BK
P26ESTP BK
P26ESTP BK
LOW
P22PWR BK
+
H1
-
V155PCE OR/RD
TS4
ENGINE
RPM
HIGH
C7-1
D12
L48
C4-4
C1-9
C1-8
C1-7
C1-1
C7-2
C1-2
C3-12
C2-5
TB132
1
C35RPM BK/RD
LOW
D64
D67
D68
P134PWR RD
C41RPM OR/BK
D4
C27AUX + FE RD
C27AUX RD
D13
TB34
RD
TB33
TB155
D2
WH
TB35
TB27
TB23
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
RD
GR/BK
GBOX
GROUND
HIGH
TB28
TS54
ENG.
RPM
P4
FUNC. ENABLE
C34SA BK/WH
8
C32
TS56
GLOW
PLUG
C33STR BK
12
TS52
ENGINE
START
C27AUX RD
TB133
WH
7
AUXILIARY
PUMP
TB20
TS51
P23PWR WH
6
C28TTA RD/BK
5
C46HRN GR
1
3
4
PLAT
GND
P109LS GR/WH
TB22
3
B
4
TS6
GLOW
PLUG
4
KS1
3
P24FS WH
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
D40
TB134
RD
2
B1
RD
C177LS BL/RD
P134PWR RD
P1
RD
C1-12
C2-6
CB2
15AMP
P24FS WH
P25FS RD
P25FS RD
BK
P24FS WH
P3
HORN
TB46
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING WH
C24TSPS WH
CB20
10A
CR15
NO
CR4
NO
PR1
NO
PR2
V155PCE OR/RD
R35RPM BK/RD
RD
WH
R34SA BK/WH
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
RD
C
+
G6
-
CR3
NO
NO
D51
FB
M3
SW4
NO
Y74
M2
H2
BK
FB
-
REGULATOR
ES0503D
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM POWER RELAY
RPM CONTROL RELAY
RPM SOLENOID
FUEL PUMP
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
SERVICE HORN
RELAY
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
S-80 • S-85 • S-80X
M4
S1
NO
S2
NC
B
IND
START BATTERY
CONTROL BATTERY
6 - 58
A
STA
M1
8
P134PWR RD
7
C28TTA RD/BK
BAT-
R46HRN GR
BAT+
+
C116HYD WH
12V DC
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
C41RPM OR/BK
P134FB RD
AUX MAIN
D22
EXCT
B1
TB21
C5-11
F22
60A
CR2
CR39A
NO
CR1
NO
6
B2
C5-19
B1BAT RD
F7
20A
-
L2
R21ING WH
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12V DC
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
BL/RD
F17
20A
5
N
C9P-3
RD
2
M
C28TTA RD/BK
P26ESTP BK
1
L
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
LED BL/RD
9
6
7
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
UP
DOWN
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
P134PWR RD
C3PBF RD/WH
C8PBR BK/WH
C9PER BK/RD
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
SNSR-GND BR
C123PBS RD/BK
C6-7
C6-8
C6-9
C6-11
J114
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C6-31
C118LS OR
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
C37STCC BL/BK
C36STC BL
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C1PUB RD
C2PBD RD/BK
C3PBF RD/WH
C129DA RD/BK
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C30EDC WH
C31EDC WH/BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
4 3 2 1
RD
RD
BR
BK
WH
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
GROUND
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 59
S-80 • S-85 • S-80X
10
15
8
C144DER BL/WH
RIGHT
16
LEFT
C143DEL BL/BK
4
5
13
14
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C17PRL GR
PLAT. ROTATE
4 3 2 1
3
C4-5
CCW
CW
24
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
23
NO
14 13
NO
U4
7
22
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
P24FS WH
P26ESTP BK
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-11
14
LSB2S
NC
21
14
21
NC
13
NO
22
13
NO
24 23
NO
NO
4 3 2 1
3
6
4 3 2 1
2
TB118
14
14
CR34
TB37
TB36
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
TB42
TB13
5
TB3
TB14
TB44
CR34
13
NO
24 23
NO
13
TB5
4
R14
10W
TB4
TB1
TB7
TB17
TS62
TB30
TB31
TB29
J1
J1
J1
J1
ROCKER / STEER OPTION
TB40
TB32
TS61
TS63
TB59
TS59
TB8
TB15
TB43
TB18
CCW
CW
J22-7
J22-12
J22-10
J22-9
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y20
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y19
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
7.5W
C27AUX RD
J2
J2
Y72 Y73
TS58
TS57
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
Y70 Y71
JC3
DRIVE / STEER
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 59
6 - 60
Section 6 • Schematics
September 2015
Ground Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 61
6 - 62
8
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A(D)
BK-GND
BL-GND
GR-GND
7
6 - 62
ES503D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C5-3
WH L2(-)
U1
C7B
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
12V TO PLAT
1
2
3
4
5
6
7
8
9
10
WH-TB23B
CABLE
RESTRAINT
H
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
CR23
BR-GND STUD
G
BK-C32-5
F
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
TB21C
RD-TB20A
E
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
F19
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
DRIVE LIGHT OPTION RELAY
RD-TB20B
1
WH/12 C7B-2
BR GND2
D
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
3
BL/BK C6-37
BL C6-36
BK/RD C5-9
RD DL2
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
JIB BOOM DOWN S-85
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
(UNUSED)
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
C
OR/RD C6-22
OR/BK C5-2
OR C6-40
BK GND1
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
WH DL1
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
(UNUSED)
B
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
A
OR/RD C5-19
RD C6-23
RD C6-24
WH/BK C4B-9
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
10 AMP FUSE
C32
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK- TB133C
BR-GND
2
5
6
7
8
12
4
RD - TB134C
BL/WH-TB132C
BK-TB22C
A
BASE TERMINATION BLOCK
155
134A
134
133
132
118
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
OR/BK ISM #2
41
40
39
37
36
BK/RD TS54-1(D13)
35
34
BK/WH TS56-3
BK ISM-3
BK TS52-3
33
WH/RD-TRAVEL ALARM 32
31
30
29
28
RD TS51-4
27
RD ISM #4
D6
24
WH ISM #7
WH KS1-1(D2)
23
BK/12 KS1-3
BK C32-4
22
WH HM(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
6
C
D
OR/RD TS62-5(D68)
OR & WH-BEACONS
RD C32-1
RD KS1-2
GR/BK C32-8
BL/WH C32-3
OR CR34 #86
BL/BK L46(+)
5
1
3
4
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models
I
J
K
C1B
LABEL
L
FUNCTIONS
ENGINE
C6
C5
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
M
GROUND STUD
3 1 2
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
IGNITION START MODULE
NOTE: DASHED LINES INDICATE OPTIONS
HARNESS TO
SWITCH PANEL
N
Part No. 122985
2
1
TS62
6
3
5
2
4
1
L46
4
2
CB2
4
5
TS61
6
1
1
1
2
3
P4
3
2
1
5
4
2
3
TS51
4
3
6
NO
D64
1
WH-TS51-2
RD-TB20D
S-80 • S-85 • S-80X
BR-GND STUD
GR/BK-TB18D
BL/BK-TB59D
TO GROUND
CONTROL BOX
CONNECTIONS
C
BR-HM(-)
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
E
D68
6
1
2
BR-L46(-)
BR-CR34#85
F
3
1
2
3
-
G
TS57
1
2
TS63
3
TS56
G6
H
3
3
+
I
3
1 D13
TS58
2
B
B1
4
WH-TB21D
BK-TB22D
RD-TB134D
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
J
TS59
3
TS54
D2
1
2
KS1
R16
OR-TB118D
RD/WH-TB3D
K
L2
NC
NC
2A
2B
E-STOP
1B
1A
R14(A)
R14
RD/WH-TS61-1
L
P1
CR34
87A
85
86
30
BR-HM(-)
M
+
N
+
87
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models
B
A
1
2
3
4
5
6
7
8
ES0503D
6 - 63
September 2015
Section 6 • Schematics
Ground Control Switch Panel Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 63
6 - 64
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 65
6 - 66
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS GR/WH C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C177LS BL/RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J22
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
CR30
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
WH TS14
WH TS7
7
BK P2
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
J1 C28TTA RD/BK
FOOT
SWITCH
WH L1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
Part No. 122985
S-80 • S-85 • S-80X
6 - 66
RD C2P-6
4
ES0503D
12V
BATTERY
6
1
BR BATGND
(GROUND STUD)
CR27
8
OPTION
C9
H1
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
6
1
OPTION
C7P
+
J22-1,2,9,10,11 AND 12
D40
J1
1
2
1
3
RD LS18
3
J2
2
9
11
J8
J7
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
1
D12
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
BL/RD J1-16
TS15
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
GR/BK C4P-8 / J22-6
GR C4P-7 / J22-5
BR GND STUD
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
JC3
JC7
3
TS6
+
TS2
6
L47
+
1
6
1
L1
4
TS9
TS8
TS1
TS14
TS7
+
NO
P3
NC
P2
L48
RD
5
BK
RD
RD
ES0503D
6
COMPONENT INDEX
H1
TILT ALARM
TS8
JC3
JOYSTICK - DRIVE / STEER
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS14
DRIVE SPEED TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS15
DRIVE ENABLE TOGGLE SWITCH
L47
LED - CABLE TENSION
U13
ALC500 JOYSTICK CONTROLLER CARD
L48
LED - TILT ALARM
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
TS7
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 67
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Perkins 804D-33 Models
6 - 67
6 - 68
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 69
6 - 70
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
C132PLI BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
LS18A
1
FS1
P2
LS18
C9P-1
BK
PBOX
GROUND
V155PCE OR/RD
2
LOW
HIGH
+
H1
L4
D39
9
2 SEC.
NO
30A
5
2
U34
U35
C4-10
PBOX
GROUND
8
C4-10
C4-4
C1-9
C1-8
C1-7
PBOX
GROUND
C7-2
C1-2
C3-12
C2-5
C1-1
D40
9
NO
10A
3
D12
8
2 SEC.
H6
-
D67
D68
P134PWR RD
C41RPM OR/BK
D4
C27AUX + FE RD
C27AUX RD
D13
TB34
TB155
TB35
TB27
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
GR/BK
RD
+
C35RPM BK/RD
TB23
HIGH
D2
LOW
RD
TB28
WH
GBOX
GROUND
D64
TB33
TS54
ENG.
RPM
P4
FUNC. ENABLE
C34SA BK/WH
8
12
TS56
GLOW
PLUG
C33STR BK
TB133
WH
7
AUXILIARY
PUMP
U33
TS51
P23PWR WH
TB20
TS52
ENGINE
START
C27AUX RD
5
6
C28TTA RD/BK
C133PLS GR/BK
4
PLAT
GND
C46HRN GR
1
3
1
TB22
3
B
4
TS4
ENGINE
RPM
4
KS1
3
5
3
TB132
TS6
GLOW
PLUG
P26ESTP BK
R14
4.7KW
TB134
RD
2
B1
RD
P22PWR BK
C132PLI BL/WH
P134PWR RD
P1
RD
R26ESTP BK
P3
HORN
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
C7-1
C1-12
C2-6
CB2
15AMP
P25FS RD
P24FS WH
RD
2
C9P-3
P25FS RD
BK
D88
TB46
L45
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING(A) WH
C24TSPS WH
C5-11
F22
60A
Y74
S1
NO
S2
NC
ES0503A
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM POWER RELAY
RPM CONTROL RELAY
RPM SOLENOID
FUEL PUMP
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
S-80 • S-85 • S-80X
V155PCE OR/RD
M4
M2
B
IND
R35RPM BK/RD
REGULATOR
R34SA BK/WH
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
RD
B1
FB
CR4
NO
M3
H2
BK
FB
-
START BATTERY
CONTROL BATTERY
6 - 70
WH
D51
SW4
NO
CR15
NO
PR1
NO
PR2
+
G6
-
CR3
NO
NO
C
STA
M1
8
A
RD
7
P134PWR RD
BAT-
C28TTA RD/BK
BAT+
+
R46HRN GR
12V DC
C116HYD WH
EXCT
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
C41RPM OR/BK
P134FB RD
AUX MAIN
D22
CB20
10A
CR2
CR39A
NO
CR1
NO
6
B2
C5-19
B1BAT RD
F7
20A
-
TB21
R21ING WH
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12V DC
L2
BL/RD
F17
20A
5
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
9
7
2
4
1
3
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C4-2
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C8PBR BK/WH
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
C118LS OR
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
C17PRL GR
PLAT. ROTATE
SNSR-GND BR
C123PBS RD/BK
C6-31
C6-9
C6-8
C6-7
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
3
C6-11
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
BR
BK
WH
RD
4 3 2 1
10
15
8
6
16
C144DER BL/WH
RIGHT
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
3
C3-11
C4-3
C4-8
C4-7
C4-6
C4-5
CCW
CW
C29MS RD/WH
C32BRK WH/RD
C130TA WH/RD
C31EDC WH/BK
C30EDC WH
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C129DA RD/BK
C3PBF RD/WH
C2PBD RD/BK
C1PUB RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
14
LED BL/RD
LEFT
C143DEL BL/BK
14
4
5
13
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
P24FS WH
P26ESTP BK
J22-11
4 3 2 1
5
2
6
4 3 2 1
RD
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
GROUND
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 71
S-80 • S-85 • S-80X
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
7
22
14
22
LSB2S
NC
21
14
22
21
NC
13
NO
NO
TB37
TB36
13
NO
24 23
NO
NC
HO
21
14
TB9
TB4
TB5
TB42
TB13
1
D29
D30
L46
R14(A)
5W
13
NO
24 23
NO
13
CR34
TB6
TB2
TB15
TB1
TB7
TB8
TB17
4
R14
10W
CR34
TS62
TB30
TB31
TB29
TB40
TB32
TS61
TS63
TB59
TS59
TB3
TB118
TB14
TB44
UP
PLATFORM
DOWN LEVEL
DOWN
UP
CCW
J22-7
J22-12
J22-2
S-85
(OPTION)
CW
J22-8
J22-9
J22-5
J22-3
J22-10
Y20
J22-6
Y19
J22-1
TB134A
P134PWR RD
J1
J1
J1
J1
Y72 Y73
TB43
TB18
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-4
R16
5W
C27AUX RD
J2
J2
2
TS7
PLATFORM
ROTATE
Y70 Y71
TS58
TS57
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
J114
U4
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 71
6 - 72
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 73
6 - 74
8
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (D)
BK-GND
BL-GND
GR-GND
7
6 - 74
C
RD DL2
BK GND1
BR GND2
WH DL1
WH/BK C4B-9
ES0503A
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
I
16/24 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C4-10
WH L2(-)
C7B
U1
12V TO PLAT
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
2
1
H
1
2
3
4
5
6
7
8
9
10
WH-TB23B
3
CABLE
RESTRAINT
BASE TERMINATION BLOCK
BR-GND STUD
G
BK-C32-5
F
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
H6
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
E
RD-TB20A
RD-TB20B
D
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
PLATFORM LOAD ALARM
PLATFORM LOAD INPUT
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
S-85
JIB BOOM DOWN
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
UNUSED
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
UNUSED
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
C
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
4
A
OR/RD C5-19
RD C6-23
RD C6-24
5
6
7
8
12
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
B
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
5
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
U33
3
RD-H6(+)
BL/WH-TB132C
BK-TB22C
2
1
3
4
1
CR23
C32
A
155
134A
WH-BEACON (LEFT)
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34 #86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
OR/BK ISM #2
40
39
37
36
BK/RD TS54-1(D13)
35
34
BK/WH TS56-3
BK ISM #3
BK TS52-3
33
WH/RD-TRAVEL ALARM 32
31
30
29
28
RD TS51-4
27
RD ISM #4
D6
24
WH KS1-1(D2)
23
WH ISM #7
BK/12 KS1-3
BK C32-4
22
WH G6(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34 #30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
D
OR/RD TS62-5(D68)
OR-BEACON (RIGHT)
RD L45(+)
6
DRIVE LIGHT RELAY
(OPTION)
F19
TB21C
10 AMP
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)
J
K
C1B
L
LABEL
M
FUNCTIONS
ENGINE
C6
C5
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
GROUND STUD
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
H6
PLATFORM OVERLOAD ALARM
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
IGNITION START MODULE
U33
LOAD SENSE MODULE
HARNESS TO
SWITCH PANEL
N
3
Part No. 122985
2
TS62
6
3
5
2
4
1
L46
4
1
3
2
1
CB2
4
5
TS61
6
2
1
1
2
3
P4
D64
4
5
6
NO
3
L45
TS51
4
3
2
3
1
2
1
BR-L46(-)
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-G6(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
GR-TB17D
WH-TB4D
WH/BK-TB5D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
OR-TB14D
GR/BK-TB44D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34 #85
E
D68
6
TS63
3
TS56
-
F
1
1
2
3
D13
G6
G
TS57
1
1
TS58
2
B
3
+
H
2
3
TS54
D2
B1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
I
3
2B
2A
1
2
KS1
R16
RD-TS61-2
J
TS59
NC
NC
R14(A)
OR-TB118D
RD/WH-TB3D
K
L2
1B
1A
P1
CR34
R14
RD/WH-TS61-1
BR-G6(-)
L
+
M
+
N
+
87
87A
85
86
30
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)
B
A
1
2
3
4
5
6
7
8
ES0503A
6 - 75
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 75
6 - 76
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 77
6 - 78
7
CR27
8
RD LS18 CABLE
WH TS14
WH TS7
R20
BR BATGND
(GROUND STUD)
ES0503A
RD-E-STOP
P134PWR RD
P134PWR RD
RD-H1+
C4P(BR)
C3P(GN)
C2P(BK)
C1P(GY)
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
CR30
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
R26ESTP BK C9P-1
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
LS18-C132PLI2 BK C3P-10
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C2P-10
J1-P109ANG GR/WH C2P-9
P3-C46HRN GR C2P-5
TS47 C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
C3-10
C4-10
BATGND J3-1
U35
LS18-C132PLI1 BK C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
F.S.
P26ESTP BK E-STOP
BR GND
BK P2
WH L1
WH C9P-2
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
1
5
JC3-5 C159STC BL/WH
1
GR/BK C3P-12
12V BATT
H1
Part No. 122985
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
OPT.
LS18
C9
J22
C7P
+
S-80 • S-85 • S-80X
6 - 78
RD C2P-6
D40
BATGND C7P-3
5
1
U34
J2
2
BRN
GND STUD
6
GR/BK L4
RD LS18
4
J3
COM
NO
2
3
5
3
11
J1
9
COM
NO
2
3
3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)
1
C1P-2 C28TTA RD/BK
D39
J22-1, 2, 9, 10, 11 & 12
D88
C132PLI BK C3P-12
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFROM BOX
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
WH C9P-2
BL/RD J1-16
BL/BK J1-7
BL/WH J1-6
RD C1P-1
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD/WH J1-8
GR/BK C4P-8/J22-6
GR C4P-7/J22-5
BR GND STUD
GR/BK H1 (D39)
BL/BK C3P-11
GR C4P-5/J22-4
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
TS15
1
D12
L4
JC3
3
JC7
TS6
+
TS2
6
L47
L1
+
1
4
1
TS9
TS1
TS8
TS7
TS14
5
L48
+
NO
6
NC
P3
P2
RD
BK
RD
RD
6
RD
ES0503A
COMPONENT INDEX
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
LS18
PLATFORM OVERLOAD LIMIT SWITCH
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
P2
EMERGENCY STOP BUTTON
TS14
DRIVE SPEED TOGGLE SWITCH
H1
J22
TILT ALARM
PLATFORM MANIFOLD
P3
HORN BUTTON
TS15
DRIVE ENABLE TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
R20
TS1
RESISTOR - 4700W
AUXILIARY TOGGLE SWITCH
U13
U34
ALC500 JOYSTICK CONTROLLER CARD
TIME DELAY RELAY - 2 SECONDS, 10A
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS2
ENGINE START TOGGLE SWITCH
U35
TIME DELAY RELAY - 2 SECONDS, 30A
L1
LED - DRIVE ENABLE
RPM SELECT TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTIONS
1
L4
LED - PLATFORM OVERLOAD
TS4
TS6
L47
LED - CABLE TENSION
TS7
PLATFORM ROTATE TOGGLE SWITCH
L48
LED - TILT ALARM
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
7
8
ROCKER / STEER OPTION
Part No. 122985
S-80 • S-85 • S-80X
6 - 79
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (before serial number 8111)
6 - 79
6 - 80
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
6 - 81
6 - 82
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
D89
C28TTA RD/BK
P26ESTP BK
P24FS WH
LS18A
1
FS1
P2
LS18
C9P-1
BK
PBOX
GROUND
2 SEC.
NO
D12
8
C3-10
C4-4
C1-9
C1-8
PBOX
GROUND
C7-2
C1-2
C3-12
C2-5
C1-7
U35
30A
C1-1
D40
C132PLI2 BK
V155PCE OR/RD
9
LOW
HIGH
5
C35RPM BK/RD
HIGH
-
5
2 SEC.
3
TB23
C27AUX + FE RD
9
C27AUX RD
8
TB155
TB35
TB27
C41RPM OR/BK
D4
U34
10A
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
GR/BK
RD
+
H6
LOW
RD
D2
P134PWR RD
2
D13
TB34
TB33
WH
GBOX
GROUND
D67
D68
NO
D64
TB28
TS54
ENG.
RPM
P4
FUNC. ENABLE
C34SA BK/WH
8
12
TS56
GLOW
PLUG
C33STR BK
TB133
WH
7
AUXILIARY
PUMP
U33
TS51
P23PWR WH
6
TB20
TS52
ENGINE
START
C27AUX RD
5
C28TTA RD/BK
C133PLS GR/BK
4
PLAT
GND
C46HRN GR
1
3
1
TB22
3
B
4
2
+
H1
L4
D39
3
TB132
TS4
ENGINE
RPM
P26ESTP BK
R14
4.7KW
P3
HORN
TS6
GLOW
PLUG
4
KS1
3
R26ESTP BK
TB134
RD
2
B1
RD
P22PWR BK
C132PLI BL/WH
P134PWR RD
P1
RD
P24FS WH
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
C7-1
C1-12
C2-6
CB2
15AMP
P25FS RD
P24FS WH
RD
2
C9P-3
P25FS RD
BK
D88
TB46
L45
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
D6
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21ING(A) WH
C24TSPS WH
C5-11
R35RPM BK/RD
WH
FB
M4
M3
SW4
NO
ES0503D
CHECK ENGINE LED
HOURMETER
PRESSURE COMP. VALVE
(FUNCTION ENABLE)
RPM POWER RELAY
RPM CONTROL RELAY
RPM SOLENOID
FUEL PUMP
GLOW PLUG
CONTROL RELAY
GLOW PLUG
OLI TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
FUEL SOLENOID
FUEL SOLENOID
CONTROL RELAY
AUXILIARY PUMP
CONTROL RELAY
AUXILIARY PUMP
Part No. 122985
AUXILIARY PUMP
POWER RELAY
IGNITION / STARTER
RELAY
STARTER
POWER RELAY
STARTER
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
OIL COOLER TEMP. SWITCH
(OPTION)
OIL COLLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY
SEPERATOR
S-80 • S-85 • S-80X
S1
NO
S2
NC
B
IND
Y74
M2
H2
REGULATOR
V155PCE OR/RD
CR4
NO
R34SA BK/WH
C24TSPS WH
R21ING WH
R27AUX RD
R33STR BK
RD
CR15
NO
PR1
NO
PR2
+
G6
-
CR3
NO
NO
BK
FB
-
START BATTERY
6 - 82
CR39A
NO
D51
M1
B1
CB20
10A
CR2
C
STA
CONTROL BATTERY
8
A
RD
7
P134PWR RD
BAT-
C28TTA RD/BK
BAT+
+
R46HRN GR
12V DC
C116HYD WH
EXCT
CR5
NO
CR17
NO
R116HYD OR
P134FB RD
C41RPM OR/BK
D22
P134FB RD
AUX MAIN
6
-
C5-19
F22
60A
CR1
NO
F7
20A
B2
TB21
R21ING WH
B1BAT RD
BAT2 APU
+
C5-18
B1BAT RD
C5-22
C5-15
P24PWR RD
12V DC
L2
BL/RD
F17
20A
5
START RELAY
TACHOMETER
START INPUT
AUXILIARY ON
GROUND
IGN / START
BATTERY
MODULE
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
LED BL/RD
7
2
4
1
3
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
P134PWR RD
C9PER BK/RD
C8PBR BK/WH
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
SNSR-GND BR
C123PBS RD/BK
C6-7
C6-8
C6-9
C6-11
J114
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C6-31
C118LS OR
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PUB RD
C2PBD RD/BK
C3PBF RD/WH
C129DA RD/BK
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C30EDC WH
C31EDC WH/BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
4 3 2 1
RD
RD
BR
BK
WH
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
GROUND
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 83
S-80 • S-85 • S-80X
9
6
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
P134PWR RD
C59CNK BL/BK
C14PLU OR
4 3 2 1
3
6
4 3 2 1
10
15
8
C144DER BL/WH
RIGHT
16
LEFT
C143DEL BL/BK
4
5
13
14
1
3
1
2
11
12
GND BR
2
4
P24FS WH
P24FS WH
3
C4-2
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
C17PRL GR
PLAT. ROTATE
U4
23
NO
14 13
NO
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
24
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
3
C3-11
C4-3
C4-8
C4-7
C4-6
C4-5
CCW
CW
7
LSB2S
22 NC
21
14
21
NC
13
NO
22
14
14
CR34
4 3 2 1
5
2
TB118
13
NO
24 23
NO
NO
P26ESTP BK
J22-11
14
TB9
TB37
TB36
TB42
TB13
1
D29
D30
L46
R14(A)
5W
13
NO
24 23
NO
13
CR34
TB4
TB5
4
R14
10W
TB6
TB2
TB15
TB1
TB7
TB8
TB17
TS62
TB30
TB31
TB29
TB40
TB32
TS61
TS63
TB59
TS59
TB3
TB14
TB44
UP
PLATFORM
DOWN LEVEL
DOWN
UP
CCW
J22-7
J22-12
J22-2
S-85
(OPTION)
CW
J22-8
J22-9
J22-5
J22-3
J22-10
Y20
J22-6
Y19
J22-1
TB134A
P134PWR RD
J1
J1
J1
J1
Y72 Y73
TB43
TB18
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-4
R16
7.5W
C27AUX RD
J2
J2
2
TS7
PLATFORM
ROTATE
Y70 Y71
TS58
TS57
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE)
Perkins 804D-33 Models (after serial number 8110)
6 - 83
6 - 84
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
6 - 85
6 - 86
6 - 86
3
7
U34
ES0503D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
U1
WH-TB23B
3
1
2
C7B
1
2
3
4
5
6
7
8
9
10
BR-GND STUD
CABLE
RESTRAINT
BK-C32-5
G
H
12V TO PLAT
WH-U34 #9
WH L2(-)
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
F
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
RD-TB20A
RD-TB20B
E
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
PLATFORM LOAD ALARM
PLATFORM LOAD INPUT
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
S-85
JIB BOOM DOWN
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
(UNUSED)
STEER CCW
STEER CW
ENGINE SPEED
GLOW PLUG
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
H6
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
A
OR/RD C5-19
RD C6-23
RD C6-24
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
D
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
BR GND2
5
6
7
8
12
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
C
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
RD DL2
BK GND1
U33
RD-H6(+)
BL/WH-TB132C
BK-TB22C
B
155
RD U34-2
134A
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34 #86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
OR/BK ISM #2
40
39
37
36
BK/RD TS54-1(D13)
35
34
BK/WH TS56-3
BK TS52-3
BK ISM #3
33
32
WH/RD-TRAVEL ALARM
31
30
29
28
RD TS51-4
27
RD ISM #4 D6
24
WH KS1-1(D2)
23
WH ISM #7
BK/12 KS1-3
BK C32-4
22
WH G6(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34 #30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
C
6
D
OR/RD TS62-5(D68)
OR & WH-BEACONS
RD L45(+)
BK C3B-10
WH DL1
WH/BK C4B-9
1
3
4
C32
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (D)
BK-GND
BL-GND
GR-GND
5
CR23
TB21C
4
BR GND
RD TB134C (A)
F19
10 AMP FUSE
3
WH ISM-#9
5
DRIVE LIGHT OPTION RELAY
1
2
8
WH C5-3
2
9
8
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)
I
J
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
K
C1B
L
LABEL
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
U1
IGNITION START MODULE
U33
LOAD SENSE MODULE
U34
LOAD SENSE TIME DELAY
M
FUNCTIONS
ENGINE
C6
C5
CB2
CONTROLS CIRCUIT BREAKER, 15A
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
GROUND STUD
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
H6
PLATFORM OVERLOAD ALARM
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
HARNESS TO
SWITCH PANEL
N
3
TS57
1
2
3
1
1
2
3
TS58
2
TS54
D13
D2
TS62
5
2
Part No. 122985
L46
4
1
TS56
3
2
1
CB2
4
5
TS61
6
2
1
P4
2
3
1
-
D64
G6
3
4
5
6
NO
L45
TS51
4
3
2
3
1
2
1
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-G6(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
RD-C32-7
WH-ISM #10
TS52
BK/WH-TB34D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34 #85
BR-L46(-)
E
D68
4
1
3
F
6
3
6
TS63
3
B
B1
+
G
2
2B
2A
1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
H
1
NC
NC
2
KS1
R16
OR-TB118D
RD/WH-TB3D
I
3
1B
R14(A)
R14
RD/WH-TS61-1
BR-G6(-)
J
TS59
L2
86
CR34
85
30
1A
P1
87
K
+
L
+
M
+
N
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)
B
A
1
2
3
4
5
6
7
8
ES0503D
6 - 87
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
6 - 87
6 - 88
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
6 - 89
6 - 90
RD LS18 CABLE
8
RD-E-STOP
P134PWR RD
CR30
R20
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
4700W
R26ESTP BK C9P-1
J22
CR27
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
BR BATGND
(GROUND STUD)
P134PWR RD
RD-H1+
P26ESTP BK E-STOP
BR GND
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
ES0503D
12V
BATTERY
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C132PLI2 BK C3P-10
D39
BK P2
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
C132PLI1 BL/WH C1P-12
D88
5
U35
J1 C28TTA RD/BK
4
WH L1
1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
GR/BK C3P-12
GR/BK L4
RD C2P-6
RD LS18
Part No. 122985
S-80 • S-85 • S-80X
6 - 90
1
C1P-2 C28TTA RD/BK
BATGND J3-1
OPTION
C9
H1
6
6
1
LS18
C7P
+
J22-1,2,9,10,11 AND 12
D40
J1
1
2
1
3
COM
NO
2
3
5
3
J2
2
9
11
J8
J7
J3
U13 - JOYSTICK
CONTROL CARD
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)
1
BATGND C7P-3
GROUND
D89
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
BL/RD J1-16
TS15
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
GR/BK C4P-8 / J22-6
GR C4P-7 / J22-5
BR GND STUD
GR/BK H1 (D39)
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
L4
D12
JC3
JC7
+
TS2
3
TS6
6
L47
+
1
6
1
L1
4
TS9
TS8
TS1
TS14
TS7
+
NO
P3
NC
P2
L48
RD
5
BK
RD
RD
ES0503D
6
COMPONENT INDEX
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
TS7
PLATFORM ROTATE TOGGLE SWITCH
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
H1
TILT ALARM
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS14
DRIVE SPEED TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS15
DRIVE ENABLE TOGGLE SWITCH
L1
LED - DRIVE ENABLE
U13
ALC500 JOYSTICK CONTROLLER CARD
L4
LED - PLATFORM OVERLOAD
U35
TIME DELAY RELAY
L47
LED - CABLE TENSION
L48
LED - TILT ALARM
LS18
PLATFORM OVERLOAD LIMIT SWITCH
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
R20
TS1
RESISTOR - 4700W
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
TS6
GLOW PLUG TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 91
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Perkins 804D-33 Models (after serial number 8110)
6 - 91
6 - 92
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Perkins 804D-33 Models
6 - 93
6 - 94
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Perkins 804D-33 Models
A
B
C
D
E
F
G
H
I
J
K
P26ESTP BK
1
P2
C9P-3
P25FS RD
P24FS WH
V155PCE OR/RD
C1-9
B1BAT RD
D2
P134PWR RD
C41RPM OR/BK
C27AUX + FE RD
C27AUX RD
TB155
TB35
TB46
P210PWR BK
D68
D4
TB34
TB23
GROUND
D67
D13
TB33
TB27
LOW RPM
D64
C35RPM BK/RD
500 LB (A & B)
P4
TS54
FUNCTION
ENGINE
ENABLE
RPM
HIGH RPM
TB28
TS56
GLOW
PLUG
C34SA BK/WH
C32
C33STR BK
8
TS52
ENGINE
START
C27AUX RD
TB133
12
TS51
AUXILIARY
PUMP
7
LOW RPM
HIGH RPM
(FS)
C1-8
C1-1
1000 LB (A)
P23PWR WH
6
C28TTA RD/BK
GRD
TB20
4
OFF
ZONE B
C7-2
C1-2
1
5
P26ESTP BK
D12
ZONE A
3
4
PLAT
C46HRN GR
3
1
TB22
3
C28TTA RD/BK
P26ESTP BK
TS4
ENGINE
RPM
D101
4
KS1
B
P24FS WH
TS6
GLOW
PLUG
TS2
ENGINE
START
L48
C2-5
TB132
2
B1
TS1
AUXILIARY
PUMP
C1-7
P22PWR BK
P134PWR RD
15 AMP
C28TTA RD/BK
H1
D40
TB134
P1
C9P-2
+
-
D6
C27AUX RD
C41RPM OR/BK
P23PWR WH
C33STR BK
TB41
1
2
3
4
5
6
7
8
9
10
C33STR BK
C27AUX RD
P24PWR RD
C5-3
C5-1
C5-6
C5-5
C6-28
C6-24
C5-7
C5-2
C21IGN WH
C24TSPS WH
30
30
NO
87
CR2
87
+
HM
-
85
NO
CR15
86
CR4
85
R34SA BK/WH
V155PCE OR/RD
87
C24TSPS WH
R21IGN WH
C
85
CB20
10A
86
30
PR2
PR1
NO
M3
M2
BK
H2
CR39A
85
WH
RD
FB
SW4
NO
NO
R27AUX RD
A
R46HRN GR
C116HYD WH
85
86
R33STR BK
86
CR5
87
C28TTA RD/BK
30
NO
CR1
86
S2
S1
NC
NO
M4
Y74
REGULATOR
IND
B
HOUR METER
PRESSURE COMP VALVE
(FUNCTION ENABLE)
POWER RELAY
RPM RELAY
RPM SOLENOID
FUEL PUMP
GLOW PLUG
RELAY
GLOW PLUG
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
IGNITION POWER
RELAY
FUEL SOLENOID
AUXILIARY PUMP
RELAY
AUXILIARY PUMP
POWER RELAY
Part No. 122985
AUXILIARY PUMP
IGNITION / START
RELAY
POWER RELAY
STARTER MOTOR
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
S-80 • S-85 • S-80X
OIL COOLER
TEMPERATURE SWITCH
(OPTION)
OIL COOLER FAN
(OPTION)
FLASHING BEACONS
(OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
6 - 94
CONTROL BATTERY
8
HYD
FAN
FB
-
85
87
D51
STA
B1
87
86
BAT
-
7
-
CR17
R116HYD OR
+
P134FB RD
BAT
+
P134FB RD
EXCT
12V DC
C41RPM OR/BK
ALTERNATOR
NO
P134PWR RD
AUX. MAIN
30
D22
NO
CR3
TB21
NO
F22
60A
30
6
B2
C5-19
B1BAT RD
20A
+
C5-11
R21IGN WH
BAT2 APU RD
12V DC
C5-18
B1BAT RD
20A
C5-22
C5-15
P24PWR RD
F7
START RELAY
TACHOMETER
START INPUT
AUXILIARY
IGN / START
GROUND
MODULE
BATTERY
KEY POWER
KEY BYPASS
IGN / FUEL ON
ENGINE FAULT
BL/RD
F17
5
N
P25FS RD
C7-1
C2-6
CB2
P3
HORN
M
P24FS WH
FS1
C9P-1
2
L
ES0503D
L2
H1 RD/BK
C29MS RD/WH
9
10
2
4
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C3-6
C3-5
C3-4
C3-9
C3-8
C3-7
C3-12
C2-3
GR/WH
C1-12
D23
BL/RD
CW
GND BR
C123PBS RD/BK
SNSR-GND BR
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
CCW
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
C177LS BL/RD
P109LS GR/WH
RETRACT
UP
DOWN
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C37STCC BL/BK
C36STC BL
C6-33
C6-34
C6-35
C6-22
C6-40
C6-23
C6-25
C6-13
C123PBS RD/BK
SNSR-GND BR
BL/RD
C6-5
C6-6
C6-7
C6-8
C6-9
C6-31
C6-3
C6-2
C6-1
C6-12
C211PLO BL/BK
S212PLO GR/BK
GR/WH
C6-4
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6-16
C6-38
C6-30
C6-21
P134PWR RD
P210PWR BK
C118LS OR
C5-21
C5-20
C6-37
C6-36
C5-23
C5-24
6
OR
BR
YL
RD
OR
WH
BK
WH
BR
RD
BK
WH
BR
RD
BK
WH
BR
RD
RD
BK
BL
5
BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C37STCC BL/BK
C31EDC WH/BK
C30EDC WH
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
BL
BR
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
14
4
1
3
9
11
10
14
13
12
5
1
7
C3-1
C3-2
C3-3
C1-4
C1-5
C1-11
C1-10
C1-6
C1-3
14
13
NO
NO
13
NO
5
13
14
15
8
7
16
6
LED BL/RD
C144DER BL/WH
RIGHT
5
10
8
6
2
6
7
8
15
16
18
17
19
20
C6-24
WH
RD
RD
BL
BR
BK
BK/WH
BL
BR
BK
BK/WH
BK
WH
BR
RD
NC
BR
BK
WH
BR
BK
Y23
Y24
Y13
Y26
Y25
7
22
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DESCENT ALARM
LOOSE CABLE LED’S
LSB2S
LOOSE CABLE
LIMIT SWITCH
MOTOR STROKE
BRAKE RELEASE
STEER CW
STEER CCW
DRIVE EDC REVERSE
DRIVE EDC FORWARD
GROUND
CR34 - PRIMARY BOOM
SPEED REDUCTION RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
LST3O - BOOM UP/DOWN
GROUND BOX - ZONE A
OPERATION AND SPEED
REDUCTION LIMIT SWITCH
LSB1EO - BOOM EXTEND
CAPACITY OPERATIONAL
LIMIT SWITCH
LSB1ES - BOOM EXTEND
CAPACITY SAFETY
LIMIT SWITCH
LST3S - BOOM ANGLE
STOWED
GROUND BOX - ZONE A
SAFETY LIMIT SWITCH
PRIMARY BOOM
EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CCW
TURNTABLE ROTATE
CW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO
BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O
ANGLE STOWED
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CCW
6 - 95
S-80 • S-85 • S-80X
Part No. 122985
LEFT
C143DEL BL/BK
C209LED BL
C208LED GR
SNSR BR
ZONE SELECT
P109TS GR/WH
C184PL WH
3
1
2
11
1
12
GND BR
4
2
P24FS WH
3
J114
C6-11
13
NO
14
13
NO
14
14
13
NO
NO
U4
1
NC
13
NO
14
6
C129DA RD/BK
14
21
24
2 1
1
2
3
4
1
3
4
2
22
23
NO
BK
Y15
NC
NC
21
22
21
22
21
22
23
24
NC
Y22
1
2
3
4
J134
1
2
3
4
TB9
23
24
GR
6
J133
3
BL
2
1
2
3
4
NO
TB7
2
1
J133
2
5
21
13
NO
14
13
H4
TB118
4
1
TB8
D29
Y21
Y12
Y6
Y5
Y3
Y4
Y2
Y27
P24FS WH
P26ESTP BK
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
C43JU GR
DOWN
C44JD GR/BK
C17PRL GR
C18PRR GR/BK
CW
CCW
TB3
TB4
TB1
TB37
TB36
TB44
CR68
CR34
4
CR53
R16
10W
TB5
TB18
R14(A)
5W
CR52
L46
TB42
TB13
TB30
TB31
TB32
TB29
TS62
TURNTABLE
ROTATE
TS63
PRI. BOOM
EXT. / RET.
TS61
PRI. BOOM
UP / DOWN
C27AUX RD
3
C3-11
C4-2
TB134A
P210PWR BK
2
J1
J1
J1
D24
C59CNK BL/BK
C4-3
C4-7
C4-8
C4-5
C4-6
TB59
TS59
P162JPW2-OR
CR69
TB2
TB15
TB17
UP
DOWN
J22-11
J22-12
J22-9
J22-10
J22-2
J22-1
P134PWR RD
P134PWR RD
P162JPW1-OR
2
5
TB14
TB43
D30
CW
CCW
J22-7
J22-8
J22-5
J22-6
J22-4
J22-3
Y20
Y19
Y70
R16
7.5W
TS57
PLATFORM
ROTATE
J2
J2
Y71
C159STC-BL/WH
2
C164PES-RD/WH
J8
3
C165TRS-WH/RD
3
J8
CR30
J1
JSGND1-BR
1
J25
JSGND2-BR
1
J127
NO
JOYSTICK CONTROL CARD
J3
C160JPL-WH/RD
4
4
TS9
PLATFORM
LEVEL
TS7
PLATFORM
ROTATE
LIFT / DRIVE
(OPTION)
C159STC-BL/WH
5
C163PLS-WH/BK
6
L50
L51
6
JC3
DRIVE / STEER
5
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
L47
TS14
DRIVE
SELECT
L1
TS15
DRIVE
ENABLE
TS75
ZONE SELECT
NC
1
ZONE B
ZONE A
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Perkins 804D-33 Models
GND BR
C28TTA RD/BK
P24FS WH
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80X,
Perkins 804D-33 Models
6 - 95
6 - 96
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Perkins 804D-33 Models
6 - 97
6 - 98
8
6 - 98
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A(C)
BK-GND
BL-GND
GR-GND
7
ES0503D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
I
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
WH-C5-3
WH L2(-)
1
U1
C7B
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
12V TO PLAT
1
2
3
4
5
6
7
8
9
10
3
WH-TB23B
CABLE
RESTRAINT
BK-C32-5
BR-GND STUD
H
BK-C5-5
OR/BK-TB41C
BK-TB33C
RD-TB27C
BR GND
RD-C5-1
WH-TB23C
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
G
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
TB21C
RD-TB20A
F
WH/12 C7B-2
DRIVE LIGHT OPTION RELAY
RD-TB20B
1
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
BL/BK C6-37
BL C6-36
BK/RD C5-18
E
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
(UNUSED)
(UNUSED)
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR (OPTION)
(UNUSED)
(UNUSED)
LIMIT SWITCH - LST20
RPM / TACH SIGNAL
LIMIT SWITCH - LSB1RO
(UNUSED)
STEER CCW
STEER CW
ENGINE RPM
GLOW PLUG
ENGINE START
BRAKE RELEASE
REVERSE / EDCFORWARD / EDC+
DRIVE SPEED
PLATFORM LEVEL ALARM
AUXILIARY POWER
12V POWER
POWER TO PLATFORM
KEYSWITCH PWR TO PLATFORM
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
D
OR/RD C6-22
OR/BK C5-2
OR C6-40
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
A
OR/RD C5-19
RD C6-23
RD C6-24
3
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
BR GND2
155
134A
134
133
132
118
59
46
45
D29
TB2C-DESC. ALARM 44
43
42
OR/BK ISM#2
41
40
39
37
36
35
BK/RD TS54-1(D13)
BK/WH TS56-3
34
33
BK TS52-3
BK ISM#3
32
31
30
29
28
RD TS51-4
D6
27
RD ISM#4
24
WH KS1-1(D2)
23
WH ISM#7
BK C32-4
BK/12 KS1-3
22
WH HM(+)
21
RD/12 CB2-2
20
18
GR/BK TS57-1
17
GR TS57-3
OR/BK TS59-3
15
OR TS59-1
14
13
BK/RD R14(A)
9
BK/WH TS63-3
8
BK CR69-87A
7
6
WH/RD R14(A)
5
WH/BK TS62-1
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TB44C
2
RD/BK CR68-87A
D30
1
RD TS61-4
BK GND1
C6-30 C211LO BL/BK
C
C
D
OR/RD TS62-5(D68)
OR-BEACON (RIGHT) WH-BEACON (LEFT)
RD C32-1
KS1-2
GR/BK C32-8
BL/WH C32-3
OR CR34#86
BL/BK L46(+)
RD DL2
C6-38 C212LO GR/BK
WH DL1
TB2D R2PBD RD/BK
CR69
WH/BK C4B-9
TB7D R7PBE BK
5
CR68
B
GND BR
CR53
4
CR52
F19
RD/BK
BK
10 AMP FUSE
C32
BK-C7B-1
WH-TS51-5
RD-TS56-2
GN/BK-TB133C
BR-GND
2
5
6
7
8
12
RD - TB134C
BL/WH-TB132C
BK-TB22C
A
TS61-6 C2PBD RD/BK
TS63-1 C7PBE BK
6
1
3
4
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Perkins 804D-33 Models
J
K
L
C1B
LABEL
M
FUNCTIONS
ENGINE
C6
C5
N
GROUND STUD
2
CR23
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
CR52
CR53
PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL
PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL
CR68
PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY
CR69
PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
R14
FUNCTION ENABLE TOGGLE SWITCH
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
TS51
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS56
GLOW PLUG TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U1
IGNITION START MODULE
HARNESS TO
SWITCH PANEL
3
Part No. 122985
1
D13
TS62
6
3
5
2
1
L46
4
1
4
5
6
2
CB2
TS61
2
1
1
3
1
2
3
4
4
5
6
NO
D101
NO
3
P4
TS51
4
D64 3
2
1
2
3
1
S-80 • S-85 • S-80X
GN/BK-TB18D
BL/BK-TB59D
BR-GND STUD
TO GROUND
CONTROL BOX
CONNECTIONS
C
BR-HM(-)
RD-TB20D
RD-P1-2
D
WH-C32-6
RD-TB27D
RD-TS61-2
WH-KS1-1
D4
OR/RD-TB155D
WH/BK-TB5D
WH/RD-R14(A)
WH-TB4D
GN-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-CR52-30
BK-CR53-30
RD-R16
BK/WH-TB8D
BK/RD-TB9D
BK C6-12
OR-TB14D
OR/BK-TB15D
WH-ISM#10
BK-TB33D
RD-C32-7
E
D68
4
3
6
TS63
3
TS56
TS52
BL/WH-TB34D
WH-TB23D
RD-CB2-1
BK/RD-TB35D
WH-TS51-2
BR-CR34#85
BR-L46(-)
F
2
1
-
G6
G
TS57
1
2
B
3
H
2
3
TS54
D2
B1
+
I
3
2B
2A
1
4
J
TS59
NC
NC
2
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
K
L2
1B
KS1
R16
OR-TB118D
RD/WH-TB3D
L
1A
R14(A)
R14
RD/WH-TS61-1
M
P1
CR34
86
BR-HM(-)
N
85
30
87
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Perkins 804D-33 Models
B
A
1
2
3
4
5
6
7
8
ES0503D
6 - 99
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Perkins 804D-33 Models
6 - 99
6 - 100
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram, S-80X,
Perkins 804D-33 Models
6 - 101
6 - 102
BK P2
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS GR/WH C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C177LS BL/RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS6-C34SA BK/WH C1P-8
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
J22
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
CR30
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
WH TS14
WH TS7
7
ES0503D
FOOT
SWITCH
WH L1
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
1
WH C9P-2
JC3-5 C159STC BL/WH
CAN HI
CAN LOW
L51(-) C169LED1 GR
L50(-) C169LED2 GR
TS75-1 P109TS GR/WH
C3P-12 P109LS BL/WH
C1P-12 C177LS BL/WH
TS75-2 C184PL WH
TS75-3 SNSR BR
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
1
BR BATGND
(GROUND STUD)
CR27
8
OPTION
12V
BATTERY
H1
Part No. 122985
S-80 • S-85 • S-80X
6 - 102
1
OPTION
C9
+
J22-1,2,9,10,11 AND 12
D40
C7P
6
RD C2P-6
4
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
6
11
J8
J7
J1
1
2
3
RD LS18
3
J2
2
9
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80X,
Perkins 804D-33 Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Perkins 804D-33 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
1
D12
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
GR J8-5
BR J8-8
GR/WH J8-6
WH J8-2
GR J8-10
TS15
BL/RD J1-16
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
RD C9P-3
OR/RD C4P-4
BK/WH C1P-8
BK/RD C1P-9
BK C1P-7
RD C1P-1
RD/WH J1-8
BR GND STUD
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS4
1
2
JC3
JC7
TS6
3
+
TS2
6
L47
+
1
6
1
L1
4
TS9
TS1
TS7
P3
+
+
TS14
+
NO
L48
L51
TS75
NC
P2
L50
RD
BK
RD
BK
5
BK
RD
ES0503D
6
COMPONENT INDEX
H1
TILT ALARM
TS6
GLOW PLUG TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS7
PLATFORM ROTATE TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS14
DRIVE SPEED TOGGLE SWITCH
L47
LED - CABLE TENSION
TS15
DRIVE ENABLE TOGGLE SWITCH
L48
LED - TILT ALARM
TS75
ZONE SELECT TOGGLE SWITCH (OPTION)
L50
LED - ZONE B, 500 LB CAPACITY
U13
ALC500 JOYSTICK CONTROLLER CARD
L51
LED - ZONE A, 1000 LB CAPACITY
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS4
RPM SELECT TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 103
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Perkins 804D-33 Models
6 - 103
6 - 104
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS)
Continental TME27 Models
6 - 105
6 - 106
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models
A
B
C
D
E
F
G
H
I
J
K
L
M
N
C28TTA RD/BK
C28TTA RD/BK
P26ESTP BK
1
FS1
P2
C9P-1
BK
C9P-3
P24FS WH
GAS
LP
C2-1
GAS
LP
LOW
L2
TS53
FUEL
SELECT
C39LP BL/RD
TS54
ENGINE
RPM
TS64
ENGINE
FAULT
P134PWR RD
C41RPM OR/BK
D4
C27AUX+FE RD
D11
C27AUX RD
D13
TB33
TB155
TB23
GBOX GND
TB21
TB35
TB39
C27AUX RD
RD
GN/WH
4
+
G6
-
TB27
D2
WH
D67
C35RPM BK/RD
RD
TB28
D68
HIGH
8
TS52
ENGINE
START
C33STR BK
12
TB133
PUMP AUXILIARY
C32
WH
7
P23PWR WH
TB20
TS51
C27AUX RD
5
6
C28TTA RD/BK
1
C109LS GR/WH
B
C1-9
C4-4
C1-7
C1-1
C7-2
C1-2
P4
FUNCTION
ENABLE
3
4
C46HRN GR
3
1
TB22
LOW
D12
L48
C3-12
C2-5
KS1
TS3
FUEL
SELECT
D40
TB132
PLAT
GND
HIGH
+
B1 4
3
TS4
ENGINE
RPM
V155PCE OR/RD
TS2
ENGINE
START
H1
-
TB134
RD
2
RD
D43
P22PWR BK
P134PWR RD
C177LS BL/RD
P1
RD
TS1
AUXILIARY
PUMP
C9P-2
C7-1
C1-12
C2-6
CB2
15 AMP
P25FS RD
P24FS WH
P3
HORN
P24FS WH
D10
P25FS RD
BK
RD
2
P26ESTP BK
P134PWR RD
P23PWR WH
TB46
TB41
RD
C5-11
C5-19
C5-5
C5-1
C5-6
C6-28
C6-24
C5-7
C5-2
F17
20 A
5
V155PCE OR/RD
C
RD
CR39B
NC
R27AUX RD
C28TTA RD/BK
R21IGN WH
7
C21RET WH
2
R33STR BK
5
R23PWR WH
WH
PR1
NO
+
1
C38FP BL/WH
4
C38RET BL
M4
3
SW4
NO
M2
H2
FB
FB
REGULATOR
IND
Y74
BK
WH - 14GA
M3
CHECK ENGINE LIGHT
FUEL PUMP
ENGINE FAULT CODE
TEST SWITCH
HOUR METER
STARTER
PRESSURE COMP VALVE
FUNCTION ENABLE
IGNITION RELAY
START RELAY
APU CUT-OUT
RELAY
VOLTAGE DROP
RELAY
Part No. 122985
AUXILIARY PUMP
RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING BEACON
(OPTION)
HORN RELAY
HORN
HYD. OIL COOLER
TEMP. SWITCH
(OPTION)
HYD. OIL COOLER
FAN (OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
CONTROL BATTERY
S-80 • S-85 • S-80X
B
HARNESS
-
BK - 12GA
M1
-
P134PWR RD
P134FB RD
P134FB RD
R46HRN GR
A
CR39A
NO
RD - 12GA
STA
6 - 106
C116HYD WH
R116HYD OR
+
7
8
10
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
B1BAT RD
BAT
-
BAT
+
CR5
NO
CR17
NO
EXCT
12V DC
B1
9
C127TSW GR
CR2
NO
CR1
NO
R6
510W
-
8
C108ESL BL/WH
C5-8
6
B2
11
C35RPM BK/RD
C5-13
P20BAT RD
F7
20 A
+
6
C39LP BL/RD
C5-9
R21IGN WH
BAT2 APU
12V DC
C41RPM OR/BK
C5-10
P24PWR RD
ES0505D
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
9
10
15
8
6
7
16
C144DER BL/WH
RIGHT
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C8PBR BK/WH
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
C118LS OR
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
SNSR-GND BR
C123PBS RD/BK
C6-31
C6-9
C6-8
C6-7
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
3
C6-11
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C29MS RD/WH
C32BRK WH/RD
C130TA WH/RD
C31EDC WH/BK
C30EDC WH
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C129DA RD/BK
C3PBF RD/WH
C2PBD RD/BK
C1PUB RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
14
LED BL/RD
LEFT
C143DEL BL/BK
14
4
5
13
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C17PRL GR
PLAT. ROTATE
4 3 2 1
RD
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
GROUND
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 107
S-80 • S-85 • S-80X
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
4 3 2 1
2
6
4 3 2 1
3
C4-5
CCW
CW
7
22
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
P24FS WH
P26ESTP BK
J22-11
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-12
14
21
NC
HO
22
LSB2S
NC
21
14
21
NC
13
NO
14
22
13
NO
24 23
NO
NO
TB37
TB36
13
NO
24 23
NO
13
TB5
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
TB42
TB13
5
TB3
TB118
TB14
TB44
CR34
TB4
TB1
TB7
TB8
TB17
4
R14
10W
CR34
TS62
TB30
TB31
TB29
J1
J1
J1
J1
TB40
TB32
TS61
TS63
TB59
TS59
TS58
TS57
TB15
TB43
TB18
CCW
CW
J22-7
J22-9
J22-10
Y20
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y19
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y72 Y73
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
5W
C27AUX RD
J2
J2
Y70 Y71
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS)
Continental TME27 Models
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
J114
U4
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models
6 - 107
6 - 108
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models
6 - 109
6 - 110
8
6 - 110
7
S-80 • S-85 • S-80X
Part No. 122985
CABLE
RESTRAINT
WH-TB23B
3
1
2
G
BK-C32-5
BR-GND STUD
RD-TB20A
F
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
RD-TB20B
3
2
1
E
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
WH C5-1
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
GR-C5-8
BR-GND STUD
D
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
JIB BOOM DOWN S-85
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
GAS/LP FUEL SELECT
STEER CCW
STEER CW
ENGINE SPEED
BR GND2
BK GND1
RD DL2
WH DL1
WH/BK C4B-9
1
OR/RD C6-22
OR/BK C5-2
OR C6-40
BL/RD C5-10
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
CR23
C
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
A
OR/RD C5-19
RD C6-23
RD C6-24
3
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK- TB133C
BR-GND
TB21C
B
BASE TERMINATION BLOCK
155
134A
134
GR/BK C32-8
133
BL/WH C32-3
132
OR CR34#86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
40
39
BL/RD TS53-1(D11)
37
36
BK/RD TS54-1(D13)
35
34
BK TS52-3
33
32
WH/RD-TRAVEL ALARM
31
30
29
28
RD TS51-4
27
24
WH KS1-1(D2)
23
BK/12 KS1-3
BK C32-4
22
WH HM(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TS61-6
2
D29
RD/BK TB44C
RD TS61-4
1
6
C
D
OR/RD TS62-5(D68)
WH-BEACON (RIGHT) WH-BEACON (LEFT)
5
10 AMP FUSE
F19
DRIVE LIGHT OPTION RELAY
A
C32
4
RD
BL/WH-TB132C
BK-TB22C
2
5
6
7
8
12
1
3
4
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
H
I
12V TO PLAT
C7B
J
TS64
18/22 CABLE
16/22 CABLE
C4B
C2B
C3B
K
C1B
LABEL
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS53
FUEL SELECT TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
L
FUNCTIONS
ENGINE
C6
C5
CB2
CONTROLS CIRCUIT BREAKER, 15A
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS64
ENGINE FAULT CODE TEST TOGGLE SWITCH
M
GROUND STUD
DESCRIPTION
ES0505D
HARNESS TO
SWITCH PANEL
N
Part No. 122985
1
2
TS62
6
3
5
2
4
1
L46
4
1
D11
2
CB2
4
5
TS61
6
1
1
2
3
P4
3
4
5
6
NO
TS51
4
3
2
1
2
3
TS52
1
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
C
BR-HM(-)
RD-TB20D
D
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
BL/RD-TB39D
RD-C32-7
OR/BK-TB15D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34#85
BR-L46(-)
E
D68
6
3
1
-
F
3
1
2
TS63
2
G6
G
TS57
1
3
3
3
+
H
3
D13
TS53
B
B1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/WH-C5-13
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
I
2
1
TS58
2
D2
1
2
KS1
R16
RD-TS61-2
J
TS59
3
TS54
R14(A)
OR-TB118D
RD/WH-TB3D
K
L2
NC
NC
2A
2B
E-STOP
1B
1A
CR34
R14
RD/WH-TS61-1
BR-HM(-)
L
P1
87
M
+
N
+
87A
85
86
30
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
B
A
TO GROUND
CONTROL BOX
CONNECTIONS
1
2
3
4
5
6
7
8
ES0505D
6 - 111
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
6 - 111
6 - 112
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS),
Continental TME27 Models
6 - 113
6 - 114
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS BL/WH C3P-12
L47-C59CNK BL/BK C3P-11
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
TS3-C39LP BL/RD C2P-1
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
J22
ES0505D
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
OPTION
12V
BATTERY
BK P2
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C132PLI RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
4
WH L1
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
RD C2P-6
Part No. 122985
S-80 • S-85 • S-80X
6 - 114
6
1
1
2
1
OPTION
C9
H1
6
J1
C7P
+
J22-1,2,9,10,11 AND 12
D40
J2
2
9
3
RD LS18
3
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
11
J8
J7
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
BR BATGND
(GROUND STUD)
CR27
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
CR30
8
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
WH C9P-2
BL/RD J1-16
BL/BK J1-7
BL/WH J1-6
RD C1P-1
RD/BK H1 (D40)
TS4
RD C9P-3
OR/RD C4P-4
BK/RD C1P-9
BK C1P-7
RD/WH J1-8
BL/RD C2P-1
GR/BK C4P-8/J22-6
GR C4P-7/J22-5
BR GND STUD
BL/BK C3P-11
GR C4P-5/J22-4
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS3
1
2
TS15
1
D12
JC7
3
JC3
D10
6
TS2
+
1
L47
4
+
L1
1
6
D43
TS7
TS14
L48
+
NO
5
TS1
TS8
TS9
NC
P3
P2
RD
6
BK
RD
RD
ES0505D
7
COMPONENT INDEX
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
TS1
AUXILIARY TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTIONS
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
TS2
ENGINE START TOGGLE SWITCH
1
H1
TILT ALARM
TS3
FUEL SELECT TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS4
RPM SELECT TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS7
PLATFORM ROTATE TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
L47
LED - CABLE TENSION
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
L48
LED - TILT ALARM
TS14
DRIVE SPEED TOGGLE SWITCH
P2
EMERGENCY STOP BUTTON
TS15
DRIVE ENABLE TOGGLE SWITCH
P3
HORN BUTTON
U13
ALC500 JOYSTICK CONTROLLER CARD
ROCKER STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 115
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models
6 - 115
6 - 116
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 117
6 - 118
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
C132PLI BK
C28TTA RD/BK
1
P26ESTP BK
LS18A
LS18
FS1
P2
C9P-1
BK
D88
3
C2-1
C1-9
GAS
C39LP BL/RD
LP
LOW
C35RPM BK/RD
TB33
TB35
TB155
P134PWR RD
C41RPM OR/BK
D4
C27AUX+FE RD
D11
C27AUX RD
TB39
TB21
C27AUX RD
RD
GN/BK
+
H6
L2
TS53
FUEL
SELECT
D13
TB23
4
+
G6
-
TS54
ENGINE
RPM
TS64
ENGINE
FAULT
TB27
D2
WH
GBOX GND
D68 D67
HIGH
RD
TB28
C33STR BK
8
12
TS52
ENGINE
START
C27AUX RD
TB133
WH
7
TS51
PUMP AUXILIARY
U33
-
C3-10
P4
FUNCTION
ENABLE
P23PWR WH
6
C28TTA RD/BK
C133PLA GR/BK
5
TB20
C4-10
C4-4
C1-7
C1-1
C7-2
C1-2
C3-12
1
D12
3
4
C46HRN GR
B
1
TB22
8
PBOX GND
PBOX GND
TB132
PLAT
GND
3
8
D40
C2-5
KS1
3
NO
10A
U34
D39
B1 4
3
GAS
-
2 SEC.
2
TS3
FUEL
SELECT
LP
NO
30A
TS4
ENGINE
RPM
9
LOW
2
+
H1
L4
9
2 SEC.
5
HIGH
P3
HORN
P24FS WH
TS2
ENGINE
START
V155PCE OR/RD
U35
5
TB134
RD
2
RD
D43
P22PWR BK
RD
C132PLI BL/WH
P134PWR RD
P1
TS1
AUXILIARY
PUMP
C9P-2
R20
4.7KW
P24FS WH
D10
P25FS RD
P24FS WH
C7-1
C1-12
C2-6
CB2
15 AMP
C9P-3
P25FS RD
RD
PBOX GND
2
P26ESTP BK
P134PWR RD
P23PWR WH
TB46
L45
TB41
RD
C5-11
C5-15
C5-19
C5-17
C5-5
C5-1
C5-6
C6-28
C6-24
C5-7
5
C5-2
F17
20 A
CR39B
NC
V155PCE OR/RD
R27AUX RD
C28TTA RD/BK
C
RD
WH
PR1
NO
R21IGN WH
7
C21RET WH
2
R33STR BK
5
R23PWR WH
1
C38FP BL/WH
+
4
C38RET BL
M4
3
M2
H2
FB
FB
IND
WH - 14GA
M3
CHECK ENGINE LIGHT
FUEL PUMP
ENGINE FAULT CODE
TEST SWITCH
HOUR METER
STARTER
PRESSURE COMP VALVE
FUNCTION ENABLE
IGNITION RELAY
START RELAY
APU CUT-OUT
RELAY
VOLTAGE DROP
RELAY
Part No. 122985
AUXILIARY PUMP
RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING BEACON
(OPTION)
HORN RELAY
HORN
HYD. OIL COOLER
TEMP. SWITCH
(OPTION)
HYD. OIL COOLER
FAN (OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
CONTROL BATTERY
S-80 • S-85 • S-80X
B
Y74
BK
HARNESS
BK - 12GA
SW4
NO
REGULATOR
-
P134PWR RD
P134FB RD
P134FB RD
R46HRN GR
M1
6 - 118
A
CR39A
NO
RD - 12GA
STA
8
R21IGN WH
R116HYD OR
BAT
-
BAT
+
+
B1
10
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
B1BAT RD
12V DC
CR5
NO
CR17
NO
EXCT
-
9
C127TSW GR
CR2
NO
CR1
NO
R6
510W
B2
8
C108ESL BL/WH
C5-8
F7
20 A
+
11
C35RPM BK/RD
C5-13
P20BAT RD
6
7
6
C39LP BL/RD
C5-9
R21IGN WH
BAT2 APU
12V DC
C41RPM OR/BK
C5-10
P24PWR RD
ES0505A
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
9
10
15
8
6
7
16
C144DER BL/WH
RIGHT
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C8PBR BK/WH
C9PER BK/RD
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
C118LS OR
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
SNSR-GND BR
C123PBS RD/BK
C6-31
C6-9
C6-8
C6-7
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
3
C6-11
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C29MS RD/WH
C32BRK WH/RD
C130TA WH/RD
C31EDC WH/BK
C30EDC WH
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C129DA RD/BK
C3PBF RD/WH
C2PBD RD/BK
C1PUB RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
14
LED BL/RD
LEFT
C143DEL BL/BK
14
4
5
13
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C17PRL GR
PLAT. ROTATE
4 3 2 1
RD
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
GROUND
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 119
S-80 • S-85 • S-80X
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
4 3 2 1
2
6
4 3 2 1
3
C4-5
CCW
CW
7
22
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
P24FS WH
P26ESTP BK
J22-11
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-12
14
21
NC
HO
22
LSB2S
NC
21
14
21
NC
13
NO
14
22
13
NO
24 23
NO
NO
TB37
TB36
13
NO
24 23
NO
13
TB5
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
TB42
TB13
5
TB3
TB118
TB14
TB44
CR34
TB4
TB1
TB7
TB8
TB17
4
R14
10W
CR34
TS62
TB30
TB31
TB29
J1
J1
J1
J1
TB40
TB32
TS61
TS63
TB59
TS59
TS58
TS57
TB15
TB43
TB18
CCW
CW
J22-7
J22-9
J22-10
Y20
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y19
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y72 Y73
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
5W
C27AUX RD
J2
J2
Y70 Y71
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
J114
U4
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 119
6 - 120
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 121
6 - 122
8
6 - 122
RD DL2
ES0505A
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
1
2
CABLE
RESTRAINT
WH-TB23B
3
G
BK-C32-5
BR-GND STUD
RD-TB20A
F
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
WH C5-1
E
WH/12 C7B-2
RD-TB20B
3
2
1
D
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
BR-GND STUD
GR-C5-8
C
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR
JIB BOOM DOWN S-85
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
GAS/LP FUEL SELECT
STEER CCW
STEER CW
ENGINE SPEED
H6
OR/RD C6-22
OR/BK C5-2
OR C6-40
BL/RD C5-10
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
3
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
A
OR/RD C5-19
RD C6-23
RD C6-24
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
5
6
7
8
12
B
155
WH-BEACON (LEFT)
134A
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34#86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
40
39
BL/RD TS53-1(D11)
37
36
BK/RD TS54-1(D13)
35
34
BK TS52-3
33
32
WH/RD-TRAVEL ALARM
31
30
29
28
RD TS51-4
27
24
WH KS1-1(D2)
23
BK/12 KS1-3
BK C32-4
22
WH HM(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34#30
3
RD/BK TS61-6
2
D29
RD/BK TB44C
RD TS61-4
1
C
6
D
OR/RD TS62-5(D68)
WH-BEACON (RIGHT)
RD L45(+)
BR GND2
BK GND1
U33
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (C)
WH-134A (C)
BK-GND
BL-GND
GR-GND
7
WH DL1
RD-H6(+)
BL/WH-TB132C
BK-TB22C
2
WH/BK C4B-9
1
3
4
C32
1
CR23
TB21C
4
10 AMP FUSE
5
F19
DRIVE LIGHT OPTION RELAY
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)
H
I
12V TO PLAT
C7B
J
TS64
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
K
C1B
LABEL
L
CB2
CONTROLS CIRCUIT BREAKER, 15A
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
TS51
RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS53
FUEL SELECT TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
M
FUNCTIONS
ENGINE
C6
C5
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TS63
TURNTABLE ROTATE TOGGLE SWITCH
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
U33
LOAD SENSE MODULE
GROUND STUD
DESCRIPTION
HARNESS TO
SWITCH PANEL
N
Part No. 122985
2
1
TS62
6
3
5
2
4
1
1
2
CB2
4
5
TS61
6
1
1
2
3
P4
3
4
5
6
NO
L45
TS51
4
3
2
1
2
3
TS52
1
BR-L46(-)
S-80 • S-85 • S-80X
GR/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-HM(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
RD-P1-2
WH-C32-6
RD-TS61-2
WH-KS1-1
D4
WH/RD-R14(A)
OR/RD-TB155D
RD-TB27D
WH-TB4D
WH/BK-TB5D
GR-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-TB2D
BK-TB7D
RD-R16
BK/WH-TB8D
BK/RD-TB9D
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
BK-TB33D
BL/RD-TB39D
RD-C32-7
OR/BK-TB15D
BK/RD-TB35D
WH-TB23D
RD-CB2-1
WH-TS51-2
BR-CR34#85
D
L46
4
1
D11
-
E
D68
6
3
TS63
2
G6
F
3
1
2
3
3
+
G
TS57
1
3
D13
TS53
B
B1
4
WH-TB21D
BK-TB22D
RD-L45(+)
BL/WH-C5-13
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
H
2
1
TS58
2
D2
1
2
KS1
R16
OR-TB118D
RD/WH-TB3D
I
3
3
TS54
R14(A)
R14
RD/WH-TS61-1
BR-HM(-)
J
TS59
L2
NC
NC
2B
2A
E-STOP
1B
CR34
1A
P1
87
K
+
L
+
M
+
N
87A
85
86
30
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)
B
A
1
2
3
4
5
6
7
8
ES0505A
6 - 123
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 123
6 - 124
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 125
6 - 126
CR27
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
CR30
8
RD LS18 CABLE
WH TS14
WH TS7
R20
7
RD-E-STOP
P134PWR RD
BR BATGND
(GROUND STUD)
ES0505A
P134PWR RD
RD-H1+
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
R26ESTP BK C9P-1
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
C1P(GY)
C2P(BK)
C3P(GN)
C4P(BR)
F.S.
J1-SNSR GND BR C2P-10
J1-P109ANG GR/WH C2P-9
TS3-C39LP BL/RD C2P-1
P3-C46HRN GR C2P-5
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C132PLI RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
C3-10
C4-10
BATGND J3-1
U35
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
OPT.
12V BATT
P26ESTP BK E-STOP
BR GND
BK P2
WH L1
WH C9P-2
JC3-5 C159STC BL/WH
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
Part No. 122985
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
H1
D88
D39
LS18
C9
J22
C7P
+
1
GR/BK C3P-12
D40
BATGND C7P-3
5
S-80 • S-85 • S-80X
6 - 126
RD C2P-6
4
BRN
GND STUD
6
GR/BK L4
RD LS18
3
3
COM
NO
2
3
5
1
5
J2
2
1
U34
11
J1
9
COM
NO
2
3
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)
1
C1P-2 C28TTA RD/BK
J22-1, 2, 9, 10, 11 & 12
C132PLI BK C1P-12
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
WH C9P-2
BL/RD J1-16
BL/BK J1-7
BL/WH J1-6
RD C1P-1
RD/BK H1 (D40)
TS4
RD C9P-3
OR/RD C4P-4
BK/RD C1P-9
BK C1P-7
BL/RD C2P-1
RD/WH J1-8
GR/BK C4P-8/J22-6
GR C4P-7/J22-5
BR GND STUD
GR/BK H1 (D39)
BL/BK C3P-11
GR C4P-5/J22-4
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS3
1
2
TS15
1
D12
L4
JC3
3
D10
JC7
+
TS2
6
L47
L1
4
+
1
1
6
D43
TS9
TS1
TS8
5
TS14
L48
+
NO
NC
TS7
P3
P2
RD
BK
RD
6
RD
ES0505A
COMPONENT INDEX
C1P
18/22 CONTROL CABLE (GREY)
P3
HORN BUTTON
C2P
18/22 CONTROL CABLE (BLACK)
R20
RESISTOR - 4700W
C3P
16/22 CONTROL CABLE (GREEN)
TS1
AUXILIARY TOGGLE SWITCH
C4P
16/22 CONTROL CABLE (BROWN)
TS2
ENGINE START TOGGLE SWITCH
C7P
12VDC POWER TO PLATFORM
TS3
FUEL SELECT TOGGLE SWITCH
C9
FOOT SWITCH
TS4
RPM SELECT TOGGLE SWITCH
CR27
LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)
TS7
PLATFORM ROTATE TOGGLE SWITCH
CR30
LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)
TS8
JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
H1
TILT ALARM
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
J22
PLATFORM MANIFOLD
TS14
DRIVE SPEED TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS15
DRIVE ENABLE TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
U13
ALC500 JOYSTICK CONTROLLER CARD
L1
LED - DRIVE ENABLE
L4
LED - PLATFORM OVERLOAD
U34
U35
TIME DELAY RELAY - 2 SECONDS, 10A
TIME DELAY RELAY - 2 SECONDS, 30A
L47
LED - CABLE TENSION
L48
LED - TILT ALARM
LS18
PLATFORM OVERLOAD LIMIT SWITCH
P2
EMERGENCY STOP BUTTON
7
8
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER STEER OPTION
Part No. 122985
S-80 • S-85 • S-80X
6 - 127
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (before serial number 8111)
6 - 127
6 - 128
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 129
6 - 130
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
A
B
C
D
E
F
G
H
I
P26ESTP BK
1
P2
C2-1
TB155
TB23
TB35
TB21
GAS
TB33
TB27
D2
FUEL
SELECT
C39LP BL/RD
D13
TS53
LP
TB28
P134PWR RD
C27AUX + FE RD
C27AUX RD
D11
TB39
B1BAT RD
P134PWR RD
P23PWR WH
TB46
TB41
C5-11
C5-19
C5-17
C5-15
C5-5
C5-1
C5-6
C6-28
C6-24
C5-7
C5-2
F17
20A
C5-10
R21ING WH
C5-9
C5-8
BAT 2 APU RD
CR1
CR39A
CR39B
NC
V155PCE OR/RD
8
C108ESL BL/WH
9
C127TSW GR
10
R21ING WH
7
R21RET WH
2
R33STR BK
5
R23PWR WH
1
C38FP BL/WH
4
C38RET BL
M2
Y74
M4
3
BK 12GA
FB
RD 12GA
FB
BK
B1
H2
+
WH 14GA
PR1
NO
11
C35RPM BK/RD
CR2
R27AUX RD
C
WH
-
M3
VOLT REG.
IND
B
CHECK ENGINE
LIGHT
FUEL PUMP
ENGINE FAULT CODE
TEST SWITCH
HOUR METER
STARTER MOTOR
PRESSURE COMP VALVE
(FUNCTION ENABLE)
ENGINE IGNITION
RELAY
START RELAY
AUXILIARY POWER
CUT OUT RELAY
VOLTAGE DROP
RELAY
Part No. 122985
AUXILIARY PUMP
RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING BEACONS
(OPTION)
SERVICE HORN
RELAY
S-80 • S-85 • S-80X
SERVICE HORN
HYD. OIL COOLER
TEMP. SWITCH
(OPTION)
HYD. OIL COOLER
(OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
6 - 130
CONTROL BATTERY
8
RD
SW4
NO
M1
B2
NO
NO
+
STA
-
A
C28TTA RD/BK
BAT -
P134FB RD
+
7
BAT +
R46HRN GR
12V DC
CR5
NO
C116HYD WH
12V DC
R116HYD OR
EXCT
CR17
NO
P134FB RD
AUX MAIN
R6
510W
P134PWR RD
F7
20A
NO
6
C39LP BL/RD
VEHICLE INTERFACE 1 HARNESS
C5-13
C41RPM OR/BK
CONTINENTAL TME27 ENGINE
B1BAT RD
P24PWR RD
B1BAT RD
6
C41RPM OR/BK
D4
C27AUX RD
GR/BK
GROUND
GROUND BOX
ENGINE
RPM
L2
C32
5
GAS
C1-9
ENGINE
FAULT
CODE
LOW
+
G6
-
TS54
C35RPM BK/RD
D67
HIGH
8
TS64
D68
RUN
12
P4
FUNCTION
ENABLE
TEST
TB133
TS51
AUX.
PUMP
C33STR BK
7
TS52
ENGINE
START
C27AUX RD
TB20
4
LP
HIGH
C4-4
C1-7
C1-1
5
6
P23PWR WH
1
TS3
FUEL
SELECT
D12
C28TTA RD/BK
B
P24FS WH
3
4
PLAT
GRND
C46HRN GR
3
1
TB22
3
TS4
ENGINE
RPM
L48
C7-2
KS1
H1
C1-2
TB132
4
P24FS WH
+
C2-5
2
C28TTA RD/BK
P26ESTP BK
LOW
P22PWR BK
P134PWR RD
B1
C28TTA RD/BK
D40
TB134
P1
N
P26ESTP BK
V155PCE OR/RD
C7-1
C2-6
CB2
15 AMP
TS2
ENGINE
START
TS1
D43
-
M
P25FS RD
C9P-2
P3
HORN
L
D10
P25FS RD
P24FS WH
2
K
C9P-3
FS1
C9P-1
J
ES0505D
WH
1
P26ESTP BK
H1 RD/BK
C29MS RD/WH
LED BL/RD
9
6
7
2
4
1
3
18
17
9
11
10
6
7
8
14
13
12
5
15
16
19
20
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C1-11
C1-10
C3-6
C3-5
C3-4
C3-1
C3-2
C3-3
C3-9
C3-8
C3-7
C2-3
C1-4
C1-5
C1-6
C1-3
C123PBS RD/BK
SNSR-GND BR
P109ANG GN/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C6-33
C6-34
C6-35
C6-22
C6-40
C6-25
C6-13
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C13DRE BL/RD
CW
CCW
DOWN
UP
PRIMARY BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
P134PWR RD
C8PBR BK/WH
C9PER BK/RD
PRIMARY BOOM
C7PBE BK
EXTEND
RETRACT
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLAT. LEVEL
C15PLD OR/BK
UP
DOWN
C44JD GR/BK
C43JU GR
DOWN JIB BOOM
(S-85 OPTION)
C18PRR GR/BK
UP
SNSR-GND BR
C123PBS RD/BK
C6-7
C6-8
C6-9
C6-11
J114
YL
BR
OR
BL
BK
RD
BR
BK
WH
RD
BR
BK
WH
RD
RD
BR
BK
WH
C6-31
C118LS OR
C6-3
C6-2
C6-1
C6-6
C6-5
C6-4
C6-36
C6-37
P134PWR RD
C13DRE BL/RD
C40LS OR
C42LS OR/RD
P109ANG GN/WH
BR
C5-21
C5-20
C5-23
C5-24
5 6
4
C37STCC BL/BK
C36STC BL
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C1PUB RD
C2PBD RD/BK
C3PBF RD/WH
C129DA RD/BK
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C30EDC WH
C31EDC WH/BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
4 3 2 1
RD
RD
BR
BK
WH
BR
PLATFORM ROTATE CCW
JIB BOOM UP
JIB BOOM DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
GROUND
L46 / L47
LOOSE CABLE LED
LSB2S
LOOSE CABLE
LIMIT SWITCH
2 SPEED
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM (OPTION)
EDC - DRIVE REVERSE
EDC - DRIVE FORWARD
PRIMARY BOOM
EXTEND / RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
LST3O - BOOM UP / DOWN
SPEED REDUCTION
LIMIT SWITCH
CR34 - SPEED REDUCTION
RELAY
DESCENT ALARM
PRIMARY BOOM
UP / DOWN
FLOW CONTROL
PRIMARY BOOM
DOWN
PRIMARY BOOM
UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CW
TURNTABLE ROTATE
CCW
STEER CW
STEER CCW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO - BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O - STOWED ANGLE
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CW
6 - 131
S-80 • S-85 • S-80X
10
15
8
C144DER BL/WH
RIGHT
16
LEFT
C143DEL BL/BK
4
5
13
14
1
3
1
2
11
12
GND BR
4
2
P24FS WH
3
C4-2
C3-11
C4-3
C4-8
C4-7
C4-6
C17PRL GR
PLAT. ROTATE
4 3 2 1
3
C4-5
CCW
CW
24
Part No. 122985
Y3
Y4
Y24 Y23
Y13
Y21 Y22
Y12
H4
23
NO
14 13
NO
U4
7
22
Y26
Y25
Y15
Y6
Y5
H3
Y27 Y2
P24FS WH
P26ESTP BK
J22-11
UP
PLATFORM
DOWN LEVEL
UP
DOWN
J22-12
14
LSB2S
NC
21
14
21
NC
13
NO
22
13
NO
24 23
NO
NO
4 3 2 1
3
6
4 3 2 1
2
TB118
14
14
CR34
TB37
TB36
1
D29
D30
L46
TB6
TB2
TB9
R14(A)
5W
TB42
TB13
5
TB3
TB14
TB44
CR34
13
NO
24 23
NO
13
TB5
4
R14
10W
TB4
TB1
TB7
TB8
TB17
TS62
TB30
TB31
TB29
J1
J1
J1
J1
TB40
TB32
TS61
TS63
TB59
TS59
TS58
TS57
TB15
TB43
TB18
CCW
CW
J22-7
J22-9
J22-10
Y20
J22-2
S-85
(OPTION)
J22-8
J22-6
J22-5
Y19
TS8
TS9
JIB BOOM
(S-85 OPTION)
J22-3
Y72 Y73
J22-1
TB134A
P134PWR RD
2
TS7
PLATFORM
ROTATE
J22-4
R16
7.5W
C27AUX RD
J2
J2
Y70 Y71
JC3
DRIVE / STEER
C163PES-WH/BK
C165TRS-WH/RD
C164PLS-RD/WH
P162JPW2-OR
JSGND2-BR
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
NC
U13
ALC-500 JOYSTICK
CONTROL CARD
J2
CR30
NO
LIFT / DRIVE
(OPTION)
ROCKER / STEER OPTION
J25
6
5
4
3
2
1
J127
6
5
4
3
2
1
L47
J3
L1
C159STC-BL/WH
C160JPL-WH/RD
C159STC-BL/WH
P162JPW1-OR
JSGND1-BR
TS14
DRIVE MODE
TS15
DRIVE ENABLE
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
C28TTA RD/BK
GND BR
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 131
6 - 132
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 133
6 - 134
6 - 134
7
C
6
U34
ES0505D
S-80 • S-85 • S-80X
CABLE
RESTRAINT
Part No. 122985
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
WH C5-11
RD/12 BATT+
CABLE
RESTRAINT
WH-TB23B
3
1
2
G
BK-C32-5
BR-GND STUD
RD-TB20A
F
BASE TERMINATION BLOCK
RD/12 BATT+
GR/BK C4B-6
GR C4B-5
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LS
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
TS64
RD-TB20B
3
2
1
E
WH C5-1
BR-GND STUD
GR-C5-8
D
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
PLATFORM LOAD ALARM
PLATFORM LOAD INPUT
LIFT SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR (OPTION)
JIB BOOM DOWN S-85
(OPTION)
JIB BOOM UP
BOOM ANGLE STOWED LS
RPM SIGNAL
BOOM RETRACTED LS
FUEL SELECT
STEER CCW
STEER CW
ENGINE SPEED
(UNUSED)
START
BRAKE
REVERSE/EDCFORWARD/EDC+
DRIVE SPEED
LEVEL SENSOR ALARM
AUXILIARY POWER
BK-C7B-1
WH-TS51-5
RD-TS53-2
GR/BK-H6(-)
BR-GND
H6
OR/RD C6-22
OR/BK C5-2
OR C6-40
BL/RD C5-10
BL/BK C6-37
BL C6-36
BK/RD C5-9
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
A
OR/RD C5-19
RD C6-23
RD C6-24
5
6
7
8
12
RD-P134PWR TB134C
GR/BK-TB133C
GR/BK-L45(-)
C
WH/12 C7B-2
BL/BK C3B-11
GR C2B-5
GR/WH C2B-7
GR/BK C4B-8
GR C4B-7
OR/RD C2B-4
OR/BK C2B-3
OR C2B-2
BL/RD C2B-1
BL/BK C1B-11
BL C1B-10
BK/RD C1B-9
BK/WH C1B-8
BK C1B-7
WH/RD C1B-6
WH/BK C1B-5
WH C1B-4
RD/WH C1B-3
RD/BK C1B-2
RD C1B-1
B
OR/RD C4B-4(D67)
RD C6-25
RD C2B-6
GR/BK C3B-12
BL/WH C1B-12
U33
RD-H6(+)
BL/WH-TB132C
BK-TB22C
B
155
RD U34-2
134A
134
RD H6(+)
GR/BK H6(-)
133
BL/WH C32-3
132
OR CR34 #86
118
BL/BK L46(+)
59
46
45
GR/BK TS58-3
D30
2C/RD-DESCENT ALARM 44
GR TS58-1
43
42
41
40
BL/RD TS53-1(D11)
39
37
36
BK/RD TS54-1(D13)
35
34
BK TS52-3
33
32
WH/RD-TRAVEL ALARM
31
30
29
28
RD TS51-4
27
24
WH KS1-1(D2)
23
BK/12 KS1-3
BK C32-4
22
WH G6(+)
21
RD/12 CB2-2
20
GR/BK TS57-1
18
GR TS57-3
17
OR/BK TS59-3
15
OR TS59-1
14
13
9
BK/RD TS63-6
BK/WH TS63-3
8
BK TS63-1
7
WH/RD R14(A)
6
WH/BK TS62-1
5
4
WH TS62-3
RD/WH CR34 #30
3
RD/BK TS61-6
2
D29
TB44C
RD TS61-4
1
D
OR/RD TS62-5(D68)
OR & WH-BEACONS
RD L45(+)
BR GND2
BK GND1
RD DL2
WH DL1
WH/BK C4B-9
1
3
4
C32
A
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A (D)
BK-GND
BL-GND
GR-GND
5
BR GND
BK C3B-10
CR23
TB21C
4
3
RD TB134C (A)
F19
10 AMP FUSE
3
WH C5-15
5
DRIVE LIGHT OPTION RELAY
1
2
8
WH C5-17
2
9
8
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)
H
I
12V TO PLAT
C7B
J
16/22 CABLE
18/22 CABLE
C4B
C2B
C3B
K
C1B
L
LABEL
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS53
FUEL SELECT TOGGLE SWITCH
M
FUNCTIONS
ENGINE
C6
C5
TS54
RPM SELECT TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
TS64
ENGINE FAULT CODE TEST TOGGLE SWITCH
U33
LOAD SENSE MODULE
U34
LOAD SENSE TIME DELAY
GROUND STUD
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
G6
HOUR METER
H6
PLATFORM OVERLOAD ALARM
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L45
LED - PLATFORM OVERLOAD
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS58
JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
HARNESS TO
SWITCH PANEL
N
Part No. 122985
1
D13
TS62
6
3
3
5
2
1
1
L46
4
1
D11
2
4
5
6
NO
P4
TS51
4
L45
1
1
2
3
4
D101
NO
3
2
1
2
3
1
S-80 • S-85 • S-80X
GN/BK-TB18D
BL/BK-TB59D
BR-GND STUD
BR-HM(-)
TO GROUND
CONTROL BOX
CONNECTIONS
C
RD-TB20D
RD-TB134D
GR/BK-H6(-)
RD-KS1-2
RD-P1-2
WH-C32-6
RD-TB27D
RD-TS61-2
WH-KS1-1
D4
OR/RD-TB155D
WH/BK-TB5D
WH/RD-R14(A)
WH-TB4D
GN-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-CR52-30
BK-CR53-30
RD-R16
BK/WH-TB8D
BK/RD-TB9D
BK C6-12
GR-TB43D
GR/BK-TB44D
OR-TB14D
OR/BK-TB15D
RD-C32-7
BK-TB33D
BL/RD-TB39D
D
3
CB2
TS61
4
5
6
3
3
E
D68
4
3
6
TS63
2
TS52
WH-TB23D
RD-CB2-1
BK/RD-TB35D
WH-TS51-2
BR-CR34#85
BR-L46(-)
F
2
1
2
1
-
G6
G
TS57
1
2
3
TS58
2
TS53
B
3
H
3
3
TS54
D2
B1
+
I
3
2B
2A
1
4
J
TS59
NC
NC
2
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-13
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
K
L2
1B
KS1
R16
OR-TB118D
RD/WH-TB3D
L
1A
R14(A)
R14
RD/WH-TS61-1
M
P1
CR34
86
BR-HM(-)
N
85
30
87
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)
B
A
1
2
4
5
6
7
8
ES0505D
6 - 135
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 135
6 - 136
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 137
6 - 138
RD LS18 CABLE
8
RD-E-STOP
P134PWR RD
CR30
R20
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
4700W
R26ESTP BK C9P-1
J22
CR27
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
BR BATGND
(GROUND STUD)
P134PWR RD
RD-H1+
P26ESTP BK E-STOP
BR GND
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS8-C43JU GR C4P-7
TS8-C44JD GR/BK C4P-8
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
H1-C133PLA GR/BK C3P-12
L47-C59CNK BL/BK C3P-11
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
ES0505D
12V
BATTERY
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
TS3-C39LP BL/RD C2P-1
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C132PLI2 BK C3P-10
D39
BK P2
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
C132PLI1 BL/WH C1P-12
D88
5
U35
J1 C28TTA RD/BK
4
WH L1
1
WH C9P-2
CAN HI
CAN LOW
JC3-5 C159STC BL/WH
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
GR/BK C3P-12
GR/BK L4
RD C2P-6
RD LS18
Part No. 122985
S-80 • S-85 • S-80X
6 - 138
1
C1P-2 C28TTA RD/BK
BATGND J3-1
OPTION
C9
H1
6
6
1
LS18
C7P
+
J22-1,2,9,10,11 AND 12
D40
J1
1
2
1
3
COM
NO
2
3
5
3
J2
2
9
11
J8
J7
J3
U13 - JOYSTICK
CONTROL CARD
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)
1
BATGND C7P-3
GROUND
D89
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
+
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
BL/RD J1-16
TS15
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
TS4
RD C9P-3
BK/RD C1P-9
OR/RD C4P-4
BL/RD C2P-1
BK C1P-7
RD C1P-1
RD/WH J1-8
GR/BK C4P-8/J22-6
GR C4P-7/J22-5
BR GND STUD
GR/BK H1(D39)
GR C4P-5/J22-4
BL/BK C3P-11
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS3
1
2
L4
D12
JC3
JC7
D10
3
+
TS2
6
L47
+
1
6
1
L1
4
D43
TS9
TS1
TS14
+
NO
NC
TS7
P3
L48
P2
TS8
RD
5
BK
RD
RD
ES0505D
6
COMPONENT INDEX
H1
TILT ALARM
TS4
RPM SELECT TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS7
PLATFORM ROTATE TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS8
JIB BOOM UP / DOWN TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
L4
LED - PLATFORM OVERLOAD
TS14
DRIVE SPEED TOGGLE SWITCH
L47
LED - CABLE TENSION
TS15
DRIVE ENABLE TOGGLE SWITCH
L48
LED - TILT ALARM
U13
ALC500 JOYSTICK CONTROLLER CARD
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
TS2
ENGINE START TOGGLE SWITCH
TS3
FUEL SELECT TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 139
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram,
S-80 and S-85 (CE),
Continental TME27 Models (after serial number 8110)
6 - 139
6 - 140
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Continental TME27 Models
6 - 141
6 - 142
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Continental TME27 Models
A
B
C
D
E
F
G
H
I
J
K
L
M
N
C28TTA RD/BK
C28TTA RD/BK
P26ESTP BK
1
P2
FS1
C9P-1
P25FS RD
P25FS RD
P24FS WH
TB21
TB35
GR/BK
P23PWR WH
C5-11
C5-19
C5-17
C5-15
C5-5
C5-1
C5-6
C6-28
C6-24
C5-7
C5-2
C35RPM BK/RD
8
C108ESL BL/WH
9
C127TSW GR
10
R21IGN WH
7
C21RET WH
2
C5-8
86
30
CR1
30
30
85
87
C
A
RD
CR39A
86
85
86
CR39B
85
30
NC
85
87
30
NO
87
CR2
86
85
87A
WH
V155PCE OR/RD
M4
SW4
NO
M1
-
M2
H2
FB
FB
REGULATOR
B
Y74
BK
5
R23PWR WH
1
C38FP BL/WH
4
C38RET BL
3
HARNESS
-
STA
7
R33STR BK
BK - 12GA
RD - 12GA
PR1
NO
+
WH - 14GA
R46HRN GR
BAT
-
NO
NO
R27AUX RD
87
C116HYD WH
85
CR5
P134FB RD
NO
86
P134PWR RD
86
C28TTA RD/BK
CR17
87
BAT
+
+
NO
R116HYD OR
12V DC
30
P134FB RD
AUX MAIN
R6
510W
EXCT
M3
IND
CHECK ENGINE LIGHT
FUEL PUMP
ENGINE FAULT CODE
TEST SWITCH
STARTER
HOUR METER
PRESSURE COMP. VALVE
FUNCTION ENABLE
IGNITION RELAY
START RELAY
APU CUT-OUT
RELAY
Part No. 122985
VOLTAGE DROP
RELAY
AUXILIARY PUMP
AUXILIARY PUMP
RELAY
TILT ALARM
LEVEL SENSOR
FLASHING BEACON
(OPTION)
HORN RELAY
S-80 • S-85 • S-80X
HORN
HYD. OIL COOLER
TEMP. SWITCH
(OPTION)
HYD. OIL COOLER
FAN (OPTION)
ALTERNATOR
BATTERY SEPERATOR
START BATTERY
CONTROL BATTERY
6 - 142
11
C5-13
B1BAT RD
6
8
6
C39LP BL/RD
C5-9
R21IGN WH
20A
B1
C41RPM OR/BK
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
B1BAT RD
20A
BAT2 APU RD
-
C27AUX RD
TB39
C5-10
F7
B2
C27AUX + FE RD
TB41
P24PWR RD
+
C41RPM OR/BK
D4
P134PWR RD
F17
12V DC
P210PWR BK
P134PWR RD
C27AUX RD
TB46
5
D11
C39LP BL/RD
TB27
TB23
B1BAT RD
4
TB155
LP
D13
TS53
FUEL
SELECT
GAS
D2
L2
C35RPM BK/RD
+
G6
-
TB33
GROUND
TS54
ENGINE
RPM
TS64
ENGINE
FAULT
D67
D68
HIGH RPM
TB28
P4
FUNCTION
ENABLE
LOW RPM
8
C33STR/BK
C32
C27AUX RD
TB133
AUXILIARY
PUMP
7
TS51
P23PWR WH
6
TB20
12
C2-1
500 LB (A & B)
TS52
ENGINE
START
5
C28TTA RD/BK
1
1000 LB (A)
C46HRN GR
3
ZONE B
3
4
PLAT
GRD
C1-9
C4-4
TB22
3
B
C1-7
KS1
1
C1-1
4
C7-2
TB132
2
B1
C1-2
C2-5
TB134
P1
LP
ZONE A
OFF
CB2
15 AMP
GAS
D12
D101
L48
TS3
FUEL
SELECT
HIGH RPM
(FS)
P22PWR BK
P134PWR RD
D40
TS4
ENGINE
RPM
V155PCE OR/RD
C7-1
C2-6
D43
+
H1
-
TS2
ENGINE
START
TS1
AUXILIARY
PUMP
C9P-2
P3
HORN
P24FS WH
D10
P24FS WH
2
P26ESTP BK
P26ESTP BK
C9P-3
ES0505D
H1 RD/BK
C29MS RD/WH
9
10
4
2
4
1
3
9
11
10
14
13
12
5
1
7
C7-3
C2-10
C2-9
C2-8
C2-4
C2-2
C4-1
C3-6
C3-5
C3-4
C3-9
C3-8
C3-7
C3-12
C2-3
GR/WH
C1-12
D23
BL/RD
C3-1
C3-2
C3-3
C1-4
C1-5
C1-11
CW
GND BR
C123PBS RD/BK
SNSR-GND BR
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
CCW
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
C177LS BL/RD
P109LS GR/WH
RETRACT
UP
DOWN
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C37STCC BL/BK
C36STC BL
C6-33
C6-34
C6-35
C6-22
C6-40
C6-23
C6-25
C6-13
C123PBS RD/BK
SNSR-GND BR
BL/RD
C6-5
C6-6
C6-7
C6-8
C6-9
C6-31
C6-3
C6-2
C6-1
C6-12
C211PLO BL/BK
S212PLO GR/BK
GR/WH
C6-4
P109ANG GR/WH
C42LS OR/RD
C40LS OR
P134PWR RD
C13DRE BL/RD
C6-16
C6-38
C6-30
C6-21
P134PWR RD
P210PWR BK
C118LS OR
C5-21
C5-20
C6-37
C6-36
6
OR
BR
YL
RD
OR
WH
BK
WH
BR
RD
BK
WH
BR
RD
BK
WH
BR
RD
RD
BK
BL
5
BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C37STCC BL/BK
C31EDC WH/BK
C30EDC WH
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
BL
BR
C9PERF BK/RD
C8PBR BK/WH
C7PBE BK
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
14
3
C1-10
C5-23
C5-24
14
13
NO
NO
13
NO
5
13
14
15
8
7
16
6
LED BL/RD
C144DER BL/WH
RIGHT
5
10
8
6
2
6
7
8
15
16
18
17
C1-6
C1-3
C6-24
WH
RD
RD
BL
BR
BK
BK/WH
BL
BR
BK
BK/WH
BK
WH
BR
RD
NC
BR
BK
WH
BR
BK
Y23
Y24
Y13
Y26
Y25
7
22
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DESCENT ALARM
LOOSE CABLE LED’S
LSB2S
LOOSE CABLE
LIMIT SWITCH
MOTOR STROKE
BRAKE RELEASE
STEER CW
STEER CCW
DRIVE EDC REVERSE
DRIVE EDC FORWARD
GROUND
CR34 - PRIMARY BOOM
SPEED REDUCTION RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
LST3O - BOOM UP/DOWN
GROUND BOX - ZONE A
OPERATION AND SPEED
REDUCTION LIMIT SWITCH
LSB1EO - BOOM EXTEND
CAPACITY OPERATIONAL
LIMIT SWITCH
LSB1ES - BOOM EXTEND
CAPACITY SAFETY
LIMIT SWITCH
LST3S - BOOM ANGLE
STOWED
GROUND BOX - ZONE A
SAFETY LIMIT SWITCH
PRIMARY BOOM
EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM
RETRACT
PRIMARY BOOM
EXTEND
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE
CCW
TURNTABLE ROTATE
CW
LST1O
DRIVE ENABLE
LIMIT SWITCH
LSB1RO
BOOM RETRACT
DRIVE / ROTATE SPEED
LIMIT SWITCH
LST2O
ANGLE STOWED
DRIVE SPEED REDUCTION
LIMIT SWITCH
S17
PRIMARY BOOM ANGLE
SENSOR - OPERATIONAL
S18
PRIMARY BOOM ANGLE
SENSOR - SAFETY
8
PLATFORM ROTATE CCW
6 - 143
S-80 • S-85 • S-80X
Part No. 122985
LEFT
C143DEL BL/BK
C209LED BL
C208LED GR
SNSR BR
ZONE SELECT
P109TS GR/WH
C184PL WH
3
1
2
11
1
12
GND BR
2
4
19
20
J114
C6-11
13
NO
14
13
NO
14
14
13
NO
NO
U4
1
NC
13
NO
14
6
C129DA RD/BK
14
21
24
2 1
1
2
3
4
1
3
4
2
22
23
NO
BK
Y15
NC
NC
21
22
21
22
21
22
23
24
NC
Y22
1
2
3
4
J134
1
2
3
4
TB9
23
24
GR
6
J133
3
BL
2
1
2
TB7
2
1
J133
2
5
21
13
3
4
NO
NO
14
13
H4
TB118
4
1
TB8
D29
Y21
Y12
Y6
Y5
Y3
Y4
Y2
Y27
P24FS WH
P24FS WH
3
P134PWR RD
C59CNK BL/BK
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
C43JU GR
DOWN
C44JD GR/BK
C17PRL GR
C18PRR GR/BK
CW
CCW
TB3
TB4
TB1
TB37
TB36
TB44
1
P24FS WH
4
CR53
R14
10W
TB5
TB18
R14(A)
5W
CR68
CR34
TB42
TB13
TB30
TB31
TB32
TB29
CR52
L46
P26ESTP BK
C3-11
C4-2
TB134A
P210PWR BK
J1
J1
J1
D24
C59CNK BL/BK
C4-3
C4-7
C4-8
C4-5
C4-6
TB59
TS59
TS62
TURNTABLE
ROTATE
C27AUX RD
CR69
TB2
TB15
TB17
UP
DOWN
J22-11
J22-12
J22-9
J22-10
J22-2
J22-1
P134PWR RD
P134PWR RD
TS63
PRI. BOOM
EXT. / RET.
TS61
PRI. BOOM
UP / DOWN
R16
7.5W
TS57
PLATFORM
ROTATE
P162JPW2-OR
5
TB14
TB43
D30
CW
CCW
J22-7
J22-8
J22-5
J22-6
J22-4
J22-3
Y20
Y19
Y70
P162JPW1-OR
2
CR30
J2
J2
Y71
2
2
J8
C159STC-BL/WH
C164PES-RD/WH
J8
JSGND1-BR
1
J25
JSGND2-BR
1
J127
NO
J1
C160JPL-WH/RD
3
3
TS9
PLATFORM
LEVEL
JOYSTICK CONTROL CARD
J3
4
C165TRS-WH/RD
TS7
PLATFORM
ROTATE
LIFT / DRIVE
(OPTION)
C159STC-BL/WH
5
C163PLS-WH/BK
4
6
L50
L51
6
JC3
DRIVE / STEER
5
JC7
PRIMARY BOOM
UP / DOWN
EXTEND / RETRACT
TURNTABLE ROTATE
CR27
L47
TS14
DRIVE
SELECT
L1
TS15
DRIVE
ENABLE
TS75
ZONE SELECT
NC
ZONE B
ZONE A
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
September 2015
Electrical Schematic, S-80X,
Continental TME27 Models
GND BR
C28TTA RD/BK
C41RPM OR/BK
C27AUX + FE RD
September 2015
Section 6 • Schematics
Electrical Schematic, S-80X,
Continental TME27 Models
6 - 143
6 - 144
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Continental TME27 Models
6 - 145
6 - 146
6 - 146
8
RD-44C
WH/BK-32C
OR-134A(D)
WH-134A(C)
BK-GND
BL-GND
GR-GND
TS63 C7PBE BK
7
ES0505D
S-80 • S-85 • S-80X
C
B
6
Part No. 122985
D30
WH/RD C6-6
WH/BK C6-5
WH C6-4
RD/WH C6-3
RD/BK C6-2
RD C6-1
TURNTABLE ROTATE FLOW
TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
PRI BOOM FLOW
PRI BOOM DOWN
PRI BOOM UP
H
18/22
CABLE
C4B
C3B
BASE TERMINATION BLOCK
RD/BK TB44C
WH/RD C3B-6
WH/BK C3B-5
WH C3B-4
RD/WH C3B-3
RD/BK C3B-2
RD C3B-1
C7B
6
5
4
3
2
1
12V TO
PLATFORM
WH/RD R14(A)
WH/BK TS62-1
WH TS62-3
RD/WH CR34#30
RD/BK CR68-87A
RD TS61-4
BL/RD C6-13
BK/RD C6-9
BK/WH C6-8
BK C6-7
G
BK/RD R14(A)
BK/WH TS63-3
BK CR69-87A
WH-TB23B
1
OR/BK C4B-3
OR C4B-2
BL/RD C4B-1
BK/RD C3B-9
BK/WH C3B-8
BK C3B-7
3
15
14
13
9
8
7
BR-GND STUD
BK-C32-5
CABLE
RESTRAINT
OR/BK TS59-3
OR TS59-1
WH C5-11
RD/12 BATT+
3
2
1
F
RD U16-2
RD-TB20A
RD-TB20B
GR-C5-8
E
BK C5-5
WH/RD C5-23
WH/BK C5-20
WH C5-21
RD/WH C5-24
RD/BK C6-28
RD C5-6
LIMIT SWITCH - LST20
RPM / TACH SIGNAL
LIMIT SWITCH - LSB1RO
GAS/LP FUEL SELECT
STEER CCW
STEER CW
ENGINE RPM
(UNUSED)
ENGINE START
BRAKE RELEASE
REVERSE / EDCFORWARD / EDC+
DRIVE SPEED
PLATFORM LEVEL ALARM
AUXILIARY POWER
12V POWER
POWER TO PLATFORM
KEYSWITCH PWR TO PLATFORM
12V IGNITION SUPPLY
12V BATT SUPPLY
PLATFORM ROTATE CCW
PLATFORM ROTATE CW
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE
PRI BOOM EXT/RET FLOW
PRI BOOM RETRACT
PRI BOOM EXT
(UNUSED)
BOOM SPEED REDUCTION
LOOSE CABLE LED
HORN
AC GENERATOR (OPTION)
(UNUSED)
PRESSURE COMP ENABLE
KEY SWITCH POWER (A)
KEY SWITCH POWER
(UNUSED)
(UNUSED)
BR-GND STUD
D
OR/RD C6-22
OR/BK C5-2
OR C6-40
BL/RD C5-10
BL/BK C6-37
BL C6-36
BK/RD C5-18
OR C6-31
BL/BK C6-11
GR C5-7
GR/WH C6-39
OR/RD C5-19
RD C6-23
RD C6-24
C6-30 C211LO BL/BK
C6-38 C212LO GR/BK
BR GND2
1
OR/RD TS62-5(D68)
OR-BEACON (RIGHT)
KS1-2
4
A
CR69
C
155 OR/RD C4B-4(D67)
WH-BEACON (LEFT)
134A RD C6-25
RD C32-1
134 RD C2B-6
GR/BK C32-8
133
BL/WH C32-3
132
118
OR CR34#86
59 BL/BK C3B-11
BL/BK L46(+)
46 GR C2B-5
45 GR/WH C2B-7
D29
TB2C-DESC. ALARM
44 GR/BK C4B-8
43 GR C4B-7
42 OR/RD C2B-4
41 OR/BK C2B-3
40 OR C2B-2
39 BL/RD C2B-1
BL/RD TS53-1(D11)
37 BL/BK C1B-11
36 BL C1B-10
35 BK/RD C1B-9
BK/RD TS54-1(D13)
34
33 BK C1B-7
BK TS52-3
32 WH/RD C1B-6
31 WH/BK C1B-5
30 WH C1B-4
29 RD/WH C1B-3
28 RD/BK C1B-2
RD TS51-4
27 RD C1B-1
24
WH KS1-1(D2)
23 WH/12 C7B-2
BK C32-4
BK/12 KS1-3
22
WH HM(+)
21
RD/12 CB2-2
20 RD/12 BATT+
18 GR/BK C4B-6
GR/BK TS57-1
17 GR C4B-5
GR TS57-3
D
TB2D R2PBD RD/BK
TB7D R7PBE BK
CR68
BK GND1
RD DL2
WH DL1
WH/BK C4B-9
B
GND BR
CR53
BK
5
CR52
RD/BK
CR23
TB21C
A
TS61 C2PBD RD/BK
C32
10 AMP FUSE
F19
DRIVE LIGHT OPTION RELAY
3
BK-C7B-1
WH-TS51-5
RD-TS53-2
GN/BK-TB133C
BR-GND
RD - TB134C
BL/WH-TB132C
BK-TB22C
2
5
6
7
8
12
1
3
4
Section 6 • Schematics
September 2015
Ground Control Box Terminal Strip Wiring Diagram, S-80X,
Continental TME27 Models
I
J
16/22
CABLE
C2B
C1B
K
LABEL
L
TS64
FUNCTION
MANIFOLD
ENGINE
HARNESS
C6
C5
TS51
AUXILIARY PUMP
TS52
ENGINE START TOGGLE SWITCH
TS53
FUEL SELECT TOGGLE SWITCH
TS54
RPM SELECT TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
TS59
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
TS61
PRIMARY BOOM UP / DOWN TOGGLE SWITCH
TS62
TURNTABLE ROTATE TOGGLE SWITCH
GROUND
STUD
2
CB2
CONTROLS CIRCUIT BREAKER, 15A
DESCRIPTION
CR23
DRIVE LIGHT RELAY (OPTION)
CR34
PRIMARY BOOM SPEED REDUCTION RELAY
CR52
PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL
CR53
PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL
CR68
PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY
CR69
PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY
G6
HOUR METER
KS1
KEY SWITCH
L2
LED - CHECK ENGINE
L46
LED - CABLE TENSION
P1
EMERGENCY STOP BUTTON
P4
FUNCTION ENABLE TOGGLE SWITCH
R14
RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
R14(A)
RESISTOR, 5W, TURNTABLE ROTATE SPEED
R16
RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
TS63
PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
TS64
ENGINE FAULT CODE TEST TOGGLE SWITCH
CABLE
RESTRAINT
HARNESS TO
SWITCH PANEL
M
N
3
Part No. 122985
1
D13
TS62
6
3
2
5
2
1
L46
2
CB2
TS61
4
5
6
1
3
1
2
3
4
4
5
6
NO
D101
NO
3
TS52
P4
TS51
4
3
2
1
2
3
1
WH-TS51-2
S-80 • S-85 • S-80X
GN/BK-TB18D
BL/BK-TB59D
BR-GND STUD
TO GROUND
CONTROL BOX
CONNECTIONS
C
BR-HM(-)
RD-TB20D
RD-P1-2
D
WH-C32-6
RD-TB27D
RD-TS61-2
WH-KS1-1
D4
OR/RD-TB155D
WH/BK-TB5D
WH/RD-R14(A)
WH-TB4D
GN-TB17D
RD-TB1D
RD/WH-R14
RD-R16
RD-TS51-1
RD/BK-CR52-30
BK-CR53-30
RD-R16
BK/WH-TB8D
BK/RD-TB9D
BK C6-12
OR-TB14D
OR/BK-TB15D
WH-ISM#10
BK-TB33D
RD-C32-7
BL/RD-TB39D
WH-TB23D
RD-CB2-1
BK/RD-TB35D
E
D68
4
4
6
D11
1
1
3
TS63
3
BR-L46(-)
BR-CR34#85
F
2
1
-
G6
G
TS57
1
2
TS53
B
3
H
2
3
TS54
D2
B1
+
I
3
2B
2A
1
4
J
TS59
NC
NC
2
WH-TB21D
BK-TB22D
RD-L45(+)
BL/RD-C5-15
WH/RD-TS62-4
WH/RD-TB6D
RD-TS63-2
RD-TS61-2
K
L2
1B
KS1
R16
OR-TB118D
RD/WH-TB3D
L
1A
R14(A)
R14
M
P1
86
BR-HM(-)
RD/WH-TS61-1
N
CR34
85
30
87
87A
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models
B
A
1
2
3
4
5
6
7
8
ES0505D
6 - 147
September 2015
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models
6 - 147
6 - 148
Section 6 • Schematics
September 2015
Platform Control Box Wiring Diagram, S-80X,
Continental TME27 Models
6 - 149
6 - 150
TS7-C18PRR GR/BK J22-3
TS7-C17PRL GR J22-4
TS9-C14PLU OR J22-7
TS9-C15PLD OR/BK J22-8
P2-P26ESTP BK C9P-1
TS2-P25FS RD C9P-3
J3-P24FS WH C9P-2
P2-P23PWR WH C7P-2
P2-P22PWR BK C7P-1
TS1-V155PCE OR/RD C4P-4
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
TS7-C17PRL GR C4P-5
TS9-C14PLU OR C4P-2
TS9-C15PLD OR/BK C4P-3
J8-P109LS GR/WH C3P-12
L47-C59CNK BL/BK C3P-11
J22
LIFT / DRIVE SELECT (OPTION)
OR/RD C40LS
(SPLICE TO
C40LS, C2P-2)
WH TS14
WH TS7
7
J1-SNSR GND BR C1P-10
J1-P109ANG GR/WH C2P-9
TS3-C39LP BL/RD C2P-1
P3-C46HRN GR C2P-5
TS47-C45GEN GR/WH C2P-7
C1P(GY)
C2P(BK)
C3P(GR)
C4P(BR)
FOOT
SWITCH
ES0505D
12V
BATTERY
BK P2
C40LS OR C2P-2
C6TRF WH/RD C3P-6
C123PBS RD/BK C2P-8
C7PBE BK C3P-7
C13DRE BL/RD C4P-1
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4
C9PERF BK/RD C3P-9
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C4TRL WH C3P-4
C32BRK WH/RD C1P-6
C5TRR WH/BK C3P-5
C29MS RD/WH C1P-3
LS18-C177LS BL/RD C1P-12
TS1-C27AUX RD C1P-1
TS2-C33STR BK C1P-7
TS4-C35RPM BK/RD C1P-9
L48-C28TTA RD/BK H1
J1 C28TTA RD/BK
4
WH L1
C2P-9 P109ANG GR/WH
JC7-4 C165TRS WH/RD
C2P-10 SNSR GND BR
JC7-3 C164PES RD/WH
JC7-2 P162JPW2 OR
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
JC3-3 C159STC BL/WH
JC3-1 JSGND1 BR
TS15-C144DER BL/WH
1
WH C9P-2
JC3-5 C159STC BL/WH
CAN HI
CAN LOW
L51(-) C169LED1 GR
L50(-) C169LED2 GR
TS75-1 P109TS GR/WH
C3P-12 P109LS BL/WH
C1P-12 C177LS BL/WH
TS75-2 C184PL WH
TS75-3 SNSR BR
1
TS15-C143DEL BL/BK
L1-C13DRE(A) BL/RD
TS14-C29MS RD/WH
RD C2P-6
Part No. 122985
S-80 • S-85 • S-80X
6 - 150
1
OPTION
C9
H1
6
1
OPTION
C7P
+
J22-1,2,9,10,11 AND 12
D40
6
11
J8
J7
J1
1
2
3
RD LS18
3
CONTROL HARNESS
TO PLATFORM
SWITCH PANEL
J2
2
9
J3
U13
ALC-500
N
M
L
K
J
I
H
G
F
E
D
C
B
A
September 2015
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80X,
Continental TME27 Models
1
C1P-2 C28TTA RD/BK
BATGND J3-1
BATGND C7P-3
5
GROUND
BR BATGND
(GROUND STUD)
CR27
WH/RD C32BRK
(SPLICE TO
C32BRK, C1P-6)
CR30
8
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
CONTROL HARNESS
TO PLATFORM BOX
1
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH/RD J1-4
BL/WH J1-5
OR J1-13
BR J1-14
GR J8-5
BR J8-8
GR/WH J8-6
WH J8-2
GR J8-10
TS15
BL/RD J1-16
WH C9P-2
BL/BK J1-7
BL/WH J1-6
RD/BK H1 (D40)
TS4
RD C9P-3
RD C1P-1
OR/RD C4P-4
BK/RD C1P-9
BL/RD C2P-1
BK C1P-7
RD/WH J1-8
BR GND STUD
BL/BK C3P-11
GR C4P-5/J22-4
GR/BK C4P-6/J22-3
RD/WH J1-2
OR J1-11
BR J1-12
WH/BK J1-3
WH/RD J1-1
OR C4P-2/J22-7
OR/BK C4P-3/J22-8
GR C2P-5
TS3
1
2
D12
JC3
D10
JC7
TS2
3
+
6
1
+
L47
6
1
4
TS1
TS9
+
+
TS7
P3
+
TS14
NO
L48
L51
BK
RD
TS75
BK
NC
P2
L50
RD
BK
5
RD
ES0505D
6
COMPONENT INDEX
CR27
BRAKE CIRCUIT (LIFT / DRIVE OPTION)
TS2
ENGINE START TOGGLE SWITCH
CR30
LIMIT SWITCH (LIFT / DRIVE OPTION)
TS3
FUEL SELECT TOGGLE SWITCH
H1
TILT ALARM
TS4
RPM SELECT TOGGLE SWITCH
JC3
JOYSTICK - DRIVE / STEER
TS7
PLATFORM ROTATE TOGGLE SWITCH
JC7
JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
TS9
PLATFORM LEVEL UP/DOWN TOGGLE SWITCH
L1
LED - DRIVE ENABLE
TS14
DRIVE SPEED TOGGLE SWITCH
L47
LED - CABLE TENSION
TS15
DRIVE ENABLE TOGGLE SWITCH
L48
LED - TILT ALARM
TS75
ZONE SELECT TOGGLE SWITCH
L50
LED - ZONE B, 500 LB CAPACITY
U13
ALC500 JOYSTICK CONTROLLER CARD
L51
LED - ZONE A, 1000 LB CAPACITY
P2
EMERGENCY STOP BUTTON
P3
HORN BUTTON
TS1
AUXILIARY TOGGLE SWITCH
7
NOTE: DASHED LINES INDICATE OPTIONS.
1
ROCKER / STEER OPTION
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 151
September 2015
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-80X,
Continental TME27 Models
6 - 151
6 - 152
Section 6 • Schematics
September 2015
Continental TME27 Engine Harness
6 - 153
6 - 154
Section 6 • Schematics
September 2015
Continental TME27 Engine Harness
A
B
C
D
E
ORANGE 18
G
H
I
J
K
BLACK/LT GREEN 18 A
YELLOW/GRAY 18
B
LT GREEN/BLACK 18
1
F
TX
B
5V
C
BLK/LT GREEN 18
RTN D
M
ECT
OIL PRESSURE SWITCH
BLACK/LT GREEN 18 1
TAN 18 2
LT GREEN/RED 18 3
LT GREEN 18 4
RX A
DK GREEN 18
LT GREEN/RED 18
L
TMAP
SPLICE WITHIN 6" OF CONNECTOR
COMM
BLACK/LT GREEN 18
DK GREEN/ORANGE 18
PINK/DK GREEN 16
BLACK/WHITE 16
A
B
C
D
BLACK/LT GREEN 18 A
TAN/DK GREEN 18 B
PINK/DK GREEN 16 C
BLACK/YELLOW 16 D
PRE CAT HEGO
POST CAT HEGO
BLUE/WHITE 18 1
WHITE/ORANGE 18
2
WHITE/ORANGE 18 3
BLACK 16 6
2
PINK/YELLOW 16 7
WHITE/ORANGE 18
BLUE/WHITE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
1 DK GREEN/ORANGE 18
2 TAN/DK GREEN 18
3
4
5 PURPLE/LT BLUE 18
6 LT BLUE/DK BLUE 18
7 LT GREEN 18
8
9 DK BLUE 18
10 PURPLE/YELLOW 18
11 WHITE/RED 18
12
13 WHITE/ORANGE 18
14 WHITE/ORANGE 18
15 BLUE/WHITE 18
CAN 2 CAN 2 +
CAN 2 TERM +
5V EXT
5V RTN
CRK POS
CRK NEG
CAM POS
CAM NEG
SPD POS
SPD NEG
KNK 1 +
KNK 1 KNK 2 +
KNK 2 -
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
4
5
6
SPK COIL 1A
SPK COIL 1B
SPK COIL 2A
SPK COIL 2B
SPK COIL 3A
SPK COIL 3B
SPK COIL 4A
SPK COIL 4B
IAT
ECT
EGT
AUX DIG 1
AUX DIG 2
AUX DIG 3
V SWITCH
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
AUX ANA PU1
AUX ANA PU2
AUX ANA PU3
5V EXT
5V RTN
GOV 1
GOV 2
OIL P
AUX ANA PUD1
PC TX
PC RX
PULSE IN
TACH
V BAT PROT
V BAT
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
INJ6 LS
INJ7 LS
INJ8 LS
GROUND
STARTER
RELAY
EGOH 1
EGOH 2
EGOH 3
FUEL LOCKOFF
BUZZ
AUX PWM5
AUX PWM5 RECIRC
V BAT
MIL
GROUND
DBW+/STEP +
DBW-/STEP FPUMP
AUX PWM3 RECIRC
AUX PWM3
AUX PWM1
AUX PWM2
AUX PWM4
AUX PWM4 RECIRC
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
COBRA EPR
PURPLE/WHITE 18
PURPLE/WHITE 18
WHITE/PURPLE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
WHITE/PURPLE 18 C
CRANK SENSOR
WHITE/RED 18 A
LT GREEN/RED 18
BLACK/LT GREEN 18
PURPLE/WHITE 18
WHITE/PURPLE 18
GRAY/BROWN 18
PURPLE/ORANGE 18
LT GREEN/RED 18
GRAY/BROWN 18
BLACK/LT GREEN 18
A
GRAY/BROWN 18 B
PURPLE/ORANGE 18
PURPLE/ORANGE 18
B
LPG TEMP
CAM SENSOR
C
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
BLK/LT GREEN 18
JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
YELLOW 18
YELLOW/RED 18
YELLOW/BLACK 18
YELLOW/LT GREEN 18
BLACK/LT GREEN 18
LT GREEN/WHITE 18
LT GREEN/RED 18
WHITE/LT GREEN 18
TAN 18
YELLOW/GRAY 18
1
2
3
4
GASOLINE SENSOR INTERFACE
TAN/BROWN 18
TAN/ORANGE 18
BLK/LT GREEN 18
LT GREEN/RED 18
PINK/WHITE 18
LT BLUE/DK BLUE 18
PURPLE/LT BLUE 18
PINK/TAN 18
DK BLUE/YELLOW 18
LT GREEN/WHITE 18
GRAY/DK BLUE 18
GRAY/WHITE 18
LT GREEN/BLACK 18
WHITE/LT GREEN 18
DK GREEN 18
ORANGE 18
1
2
3
4
5
6
VEHICLE INTERFACE 2
DEUTSCH DT06 PLUG
DBW THROTTLE CONNECTOR
YELLOW/LT GREEN 18
PINK/YELLOW 16
RED/TAN 16
BROWN/BLUE 16
BROWN/GREEN 16
BROWN/YELLOW 16
BROWN/WHITE 16
LT GREEN/RED 18
DK BLUE 18
BLACK/LT GREEN 18
DK BLUE/YELLOW 18
PURPLE/YELLOW 18
BLUE/GREEN 14
BLACK 16
1
2
3
4
5
6
7
8
9
WHITE/ORANGE 18 10
BLUE/WHITE 18 11
12
VREF
FPP1
ANA RETURN
AUX ANA PU1
FPP2 IVS
START IN (AUTOCRANK)
GROUND
NOT USED (PLUGGED)
NOT USED (PLUGGED)
CAN HIGH
CAN LOW
NOT USED (PLUGGED)
BLACK 16
WHITE/BLUE 18
BLACK/WHITE 16
BLACK/YELLOW 16
VEHICLE INTERFACE 1
DEUTSCH DT04 RECEPTACLE
WHITE/BLACK 18
76
77
78
79 RED/TAN 16
80 LT BLUE/BLK 18
81 BLACK 16
82 PINK/WHITE 18
83 TAN/ORANGE 18
84 TAN/BLACK 18
85 PINK/YELL 16
86 BLACK/RED 16
87 RED/BLACK 18
88 GRAY/RED 18
89 PINK/BLACK 18
90
BLACK 16
BLACK 16
WHITE/BLACK 18
BLACK 12
PINK 18
RED/BLACK 18
BLACK/RED 16
PINK/YELLOW 16
LT BLUE/PINK 14
YELLOW/LT GREEN 18
GRAY/DK BLUE 18
GRAY/WHITE 18
LT BLUE/BLACK 18
ORANGE 18
TAN/BROWN 18
GRAY/RED 18
GROUND
A
PINK/TAN 18
B
FUEL LOCKOFF
WHITE/ORANGE 18
STARTER RELAY
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
30
87 PINK/YELLOW 16
RED 14
RED/TAN 14
WHITE/BLUE 18
30
87 PINK/DK GREEN 16
PINK/DK GREEN 16
A
B
C
COIL 4
D
A
B
C
A
D
COIL 3
B
C
D
COIL 2
NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B
PINK/DK GREEN 16
15A
86
85
F3
POWER RELAY
BROWN/BLUE 16
PINK/TAN 18
F2
PINK 18
BROWN/WHITE 16
5A
RED/TAN 14
F1
BROWN/GREEN 16
RED 14
RED 12
BROWN/YELLOW 16
BAT +
20A
RED 14
S-80 • S-85 • S-80X
INJECTOR 4
INJECTOR 3
INJECTOR 2
NOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER
Part No. 122985
INJECTOR 1
A
C
COIL 1
PINK/DK GREEN 16
BLACK/LT GREEN 18
B
YELLOW 18
BLACK 16
85
PINK/YELLOW 16
FUEL PUMP RELAY
PINK/DK GREEN 16
TAN/BLACK 18
F4
15A
86
BLACK/LT GREEN 18
87 PINK/YELLOW 16
PINK/TAN 18
BLACK 16
30
BLUE/GREEN 14
STARTER RELAY
YELLOW/LT GREEN 18
RED 14
87
PINK/DK GREEN 16
85
YELLOW/BLACK 18
PINK/BLACK 18
87A LT BLUE/PINK 14
BLACK/LT GREEN 18
86
BLACK 16
30
PINK/DK GREEN 16
WHITE 14
PINK/TAN 18
15A
EPR RELAY
BLACK/LT GREEN 18
85
BLACK 16
86
PINK/YELLOW 16
YELLOW/RED 18
RED/TAN 14
WHITE/BLUE 18
F5
PINK/DK GREEN 16
PINK/YELLOW 16
6 - 154
B
BLK/LT GREEN 18
JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
BLUE/WHITE 18
8
GROUND
LT GREEN/RED 18 A
SPLICE WITHIN 6" FROM CONNECTOR
WHITE 14
7
CAN +
VBAT
BLUE/WHITE 18
WHITE/ORANGE 18
BLACK 16
3
EGO 1
EGO 2
EGO 3
EGO 4
TPS1/STEP2 +
TPS2/STEP2 MAP
AUX ANA PD1
FPP1
FPP2-IVS
AUX ANA PD2
AUX ANA PD3
CAN 1 TERM +
CAN 1 +
CAN 1 -
CAN CAN + TERM
D
1
2
3
4
5
6
7
8
9
10
11
12
VSW
IGN OUT
FUEL PUMP FUEL PUMP +
START COMMAND
TACH
GOV SELECT 1
GOV SELECT 2
MIL
ESL/TEST SWITCH
FUEL SELECT
TEMP SENDER
N
September 2015
Section 6 • Schematics
Platform Level Cutout, CTE Option
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLATFORM BOX
1
TS9-1
TS9-3
2
C14PLU OR
C15PLD OR/BK
C42LS OR/RD
J2-4
3
C2P-4
CR20
NO
CR21
NO
4
C15PLD OR/BK
C14PLU OR
J22-8
J22-7
6
Y20
C4-3
C4-2
Y19
5
7
TB15
TB14
PLATFORM LEVEL
UP
PLATFORM LEVEL
DOWN
GROUND
8
GROUND BOX
MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED
Part No. 122985
S-80 • S-85 • S-80X
6 - 155
September 2015
Section 6 • Schematics
Platform Level Cutout, CTE Option
6 - 155
6 - 156
Section 6 • Schematics
September 2015
Continental Options Schematic
6 - 157
6 - 158
Section 6 • Schematics
September 2015
Continental Options Schematic
A
B
C
D
E
F
G
H
I
J
P26ESTP BK
1
FS1
P2
C9P-1
P22BAT BK
BK
K
L
M
N
P26ESTP BK
C9P-3
P25FS RD
P25FS RD
P24FS WH
P25FS RD
P24FS WH
P24FS WH
C9P-2
F18
10 A
TS43
CONTROL BOX
HEATER
P134PWR RD
WH
L30
L30
BK
R21
10W
BK
THS1
NC
WH
2
TS48
DRIVE LIGHT
TS49
WORK LIGHT
R22
10W
3
C4-9
PLATFORM BOX
GROUND
4
TB21
R21IGN WH
C49LITE WH/BK
5
F19
10A
G2
C25PSR BL/BK
6
G3
C26TSR GR/BK
12
CONTINENTAL TME27 ENGINE
VEHICLE INTERFACE 1
G1
CR23
L29
L29
HARNESS
7
ES0505C
Part No. 122985
DRIVE LIGHTS
S-80 • S-85 • S-80X
WORK LIGHTS
6 - 158
PLATFORM CONTROL
BOX HEATER
COOLANT TEMP.
GAUGE
OIL PRESSURE
GAUGE
VOLT METER
8
September 2015
Section 6 • Schematics
Deutz and Perkins Options Schematic
N
M
L
K
J
I
H
G
F
E
D
C
B
P26ESTP BK
P2
P22BAT BK
FS1
C9P-1
BK
A
P26ESTP BK
C9P-3
P25FS RD
P24FS WH
P25FS RD
P25FS RD
P24FS WH
P24FS WH
C9P-2
1
F18
10 A
TS43
CONTROL BOX
HEATER
P134PWR RD
WH
L30
L30
BK
BK
R21
10W
WH
THS1
NC
TS47
GENERATOR
TS48
DRIVE LIGHT
TS49
WORK LIGHT
2
R22
10W
3
C2-7
C4-9
PLATFORM BOX
GROUND
TB21
TB45
4
C10-2
R21IGN WH
C6-39
G1
C49LITE WH/BK
F19
10A
G3
5
G2
C10-1
C45GEN GR/WH
C25PSR WH/BK
C26TSR WH/RD
C10-4
CR23
6
C10-3
L29
L29
7
Y29
CR46
ES0503D
ES0504D
HYDRAULIC
GENERATOR
OPTION
BELT DRIVEN
GENERATOR
OPTION
DRIVE LIGHTS
WORK LIGHTS
OIL PRESSURE
GAUGE
VOLT METER
COOLANT TEMP.
GAUGE
PLATFORM CONTROL
BOX HEATER
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 159
September 2015
Section 6 • Schematics
Deutz and Perkins Options Schematic
6 - 159
6 - 160
Section 6 • Schematics
September 2015
12 kW Hydraulic Generator Wiring Diagram
6 - 161
6 -162
Section 6 • Schematics
September 2015
12 kW Hydraulic Generator Wiring Diagram
A
B
C
D
E
F
G
H
I
12.5 KW HYDRAULIC GENERATOR
1
NEUTRAL BUSS BAR
L2
L1
2
L3
Y
X
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
208 VAC
OUTLET
L2
RED
3
ORANGE
N
3
6
5
4
1
2
L3
RED
Z
WHITE
N
BLACK
L1
4
BLACK
GREEN
BLACK 12GA
GREEN
20 AMP CIRCUIT
BREAKER
NEMA 4 CONTROL BOX
GROUND
STUD ON
PANEL
5
BLACK 12GA
SILVER
8 GA 4 CONDUCTOR
8 GA 5 CONDUCTOR
BRASS
120 VAC GFI
6
GREEN 12GA
12 GA 3 CONDUCTOR
7
110 VAC
GFI
ENCLOSURE
SILVER
BRASS
WHITE
8
GREEN
GREEN
BLACK
ES0506B
6 - 162
12 GA 3 CONDUCTOR
S-80 • S-85 • S-80X
Part No. 122985
J
K
L
M
N
September 2015
Section 6 • Schematics
12 kW Hydraulic Generator Electrical Schematic
L
K
J
I
H
G
E
D
C
B
A
1
FOOTSWITCH
P2
ALC-500
F
P25FS-RD
P26ESTP-BK
P22PWR-BK
P24FS-WH
19
RPM HI
RPM LO
2
D12
OMRON
RELAY
CR66
5 SW INPUT
8
TIME DELAY
MODULE 4S
C2B-7
C5-21
C5-20
C5-4 WH
3 GND
C45GEN GR/WH
4
2 COM
TB24
3
C1B-9
C1B-3
C1B-4
C1B-5
1 N.O.
C32BRK WH/RD
C35RPM BK/RD
C29MS RD/WH
C30EDC WH
C31EDC WH/BK
8 N.C.
C2P-7
C1P-9
C1P-3
C1P-4
C1P-6
C32BRK WH/RD
C1P-5
TS47
GENERATOR
ON
7
20
15
16
TS4
5
124 ohms
C5-21
C5-20
1
124 ohms
8
BK 16-2
NC
Y75
RS232TxD
RS232RxD
C1TxD
C2RxD
C3/BOOT
C6-39
F1DIG IN 0
F2DIG IN 1 GENERATOR ON
F3DIG IN 2
SX Controller
BRAKE
RELEASE
E1NOT USED
E2NOT USED
E3NOT USED
C41RPM OR/BK
D1ANALOG 0 JOYSTICK
D2ANALOG 1 NC
D3C41 RPM
CR4
HIGH IDLE
RELAY
BR-2
(16-2)
N.O.
A
B
C
MOTOR
STROKE
VALVE
DRIVE EDC +
DRIVE EDC -
Y75
PS4
PRESSURE SWITCH
200 PSI
BYPASS COIL
C
B
A
D
U4
RD-1
7
6
BK-2
5
OMRON
RELAY
CR50
C57
6
C45GEN GR/WH
C57
TB41
C5-12 OR/BK
4
TB45
C5-12
2
TB21
C5-23
3
D65
C5-18
1
B1VALVE 0 FWD COIL
B2VALVE 1 NC
B3DIGITAL OUTPUT BYPASS
D98
C5-24
V151HG GR
V150HG GR/BK
A1BATTERY +
A2SENSOR POWER +5 VDC
A3BATTERY-
6
2
TB32
TB35
5
1k ohms
TB29
2 4
C1B-4
C1B-5
D99
3
3
M
1
N
7
8
PILOT PRESSURE SIGNAL
FROM GENERATOR MANIFOLD
DIVERTER MANIFOLD
Part No. 122985
S-80 • S-85 • S-80X
6 - 163
September 2015
Section 6 • Schematics
12 kW Hydraulic Generator Electrical Schematic
6 - 163
6 - 164
Section 6 • Schematics
September 2015
Belt Driven Generator Option
6 - 165
6 - 166
Section 6 • Schematics
September 2015
Belt Driven Generator Option
A
B
C
D
E
F
G
H
I
J
K
L
M
N
R20BAT RD
VOLTAGE
REGULATOR
1
NEUTRAL WH
GND BR
LINE BK
FIELD BK/WH
GENERATOR
2
BELT DRIVEN
GENERATOR
CB4
LINE BK
TG2
NEUTRAL WH
CB6
P20BAT
LINE
LINE BK
30A
GND
CR46
87A
30
+
BATTERY
86
120VAC / 60HZ
GFI OUTLET
GND GR
TG4
TG1
FIELD GR
3
15A
NEUTRAL WH
VOLTAGE
REGULATOR
NEU
87
C45GEN
85
TO GBOX
CB4
12.5A- 220V
15A- 120V
A
B
C45GEN
TG3
-
GND BR
BATTERY+
A
120 VAC / 60 HZ with Regulator
B
TG
CR46
4
BATTERY1
2
3
4
OUTLET
5
R20BAT RD
VOLTAGE
REGULATOR
NEUTRAL WH
GND BR
LINE BK
B
A
FIELD BK/WH
6
CB6
30A
GENERATOR
PIN# COLOR
1 WH
2 GR
3 BK
4
CIRCUIT #
NEUTRAL
FIELD
LINE
PLUG
BELT DRIVEN
GENERATOR
CB2
LINE BK
TG2
NEUTRAL WH
7
12.5A
FIELD GR
CB6
30A
GND
CR46
87A
30
+
BATTERY
86
NEUTRAL WH
C45GEN
85
-
8
220 VAC / 50 HZ with Regulator
6 - 166
S-80 • S-85 • S-80X
NEU
87
TG3
GND BR
220VAC / 50HZ
GFI OUTLET
GND GR
TG4
TG1
P20BAT
LINE
LINE BK
Part No. 122985
TO GBOX
1
2
3
4
5
VOLTAGE REGULATOR
PIN# COLOR
1 RD 12GA
2 WH 12GA
3 BR 12GA
4 BK 12GA
5 BK/WH 14GA
CIRCUIT#
R20BAT
NEUTRAL
GND
LINE
FIELD
September 2015
Section 6 • Schematics
Relay and Fuse Panel Legend
N
M
L
K
J
I
H
G
F
E
D
C
B
A
Deutz TD2011L04i
5
6
8
7
NOT USED
B1BAT
F22
F17
CR17
CR2
F7
F20
1
2
4
3
P24PWR
R21IGN
CR1
CR5
CR15
CR39
CR3
02GND
LABEL
DESCRIPTION
CR1
START RELAY
CR2
IGNITION / FUEL RELAY
CR3
HIGH IDLE RELAY
CR5
HORN RELAY
CR15
GLOW PLUG RELAY
CR17
HYDRAULIC OIL COOLER RELAY
CR39
AUXILIARY PUMP RELAY
CR39
AUXILIARY PUMP RELAY
F7
FUSE, 30A, OIL COOLER FAN / HORN
F17
FUSE, 30A, ENGINE / AUXILIARY PUMP
F20
FUSE, 20A, ENGINE RPM SOLENOID
F22
FUSE, 60A, GLOW PLUGS
1
5
6
8
7
B1PBAT
F17
CR17
CR39B
F7
1
2
B3PBAT
4
3
2
R21PIGN
CR5
CR1
CR2
CR39A
02PGND
3
Continental TME27
5
6
8
7
B1BAT
F22
F17
CR17
CR2
CR4
F7
CB20
1
2
4
3
P24PWR
R21IGN
CR1
CR5
02GND
CR15
CR39
CR3
LABEL
DESCRIPTION
CR1
START RELAY
CR2
IGNITION / FUEL RELAY
CR5
HORN RELAY
Perkins 804D-33
CR17
HYDRAULIC OIL COOLER RELAY
CR39A
AUXILIARY PUMP RELAY
LABEL
DESCRIPTION
CR39B
AUXILIARY PUMP ENGINE CUTOUT RELAY
CB20
CIRCUIT BREAKER, 10A, ENGINE RPM SOLENOID
F7
FUSE, 30A, OIL COOLER FAN / HORN
CR1
START RELAY
F17
FUSE, 30A, ENGINE / AUXILIARY PUMP
CR2
IGNITION / FUEL RELAY
CR3
HIGH IDLE RELAY
CR4
ENGINE RPM SOLENOID RELAY
CR5
HORN RELAY
CR15
GLOW PLUG RELAY
CR17
HYDRAULIC OIL COOLER RELAY
CR39
AUXILIARY PUMP RELAY
F7
FUSE, 30A, OIL COOLER FAN / HORN
F17
FUSE, 30A, ENGINE / AUXILIARY PUMP
F22
FUSE, 60A, GLOW PLUGS
4
5
6
7
8
Part No. 122985
S-80 • S-85 • S-80X
6 - 167
September 2015
Section 6 • Schematics
Relay and Fuse Panel Legend
6 - 167
6 - 168
Section 6 • Schematics
September 2015
Hydraulic Schematic, 2WD Models
6 - 169
6 - 170
Section 6 • Schematics
September 2015
Hydraulic Schematic, 2WD Models
A
B
C
D
E
F
G
H
I
TURNTABLE ROTATE
3 gpm / 11.4 L/min
PRIMARY LIFT CYLINDER
15 gpm / 57 L/min (UP)
8 gpm / 30 L/min (DOWN)
1
BRAKE/2 SPEED
MANIFOLD
0.025 inch
0.6 mm
BB
2
BD
MEDIUM
PRESSURE
FILTER
51 psi
3.5 bar
T2
0.030 inch
0.8 mm
S1
2SPEED
TEST
1
2
B
M2
X
X
3750 psi
256 bar
E
T5
P1
SW1 SW2
L2
L1
S
EXT
F
PB
G
G
PR2
PR1
PLS1 PLS2
SI
PTEST
PR2
PR1
2400 psi
165 bar
SN
SP
EA
2400 psi
165 bar
SS
ST
T1
SC
SD
SM
950 psi
66 bar
EF
EB
SH
SE
25 psi
2 bar
C
SR
SO
L1
P4
P4
T4
T4
0.3 gpm
1.1 L/min
0.6 gpm
2.3 L/min
30 psi
2 bar
3.5 gpm
13 L/min
EH
EE
EG
0.8 gpm
3 L/min
S80 PLATFORM MANIFOLD
SL
3.5 gpm
13 L/min
FUNCTION MANIFOLD
30 psi
2 bar
T2
OIL COOLER
ST2
OSC
RESERVOIR
X
T3
ST1
X
P3
OSC TEST
5
6
8
X
6A
X
8A
3
1
2
7
4
5
2B
7
4
5
HYDRAULIC ROTARY COUPLER
X
8B
X
6B
8C
6C
3
X
2A
1
COUNTERBALANCE VALVES
2C
RATIO
6
TEST
RIGHT
REAR
A
DF
DC
M2
7
50%
0.070 inch
1.8 mm
3000 psi / 207 bar
1:1
3500 psi / 241 bar
D
4.5:1
1000 psi / 69 bar
E
4.5:1
3500 psi / 241 bar
RIGHT
F
3:1
3300 psi / 228 bar
STEER CYLINDER
G
3:1
3000 psi / 207 bar
DE
280 psi
19 bar
LEFT
DB
G
G
G
T
A
LEFT
REAR
B
A
IN
M3
OUT
B
OC
TRACTION MANIFOLD
OSCILLATE VALVE
6 - 170
G
DD
CDL
8
RIGHT
DA
50%
M1
1000 psi / 69 bar
1.5:1
A
CDR
3:1
B
M4
B
PRESS
A
C
B
LEFT
S-80 • S-85 • S-80X
Part No. 122985
J2
ED
C
SF
3200 psi
221 bar
S
J1
SQ
SG
RETURN
FILTER
PLM2
RET
SK
1.7 gpm
6.4 L/min
FUNCTION
PUMP
38cc
4
E
R
D
EC
SJ
SB
9
PA
MASTER
CYLINDER
SA
AUXILIARY
PUMP
E
F
JIB BOOM CYLINDER
(S-85 OPTION)
B
V1
P2
2900 psi
200 bar
L
N
102 psi
7 bar
M
3
PLATFORM
ROTATE
SLAVE
CYLINDER
PLM1
250 psi
17 bar
M
RD
RC
V2
B
310 psi
21 bar
L
PLATFORM LEVEL
CYLINDERS
BOOM EXTEND / RETRACT
16 gpm / 61 L/min (EXTEND)
7 gpm / 26.5 L/min (RETRACT)
A
HIGH PRESSURE
FILTER
DRIVE PUMP
K
A
B
BC
BRAKE
RB
FUNCTION
ENABLE VALVE
CP
A
BA
A RA
J
HS0166C
OSCILLATE CYLINDERS
September 2015
Section 6 • Schematics
Hydraulic Schematic, 4WD Models
N
M
L
K
J
I
H
G
F
E
TURNTABLE ROTATE
3 gpm / 11.4 L/min
0.025 inch
0.6 mm
BB
A
L
PA
E
A
JIB BOOM CYLINDER
(S-85 OPTION)
PLATFORM
ROTATE
F
E
B
B
PLATFORM LEVEL
CYLINDERS
SLAVE
CYLINDER
A
R
1
F
PB
G
G
D
B
T2
A
PR2
HIGH PRESSURE
FILTER
DRIVE PUMP
0.030 inch
0.8 mm
S1
BC
BRAKE
RB
FUNCTION
ENABLE VALVE
CP
BD
BA
A RA
MEDIUM
PRESSURE
FILTER
51 psi
3.5 bar
C
BOOM EXTEND / RETRACT
16 gpm / 61 L/min (EXTEND)
7 gpm / 26.5 L/min (RETRACT)
PRIMARY LIFT CYLINDER
15 gpm / 57 L/min (UP)
8 gpm / 30 L/min (DOWN)
BRAKE / 2 SPEED
MANIFOLD
D
TEST
2SPEED
B
V2
1
2
M2
X
102 psi
7 bar
T5
P1
SW1 SW2
PTEST
SH
SE
30 psi
2 bar
T2
EF
EB
EH
SP
EA
2400 psi
165 bar
SS
SM
950 psi
66 bar
P4
P4
T4
T4
EE
0.3 gpm
1.1 L/min
0.6 gpm
2.3 L/min
30 psi
2 bar
3.5 gpm
13 L/min
EG
0.8 gpm
3 L/min
4
PLATFORM MANIFOLD
SL
3.5 gpm
13 L/min
FUNCTION MANIFOLD
X
T3
ST2 ST1
OSC
RESERVOIR
C
SR
ST
SD
OIL COOLER
2400 psi
165 bar
SF
SN
SC
J2
3
T1
25 psi
2 bar
J1
ED
C
SO
S
PR1
RET
SK
3200 psi
221 bar
RETURN
FILTER
PR2
SQ
SG
L1
S
PLM2
EC
SJ
SI
SB
FUNCTION
PUMP
38cc
9
EXT
1.7 gpm
6.4 L/min
AUXILIARY
PUMP
E
L2
L1
SA
P2
2900 psi
200 bar
PLS1 PLS2
PLM1
M
3750 psi
256 bar
2
MASTER
CYLINDER
V1
B
250 psi
17 bar
310 psi
21 bar
PR1
RD
RC
X
P3
OSC TEST
5
6
8
3
1
2
7
4
5
2B
7
4
5
HYDRAULIC ROTARY COUPLER
8B
8C
6B
6C
6A
8A
3
1
2A
2C
COUNTERBALANCE VALVES
RATIO
TEST
RIGHT
REAR
DC
M7
A
B
DF
A
A
B
RIGHT
FRONT
M8
LEFT
STEER CYLINDERS
DJ
CDR
RIGHT
DI
M6
B
6
PRESS
A
3:1
1000 psi / 69 bar
B
1.5:1
3000 psi / 207 bar
C
1:1
3500 psi / 241 bar
D
4.5:1
1000 psi / 69 bar
E
4.5:1
3500 psi / 241 bar
F
3:1
3300 psi / 228 bar
G
3:1
3000 psi / 207 bar
7
M5
50%
0.040 inch
1 mm
50%
280 psi
19 bar
DA
DN
DK 50%
50%
50%
DB
DG
DD
DL
M3
G
50%
G
G
G
M4
B
A
RIGHT
DM
0.040 inch
1 mm
CDL
LEFT
REAR
LEFT
0.040 inch
1 mm
DE
A
DH
M1
M2
T
8
B
LEFT
FRONT
IN
A
OUT
B
OC
TRACTION MANIFOLD
HS0166C
OSCILLATE CYLINDERS
OSCILLATE VALVE
Part No. 122985
S-80 • S-85 • S-80X
6 - 171
September 2015
Section 6 • Schematics
Hydraulic Schematic, 4WD Models
6 - 171
6 - 172
September 2015
Section 6 • Schematics
12 kW Hydraulic Generator Hydraulic Schematic
K
J
I
H
G
F
E
D
C
B
A
1
B
DRIVE PUMP
3.5 GPM / 13.25L/min
OIL COOLER
A
CASE
2
PMP B
CLR
PMP A
WELDER
MANIFOLD
3
CW
0.031 inch /
0.79 mm
CV
PRESSURE SWITCH
200 PSI / 13.8 BAR
N.O.
4
CU
CX
CZ
270 PSI / 18.6 BAR
@ 3.5 GPM / 13.25 L/min
5
CY
G2
MTR B
MTR A
G1
6
HYDRAULIC
ROTARY
COUPLER
L
3
M
1
N
7
TANK
8
21CC
21 GPM / 79.5 L/min
G2
G1
HS0166C
GENERATOR
12.5 KW
Part No. 122985
S-80 • S-85 • S-80X
6 - 173
September 2015
Section 6 • Schematics
12 kW Hydraulic Generator Hydraulic Schematic
6 - 173
6 - 174
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
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Phone
Fax
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