Download Repair Procedures

Introduction
February 2012
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 Industries 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
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 © 1994 by Genie Industries
122149 Rev B February 2012
Sixth Edition, First Printing
"Genie" and "S" are registered trademarks of
Genie Industries 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]
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S-80 • S-85
Part No. 122149
February 2012
Revision History
Revision
Date
Section
Procedure / Schematic Page / Description
B
2/2012
2 - Spec.
2-1
3 - Maint.
3-1
4 - Repair
4-3 to 4-6
6 - Schem.
6-7, 6-11, 6-21, 6-25, 6-35, 6-39
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. 122149
S-80 • S-85
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
February 2012
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 #.
S-80 • S-85
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Part No. 122149
February 2012
Introduction
Serial Number Legend
Model: S-80
S8006-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0274
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 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 80 ft/ 24.38 m
Sequence
number
Model
Maximum platform reach : 72 ft 5 in/ 22.07 m
Gradeability: N/A
Model year
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Serial number
(stamped on chassis)
Serial label
(located under cover)
PN - 77055
Part No. 122149
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S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
v
Section 1 - Safety Rules
February 2012
SAFETY RULES
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Personal 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.
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.
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.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
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.
Workplace Safety
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.
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.
Note: Used to indicate operation or maintenance
information.
vi
S-80 • S-85
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.
Part No. 122149
February 2012
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1
Safety Rules
General Safety Rules .................................................................................................. v
Section 2
Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 2
Hydraulic Component Specifications ...................................................................... 2 - 3
Valve Coil Resistance Specifications ..................................................................... 2 - 4
Continental TME27 Engine Specifications ............................................................. 2 - 5
Deutz BF4L-2011 Engine Specifications ................................................................ 2 - 6
Perkins 804C-33 Engine Specifications ................................................................. 2 - 8
Machine Torque Specifications .............................................................................. 2 - 9
Manifold Component Specifications ....................................................................... 2 - 9
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12
SAE and Metric Torque Specifications ................................................................. 2 - 11
Part No. 122149
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February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1
Inspect the Manuals and Decals .................................................................. 3 - 7
A-2
Perform Pre-operation Inspection ................................................................. 3 - 8
A-3
Grease the Extendable Axles ....................................................................... 3 - 8
A-4
Perform Engine Maintenance ....................................................................... 3 - 9
A-5
Perform Function Tests .............................................................................. 3 - 10
A-6
Test the Oscillate Axle ............................................................................... 3 - 10
A-7
Test the Extendable Axles ......................................................................... 3 - 11
A-8
Check the Hydraulic Filter Condition Indicators .......................................... 3 - 12
A-9
Perform 30 Day Service ............................................................................. 3 - 13
A-10 Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 13
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15
A-13 Perform Engine Maintenance ..................................................................... 3 - 15
A-14 Replace the Drive Hub Oil .......................................................................... 3 - 16
A-15 Perform Engine Maintenance - Perkins Models .......................................... 3 - 18
Checklist B Procedures
viii
B-1
Inspect the Battery(s) ................................................................................. 3 - 19
B-2
Inspect the Electrical Wiring ....................................................................... 3 - 20
B-3
Test the Key Switch ................................................................................... 3 - 22
B-4
Check the Exhaust System ....................................................................... 3 - 22
S-80 • S-85
Part No. 122149
February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
`
B-5
Inspect the Engine Air Filter ....................................................................... 3 - 23
B-6
Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 24
B-7
Confirm the Proper Brake Configuration ...................................................... 3 - 25
B-8
Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 26
B-9
Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 27
B-10 Check and Adjust the Engine RPM ............................................................ 3 - 28
B-11 Perform Engine Maintenance ..................................................................... 3 - 30
B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 31
B-13 Test the Ground Control Override ............................................................... 3 - 31
B-14 Test the Platform Self-leveling ................................................................... 3 - 32
B-15 Test the Engine Idle Select Operation ........................................................ 3 - 32
B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 33
B-17 Test the Drive Enable System ................................................................... 3 - 34
B-18 Test the Drive Brakes ................................................................................ 3 - 35
B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 36
B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 36
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 37
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38
B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 39
Checklist C Procedures
Part No. 122149
C-1
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 41
C-2
Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 42
C-3
Test the Platform Overload System (if equipped) ....................................... 3 - 42
C-4
Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 45
C-5
Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 45
S-80 • S-85
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February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1
Check the Boom Wear Pads ...................................................................... 3 - 48
D-2
Check the Extendable Axle Wear Pads ...................................................... 3 - 49
D-3
Check the Free-wheel Configuration ........................................................... 3 - 50
D-4
Check the Turntable Rotation Bearing Bolts ............................................... 3 - 51
D-5
Inspect the Turntable Bearing Wear ........................................................... 3 - 52
D-6
Perform Engine Maintenance ..................................................................... 3 - 54
D-7
Replace the Hydraulic Filter Elements ........................................................ 3 - 55
D-8
Replace the Drive Hub Oil .......................................................................... 3 - 56
D-9
Perform Engine Maintenance - Deutz Models ............................................. 3 - 58
Checklist E Procedures
Section 4
E-1
Test or Replace the Hydraulic Oil ............................................................... 3 - 59
E-2
Perform Engine Maintenance - Perkins Models .......................................... 3 - 61
E-3
Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 61
E-4
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 63
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 - 7
2-2
Platform Leveling Slave Cylinder .................................................................. 4 - 8
S-80 • S-85
Part No. 122149
February 2012
TABLE OF CONTENTS
Section 4
Repair Procedures, continued
2-3
Platform Rotator ........................................................................................... 4 - 9
2-4
Calibrate the Platform Overload System .................................................... 4 - 11
Jib Boom Components, S-85
3-1
Jib Boom .................................................................................................... 4 - 14
3-3
Jib Boom Lift Cylinder ................................................................................ 4 - 15
Boom Components
4-1
Cable Track ................................................................................................ 4 - 16
4-2
Boom ......................................................................................................... 4 - 19
4-3
Boom Lift Cylinder ...................................................................................... 4 - 21
4-4
Boom Extension Cylinders ......................................................................... 4 - 24
4-5
Platform Leveling Master Cylinder .............................................................. 4 - 26
Engines
5-1
RPM Adjustment ........................................................................................ 4 - 27
5-2
Flex Plate ................................................................................................... 4 - 27
Ground Controls
6-1
Control Relays ............................................................................................ 4 - 32
Hydraulic Pumps
Part No. 122149
7-1
Function Pump ........................................................................................... 4 - 33
7-2
Drive Pump ................................................................................................ 4 - 34
S-80 • S-85
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February 2012
TABLE OF CONTENTS
Section 4
Repair Procedures, continued
Manifolds
8-1
Function Manifold Components - View 1 .................................................... 4 - 36
8-2
Function Manifold Components - View 2 .................................................... 4 - 40
8-3
Valve Adjustments - Function Manifold ...................................................... 4 - 42
8-4
Brake/Two-speed Manifold Components .................................................... 4 - 45
8-5
Turntable Rotation Manifold Components ................................................... 4 - 48
8-6
Jib Boom Select Manifold Components, S-85 ............................................ 4 - 48
8-7
Axle Select Manifold Components .............................................................. 4 - 48
8-8
2WD Traction Manifold Components .......................................................... 4 - 50
8-9
4WD Traction Manifold Components .......................................................... 4 - 52
8-10 Drive Oil Diverter Manifold Components ..................................................... 4 - 54
8-11 Valve Adjustments - Drive Manifold ........................................................... 4 - 55
8-12 Valve Coils ................................................................................................. 4 - 56
Fuel and Hydraulic Tanks
9-1
Fuel Tank ................................................................................................... 4 - 59
9-2
Hydraulic Tank ........................................................................................... 4 - 60
Turntable Rotation Components
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 62
2WD Steer Axle Components
11-1 Yoke and Hub ............................................................................................ 4 - 65
11-2 Steer Cylinder ............................................................................................ 4 - 66
11-3 Tie Rod Cylinder ......................................................................................... 4 - 67
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Part No. 122149
February 2012
TABLE OF CONTENTS
Section 4
Repair Procedures, continued
4WD Steer Axle Components
12-1 Yoke and Drive Hub ................................................................................... 4 - 68
12-2 Drive Motor ................................................................................................ 4 - 69
12-3 Drive Hub ................................................................................................... 4 - 70
12-4 Steer Cylinders ........................................................................................... 4 - 70
12-5 Tie Rod Cylinder ......................................................................................... 4 - 71
Non-steer Axle Components
13-1 Drive Motor ................................................................................................ 4 - 72
13-2 Drive Hub ................................................................................................... 4 - 72
Oscillating Axle Components
14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73
14-2 Valve Adjustments - Oscillate Directional Valve ......................................... 4 - 73
Extendable Axle Components
15-1 Extendable Axles ....................................................................................... 4 - 76
15-2 Axle Extension Cylinder ............................................................................. 4 - 76
Section 5
Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Engine Fault Codes - Continental Models ............................................................... 5 - 6
Part No. 122149
S-80 • S-85
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February 2012
TABLE OF CONTENTS
Section 6
Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Electrical Schematic, S-80/85 (before S/N 5520)
Deutz BF4L2011 Models ........................................................................................ 6 - 6
Electrical Schematic, S-80/85 (after S/N 5519)
Deutz BF4L2011 Models ...................................................................................... 6 - 10
Ground Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models ..................................................................................... 6 - 14
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)
Deutz BF4L 2011 Models ..................................................................................... 6 - 16
Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)
Deutz BF4L 2011 Models ..................................................................................... 6 - 17
Electrical Schematic, S-80/85 (before S/N 5520)
Perkins 804-33 Models ........................................................................................ 6 - 20
Electrical Schematic, S-80/85 (after S/N 5519)
Perkins 804-33 Models ........................................................................................ 6 - 24
Ground Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models ........................................................................................ 6 - 28
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)
Perkins 804-33 Models ........................................................................................ 6 - 30
Platform Control Box Wiring Diagram, S-8/85 (after S/N 5519)
Perkins 804-33 Models ........................................................................................ 6 - 31
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Part No. 122149
February 2012
TABLE OF CONTENTS
Section 6
Schematics, continued
Electrical Schematic, S-80/85 (before S/N 5520)
Continental TME27 Models .................................................................................. 6 - 34
Electrical Schematic, S-80/85 (after S/N 5519)
Continental TME27 Models .................................................................................. 6 - 38
Ground Control Box Wiring Diagram, S-80/85
Continental TME27 Models .................................................................................. 6 - 42
Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)
Continental TME27 Models .................................................................................. 6 - 44
Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)
Continental TME27 Models .................................................................................. 6 - 45
Continental TME27 Engine Harness ..................................................................... 6 - 48
Joystick Wiring Diagram ...................................................................................... 6 - 49
Connector Pin Legend - View 1 ............................................................................ 6 - 52
Connector Pin Legend - View 2 ............................................................................ 6 - 53
Dual Battery Option ............................................................................................. 6 - 56
Belt Drive Generator Option ................................................................................. 6 - 57
CE Option ............................................................................................................ 6 - 60
Platform Level Cutout, CTE Option ...................................................................... 6 - 61
12kW Hydaulic Generator Option ......................................................................... 6 - 64
Hydaulic Schematiic, 12kW Generator ................................................................. 6 - 65
Hydraulic Schematic, 2WD Models ...................................................................... 6 - 68
Hydraulic Schematic, 4WD Models ...................................................................... 6 - 69
Part No. 122149
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Part No. 122149
February 2012
Section 2 • Specifications
Specifications
Machine Specifications
Fluid capacities
Tires and wheels
Tire size
Tire ply rating
Overall tire diameter
Tire weight, new foam-filled (minimum), RT
15-22.5 SAT
385/65-22.5
16
43.5 in
110.5 cm
622 lbs
282 kg
Fuel tank
33 gallons
125 liters
LPG tank
33.5 pounds
15.2 kg
Hydraulic tank
45 gallons
170 liters
Hydraulic system
(including tank)
80 gallons
303 liters
Turntable rotation drive hub
100 psi
6.9 bar
40 fl oz
1.2 liters
Rexroth drive hubs
Tire pressure, Hi-floatation
60 psi
4.1 bar
Bonfiglioli drive hubs
61 fl oz
1.8 liters
51 fl oz
1.5 liters
Wheel diameter
22.5 in
57 cm
Tire pressure, RT
Wheel width
Wheel lugs
11.75 in
29.8 cm
10 @ 3/4 -16
Lug nut torque, dry
420 ft-lbs
569 Nm
Lug nut torque, lubricated
320 ft-lbs
434 Nm
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 122149
S-80 • S-85
2-1
Section 2 • Specifications
February 2012
SPECIFICATIONS
Performance Specifications
Hydraulic Oil Specifications
Drive speed, maximum
Hydraulic Oil Specifications
Stowed position
40 ft / 7.9-8.5 sec
12.2 m / 7.9-8.5 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
Boom function speeds, maximum
from platform controls
Jib boom up (S-85)
60 to 70 seconds
Jib boom down (S-85)
40 to 50 seconds
Boom up
89 to 93 seconds
Boom down
90 to 94 seconds
Boom extend
73 to 79 seconds
Boom retract
79 to 84 seconds
Turntable rotate, 360°
boom raised or extended
Platform rotate, 160°
95 to 103 seconds
Chevron Rykon MV equivalent
Multi-viscosity
200
Cleanliness level, minimum
Water content, maximum
Refer to the Operator’s Manual
Turntable rotate, 360°
boom fully stowed
Hydraulic oil type
Viscosity grade
Viscosity index
15/13
200 ppm
Chevron Rykon 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.
Optional fluids
Biodegradable
Fire resistant
Mineral based
210 to 250 seconds
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
8 to 12 seconds
Platform level up
50 to 60 seconds
Platform level down
40 to 50 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
2-2
S-80 • S-85
Part No. 122149
February 2012
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.
Drive pressure, maximum
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Charge pump
Flow rate @ 2300 rpm
30.3 gpm
114.7 L/min
Type:
4200 psi
290 bar
gerotor
Displacement
0.85 cu in
13.9 cc
Flow rate @ 2300 rpm
8 gpm
30.3 L/min
Charge pressure @ 2300 rpm
Neutral position
320 psi
22 bar
Function pump
Type:
two-section tandem gear pump
Displacement - Pump 1 (inner)
1.4 cu in
22.9 cc
Flow rate @ 2300 rpm
12.7 gpm
48 L/min
Displacement - Pump 2 (outer)
0.24 cu in
4 cc
Flow rate @ 2300 rpm
2.25 gpm
8.5 L/min
Auxiliary pump
Type:
Displacement - static
fixed displacement gear pump
0.151 cu in
2.47 cc
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 122149
S-80 • S-85
2-3
Section 2 • Specifications
February 2012
SPECIFICATIONS
Function manifold
System relief pressure
(measured at PTEST port)
2900 psi
200 bar
Boom down relief pressure
(measured at PTEST port)
2100 psi
145 bar
Boom extend
(measured at PTEST port)
2500 psi
172 bar
Steer/axle extend
flow regulator
3.5 gpm
13.2 L/min
Oscillate relief pressure
850 psi
58.6 bar
Drive manifold
Hot oil relief pressure
280 psi
19.3 bar
Brake release pressure
Rexroth hubs
217.5 psi
15 bar
189 psi
13 bar
Bonfiglioli hubs
Drive motors
Displacement per revolution, variable
(2 speed motor)
0.9 to 2.7 cu in
14.7 to 45 cc
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 K and W)
4.8 
2 position 3 way solenoid valve
(schematic items D, R, X, TT and UU)
6.3 
2 position 3 way solenoid valve
(schematic items G)
3.3 
3 position 4 way solenoid valve
(schematic items A, E, N and S)
6.3 
2 position 3 way solenoid valve
(schematic items AK, AM, VV and WW)
6.3 
2 position 3 way solenoid valve
(schematic item G)
3.3 
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
10 micron with
25 psi / 1.7 bar bypass
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
2-4
S-80 • S-85
Part No. 122149
February 2012
Section 2 • Specifications
SPECIFICATIONS
Continental TME27 Engine
Displacement
Fuel Requirement
164 cu in
2.68 liters
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio
4
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
2
1000A
200 minutes
65A @ 13.8V DC
1 /2
inch
12 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
40 to 60 psi
2.75 to 4.14 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.
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 122149
S-80 • S-85
2-5
Section 2 • Specifications
February 2012
SPECIFICATIONS
Deutz BF4L-2011 Engine
Displacement
Lubrication system
189.6 cu in
3.1 liters
Number of cylinders
Bore and stroke
4
3.7 x 4.409 inches
94 x 112 mm
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
Low idle
Frequency
1500 rpm
382.5 Hz
High idle
Frequency
2350 rpm
599.25 Hz
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
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
40 to 60 psi
2.8 to 4.1 bar
11 quarts
10.4 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.
Oil temperature switch
Torque
Oil temperature switch point
8-18 ft-lbs
11-24 Nm
275°F
135°C
Oil pressure switch
Torque
Oil pressure switch point
8-18 ft-lbs
11-24 Nm
7 psi
0.48 bar
centrifugal mechanical
Valve clearance, cold
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
2-6
S-80 • S-85
Part No. 122149
February 2012
Section 2 • Specifications
SPECIFICATIONS
Fuel injection system
Injection pump make
Bosch
Injection pump pressure, maximum15,000 psi/1034 bar
Injector opening pressure
3046 psi
210 bar
Fuel Requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, normal load
Cranking speed
140-200A
200-250 rpm
Batteries
Type
12V DC
Group
31
Quantity
1
Cold cranking ampere
Reserve capacity @ 25A rate
Alternator output
Fan belt deflection
1000A
200 minutes
80A @ 14V DC
3/8
to 1/2 inch
9 to 12 mm
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 122149
S-80 • S-85
2-7
Section 2 • Specifications
February 2012
SPECIFICATIONS
Perkins 804C-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
Compression pressure
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
Low idle
Frequency
1650 rpm
335.5 Hz
High idle
Frequency
2300 rpm
467.67 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.
2-8
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
S-80 • S-85
Part No. 122149
February 2012
Section 2 • Specifications
SPECIFICATIONS
Machine Torque Specifications
Manifold Component
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
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
185 ft-lbs*
247 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
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Part No. 122149
S-80 • S-85
2-9
Section 2 • Specifications
February 2012
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
2 - 10
S-80 • S-85
Part No. 122149
February 2012
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
5/16
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
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
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 •
Class 4.6
Size
(mm)
5
6
7
LUBED
LUBED
DRY
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
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
Class 8.8
4.6
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
Part No. 122149
S-80 • S-85
2 - 11
Section 2 • Specifications
February 2012
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2 - 12
S-80 • S-85
Part No. 122149
February 2012
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
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.
•
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. 122149
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
S-80 • S-85
3-1
Section 3 • Scheduled Maintenance Procedures
February 2012
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.
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
Indicates that a warm engine will be
required to perform this procedure.
Checklist
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that dealer service is required
to perform this procedure.
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. Store completed forms
for three years.
3-2
S-80 • S-85
Part No. 122149
Pre-Deliver
y Preparation
Pre-Delivery
February 2012
Section 3 • Scheduled Maintenance Procedures
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
Y
N
R
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
Part No. 122149
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
S-80 • S-85
3-3
Section 3 • Scheduled Maintenance Procedures
February 2012
This page intentionally left blank.
3-4
S-80 • S-85
Part No. 122149
February 2012
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 Grease axles
Y N R
A-4 Engine maintenance
Checklist B
B-2 Electrical wiring
B-4 Exhaust system
B-5 Engine air filter
Machine owner
A-5 Function tests
B-6 Oil cooler and finsDeutz models
Inspected by (print)
A-6 Oscillate axle
B-7 Brake configuration
A-7 Extendable axles
A-8 Filter condition indicator
B-8 Tires, wheels and
lug nut torque
Perform after 40 hours:
B-9 Drive hub maintenance
A-9 30 day service
B-10 Engine RPM
Perform after 50 hours:
B-11 Engine maintenance
A-10 Engine maintenance Deutz and Continental
models
B-12 Oscillate directional
Control
Inspector signature
Inspector title
Inspector company
Instructions
• Make copies of this report to use for
each inspection.
Perform every 100 hours:
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
B-13 Ground control
override
A-11 Inspect filter/separator Diesel models
B-14 Platform self-leveling
A-12 Grease rotation
bearing
B-16 Fuel select operation
A-13 Engine maintenance
Perform after 150 hours:
B-15 Engine idle select
B-17 Drive enable system
B-18 Drive brakes
B-19 Drive speed-stowed
A+B
A-14 Replace Drive Hub oil
Six Month or 500 hour
Inspection:
A+B+C
Perform every 200 hours:
B-20 Drive speed-raised
or extended
A-15 Engine maintenance Perkins models
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
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. 122149
S-80 • S-85
3-5
Section 3 • Scheduled Maintenance Procedures
February 2012
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
Hour meter
C-3 Test the platform
overload (if equipped)
E-3 Grease axle bearings,
2WD models
C-4 Air filter element
Perform every 3000 hours:
C-5 Replace filter/separator Deutz and Perkins
models
E-4 Engine maintenance Deutz and Perkins
models
Serial number
Machine owner
Inspected by (print)
Inspector signature
Checklist D
Inspector title
D-2 Axle wear pads
Inspector company
D-3 Free-wheel
configuration
Instructions
• Make copies of this report to use for
each inspection.
D-4 Turntable rotation
bearing bolts
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
D-5 Turntable bearing wear
D-6 Engine maintenance
D-7 Replace hydraulic filters
D-8 Drive hub oil
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
Y N R
D-1 Boom wear pads
A
A+B
Six Month or 500 hour
Inspection:
A+B+C
Perform every 1500 hours:
D-9 Engine maintenance Deutz models
Comments
Annual or 1000 hour
Inspection:
A+B+C+D
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
Part No. 122149
February 2012
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. 122149
S-80 • S-85
3-7
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
A-2
Perform Pre-operation Inspection
A-3
Grease the Extendable Axles
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.
Genie specifications require that this procedure be
performed daily.
Proper lubrication of the extendable axle wear
pads is essential to smooth operation and
minimum wear of the wear pads.
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.
1 Locate the grease fitting on the platform side of
the non-steer extendable axle and behind the
drive motor on the steer extendable axle.
2 Pump grease into each fitting until grease is
visible between the axle and wear pads.
3 Repeat for each axle.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3-8
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
To access the engine:
A-4
Perform Engine Maintenance
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 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.
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 BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
Part No. 122149
111901
S-80 • S-85
3-9
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
A-5
Perform Function Tests
A-6
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.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
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.
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.
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.
If the chassis does not remain
level during the test, refer to
Repair Procedure 14-2, How to
Set Up the Directional Valve
Linkage.
3 - 10
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
6 Move and hold the function enable switch to
either side and activate the boom retract
function.
A-7
Test the Extendable Axles
Genie specifications require that this procedure be
performed daily.
Tip-over hazard. Do not raise or
extend the boom unless both
axles are fully extended. If the axle
extension system is not operating
correctly, the stability of the
machine is compromised and it
may tip over.
Note: Be sure the axles are retracted before
performing this procedure.
1 Turn the key switch to ground control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
2 Start the engine from the ground controls.
3 Move and hold the function enable switch to
either side and activate the boom up function.
Result: The boom should raise to 5° above
horizontal and then stop. The boom should not
raise above the limit switch unless both axles
are extended.
4 Move and hold the function enable switch to
either side and activate the boom down
function.
Result: The boom should retract.
7 Turn the key switch to platform controls.
8 Press down the foot switch and move the drive
control handle in the forward direction and
activate the axle extend function.
Result: The machine will drive forward and the
axles should extend.
Note: The axle extend function will only work while
the machine is moving.
Note: The steer function will override the axle
extend or the axle retract function.
9 Turn the key switch to ground controls.
10 At the ground controls, hold the function enable
switch to either side and activate the boom up
and boom down function.
Result: The boom should raise and lower
normally.
11 At the ground controls, move and hold the
function enable switch to either side and
activate the boom extend and boom retract
function.
Result: The boom should extend and retract
normally.
Result: The boom should lower and return to
the stowed position.
5 Move and hold the function enable switch to
either side and activate the boom extend
function.
Result: The boom will extend approximately
1 foot / 30 cm and then stop. The boom should
not extend farther unless both axles are
extended.
Part No. 122149
S-80 • S-85
3 - 11
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
REV B
4 Continue allowing the engine to run until the
hydraulic oil temperature is above
70° F / 21° C.
A-8
Check the Hydraulic Filter
Condition Indicators
Genie specifications require that this procedure be
performed daily.
Maintaining the hydraulic filters in good condition is
essential to good system performance and safe
machine operation. The filter condition indicators
will show when the hydraulic flow is bypassing a
clogged filter. If the filters are not frequently
checked and replaced, impurities will remain in the
hydraulic system and cause component damage.
Note: There are three hydraulic filters located on
the machine: one tank return filter, one medium
pressure filter and one high pressure filter. The
tank return and high pressure filter have a
condition indicator on them. The medium pressure
filter does not have a filter condition indicator.
Result: The needle on the gauge is operating in
the green area. The filter is good. Proceed to
step 6.
Result: The needle is operating in the red area.
Proceed to step 5.
5 Operate the machine until the hydraulic oil
temperature is above 104° F / 40° C.
Result: The needle on the gauge is operating in
the green area. The filter is good. Proceed to
step 6
Result: The needle is operating in the red area.
The filter is clogged and is being bypassed.
Replace the filter and repeat this procedure
beginning with step 1. See D-7, Replace the
Hydraulic Filter Elements.
High pressure filter:
1 Start the engine from the platform controls.
Tank return filter:
Note: The high pressure filter is located to the left
of the medium pressure filter below the hydraulic
pumps. A filter condition indicator is located on the
top of the high pressure filter.
3 Open the ground control side turntable cover
and inspect the filter condition indicator gauge.
6 Open the engine side turntable cover and
Inspect the filter condition indicator.
2 Change the engine idle to high rpm (rabbit
symbol).
Result: The needle on the gauge is operating in
the green area. The filter is good. Proceed to
step 6.
Result: The needle is operating in the red area.
Proceed to step 4.
Note: The tank return filter indicator needle may
operate in the red area when hydraulic oil is below
50° F / 10° C.
Result: The filter condition indicators should be
operating with the plungers 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-7, Replace the Hydraulic Filter
Elements.
a
a
3 - 12
filter condition indicator gauge
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-9
Perform 30 Day Service
A-10
Perform Engine Maintenance Deutz and Continental Models
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.
1 Perform the following maintenance procedures:
•
A-12
Grease the Turntable Rotation Bearing
and Rotate Gear
•
B-8
Inspect the Tires, Wheels and
Lug Nut Torque
•
B-9
Check the Drive Hub Oil Level and
Fastener Torque
•
D-4
Check the Turnable Rotation Bearing
Bolts
•
D-7
Replace the Hydraulic Filter Elements
Engine specifications require that this one-time
procedure be performed after the first 50 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 for
commissioning new and overhauled engines and
additional engine information are available in the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
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.
Part No. 122149
S-80 • S-85
3 - 13
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
A-11
Inspect the Fuel Filter/Water
Separator - Deutz and Perkins
Models
a
b
e
d
c
Genie specifications require that this procedure be
performed every 100 hours or monthly, whichever
comes first.
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.
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.
1 Open the turntable cover at the engine side of
the machine. Locate the fuel filter/water
separator.
2 Inspect the filter bowl for water.
a
b
c
d
e
4 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.
5 Clean up any fuel that may have spilled.
Note: If the fuel filter/water separator is completely
drained, you must prime the fuel filter/water
separator before starting the engine.
See C-5, Replace The Fuel Filter/Water Separator
Element, for instructions on how to prime the fuel
filter/water separator.
6 Start the engine from the ground controls and
check the fuel filter/water separator and vent
plug for leaks.
Result: Water is not visible in the filter bowl.
Result: There is water present. Proceed
to step 3.
3 Loosen the vent plug located on the head of the
fuel filter/water separator.
3 - 14
head bolt
vent plug
drain plug
filter bowl
separator head
S-80 • S-85
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.
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-12
Grease the Turntable Rotation
Bearing and Rotate Gear
A-13
Perform Engine Maintenance
Genie specifications require that this procedure be
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
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.
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.
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 BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Part No. 122149
Engine specifications require that this procedure
be performed every 100 hours.
Continental TME27 Owner's Manual
Genie part number
S-80 • S-85
111901
3 - 15
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
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.
A-14
Replace the Drive Hub Oil
Manufacture specifications require that this onetime 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.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a
b
a
a. models with pipe plugs
b.
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 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub. Torque to Specification.
Refer to Section 2, Specifications.
3 - 16
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
5 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
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:
a
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.
b
c
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 turntable rotate drive motor. Cap the
fittings on the drive motor.
a
b
c
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.
motor
drive hub
drive hub mounting bolts
6 Install the drive hub assembly onto the
machine. Torque the drive hub mounting bolts
to specification. Refer to Section 2,
Specifications.
7 Fill the drive hub with oil from the side plug hole
until the oil level is even with the bottom of the
hole. 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.
Part No. 122149
S-80 • S-85
3 - 17
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A
February 2012
PROCEDURES
A-15
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 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).
Perkins 804C-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.
3 - 18
S-80 • S-85
Part No. 77832
February 2012
Section 3 • Scheduled Maintenance Procedures
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 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.
2 Be sure that the battery cable connections are
free of corrosion.
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.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
Part No. 77832
S-80 • S-85
3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
10 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 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.
B-2
Inspect the Electrical Wiring
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 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
engine tray anchor hole
engine tray retaining fastener
3 Locate the engine tray anchor hole on the
turntable.
3 - 20
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
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:
•
Engine wiring harness
•
Battery area wiring
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.
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:
•
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 secondary boom above the turntable
covers.
10 Inspect the turntable area for burnt, chafed and
pinched cables.
11 Lower the secondary 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 boom/platform rotate manifold
•
Inside of the platform control box
Part No. 122149
S-80 • S-85
3 - 21
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
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.
To access the engine:
4 Turn the key switch to ground control.
5 Check all machine function from the platform
controls.
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.
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.
2 Be sure that all nuts and bolts are tight.
3 Inspect all welds for cracks.
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S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
B-5
Inspect the Engine Air Filter
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 requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
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 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
a
b
c
a
b
c
Part No. 122149
S-80 • S-85
clamp
canister end cap
dust discharge valve
3 - 23
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
2 Release the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
B-6
Check the Oil Cooler and Cooling
Fins - Deutz Models
3 Remove the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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 slot is pointing down.
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.
3 - 24
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
3 Remove the fasteners from the engine side
cover, then remove the cover.
B-7
Confirm the Proper
Brake Configuration
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.
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.
a
b
c
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
oil cooler
cylinder head cooling fins
fan blower fins
5 Clean the oil cooler of debris and foreign
material.
disengaged position
Cooling and fan blower fins:
6 Inspect the fan blower fins for physical damage.
engaged position
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.
Part No. 122149
S-80 • S-85
3 - 25
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the
bottom of the drive pump.
b
a
c
d
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
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.
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.
Bodily injury hazard. An overinflated tire can explode and could
result in death or serious injury.
Note: The free-wheel valve should always remain
closed.
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 - 26
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
4 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
B-9
Check Drive Hub Oil Level and
Fastener Torque
Models with O-ring plugs: Install the plugs
into the drive hub. Torque to Specification.
Refer to Section 2, Specifications.
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:
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:
1 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
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.
a
a
b
b
a
a. models with pipe plugs
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.
a
b
plug
drive hub
2 If necessary, add oil until the oil level is even
with the bottom of the plug hole. Refer to
Section 2, Specifications.
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
Part No. 122149
S-80 • S-85
3 - 27
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
B-10
Check and Adjust the
Engine RPM
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.
Continental models:
Deutz BF4L 2011 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.
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 4 if the low idle rpm is correct.
2 Loosen the locknut on the low idle adjustment
screw.
3 Adjust the low idle adjustment screw until low
idle meets specification. Tighten the locknut.
4 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
3 - 28
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
If the high idle is correct, disregard adjustment
step 5.
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.
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.
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
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.
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. 122149
S-80 • S-85
3 - 29
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
To access the engine:
B-11
Perform Engine Maintenance
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.
Note: 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.
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 BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
3 - 30
111901
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-12
Check the Oscillate Directional
Valve Linkage
B-13
Test the Ground Control Override
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Note: 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:
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.
2 Start the engine from the ground controls.
·
Lock nut is tight against yoke
3 At the ground controls, operate each boom
function through a partial cycle.
·
Yoke clevis pins are installed
Result: All boom functions should operate.
·
Cotter pins are installed through clevis pins
·
Linkage is properly attached to
directional valve
Part No. 122149
Note: The boom will not raise past horizontal and
the boom will not extend more than
12 inches / 30.5 cm unless both axles are fully
extended.
S-80 • S-85
3 - 31
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
B-14
Test the Platform Self-leveling
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 Hold the function enable toggle switch to either
side and adjust the platform to a level position
using the platform level toggle switch.
3 Raise and lower the boom through a full cycle.
B-15
Test the Engine Idle Select
Operation
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.
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive 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.
Result: The platform should remain level at
all times to within ±5 degrees.
Note: The boom will not raise past horizontal and
the boom will not extend more than
12 inches / 30.5 cm unless both axles are fully
extended.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Start the engine from the ground controls.
4 Move and hold the function enable toggle switch
in the high idle (rabbit symbol) position.
Result: The engine rpm should change to high
idle.
3 - 32
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
5 Release the function enable toggle switch.
Result: The engine rpm should change to low
idle.
B-16
Test the Fuel Select Operation Gasoline/LPG Models
6 Turn the key switch to platform controls.
7 At the platform controls, move the engine idle
select toggle switch to high idle (rabbit symbol).
Do not press down the foot switch.
Result: The engine rpm should change to high
idle.
8 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine rpm should change to low
idle.
9 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.
10 Press down the foot switch.
Result: The engine rpm should change to high
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.
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. 122149
S-80 • S-85
3 - 33
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
4 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button in to
the off position.
B-17
Test the Drive Enable System
5 Move the fuel select toggle switch to LPG.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
6 Start the engine and allow it to run at low idle.
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.
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.
Note: Perform this procedure with the boom in the
stowed position.
1 Start the engine from the platform controls.
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.
3 - 34
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
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.
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: 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: Select a test area that is firm, level and free
of obstructions.
Blue
Note; Perform this procedure with the boom in the
stowed position.
1 Mark a test line on the ground for reference.
Yellow
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.
Part No. 122149
S-80 • S-85
3 - 35
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
B-19
Test the Drive Speed Stowed Position
B-20
Test the Drive Speed Raised or Extended Position
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 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.
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.
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.
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 Extend the axles.
2 Start the engine from the platform controls.
4 Move the engine idle select toggle switch to
foot switch activated high idle (rabbit and foot
switch symbol).
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.
5 Press down the foot switch and raise the boom
10° above horizontal.
6 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.
7 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.
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
3 - 36
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
8 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.
9 Press down the foot switch and lower the boom
to the stowed position.
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:
10 Extend the boom 3 feet / 90 cm.
11 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.
12 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.
13 Continue at top 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.
•
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.
Note: The alarms and beacons will operate with
the engine running or not running.
Note: The descent alarm is standard beginning
with serial number 5612.
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 toggle switch
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. 122149
S-80 • S-85
3 - 37
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B
February 2012
PROCEDURES
3 Turn the key switch to platform controls.
B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
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.
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.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Procced to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank cap venting, air
should pass freely through the cap.
3 - 38
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
B-23
Perform Hydraulic Oil Analysis
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
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.
Part No. 122149
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.
S-80 • S-85
3 - 39
Section 3 • Scheduled Maintenance Procedures
February 2012
Checklist C Procedures
To access the engine:
C-1
Perform Engine Maintenance
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 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.
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 BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
3 - 40
111901
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-2
Grease the Platform Overload
Mechanism (if equipped)
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. Perform this procedure
more often if dusty conditions exist.
Genie specifications require that this procedure be
performed every 500 hours or six months,
whichever comes first.
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.
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.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
Note: Perform this procedure with the machine on
a firm, level surface.
2 Thoroughly pump grease into each grease
fitting.
1 Turn the key switch to platform control. Start the
engine and level the platform.
Grease Specification
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
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.
Part No. 122149
S-80 • S-85
3 - 41
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST C PROCEDURES
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity
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).
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.
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).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
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).
Illustration 1
3 - 42
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
14 Start the engine and test all machine functions
from the ground controls.
8 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
Result: All ground control functions should
operate normally.
9 Turn the key switch to ground control.
15 Turn the key switch to platform control.
10 Test all machine functions from the ground
controls.
16 Test all machine functions from the platform
controls.
Result: All ground control functions should not
operate.
11 Activate the auxiliary power toggle switch.
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: The engine will turn off when the auxiliary
power is activated.
12 Using auxiliary power, test all machine functions
from the ground controls.
17 Using a suitable lifting device, remove the
remaining test weights from the platform.
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.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.
Part No. 122149
S-80 • S-85
3 - 43
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST C PROCEDURES
C-4
Replace the Engine Air Filter
Element - Deutz and Perkins
Models
C-5
Replace the Fuel Filter/Water
Separator Element Deutz and Perkins Models
Engine specifications require that this procedure
be performed every 500 hours or six months,
whichever comes first.
Genie 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.
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.
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.
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.
Perform this procedure with the engine off.
5 Install the new filter element.
1 Open the engine side turntable cover and locate
the fuel filter/water separator.
6 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
Note: The fuel filter/water separator is located near
the hydraulic pump.
2 Disconnect and plug the fuel supply hose from
the fuel tank to the fuel filter/water separator
head.
3 - 44
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
3 Loosen the vent plug located on the fuel filter/
water separator head.
8 Apply a thin layer of oil onto the element gasket.
Install the filter/bowl assembly onto the filter
head. Tighten the drain plug and vent plug.
Component damage hazard. The
drain plug and vent plug can be
damaged if they are
overtightened.
a
d
9 Install the fuel supply hose from the fuel tank to
the fuel filter/water separator. Tighten the
clamp.
c
b
a
b
c
d
10 Clean up any diesel fuel that may have spilled
during the installation procedure.
11 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the filter element.
vent plug
drain plug
filter bowl
separator head
Bleed the fuel system:
4 Place a suitable container under the filter bowl.
Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel.
5 Rotate the filter bowl counterclockwise and
remove it from the element.
6 Rotate the filter element counterclockwise and
remove it from the filter head.
7 Install the filter bowl onto the new filter element.
Note: Before bleeding the system, fill the fuel tank.
12 Loosen the vent plug located on the
fuel filter/water separator head.
13 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the vent
plug. Tighten the vent plug.
14 Loosen the air vent screw, located on top of the
fuel injection pump.
15 Tighten the air vent screw when air stops
coming through the air vent.
16 Clean up any diesel fuel that may have spilled
during the bleeding procedure and dispose of
properly.
17 Start the engine from ground controls and
check for leaks.
Part No. 122149
S-80 • S-85
3 - 45
Section 3 • Scheduled Maintenance Procedures
February 2012
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
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
Top and bottom wear pads
(pivot end of boom)
inch
12.7 mm
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 - 46
1/2 inch
12.7 mm
Top and 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
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
3 Extend and retract the axles through the entire
range of motion to check for tight spots that
may cause binding or scraping of the axle
tubes.
D-2
Check the Extendable Axle
Wear Pads
Note: Always maintain squareness between the
outer and inner axle tubes.
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
Maintaining the axle wear pads in good condition is
essential to safe machine operation. Wear pads
are placed on axle tube surfaces to provice a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in
component damage and unsafe operating
conditions.
Axle wear pad specifications
Minimum
Outer axle
Top, bottom and side wear pads
(both ends of axle)
1/2 inch
12.7 mm
Extendable inner axle
Top, bottom and side wear pads
(both ends of axle)
1/2 inch
12.7 mm
Note: If the wear pads are not worn below
specification but are still within specification, refer
to Repair Procedure 15-1, How to Shim an
Extendable Axle.
1 Start the engine from the platform controls and
extend the axles.
2 Measure each wear pad.
If the wear pad is not less than specification,
shim as necessary to obtain zero clearance and
zero drag. Refer to Repair Procedure 15-1,
How to Shim an Extendable Axle.
Replace the wear pad if it is less than
specification. It is recommended to replace both
inner and outer wear pads. Refer to Repair
Procedure 15-1, How to Remove an Inner Axle.
Part No. 122149
S-80 • S-85
3 - 47
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST D PROCEDURES
5 Manually rotate each non-steer wheel.
D-3
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 freewheel 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
3 - 48
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
11 Manually rotate each steer wheel.
D-4
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.
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury
and property damage.
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.
All models:
13 Turn the valve in a clockwise direction to be
sure it is fully closed.
1 Start the engine from the platform controls and
extend the axles.
Note: The free-wheel valve is located on the
bottom of the drive pump, and should always
remain closed.
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
Part No. 122149
Note: The lift cylinder safety chock is available
through Genie Service Parts.
drive pump
screwdriver
lift pump
free-wheel valve
S-80 • S-85
3 - 49
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST D PROCEDURES
4 Remove the center turntable cover retaining
fasteners. Remove the cover.
5 Confirm that each turntable mounting bolt is
torqued in sequence to specification. Refer to
Section 2, Specifications.
20
24
28
1
5
9
13
16
12
8
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
17
21
25
4
30
29
26
3
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.
7
11
15
22
18
14
10
6
27 23
2
19
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.
9 Confirm that each bearing mounting bolt under
the drive chassis is torqued in sequence to
specification. Refer to Section 2, Specifications.
10
1
7
6
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.
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.
15
13
D-5
Inspect for Turntable Bearing
Wear
12
18
4
3
17
11
5
14
8
16
2
9
Bolt torque sequence
3 - 50
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
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°.
b
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
c
11 Lower the boom to the stowed position and turn
the machine off.
d
12 Remove the dial indicator from the machine.
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.
Part No. 122149
S-80 • S-85
3 - 51
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST D PROCEDURES
To access the engine:
D-6
Perform Engine Maintenance
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 1000 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 BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Continental TME27 Owner's Manual
(Continental part number WM10303).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Continental TME27 Owner's Manual
Genie part number
3 - 52
111901
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
D-7
Replace the Hydraulic Filter
Elements
6 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
Genie specifications requires that this procedure
be performed every 1000 hours or annually,
whichever come first. Perform this procedure more
often if dusty conditions exist.
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 filter be replaced more often.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
Note: Perform this procedure with the engine off.
Hydraulic return filter:
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.
7 Open the engine side turntable cover and locate
the two filters mounted below the hydraulic
pumps.
Note: The medium pressure filter is located on the
right. The high pressure filter is located on the left
with the condition indicator.
8 Place a suitable container under the filters.
9 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housings.
10 Remove the filter element from the housings.
1 Open the ground controls side turntable cover
and locate the hydraulic return filter mounted on
the hydraulic tank.
11 Inspect the housing seals and replace them if
necessary.
2 Place a suitable container under the hydraulic
tank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket of
the new oil filter.
Part No. 122149
S-80 • S-85
3 - 53
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST D PROCEDURES
12 Install the new medium and high pressure filter
elements into the housings and tighten them
securely.
D-8
Replace the Drive Hub Oil
13 Clean up any oil that may have spilled during
the installation procedure.
14 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
Genie specifications require that this procedure be
performed every 1000 hours or annually,
whichever comes first.
15 Start the engine from the ground controls.
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.
16 Inspect the filter housings and related
components to be sure that there are no leaks.
Drive hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a
b
a
a. models with pipe plugs
b.
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 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub. Torque to Specification.
Refer to Section 2, Specifications.
3 - 54
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
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.
a
b
c
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 turntable rotate drive motor. Cap the
fittings on the drive motor.
a
b
c
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.
motor
drive hub
drive hub mounting bolts
6 Install the drive hub assembly onto the
machine. Torque the drive hub mounting bolts
to specification. Refer to Section 2,
Specifications.
7 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
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.
Part No. 122149
S-80 • S-85
3 - 55
Section 3 • Scheduled Maintenance Procedures
February 2012
CHECKLIST D PROCEDURES
D-9
Perform Engine Maintenance Deutz Models
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
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929).
Deutz BF4L2011 Operation Manual
Genie part number
84794
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.
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 - 56
S-80 • S-85
Part No. 122149
February 2012
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
Genie specifications require that this procedure be
performed every 2000 hours or every two years,
whichever comes first.
Models with hydraulic tank shutoff valves:
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.
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.
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
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
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. 122149
S-80 • S-85
3 - 57
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
February 2012
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
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-2
Perform Engine Maintenance Perkins Models
E-3
Grease the Steer Axle
Wheel Bearings, 2WD Models
Engine specifications require that this procedure
be performed every 2000 hours.
Genie specifications require that this procedure be
performed every 2000 hours or 2 years, 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
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steering wheels. Center a lifting
jack under the steer axle.
To access the engine:
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support.
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.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
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. 122149
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
S-80 • S-85
3 - 59
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E
February 2012
PROCEDURES
Skip to step 10 if there is no movement.
14 Pack both bearings with clean, fresh grease.
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
15 Place the large inner bearing into the rear of the
hub.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
16 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
Note: Always replace the bearing grease seal
when removing the hub.
8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
17 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.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue to step 11 to grease
the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
11 Remove the castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
12 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
13 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
3 - 60
S-80 • S-85
Part No. 122149
February 2012
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-4
Perform Engine Maintenance Deutz and Perkins Models
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.
Required maintenance procedures and additional
engine information are available in the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).
Deutz BF4L2011 Operation Manual
Genie part number
84794
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
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. 122149
S-80 • S-85
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Section 3 • Scheduled Maintenance Procedures
February 2012
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3 - 62
S-80 • S-85
Part No. 122149
February 2012
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 Genie S-80
and Genie S-85 Operator’s Manual on your
machine.
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
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.
•
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. 122149
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
4-1
Section 4 • Repair Procedures
February 2012
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.
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.
a
Electrocution 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
d
a
b
c
d
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
ALC-500 circuit board
drive/steer joystick controller
boom extend/retract
joystick controller
boom up/down and turntable rotate
left/right 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
Part No. 122149
February 2012
Section 4 • Repair Procedures
PLATFORM CONTROLS
1-2
Joysticks
How to Adjust the Joystick
Max-out Setting
How to Calibrate a Joystick
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.
Note: Perform this procedure with the engine off.
1 Open the platform control box.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Turn the key switch to platform control. Do not
start the engine.
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.
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.
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 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 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.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
Part No. 122149
S-80 • S-85
4-3
Section 4 • Repair Procedures
February 2012
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
Part No. 122149
February 2012
Section 4 • Repair Procedures
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.
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.
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.
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. 122149
S-80 • S-85
4-5
Section 4 • Repair Procedures
February 2012
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
7.9 to 8.5 seconds
40 to 45 seconds
Part No. 122149
February 2012
Section 4 • Repair Procedures
Platform Components
7 Support and secure the platform to an
appropriate lifting device.
2-1
Platform
8 Remove the platform mounting fasteners and
remove the platform from the machine.
How to Remove the Platform
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 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. 122149
S-80 • S-85
4-7
Section 4 • Repair Procedures
February 2012
PLATFORM COMPONENTS
Crushing hazard. The jib boom
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly supported.
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.
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.
7 Carefully pull the cylinder out of the primary
boom to access the hydraulic hoses.
8 Tag, disconnect and plug the hydraulic hoses
from the slave cylinder. Cap the fittings on the
cylinder.
How to Remove the Platform
Leveling Slave 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: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the
closed loop.
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.
2 Raise the primary boom slightly and place
blocks under the platform for support.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
How to Bleed the Slave Cylinder
Note: Do not start the engine. Use auxiliary power
for this procedure.
1 Raise the primary boom to a horizontal position.
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.
Note: Do not rest the entire weight of the boom on
the blocks.
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.
4-8
S-80 • S-85
Part No. 122149
February 2012
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. 122149
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
4-9
Section 4 • Repair Procedures
February 2012
PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins.
Remove the platform rotator from the machine.
Crushing hazard. The 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:
6 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.
7 Support the jib boom leveling arms.
2 Place a suitable container underneath the
platform rotator.
8 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.
9 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 - 10
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
PLATFORM COMPONENTS
4 Move the function enable toggle switch 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.
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.
Crushing hazard. Keep clear of
the platform during rotation.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
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. 122149
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.
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
4 - 11
Section 4 • Repair Procedures
February 2012
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 - 12
S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
4 - 13
Section 4 • Repair Procedures
February 2012
Jib Boom Components, S-85
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.
3-1
Jib Boom
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.
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.
4 Remove the hose and cable clamp from the jib
boom pivot pin. Lay all hoses and cables to the
side.
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
Component damage hazard.
Hoses and cables can become
damaged if they are kinked or
pinched.
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
4 - 14
S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
4 - 15
Section 4 • Repair Procedures
February 2012
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
union and connect the hoses from the cylinder
together using a connector.
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 S-85:Remove the hose and cable cover from
the side of the jib boom.
4 Disconnect the wire connectors from the bottom
of the platform control box.
9 Tag, disconnect and plug the hydraulic hoses
from the jib boom/platform rotate select
manifold. Cap the fittings on the manifold.
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 wiring from the jib
boom/platform rotate select 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 - 16
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
BOOM COMPONENTS
11 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.
18 Attach a lifting strap from an overhead crane to
the cable track.
19 Remove the mounting fasteners that attach the
lower cable track to the boom.
20 Remove the cable track from the machine and
place it on a structure capable of supporting it.
All models:
12 From the ground controls, raise the boom to a
horizontal position.
13 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.
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.
14 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.
15 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.
16 Remove the cable clamp from the pivot end of
the boom.
17 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.
Part No. 122149
S-80 • S-85
4 - 17
Section 4 • Repair Procedures
February 2012
BOOM COMPONENTS
How to Repair the Cable Track
5 Remove the upper rollers from the replacement
section of cable track.
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
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 - 18
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
BOOM COMPONENTS
4-2
Boom
How to Remove the Boom
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.
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.
2 Extend the boom until the wear pads are
accessible.
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.
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.
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.
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Remove the platform rotator and leveling slave
cylinder. See 2-3, How to Remove the Platform
Rotator.
3 Remove the cable track. See 4-1, How to
Remove the Cable Track.
4 S-85: Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
Part No. 122149
S-80 • S-85
4 - 19
Section 4 • Repair Procedures
February 2012
BOOM COMPONENTS
5 Raise the boom to a horizontal position high
enough that the boom lift cylinder rod end can
clear the boom lift cylinder mounting boss.
11 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
6 Remove the turntable end cover.
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 Remove the pin retaining fasteners from the
master cylinder rod-end pivot pin.
8 Place a rod through the pin and twist to remove
the pin. Lower the rod end of the master
cylinder.
12 Attach an overhead 5 ton / 5000 kg crane to the
center point of the boom.
13 Attach a similar lifting device to the boom lift
cylinder for support.
14 Place support blocks under the boom lift
cylinder, across the turntable.
9 Remove the fasteners from the boom angle limit
switches (LS2RO and LS2RS) mounted to the
inside of both turntable riser side plates at the
pivot end of the boom. Do not disconnect the
wiring.
10 Remove the fasteners from the boom extend
limit switch (LS1RO) mounted next to the boom
extension cylinder at the pivot end of the boom.
Do not disconnect the wiring.
15 Remove the pin retaining fastener from the
boom lift cylinder rod-end pin. Use a soft metal
drift to remove the pin.
Crushing hazard. The boom lift
cylinder could fall if not properly
supported.
16 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
17 Remove the pin retaining fastener from the
boom pivot pin.
18 Use a soft metal drift to remove the boom pivot
pin. Carefully remove the boom from the
machine.
Crushing hazard. The boom could
become unbalanced and fall if not
properly supported by the
overhead crane.
4 - 20
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
BOOM COMPONENTS
How to Disassemble the Boom
Note: Complete disassembly of the boom is only
necessary if the outer or inner boom tubes must be
replaced. The extension cylinder can be removed
without completely disassembling the boom. See
4-4, How to Remove the Boom Extension
Cylinders.
6 Support and slide the number 2 and 3 boom
tubes out of the number 1 boom tube. Place the
number 2 and 3 boom tubes on blocks for
support.
Crushing hazard. The number 2
and 3 boom tubes could become
unbalanced and fall when they are
removed from the number 1 boom
tube if they are not properly
supported.
1 Remove the boom. See 4-2, How to Remove
the Boom.
2 Remove the external snap rings from the
extension cylinder pivot pin at the pivot end of
the number 1 boom tube. Use a soft metal drift
to remove the pin.
3 Remove and label the wear pads from the top,
side, and bottom of the number 1 boom tube at
the platform end of the boom.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
7 Tag and remove the wear pads from the top,
side, and bottom of the number 2 boom tube at
the platform end of the boom.
Note: Note the location and quantity of shims used
with each wear pad.
8 Remove the trunnion pin retaining fasteners at
the base end of the number 2 boom tube. Use a
slide hammer to remove the trunnion pins.
4 Remove the two wear pad stop bolts from each
side of the number 1 boom tube (located on the
outside).
9 Attach a lifting strap from an overhead crane to
the number 3 boom tube at the platform end of
the boom for support.
5 Attach a lifting strap from an overhead crane to
the number 2 and number 3 boom tubes at the
platform end of the boom for support.
10 Support and slide the number 3 boom tube out
of the number 2 boom tube. Place the number 3
boom tube on blocks for support.
Crushing hazard. The number 3
boom tube could become
unbalanced and fall when
removed from the number 2 boom
tube if not properly supported.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
Part No. 122149
S-80 • S-85
4 - 21
Section 4 • Repair Procedures
February 2012
BOOM COMPONENTS
11 Remove the external snap rings from the
extension cylinder pivot pin at the platform end
of the number 3 boom tube. Use a soft metal
drift to remove the pin.
12 Support and slide the extension cylinder out of
the pivot end of the number 3 boom tube. Place
the extension cylinder on blocks for support.
4-3
Boom Lift Cylinder
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 extension
cylinder could become unbalanced
and fall when it is removed from
the number 3 boom tube if not
properly supported.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
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 high
enough that the boom lift cylinder rod end can
clear the boom lift cylinder mounting boss.
2 Remove the center turntable cover fasteners.
Remove the cover.
3 Place support blocks under the boom lift
cylinder across the turntable side plates.
4 Attach an overhead 5 ton / 5000 kg crane to
the boom for support. Do not lift the boom.
4 - 22
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
BOOM COMPONENTS
5 Support the rod end of the boom lift cylinder
with an overhead crane or similar lifting device.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall when it is disconnected
from the machine if not properly
supported.
8 Remove the mounting fasteners from the
barrel-end cylinder pivot pin retaining plates.
9 With the lift cylinder being supported by the
overhead crane, pull the cylinder toward the
platform and remove it from the machine.
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.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if not properly supported.
Component damage hazard. The
cables and hydraulic hoses can be
damaged if the lift cylinder is
pulled across them.
7 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin, and lower the lift
cylinder onto the blocks. Protect the cylinder
rod from damage.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall when it is disconnected
from the machine if not properly
supported.
Part No. 122149
S-80 • S-85
4 - 23
Section 4 • Repair Procedures
February 2012
BOOM COMPONENTS
4-4
Boom Extension Cylinders
The extension cylinder consists of two cylinders
that are fastened together. The first cylinder
extends and retracts the number 2 boom tube. The
second cylinder extends and retracts the number 3
boom tube. The extension cylinders are equipped
with counterbalance valves to prevent movement
in the event of a hydraulic line failure.
How to Remove the
Boom Extension Cylinders
3 Place a 4 in x 4 in x 6 ft / 10 cm x 10 cm x 1.8 m
block on top of the number 3 boom tube and
place one end of the block against the
weldment at the platform end of the boom.
4 Retract the boom until the number 2 boom tube
is fully retracted into the number 1 boom tube.
Note: The number 3 boom tube will remain
extended approximately 6 feet / 1.8 m.
5 Remove the external snap rings from the
extension cylinder pivot pin at the platform end.
Use a soft metal drift to remove the pin.
6 Remove the turntable end cover.
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.
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 Support the rod end of the master cylinder with
a lifting device.
8 Remove the pin retaining fastener from the
master cylinder rod-end pivot pin. Place a rod
through the pin and twist to remove the pin.
Crushing hazard. The extension
cylinder could become unbalanced
and fall when it is removed from
the machine if not properly
supported.
Note: Use the platform level toggle switch with
auxiliary power to relieve pressure on the master
cylinder barrel-end pivot pin.
1 Raise the boom to a horizontal position, fully
extend the boom and fully lower the platform.
2 Remove the 2 bolts that are located on each
side of the number 3 boom tube near the
platform end of the number 2 boom tube.
9 Lay the master cylinder down. Protect the
cylinder rod from damage.
4 - 24
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
BOOM COMPONENTS
10 Remove the external snap rings from the
extension cylinder pivot pin at the pivot end of
the boom. Use a soft metal drift to remove the
pin through the access holes in the turntable
riser.
11 Using auxiliary power, move the boom
extend/retract toggle switch in the extend
direction and extend the extension cylinder out
the pivot end of the boom approximately
1 foot / 30 cm.
15 Remove the trunnion pin retaining fastener and
use a slide hammer to remove the pins.
16 Slide the cylinder out to access the wear pads
on the bottom rod support bracket. Remove the
wear pads.
17 Support and slide the extension cylinder out of
the pivot end of the boom.
Crushing hazard. The extension
cylinder could become unbalanced
and fall when it is removed from
the machine if not properly
supported.
12 Tag, disconnect and plug the 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.
13 Attach a lifting strap from an overhead crane to
the end of the extension cylinder and lift slightly
to relieve the pressure on the trunnion pins.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.
Note: During re-assembly of the boom, fully retract
the boom after installing all pins. Install the two top
¼-20 fasteners through the access holes located
mid-section of the number 1 boom tube. Then
extend the boom and install the two lower ¼-20
fasteners in the number 3 boom tube.
14 Remove the trunnion pin access covers from
both sides of the number 1 boom tube at the
pivot end of the boom.
Part No. 122149
S-80 • S-85
4 - 25
Section 4 • Repair Procedures
February 2012
BOOM COMPONENTS
5 Place a rod through the barel-end pivot pin and
twist to remove the pin.
4-5
Platform Leveling
Master Cylinder
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
6 Attach a lifting strap from an overhead crane to
the lug on the rod end of the 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.
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.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible.
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.
9 Remove the master cylinder 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.
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.
4 Remove the pin retaining fastener from the
master cylinder barrel-end pivot pin.
4 - 26
S-80 • S-85
Part No. 122149
February 2012
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 couples the engine to the pump. The
flex plate is bolted to the engine flywheel and has a
cut-out in the center for the pump coupler.
a
b
c
d
e
f
a
b
c
d
e
f
Part No. 122149
S-80 • S-85
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.185 inch / 4.7 mm gap - Deutz Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.36 inch / 9.14 mm gap - Continental Engine
4 - 27
Section 4 • Repair Procedures
February 2012
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 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
10 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
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 - 28
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
ENGINES
Perkins model:
9 Remove the relay housing from the muffler
mount. Do not disconnect the relays.
5 Tag and disconnect the wiring from the bell
housing.
6 Remove the exhaust pipe clamp at the muffler.
Burn hazard. Hot engine parts can
cause severe burns.
7 Remove the muffler mounting bracket
fasteners. Remove the muffler and bracket
assembly from the engine.
10 Disconnect and remove the ECM from the
muffler mount.
11 Close the shutoff valve on the Liquid Petroleum
Gas (LPG) tank by turning it clockwise
(if equipped).
12 Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
8 Remove the hose clamps from the air cleaner
elbow and the engine intake manifold.
9 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
assembly from the engine.
10 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing to engine fasteners.
13 Remove the muffler mount.
14 Support the drive pump with an appropriate
lifting device. Remove all of pump plate
mounting fasteners.
15 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:
5 Tag and disconnect the wire harness from the
oxygen sensor.
16 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine flywheel.
6 Remove the exhaust pipe heat shield fasteners
from the top of the muffler.
Burn Hazard. Hot engine parts can
cause severe burns.
7 Remove the muffler retainer bracket fasteners.
8 Remove the muffler fasteners securing the
muffler to the exhaust manifold. Remove the
muffler from the bracket.
Part No. 122149
S-80 • S-85
4 - 29
Section 4 • Repair Procedures
February 2012
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:
(Before serial number 6091) Torque the flex
plate mounting bolts in sequence to
28 ft-lbs / 38 Nm.
(After serial number 6090) 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.
a
b
c
d
e
3 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
4 Install the pump onto the pump mounting plate.
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.
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.
f
a
b
c
d
e
f
4 - 30
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.185 inch / 4.7 mm gap - Deutz Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.36 inch / 9.14 mm gap - Continental Engine
S-80 • S-85
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
Part No. 122149
February 2012
Section 4 • Repair Procedures
ENGINES
1
6
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
C
10
C
4
11
6
1
C
1
8
10
8
C
C
C
C
C
3
C
2
C
4
3
11
12
12
C
C
7
9
7
5
5
2
9
9
Continental Pump Mounting Plate
Deutz BF4L-2011
Pump Mounting Plate
Part No. 122149
S-80 • S-85
4 - 31
Section 4 • Repair Procedures
February 2012
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 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 85
no continuity
(infinite 
continuity
(zero )
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 - 32
Desired result
no continuity
(infinite 
continuity
(zero )
S-80 • S-85
Part No. 122149
February 2012
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. 122149
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
4 - 33
Section 4 • Repair Procedures
February 2012
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 - 34
S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
4 - 35
Section 4 • Repair Procedures
February 2012
Manifolds
8-1
Function Manifold Components - View 1
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 3 position 4 way ....... A ........... Platform rotate left/right .................... 25-30 ft-lbs / 34-41 Nm
2
Check valve, 30 psi / 2 bar ................ B ........... Platform rotate circuit
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
3
Check valve, 30 psi / 2 bar ................ C ........... Platform rotate circuit
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
4
Solenoid valve, 2 position 3 way ....... D ........... Boom retract ..................................... 33-37 ft-lbs / 45-50 Nm
5
Solenoid valve, 3 position 4 way ....... E ........... Turntable rotate left/right ................... 25-30 ft-lbs / 34-41 Nm
6
Relief valve, 2500 psi / 172 bar ......... F ........... Boom extend/retract circuit ............... 20-25 ft-lbs / 27-34 Nm
7
Solenoid valve, 2 position 3 way ....... G ........... Boom extend ..................................... 50-55 ft-lbs / 68-75 Nm
8
Check valve ....................................... H ........... Differential sensing circuit,
turntable rotate left/right ...................... 8-10 ft-lbs / 10-15 Nm
9
Differential sensing valve .................. I ............ Boom extend/retract circuit
(prevents overflowing
the proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
10
Differential sensing valve .................. J ............ Turntable rotate left/right circuit
(prevents overflowing
the proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
11
Proportional solenoid valve ............... K ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
12
Check valve ....................................... L ........... Differential sensing circuit,
platform level down ............................. 8-10 ft-lbs / 10-15 Nm
13
Check valve ....................................... M .......... Differential sensing circuit,
platform level up ................................. 8-10 ft-lbs / 10-15 Nm
14
Solenoid valve, 3 position 4 way ....... N ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm
15
Differential sensing valve .................. O ........... Boom up/down circuit
(prevents overflowing
the proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm
16
Counterbalance valve ........................ P ........... Platform level down circuit ................ 35-40 ft-lbs / 47-54 Nm
17
Counterbalance valve ........................ Q ........... Platform level up circuit ..................... 35-40 ft-lbs / 47-54 Nm
18
Solenoid valve, 2 position 3 way ....... R ........... Boom down ....................................... 33-37 ft-lbs / 45-50 Nm
19
Solenoid valve, 3 position 4 way ....... S ........... Steer left/right and
axle extend/retract ............................ 35-40 ft-lbs / 47-54 Nm
20
Relief valve, 2900 psi / 200 bar ......... T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
Function
Torque
This list continues. Please turn the page.
4 - 36
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
1
2
3
C
B
A
D
E
33
GG
32
FF
31
EE
30
DD
F
G
H
I
J
29
28
27
25
5
6
7
8
9
10
CC
K
BB
L
AA
M
26
4
11
12
13
Z
N
Y
O
P
Q
R
X
24
Part No. 122149
V
W
23
22
U
21
S-80 • S-85
T
S
14
15
16
17
18
19
20
4 - 37
Section 4 • Repair Procedures
February 2012
MANIFOLDS
Function Manifold Components - View 1, continued
Index
No.
Description
Schematic
Item
Function
Torque
21
Check valve ....................................... U ........... Blocks flow from auxiliary pump
to function pump ............................... 30-35 ft-lbs / 41-47 Nm
22
Priority flow regulator valve,
3.5 gpm / 13.2 L/min .......................... V ........... Steer circuit ....................................... 30-35 ft-lbs / 41-47 Nm
23
Proportional solenoid valve ............... W .......... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
24
Solenoid valve, 2 position 3 way ....... X ........... Boom up ............................................ 33-37 ft-lbs / 45-50 Nm
25
Check valve ....................................... Y ........... Blocks flow from function pump
to auxiliary pump ............................... 30-35 ft-lbs / 41-47 Nm
26
Check valve ....................................... Z ........... Hydraulic oil cooler bypass ............... 30-35 ft-lbs / 41-47 Nm
27
Check valve ....................................... AA ......... Boom up/down circuit ......................... 8-10 ft-lbs / 10-15 Nm
28
Needle valve ...................................... AB ......... Platform level circuit .......................... 30-35 ft-lbs / 41-47 Nm
29
Proportional solenoid valve ............... AC ........ Turntable rotate circuit ...................... 20-30 ft-lbs / 27-47 Nm
30
Differential sensing valve .................. AD ........ Meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
31
Check valve ....................................... AE ......... Differential sensing circuit,
boom extend/retract ............................ 8-10 ft-lbs / 10-15 Nm
32
Flow regulator valve,
0.1 gpm / 0.37 L/min .......................... AF ......... Bleeds off differential
sensing valves to tank ...................... 20-25 ft-lbs / 27-34 Nm
33
Flow regulator valve,
0.6 gpm / 2.27 L/min .......................... AG ........ Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm
4 - 38
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
1
2
3
C
B
A
D
E
33
GG
32
FF
31
EE
30
DD
F
G
H
I
J
29
28
27
25
5
6
7
8
9
10
CC
K
BB
L
AA
M
26
4
11
12
13
Z
N
Y
O
P
Q
R
X
24
Part No. 122149
V
W
23
22
U
21
S-80 • S-85
T
S
14
15
16
17
18
19
20
4 - 39
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-2
Function Manifold Components - View 2
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index
No.
1
2
Description
Schematic
Item
Function
Check valve, 30 psi / 2 bar ................ AH ........ Platform rotate circuit
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... (prevents hydraulic hoses
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... from draining back to tank)
12345678901234567890123456789012123456789012345678901234567
Torque
............... 20-25 ft-lbs / 27-34 Nm
Flow regulator valve,
0.3 gpm / 1.14 L/min .......................... AJ ......... Dump circuit source from
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... charge pump .....................................
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
20-25 ft-lbs / 27-34 Nm
3
Solenoid valve, 2 position 2 way ....... AK ......... Allows boom functions to
operate with the boom in
the stowed position ........................... 26-30 ft-lbs / 34-41 Nm
4
Check valve, 30 psi / 2 bar ................ AI .......... Blocks flow from charge pump
to auxiliary pump ............................... 20-25 ft-lbs / 27-34 Nm
5
Check valve, 30 psi / 2 bar ................ AL ......... Blocks flow from auxiliary pump
to charge pump ................................. 20-25 ft-lbs / 27-34 Nm
6
Pressure Switch, 180 psi / 12.4 bar ... AY ......... Axle extend pressure switch ............. 26-30 ft-lbs / 34-41 Nm
7
Solenoid valve, 2 position 3 way ....... AM ........ Provides pilot signal to redirect
steer flow to axle extension system .. 26-30 ft-lbs / 34-41 Nm
8
Directional valve, 2 position 2 way,
pilot operated ..................................... AN ........ Dump valve that allows boom
functions to operate when
axles are fully extended .............. 90-100 ft-lbs / 122-136 Nm
9
Relief valve, 2100 psi / 145 bar ......... AO ........ Boom down ....................................... 20-25 ft-lbs / 27-34 Nm
4 - 40
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
AH
AJ
AK
AI
AL
AY
AO
9
Part No. 122149
2
3
4
5
6
AM
AN
8
1
7
S-80 • S-85
4 - 41
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-3
Valve Adjustments Function Manifold
How to Adjust the Boom Down
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
How to Adjust the System
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 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 retract toggle switch with the
boom fully retracted. 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 T) 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.
1 Connect a 0 to 5000 psi / 0 to 350 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 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 AO) 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.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
4 - 42
S-80 • S-85
Part No. 122149
February 2012
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 F) 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. 122149
S-80 • S-85
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Section 4 • Repair Procedures
February 2012
MANIFOLDS
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4 - 44
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
8-4
Brake / Two Speed Manifold Components
The brake/two speed manifold is mounted inside the drive chassis.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 2 position 3 way .... EA ........... Releases brakes .............................. 47-52 ft-lbs / 64-70 Nm
2
Solenoid valve, 2 position 3 way .... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm
3
Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm
4
Orifice, 0.042 inch / 1.07 mm ......... ED ........... Controls flow to tank
1
Torque
2
EA
4
Function
EB
ED
EC
3
Part No. 122149
S-80 • S-85
4 - 45
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-5
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
Shuttle valve, 2 position 3 way .......... PP ......... Turntable rotation brake release ......... 8-10 ft-lbs / 10-15 Nm
2
Counterbalance valve ........................ QQ ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
3
Counterbalance valve ........................ RR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
1
2
PP
4 - 46
Function
Torque
3
QQ
S-80 • S-85
RR
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
8-6
Jib Boom Select 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, 2 position 3 way ....... VV ......... Platform rotate select .......................... 8-10 ft-lbs / 11-14 Nm
2
Solenoid valve, 2 position 3 way ....... WW ....... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
3
Orifice Plug, 0.035 inch / 0.89 mm .... XX ......... Jib boom circuit
1
2
VV
Part No. 122149
Function
Torque
3
WW
S-80 • S-85
XX
4 - 47
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-7
Axle Select Manifold Components
The axle select manifold is mounted next to the drive manifold at the non-steer end of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
1
Directional valve, pilot operated
2 position 3 way ................................. FA ......... Directs flow from steer cylinders
to axle extend circuit ......................... 30-35 ft-lbs / 41-47 Nm
2
Pressure reducing valve,
1000 psi / 69 bar ................................ FB ......... Limits pressure to tie rod cylinder
during axle extension ........................ 30-35 ft-lbs / 41-47 Nm
3
Directional valve, pilot operated
2 position 3 way ................................. FC ......... Directs flow from steer cylinders
to axle retract circuit .......................... 30-35 ft-lbs / 41-47 Nm
4
Directional valve, pilot operated
2 position 2 way ................................. FD ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
5
Directional valve, pilot operated
2 position 2 way ................................. FE ......... Locks out steer cylinders during
axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm
4 - 48
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
1
2
FA
3
FB
FC
FD
FE
Part No. 122149
S-80 • S-85
4
5
4 - 49
Section 4 • Repair Procedures
February 2012
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 ......... BX ......... Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
2
Flow Divider / Combiner Valve .......... BY ......... Controls flow to drive motors in
.......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
3
Check Valve, 5 psi / 0.34 bar ............ BZ ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4
Check Valve, 5 psi / 0.34 bar ............ CA ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5
Shuttle Valve, 3 position 3 way ......... CB ........ Controls flow to drive motors in
.......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm
6
Orifice Plug, 0.070 inch / 1.78 mm .... CC ........ Equalizes flow across flow divider/
.......................................................................... combiner valve BY
4 - 50
Schematic
Item
Function
S-80 • S-85
Torque
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
1
BX
BY
BZ
CA
CB
CC
Part No. 122149
S-80 • S-85
2
3
4
5
6
4 - 51
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-9
4WD 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 .......... CD ........ Charge pressure circuit ..................... 35-40 ft-lbs / 48-54 Nm
2
Flow divider/combiner valve .............. CE ........ Controls flow to non-steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3
Check valve ....................................... CF ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
4
Check valve ....................................... CG ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
5
Flow divider/combiner valve .............. CH ........ Controls flow to flow
divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6
Check valve ....................................... CI .......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm
7
Orifice, 0.040 inch / 1 mm ................. CJ ......... Equalizes pressure on both sides
of flow divider/combiner valve 5
8
Orifice, 0.040 inch / 1 mm ................. CK ........ Equalizes pressure on both sides
of flow divider/combiner valve 2
9
Orifice, 0.040 inch / 1 mm ................. CL ......... Equalizes pressure on both sides
of flow divider/combiner valve 13
10
Check valve ....................................... CM ........ Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm
11
Check valve ....................................... CN ........ Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
12
Shuttle valve, 3 position 3 way .......... CO ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13
Flow divider/combiner valve .............. CP ........ Controls flow to steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14
Check valve ....................................... CQ ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
4 - 52
Schematic
Item
Function
S-80 • S-85
Torque
Part No. 122149
February 2012
Section 4 • Repair Procedures
MANIFOLDS
CD
CE
CF
CG
14
13
CQ
CH
CP
CI
12
11
10
1
2
3
4
5
6
CO
CN
CM
CL
9
Part No. 122149
CK
CJ
7
8
S-80 • S-85
4 - 53
Section 4 • Repair Procedures
February 2012
MANIFOLDS
8-10
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, 0.030 inch / 0.080 cm . CV ........... Delays shift to drive
3
Solenoid valve ................................ CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4
Relief valve ..................................... CX ........... Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm
5
Check valve .................................... CY ........... Prevents oil to generator .................. 35-40 ft-lbs / 47-54 Nm
5
Schematic
Item
Function
Torque
CY
CU
CV
CW
CX
4 - 54
S-80 • S-85
1
2
3
4
Part No. 122149
February 2012
Section 4 • Repair Procedures
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.
8-11
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.
Part No. 122149
S-80 • S-85
4 - 55
Section 4 • Repair Procedures
February 2012
MANIFOLDS
REV B
8-12
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 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 
2 position 3 way solenoid valve
(schematic items D, R, X, TT and UU)
6.3 
2 position 3 way solenoid valve
(schematic items G)
3.3 
3 position 4 way solenoid valve
(schematic items A, E, N and S)
6.3 
2 position 3 way solenoid valve
(schematic items AK, AM, VV and WW)
6.3 
2 position 3 way solenoid valve
(schematic item G)
3.3 
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 (. 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.
4 - 56
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
REV B
MANIFOLDS
How to Test a Coil Diode
a
d
-
b
+
c
10 W
RESISTOR
c
9V
BATTERY
b
-
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
a
b
c
d
1 Test the coil for resistance. Refer to, How to
Test a Coil.
multimeter
9V DC battery
10 resistor
coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6
2 Connect a 10 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.
Note: The battery should read 9V DC or more
when measured across the terminals.
AMMETER
COIL
+
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.
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC
current, should be capable of reading up to 800
mA.
4 Connect the negative lead to the other terminal
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
Part No. 122149
S-80 • S-85
4 - 57
Section 4 • Repair Procedures
February 2012
MANIFOLDS
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 - 58
S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
4 - 59
Section 4 • Repair Procedures
February 2012
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.
open
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.
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 - 60
S-80 • S-85
Part No. 122149
February 2012
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. 122149
S-80 • S-85
4 - 61
Section 4 • Repair Procedures
February 2012
Turntable Rotation Components
10-1
Turntable Rotation Drive Hub
Assembly
How to Remove the Turntable
Rotation Drive Hub Assembly
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
1 Secure the turntable from rotating with the
turntable rotation lock pin.
b
a
b
c
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 - 62
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
Part No. 122149
February 2012
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.
b
1 Secure the turntable from rotating with the
turntable rotation lock pin.
c
a
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.
a
b
c
motor
drive hub with brake
drive hub mounting bolts
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. 122149
S-80 • S-85
4 - 63
Section 4 • Repair Procedures
February 2012
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.
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Loosen the backlash pivot plate mounting
fasteners.
b
a
b
c
4 - 64
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.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
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).
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.
c
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
S-80 • S-85
Part No. 122149
February 2012
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.
Note: Always replace the cotter pin with a new one
when installing the castle nut.
4 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
6 Remove the pin retaining fasteners from the
yoke pivot pins.
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. 122149
S-80 • S-85
4 - 65
Section 4 • Repair Procedures
February 2012
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.
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.
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.
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.
6 Install the washer and castle nut.
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 - 66
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
2WD STEER AXLE COMPONENTS
11-3
Tie Rod Cylinder
How to Perform the Toe-in
Adjustment
How to Remove the
Tie Rod Cylinder
Note: Perform this procedure on a firm, level
surface. Block the non-steer tires and be sure that
the machine is 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 Straighten the steer wheels.
2 Measure the steer tires, front to front and back
to back, using a measuring fixture.
1 Tag, disconnect and plug the hydraulic hoses
from the tie rod 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.
2 Support and secure the tie rod cylinder to a
lifting jack.
3 Remove the pin retaining fasteners from each
tie rod cylinder pivot pin.
4 Remove the pivot pin from each end of the tie
rod cylinder.
5 Remove the tie rod cylinder from the machine.
Crushing hazard. The tie rod
cylinder may become unbalanced
and fall if not properly supported
and secured to the lifting jack
when it is removed from the
machine.
3 Center a lifting jack of ample capacity under the
steer axle and raise the machine until the steer
tires are off the ground.
4 Loosen the jam nut on the adjustable end
of the tie rod cylinder.
5 Remove the pin retaining fasteners from the
adjustable end of the tie rod cylinder. Remove
the pivot pin.
6 Slide the tie rod cylinder off of the yoke and
adjust it by turning the end.
Note: One half turn on the adjustable end equals
approximately
1
/8 inch / 3.2 mm change in the front and rear
measurements.
7 Slide the tie rod cylinder onto the yoke. Install
the pivot pin and the pin retaining fastener.
8 Tighten the jam nut against the tie rod cylinder.
9 Lower the machine and repeat step 2.
If further adjustment is needed, repeat
this procedure beginning with step 3.
Toe-in specification
Part No. 122149
S-80 • S-85
0 ± 1/8 inch / 6.35 mm
4 - 67
Section 4 • Repair Procedures
February 2012
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.
4 - 68
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
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.
Part No. 122149
S-80 • S-85
4 - 69
Section 4 • Repair Procedures
February 2012
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.
4 - 70
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
4WD STEER AXLE COMPONENTS
12-5
Tie Rod Cylinder
How to Perform the Toe-in
Adjustment
This procedure is the same as the 2WD procedure.
See 11-3, How to Perform the Toe-in Adjustment.
How to Remove the
Tie Rod Cylinder
This procedure is the same as the 2WD procedure.
See 11-3, How to Remove the Tie Rod Cylinder.
Part No. 122149
S-80 • S-85
4 - 71
Section 4 • Repair Procedures
February 2012
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
Part No. 122149
February 2012
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. 122149
S-80 • S-85
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
February 2012
OSCILLATING AXLE COMPONENTS
8 Loosen the jam nut on the relief valve.
14-2
Oscillate Directional Valve
How to Adjust the Oscillate Relief
Valve Pressure
1 Remove the drive chassis cover from the nonsteer end of the machine.
2 Connect a 0 to 2000 psi / 0 to 150 bar pressure
gauge to the diagnostic nipple located near the
oscillate directional valve.
3 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis.
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 Start the engine and manually activate the valve
to confirm the valve pressure.
Result: Pressure is between 800 to 900 psi / 55
to 65 bar.
Result: Pressure is less than 800 psi / 55 bar or
more than 900 psi / 65 bar. Repeat this
procedure beginning with step 5.
4 Start the engine from the ground control.
5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge. Refer to Section 2,
Specifications.
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.
6 Turn the engine off.
7 Locate the relief valve on the directional valve.
a
a
4 - 74
relief valve
S-80 • S-85
Part No. 122149
February 2012
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 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 shoulder bolt and nut.
2 Use a "bubble type" level to be sure the surface
the machine is on is completely level.
11 Measure the distance 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: If the distance is not equal and the
adjustment to the linkage was completed with the
ground and drive chassis level, consult Genie
Industries Service Department.
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. 122149
S-80 • S-85
4 - 75
Section 4 • Repair Procedures
February 2012
Extendable Axle Components
Top and bottom wear pads:
15-1
Extendable Axles
The extendable axles are used to widen the foot
print of the drive chassis for stability.
How to Shim an Extendable Axle
Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
minimum specification, perform the following
procedure. Refer to Maintenance Procedure
D-2, Check the Extendable Axle Wear Pads.
1 Extend the axles.
Side wear pads:
2 Loosen the side wear pad mounting fasteners
on the outer axle.
3 Install the new shims under the wear pads to
obtain zero clearance and zero drag.
4 Use a round punch to align the shim to the wear
pad. Tighten the mounting fasteners.
5 Extend and retract the axle through an entire
cycle. Check for tight spots that could cause
binding or scraping.
Note: Always maintain squareness between the
inner and outer axle tubes.
4 - 76
1 Center a lifting jack of sufficient capacity under
the outer axle that needs to be shimmed. Do
not raise the machine.
2 Block the wheels at the opposite end of the
machine.
3 Raise the machine just until the weight of the
machine is relieved off of the inner axle. Do not
raise the wheels off of the ground.
4 Remove the drive chassis cover.
5 Loosen the wear pad mounting fasteners from
the top and bottom wear pads on both the inner
and outer axles.
6 Install the new shims under the wear pads of
the inner and outer axle to obtain zero
clearance and zero drag.
7 Use a round punch through the wear pad
mounting holes to align the shims with the wear
pad. Install the wear pad retaining fasteners.
8 Extend and retract the axle through an entire
cycle. Check for tight spots that could cause
binding or scraping of the axle tubes.
Note: Always maintain squareness between the
inner and outer axle tubes.
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
EXTENDABLE AXLE COMPONENTS
How to Remove an Inner Axle
7 Place blocks under the axle extension cylinder
for support.
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.
8 Remove the external snap ring from the axle
extension cylinder pivot pin. Use a soft metal
drift to remove the pin.
Note: Perform this procedure with the boom in the
stowed position and boom between the non-steer
end tires.
10 Remove all wear pads from the outer axle.
Steer end:
1 Extend the axles.
9 Attach a lifting strap from an overhead crane to
the inner axle for support.
Note: Pay careful attention to the quantity and
location of shims used when removing the wear
pads.
11 Carefully remove the inner axle from the outer
axle.
2 Remove the drive chassis cover.
3 2WD models: Remove the yoke and hub
assembly. See 11-1, How to Remove the Yoke
and Hub.
4WD models: Remove the yoke and drive hub.
See 12-1, How to Remove the Yoke and Drive
Hub Assembly.
4 4WD models: Remove the hose bracket from
the steer cylinder barrel-end pivot pin.
5 Remove the remaining steer cylinder pivot pin.
Remove the steer cylinder and lay off to the
side.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
6 Remove the steer cylinder mounting lug from
the inner axle.
Part No. 122149
Crushing hazard. The inner axle
could become unbalanced and fall
if not properly supported when it is
removed from the outer axle.
Non-steer end:
12 Loosen the wheel lug nuts. Do not remove
them.
13 Block the steer tires and center a lifting jack
under the outer axle.
14 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
15 Remove the lug nuts. Remove the tire and
wheel assembly.
16 Remove the drive motor covers from both sides
of the inner axle.
S-80 • S-85
4 - 77
Section 4 • Repair Procedures
February 2012
EXTENDABLE AXLE COMPONENTS
17 Tag, disconnect and plug the hydraulic hoses at
the drive motor. Cap the fittings on the drive
motor.
15-2
Axle Extension 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 Axle
Extension Cylinder
18 Place blocks under the axle extension cylinder
for support.
19 Remove the external snap rings from the axle
extension cylinder pivot pin of the inner axle to
be removed. Use a soft metal drift to remove
the pin.
20 Attach a strap from a lifting device through the
inner axle close to the drive hub for support.
21 Remove all wear pads from the outer axle.
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.
Note: Perform this procedure with the boom in the
stowed position and boom between the non-steer
end tires.
1 Extend the axles.
2 Remove the drive chassis cover.
Steer end:
3 Remove the engine side yoke and hub.
Note: Pay careful attention to the location and
number of shims used when removing the wear
pads.
2WD models: Remove the yoke and hub
assembly. See 11-1, How to Remove the Yoke
and Hub.
22 Carefully remove the inner axle from the outer
axle.
Crushing hazard. The inner axle
could become unbalanced and fall
if not properly supported when it is
removed from the outer axle.
4WD models: Remove the yoke and drive hub.
See 12-1, How to Remove the Yoke and Drive
Hub Assembly.
4 Remove the access cover at the end of the
inner axle.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
4 - 78
S-80 • S-85
Part No. 122149
February 2012
Section 4 • Repair Procedures
EXTENDABLE AXLE COMPONENTS
5 Tag, disconnect and plug the axle extend
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.
6 Place blocks under the axle extension cylinder
for support.
Non-steer end:
9 Remove the drive motor access covers from
both sides of the axle.
10 Remove the drive motor. Refer to 12-2, How to
Remove a Drive Motor.
11 Remove the drive hub. Refer to 12-3, How to
Remove a Drive Hub.
12 Tag, disconnect and plug the axle extend
cylinder hydraulic hoses from RAE and RAR ports
on the axle select manifold. Cap the fittings on
the manifold.
7 Remove the external snap rings from the axle
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
8 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
unbalanced and fall if not properly
supported when it is removed from
the axle.
13 Place blocks under the axle extension cylinder
for support.
14 Remove the external snap rings from the axle
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
15 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
unbalanced and fall if not properly
supported when it is removed from
the axle.
Part No. 122149
S-80 • S-85
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Section 4 • Repair Procedures
February 2012
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4 - 80
S-80 • S-85
Part No. 122149
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Section 4 • Repair Procedures
REV A
EXTENDABLE AXLE COMPONENTS
5 Tag, disconnect and plug the axle extend
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.
6 Place blocks under the axle extension cylinder
for support.
Non-steer end:
9 Remove the drive motor access covers from
both sides of the axle.
10 Remove the drive motor. Refer to 12-2, How to
Remove a Drive Motor.
11 Remove the drive hub. Refer to 12-3, How to
Remove a Drive Hub.
12 Tag, disconnect and plug the axle extend
cylinder hydraulic hoses from RAE and RAR ports
on the axle select manifold. Cap the fittings on
the manifold.
7 Remove the external snap rings from the axle
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
8 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
unbalanced and fall if not properly
supported when it is removed from
the axle.
13 Place blocks under the axle extension cylinder
for support.
14 Remove the external snap rings from the axle
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
15 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
unbalanced and fall if not properly
supported when it is removed from
the axle.
Part No. 122149
S-80 • S-85
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Section 4 • Repair Procedures
February 2012
REV A
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Part No. 122149
February 2012
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-80 and Genie S-85 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
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.
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.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steer wheels
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.
· Turntable secured with the turntable
rotation lock
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power disconnected
from the machine
Note: Perform all troubleshooting on a firm, level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 122149
S-80 • S-85
5-1
Section 5 • Fault Codes
February 2012
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 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
Part No. 122149
February 2012
Section 5 • Fault Codes
FAULT CODES
Error Source
ID
21
22
23
31
32
Name
Boom 1 Joystick
(primary boom up/
down)
Error Type
ID
11
12
15
16
Name
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Value at 5V
Value too high
Value too low
Value at 0V
Boom 1 directional
valves
Boom 1 flow
control valve
Boom 2 Joystick
(secondary boom
up/down or
primary boom
extend/retract)
Boom 2 directional
valves
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1 second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Continued on next page
Part No. 122149
S-80 • S-85
5-3
Section 5 • Fault Codes
February 2012
FAULT CODES
Error Source
ID
33
41
42
43
44
5-4
Name
Boom 2 flow
control valve
Turntable rotate
joystick
Error Type
ID
Name
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
Turntable rotate
directional valves
Turntable rotate
flow control valve
Drive enable
override switches
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Solution
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Enable override
direction is frozen at
neutral.
S-80 • S-85
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Part No. 122149
February 2012
Section 5 • Fault Codes
FAULT CODES
Error Source
ID
51
53
54
55
61
62
Name
Drive joystick
Drive flow valve
(EDC)
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
21
Fault
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Drive brake valve
High speed drive
motor Valve
Steer joystick
Steer directional
valves
Part No. 122149
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
S-80 • S-85
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
5-5
Section 5 • Fault Codes
February 2012
FAULT CODES
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
Engine Fault Codes Continental Models
4 Move and hold the run/test toggle switch to
the test position.
How to Retrieve Continental
Engine Fault Codes
Result: The check engine light should turn on.
The check engine light should begin to blink.
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.
5-6
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
times. After the fault codes, the check engine
light will blink a code 123 three times again
indicating the end of the stored codes.
Note: If any fault codes are present, the ECM will
blink a three 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, and then blink the third 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.
S-80 • S-85
Part No. 122149
February 2012
Section 5 • Fault Codes
FAULT CODES
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.
Electrocution 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.
Continued on next page
Part No. 122149
S-80 • S-85
5-7
Section 5 • Fault Codes
February 2012
Continental Engine ECM Fault Code Chart
Code
Description
Code
Description
16
Never crank synced at start
643
5V External 1 voltage high
107
MAP (manifold absolute pressure) volt low
685
Relay coil open
108
MAP (manifold absolute pressure) volt high
686
Relay control ground short
111
IAT (intake air temp) higher than expected 1
687
Relay coil short to power
112
EAT (exhaust air temperature) voltage low
1111
Fuel rev limit
113
IAT (intake air temperature) voltage high
1112
Spark rev limit
116
ECT higher than expected 1
1151
CL (closed loop) high LPG
117
ECT voltage low
1152
CL (closed loop) low LPG
118
ECT voltage high
1155
CL (closed loop) high gasoline bank 1
121
TPS1 < TPS2 (throttle position sensor)
1156
CL (closed loop) low gasoline bank 1
122
TPS1 (throttle position sensor) voltage low
1161
Al (adaptive learning) high LPG
123
TPS1 (throttle position sensor) voltage high
1162
AL (adaptive learning) low LPG
127
IAT (intake air temp) higher than expected 2
1165
LPG cat monitor
129
BP (barometric pressure) low
1171
EPR delivery pressure > than expected
134
EGO open / lazy pre-cat 1
1172
EPR delivery pressure < than expected
154
EGO open / lazy post-cat 1
1173
EPR comm lost
171
AL (adaptive learning) high gasoline bank 1
1174
EPR voltage supply high
172
AL (adaptive learning) low gasoline bank 1
1175
EPR voltae supply low
217
ECT higher than expected 2
1176
EPR intenal actuator fault detection
219
Max govern speed override
1177
EPR internal circuitry fault detection
221
TPS1 > TPS2 (throttle position sensor)
1178
EPR internal comm fault detection
222
TPS2 (throttle position sensor) voltage low
1612
RTI 1 loss
223
TPS2 (throttle position sensor) voltage high
1613
RTI 2 loss
261
Injector Loop Open or Low-Side short to gnd
1614
RTI 3 loss
262
Injector Coil shorted
1615
A/D loss
336
Crank sync noise
1616
Invalid interrupt
337
Crank sensor loss
1625
J1939 shutdown request
341
Cam sync noise
1626
J1939 CAN Tx failure
342
Cam sensor loss
1627
J1939 CAN Rx failure
420
Gasoline cat monitor
1628
J1939 CAN conflict failure
524
Oil pressure low
2111
Unable to reach < TPS
562
Battery voltage low
2112
Unable to reach > TPS
563
Battery voltage high
2122
FPP1 voltage high
601
Flash checksum invalid
2123
FPP1 voltage low
604
Ram failure
2135
TPS1/2 simultaneous voltages out of range
606
COP failure
2229
BP (barometric pressure) high
642
5V External 1 voltage low
2618
Tach output ground short
2619
Tach output short to power
5-8
S-80 • S-85
Part No. 122149
February 2012
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes the drawings.
Electrical Schematics
Electrocution 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.
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.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-80 and Genie S-85 Operator's Manual
on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 122149
S-80 • S-85
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
February 2012
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
Part No. 122149
February 2012
Section 6 • Schematics
Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
.035"
(0.89 mm)
Filter with
bypass valve
relief setting
Orifice with size
Solenoid operated
proportional valve
Shut off valve
Pump
fixed displacement
Check valve
Solenoid operated 3 position,
4 way, directional valve
2 position, 3 way, shuttle valve
Priority
flow regulator valve
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump
bi-directional,
variable displacement
Relief valve
with pressure setting
Solenoid operated 2 position,
3 way, directional valve
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. 122149
S-80 • S-85
6-3
Section 6 • Schematics
February 2012
This page intentionally left blank.
6-4
S-80 • S-85
Part No. 122149
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Deutz BF4L 2011 Models (before serial number 5520)
6-6
6-5
C7P-1
HIGH (FS)
ENGINE SPEED
OFF
GENERATOR
ON
DRIVE LIGHT
WORKLIGHT
WH
WH
C1-9
C2-7
C4-11/12
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
OPTION WIRE
BK
BK
C34SA BK/WH
GLOW
PLUG
C33STR BK
RD
C7B-2
C1B-2
C3B-10
C2B-5
DLITE
GR
BK/RD
BL/RD
C6-28
C6-23
C5-12
C5-18
GR/WH
FUSE 10A
B2BAT RD
C5-22
P34SA
C24TPS WH
C21IGN WH
RD
WH
RD
WH
BK
RD
RD
J144-3
PULL IN
HOLD
_
J144-8
C26TSR WH/RD
J144-5
C25PSR WH/BK
J144-6
J144-4
BK/WH
J144-7
C5-11
R33STR BK
RD
C5-14
C5-16
C27AUX RD
C5-5
C5-15
C6-27
C28TTA RD/BK
P134TTS RD
C43HRN BK
BK
HOUR METER
RPM RELAY
RPM SOLENOID
RPM MODULE
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
GLOW PLUG 1 RELAY
GLOW PLUG 1
CHECK ENGINE LED
GLOW PLUG 2 RELAY
GLOW PLUG 2
OIL TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
POWER RELAY
FUEL SOLENOID
IGN./START RELAY
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
OIL PRESSURE
SENDER (OPT.)
VOLT METER (OPT.)
WATER TEMP
SENDER (OPT.)
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C1-8
C1-7
ENGINE
START
C27AUX RD
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
C6-16
R21IGN WH
R116HYD OR
FLASHING BEACONS
OPTION
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
C41RPM OR/BK
P46 RD
GR/BK
C6-34
C6-33
J144-1
ADD D40 ONLY IF UNIT HAS L4 AND L48.
3
ON GLOW
PLUG
AUXILIARY
PUMP
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C2P-5
P22BAT BK
C132PLI BL/WH
P134BAT GR/BK
RD
C6-24 P134FB RD
C41RPM OR/BK
2
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
1
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
ENGINE
START
C1P-12
C2B-6
BK
C5-2
J144-2
ALTERNATOR
START BATTERY
BATTERY
SEPARATOR (OPT.)
Part No. 122149
S-80 • S-85
6-6
C107AF WH
P20BAT RD
REGULATOR
L29
L29
S1
NO
FB
NC
B
IND.
B1
S2
BRN
+
PR2
NO
PR3
NO
STARTER
PUMP
2 3
BAT.
BAT.
+
FAN
+AUX
ALTERNATOR
H2
STA.
7
WH
RD
C34SA
MOM N.O.
-COM TIME DELAY
MODULE
1
S-613
12 V
DC
TB25
TB26
NO
+BAT
C
A
G2
G3
PR1
EXCT.
TIMER30
CR23
CR23
NO
U16
NO
FUSE 70A
D22
6
D52
D44
D51
P23 RD
L5
CR3
CR3
NO
G1
CR5
NO
CR17
NO
FUSE 70A
TB33A
D13
TB23
TB23
D42
D14
TB46
D7
TB27
C21IGN WH
CR2
NO
TB21
CR1
NO
RD
20AMP.
TB20
C21IGN WH
TB24A
C5-3
CR39
NO
CB3
D6
TB24
TB34
TB41
C32-8
D8
TB28
RD
15AMP.
TB33
8
12
4
TB35
CB2
PBOX GND
7
C32
CONN.
PLUG
D2
WH
RD
8
C28TTA RD/BK
P134BAT RD
1
OR/BK
RD
RD
RD
6
L30
L30
TS4
C2P-6
GRD
H1
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
P3
HORN
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./
5 GROUND
START
6 BATTERY
MODULE
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
5
RD
RD
TB22
KS1
D40
2
P1
CB1
3
TS48
TS1
TS47
FUSE 10A
TS6
TS2
D12
L48
+
CE Option, See 6 - 60
P24FS WH
BK
F18
RD
P26ESTP BK
P26ESTP BK
P26ESTP BK
TS49
2
P24FS WH
FS1
P25FS RD
BK
P25FS RD
C9P-1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
RD
15AMP.
3
February 2012
Section 6 • Schematics
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (before serial number 5520)
P2
C27AUX RD
B2BAT RD
BRN
+
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
OR
BL
WH
14
5
13
4
7
6
12
3
12
13
14
8
7
6
10
9
11
20
19
16
15
17
18
1
4
RETRACT
EXTEND
AXLE
EXTEND
RETRACT
15
8
16
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
RKOUT 6
YOUT 5
BRN
1
2
BL
XOUT 4
BK
7
PWR 3
GND 2
RD
1
YOUT 5
XOUT 4
OR
BRN
1
11
PWR 3
GND 2
6
7
9
10
1
2
3
4
C7-3
C4P-1
C3P-11
C2P-4
C4P-4
C2P-2
C1P-11
C1P-10
C1P-5
C1P-4
C1P-6
C1P-3
C3P-6
C3P-5
C3P-4
C3P-1
C3P-3
C3P-2
C3P-9
C3P-8
C3P-7
C3P-12
C2P-3
C4P-2
C4P-3
C4P-6
C4P-5
BRN
S3LED BL/RD
C61AX BL/BK
C60AX OR/RD
C40LS OR/RD
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C5TRR WH/BK
C6TRF WH/RD
C18JD/PRR GR/BK
DOWN
PLAT LEVEL
UP
C15PLD OR/BK
C14PLU OR
C12DRE BL/WH
BK/RD
C6-21
C6-40
C6-10
C6-22
BK
EXTEND
BOOM
RETRACT
BK/WH
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
R2
5
LEFT
TURNTABLE ROTATE
RIGHT
C4TRL WH
5
C17JU/PRL GR
C61AXRT BL
6
C42LS2 GR
C40LS2 BK
C40LS1 OR
C60AX OR/RD
S3LED BL/RD
C34-1
C6-13
C6-39
C35-1
C34-2
C35-2
C25-2
C42AXDP WH
J3 WH
J1 WH
C25-1
C12-1
C16-1
C20-1
C21-1
C23-1
C22-1
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
D
A
C24-1
C6-11
J4 BK
J2 WH
WH
RD
J5 BK
C6-31
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C32BRK WH/RD C26-1
C6-32
C5-23
C14-1
C15-1
C28-1
C29MS RD/WH
GR/BK-18-M.H.
OR/BK-15-M.H.
OR-14-M.H.
C23BAT RD
C8PBR BK/WH
R16PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH C17-1
C7PBE BK
C3PBF RD/WH C29-1
C2PBD RD/BK C13-1
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C4TRL WH
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
C6-18
GR-17-M.H.
2
NC
2AO
C20-2
C21-2
C24-2
C22-2
GROUND
AXLE EXTEND RLY
AXLE NOT EXT PRESSURE SW
OPEN WHEN AXLE FULLY EXT.
AXLE EXT/RET SELECT
AXLE DUMP VALVE
LS2AO-BOOM ANGLE OP.
DRIVE LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS1RO-BOOM RETRACT OP.
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
STEER RIGHT
STEER LEFT
DRIVE EDC FORWARD
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
MOTOR STROKE
BRAKE RELEASE VALVE
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
FLOW CONTROL
PRI. BOOM UP
CUTOUT RELAY
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL
PRI. BOOM EXTEND
CUTOUT RELAY
PRI. BOOM EXTEND
PRI. BOOM RETRACT
BOOM EXT/RET
FLOW CONTROL
DRIVE ENABLE
LIMIT SWITCH
PLAT LEVEL DOWN
PLAT LEVEL UP
PLATFORM ROTATE LEFT
/JIB UP
PLATFORM ROTATE RIGHT
/JIB DOWN
6-7
S-80 • S-85
Part No. 122149
2
NOHC
2AS
NC
1RO
1
1
L5
OUT 5 YEL
4
OR
PWR 3
GND 2 BRN
1
BRN
P24FS WH
P26ESTP BK
3
5
DOWN
PLAT LEVEL
UP
D27
DOWN
UP JIB BOOM
C6-17
DESCENT ALARM
3
D28
DOWN
UP JIB BOOM
C6-19
2
4
AMP
1
Deutsch
D34
RIGHT
PLAT ROTATE
LEFT
5
2
CR8
TB42
C19JSV GR/WH
3
1
5
RIGHT
PLAT ROTATE
LEFT
C4P-7
7
U4
D57
14
13
4
4
3
H3
S3
NC
CR38
H4
2
1
3
3
2
2
3
CR20 B
NO
CR38
D41
D29
NC
CR8
4
1
NO
4
CR20 A
TB32
TB5
TB2
7
2
1
P24FS WH
JIB VALVE
C27AUX + FE RD
TB16
4
C41RPM OR/BK
P46 RD
P23 RD
1
4
3
J2
CR29
NC
D15
TB7
NC
TB6
TB3
TB18
TB4
TB1
TB8
TB15
D36
TB40
TB46
TB37
NOHC
1RS
NOHC
LS3
BRN
TS59
TS58
TS57
TB9
TB14
TB17
TS62
TS61
D37
D35
3
D38
C19JSV GR/WH
TS63
J1
J1
J1
J1
J3
TS16
TS9
TS8
TS7
JOYSTICK CONTROL CARD
2
D41
8
JIB VALVE
4
6
Joystick Adaptor Harness
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
CE Option, See 6-60
CR13
+
JC2
JC1
L1
CR26
NC
TS14
TS15
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
EXTEND/RETRACT
P24FS WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (before serial number 5520)
P134BAT RD
P26ESTP BK
C28TTA RD/BK
BRN
Section 6 • Schematics
February
2012
July 2007
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (before serial number 5520)
6-7
6-8
February 2012
Section 6 • Schematics
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (after serial number 5519)
6-9
C7P-1
HIGH (FS)
ENGINE SPEED
OFF
GENERATOR
ON
DRIVE LIGHT
WORKLIGHT
WH
WH
C1-9
C2-7
C4-11/12
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
OPTION WIRE
BK
BK
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
RD
C7B-2
C1B-2
C3B-10
C2B-5
DLITE
GR
BK/RD
BL/RD
C6-28
C6-23
C5-12
C5-18
GR/WH
FUSE 10A
B2BAT RD
C5-22
P34SA
C24TPS WH
C21IGN WH
C43HRN BK
RD
WH
RD
WH
BK
RD
RD
J144-3
PULL IN
HOLD
_
J144-8
C26TSR WH/RD
J144-5
C25PSR WH/BK
J144-6
J144-4
BK/WH
J144-7
C5-11
R33STR BK
RD
C5-14
C5-16
C27AUX RD
C5-5
C5-15
C6-27
C28TTA RD/BK
P134TTS RD
C6-16
R21IGN WH
R116HYD OR
BK
HOUR METER
RPM RELAY
RPM SOLENOID
RPM MODULE
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
GLOW PLUG 1 RELAY
GLOW PLUG 1
CHECK ENGINE LED
GLOW PLUG 2 RELAY
GLOW PLUG 2
OIL TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
POWER RELAY
FUEL SOLENOID
IGN./START RELAY
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
OIL PRESSURE
SENDER (OPT.)
VOLT METER (OPT.)
WATER TEMP
SENDER (OPT.)
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
FLASHING BEACONS
OPTION
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
C41RPM OR/BK
P46 RD
GR/BK
C6-34
C6-33
J144-1
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C1-8
C1-7
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C2P-5
P22BAT BK
C132PLI BL/WH
P134BAT GR/BK
RD
C6-24 P134FB RD
C41RPM OR/BK
ADD D40 ONLY IF UNIT HAS L4 AND L48.
3
ON GLOW
PLUG
AUXILIARY
PUMP
ENGINE
START
C1P-12
C2B-6
BK
C5-2
J144-2
2
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
1
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
L29
L29
S1
NO
BRN
D52
C107AF WH
ALTERNATOR
START BATTERY
BATTERY
SEPARATOR (OPT.)
Part No. 122149
S-80 • S-85
6 - 10
P20BAT RD
REGULATOR
STARTER
TS54
+
PR2
NO
PR3
NO
S2
FB
NC
B
IND.
B1
BAT.
BAT.
+
PUMP
2 3
MOM N.O.
-COM TIME DELAY
MODULE
1
S-613
12 V
DC
FAN
+AUX
ALTERNATOR
H2
STA.
7
WH
RD
C
A
NO
+BAT
C34SA
CR23
CR23
NO
U16
NO
TB25
TB26
PR1
EXCT.
TIMER30
G2
G3
P23 RD
L5
CR3
D44
D51
L30
L30
CR3
NO
G1
CR5
NO
CR17
NO
FUSE 70A
TB33A
D13
TB23
TB23
D42
D14
TB46
D7
TB27
C21IGN WH
CR2
NO
TB21
CR1
NO
RD
20AMP.
TB20
C21IGN WH
TB24A
C5-3
CR39
NO
CB3
D6
TB24
TB34
TB41
C32-8
D8
TB28
RD
15AMP.
TB33
8
12
4
H1
TB35
CB2
PBOX GND
7
C32
CONN.
PLUG
D2
WH
RD
8
P134BAT RD
1
OR/BK
RD
RD
RD
6
FUSE 70A
D22
6
C2P-6
GRD
P3
HORN
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
D40
2
TB134
3
TS48
TS4
TS47
FUSE 10A
TS6
TS2
D12
L48
+
CE Option, See 6 - 60
P24FS WH
BK
F18
RD
P26ESTP BK
P26ESTP BK
P26ESTP BK
TS49
TS1
2
P24FS WH
FS1
P25FS RD
BK
P25FS RD
C9P-1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./
5 GROUND
START
6 BATTERY
MODULE
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
5
RD
RD
15AMP.
RD
P1
CB1
3
February 2012
Section 6 • Schematics
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (after serial number 5519)
C28TTA RD/BK
P2
C27AUX RD
B2BAT RD
BRN
+
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
4
12
13
14
8
7
6
10
9
11
20
19
16
15
17
18
1
4
RETRACT
EXTEND
AXLE
EXTEND
RETRACT
15
8
16
5
13
BL/WH
3 BL/WH
4 WH/RD
14
5
6
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
RKOUT
XOUT
YOUT
OR
3
12
11
1
2
BRN
1
PWR
2
GND
6
5
YOUT 4 RD/WH
XOUT 3 WH/RD
OR
BRN
PWR 2
GND 1
6
5
OUT 4 WH/BK
3
9
10
1
2
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C40LS OR/RD
C60AX OR/RD
C3P-11
C2P-4
C4P-4
C40LS1 OR
C1P-3
C1P-6
C1P-5
C1P-4
C1P-10
C1P-11
C5TRR WH/BK
C6TRF WH/RD
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
C2P-2
C3P-5
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
R2
5
C6-21
C6-22
C6-10
C6-40
LEFT
TURNTABLE ROTATE
RIGHT
C4TRL WH
C3P-6
C3P-4
C3P-1
C3P-3
C3P-2
C3P-9
C3P-8
C3P-7
BK
EXTEND
BOOM
RETRACT
BK/WH
C61AXRT BL
C40LS2 BK
C42LS2 GR
6
C40LS1 OR
C6-39
C6-13
C60AX OR/RD
S3LED BL/RD
C35-1
C34-1
C34-2
C35-2
C25-2
C42AXDP WH
J1 WH
C25-1
C12-1
C16-1
C20-1
C21-1
C23-1
C22-1
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
D
A
C24-1
C6-11
J4 BK
J3 WH
J2 WH
RD
J5 BK
C6-31
WH
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C32BRK WH/RD C26-1
C6-32
C5-23
C14-1
C15-1
C28-1
C29MS RD/WH
GR-17-M.H.
GR/BK-18-M.H.
OR/BK-15-M.H.
OR-14-M.H.
C23BAT RD
C8PBR BK/WH
R16PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH C17-1
C7PBE BK
C3PBF RD/WH C29-1
C2PBD RD/BK C13-1
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C4TRL WH
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
C6-18
C6-17
C6-19
C20-2
C21-2
C24-2
C22-2
GROUND
PLATFORM ROTATE LEFT
/JIB UP
PLATFORM ROTATE RIGHT
/JIB DOWN
PLAT LEVEL DOWN
PLAT LEVEL UP
LIMIT SWITCH
DRIVE ENABLE
BOOM EXT/RET
FLOW CONTROL
PRI. BOOM RETRACT
PRI. BOOM EXTEND
PRI. BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRI. BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM RETRACT OP.
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS2AO-BOOM ANGLE OP.
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RLY
AXLE NOT EXT PRESSURE SW
OPEN WHEN AXLE FULLY EXT.
8
DESCENT ALARM
6 - 11
S-80 • S-85
2
NC
2AO
L5
OR
PWR 2
GND 1 BRN
BRN
P24FS WH
3
4
BK/RD
C12DRE BL/WH
C14PLU OR
C15PLD OR/BK
DOWN
PLAT LEVEL
UP
C18JD/PRR GR/BK
C17JU/PRL GR
D28
DOWN
UP JIB BOOM
RIGHT
PLAT ROTATE
LEFT
CR8
Part No. 122149
1
2
NOHC
2AS
NC
1RO
NOHC
1RS
4
1
3
4
3
2
1
H3
S3
NC
CR38
H4
7
3
2
2
3
NO
1
CR20 A
TB32
TB16
TB40
TB46
TB37
4
4
CR38
D41
NC
CR8
TB42
C19JSV GR/WH
U4
D57
14
13
P26ESTP BK
C27AUX + FE RD
5
D34
4
C3P-12
C2P-3
C4P-2
C4P-3
C4P-5
C4P-6
C4P-7
4
3
3
5
DOWN
PLAT LEVEL
UP
D27
DOWN
UP JIB BOOM
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
C41RPM OR/BK
P46 RD
P23 RD
CR20 B
NO
D29
D36
1
2
1
J2
CR29
NC
D15
TB7
NC
TB6
TB3
TB18
TB4
TB1
TB8
TB15
TS62
TS61
TS63
TB5
TB2
TB9
TB14
TB17
NOHC
LS3
BRN
TS59
TS58
TS57
D38
C19JSV GR/WH
D37
D35
3
J1
J1
J1
J1
J3
TS16
TS9
TS8
TS7
JOYSTICK CONTROL CARD
D41
P24FS WH
CE Option, See 6 - 60
CR13
2
+
JC2
JC1
L1
CR26
NC
TS14
TS15
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
EXTEND/RETRACT
WH
P24FS WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (after serial number 5519)
C28TTA RD/BK
P134BAT RD
P26ESTP BK
Section 6 • Schematics
February 2012
Electrical Schematic, S80/85
Deutz BF4L 2011 Models (after serial number 5519)
6 - 11
6 - 12
February 2012
Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models
6 - 14
6 - 13
Section 6 • Schematics
February 2012
Ground Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models
A
B
C
D
E
F
G
H
I
1
U16
3
5
2
BR GND STUD
BK/WH TB34D
BK TB33C
PLAT. LEVEL. UP
PLAT. LEVEL DN.
AXLE DUMP VALVE
PLAT. ROT. L.
PLAT. ROT. R.
12V BATT. SUPPLY
IGNITION PWR.
HORN
KEYSWITCH PWR/PWR TO PLAT
FUSED 12V
OIL COOLER FAN
AUX PUMP
BRAKE
START ENG
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
3
4
L.P.
LIMIT SW #1
ENG RPM
LIMIT SW #2
LIMIT SW PWR
KS POWER
KS POWER
C32
P134PWR RD-134B
GR/BK-C3B-10
GR/BK-L45
L
LABEL
DRIVE LIGHT OPTION RELAY
VOLT METER
B
1 RD CR38#86
RD/BK CR8#30
2 D15
3
4
5
6
D57
GND STUD
7 CR8#86+
8 BK/WH C6-38
9
10
11
OR C4B-2
OR C6-14
14
OR/BK C4B-3
OR/BK C6-15
D42 15
OR/RD CR20A#86 OR/RD CR38#87A
16 OR/RD CR8#87A
GR C4B-5
GR C6-17
17
GR/BK C4B-6
GR/BK C6-18
18
20
RD-B1-H1
RD-B1-H1
WH C5-3
WH CR3#86
21 WH CR17 #86
22 BK CR5#30
BK C23-4
RD C6-30 +RD U16-2
WH C7B-2
23 WH ISM#7
RD ISM#6
RD CR1#30
24 RD CR2#30
24A RD CR17#30D6
RD CR39#86&C1B-1
27 RD ISM#4
WH/RD C5-23
WH/RD C1B-6
32 WH/RD C6-32
BK U16-5
BK C1B-7
33 BK ISM#3
BK C5-5
33A BK-CR1#87
34
BK/WH C1B-8
BK/WH U16-5
BK/RD C1B-9
35 BK/RD CR3#30
BL/BK C1B-11
37 BL/BK C6-20
BL/BK C6-37
38
BL/RD C2B-1
39
OR C2B-2
OR C6-40
40 OR C6-10
41 OR/BK ISM#2
OR/BK C2B-3
OR/BK C5-2
42 OR/RD C6-22
OR/RD C4B-4
OR/RD CR29#86
RD C6-31
46B
D7
RD C2B-6
RD C6-23
134 RD-H6
RD C6-24
134A
C
RD C6-1
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
H1
C7B
12V TO PLAT
BK CR1#86
OR/BK-41B
BK-33B
RD-27B
BRN GND
RD-24D
WH-23B
BRN-GND STUD
3
BK-C23-5
1
WH-23D
2
1
2
3
4
5
6
7
8
9
10
WH-CR2#86
WH L2
RD-B1-20C
RD-B1-20D
G1
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
DIESEL ENGINE: C2-1 BL/RD
C4B
C3B
19/18 CABLES
NC
B
3
E-STOP
RD-134A
M
1
B1
2
4
RD/WH-3A
RD/BK-2A
GR/BK-H6
PLATFORM
OVERLOAD
LED L45
CHECK ENG +
LED L2
-
WH ISM #10
WH C5-15
+
-
BK-7A
D8
RD-KSI-SP
BK/WH-8A
WH-21A
+
G6
HOUR METER
TS61
TS63
BK/RD-9A
RD-C23-7
BK-33
TS52
TS56
CB3
BK/WH-34A
RD-24AA
OR/BK-15A
RD-B2-H1
BK/RD-35A
BK-22B
BK C6-16
GLOW PLUG SW
START
OIL COOLER/
OPTION
CR29
CR8
86
86
C6
86
BK/RD-35B
RD-27D
JIB
TURNTABLE
ROTATE
ENGINE
ALL BRN WIRES
C5
GROUND STUD
TB16D OR/RD
OR C6-33
WH-21B
86
CR20B
OR/RD C6-11
S-80 • S-85
RD-24AB
PLATFORM LEVEL SWITCH
TS61
PRIMARY BOOM UP/DOWN SWITCH
TS62
TURNTABLE ROTATE SWITCH
TS63
PRIMARY BOOM EXTEND/RETRACT SWITCH
CB1
CIRCUIT BREAKER, ENGINE, 15A
CB2
CIRCUIT BREAKER, CONTROLS, 15A
CB3
CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
G6
HOUR METER
G1
VOLT METER GAUGE (OPT.)
G2
OIL PRESSURE GAUGE (OPT.)
G3
WATER TEMP. GAUGE (OPT.)
L2
CHECK ENGINE LED
L45
PLATFORM OVERLOAD LED
CR1
IGNITION / START RELAY
CR2
IGNITION POWER RELAY
CR3
HIGH IDLE CUTOUT RELAY
CR5
SERVICE HORN RELAY
CR8
BOOM FUNCTION CUTOUT
CR17
HYDRAULIC COOLER FAN RELAY
CR20A
LOW VOLTAGE DROP RELAY
CR20B
LOW VOLTAGE DROP RELAY
CR23
DRIVE LIGHT RELAY OPTION
CR25
AXLE RET L/O RELAY
CR29
AXLE EXTEND LED RELAY
CR38
EXTEND FUNCTION CUTOUT
CR39
AUXILARY PUMP RELAY
R2
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
U1
IGNITION/START MODULE
U33
PLATFORM OVERLOAD MODULE
25 OIL PRESSEURE SENDER
WH/RD C5-16
WH/RD-S.P
26 WATER TEMP SENDER
WH/BK C5-14
WH/BK-S.P.
28 TILT ALARM
RD/BK C1B-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
RD-B1-20A
30 E.D.C. FWD
WH C1B-4
WH C5-21
OR-14A
GR-17A
GR/WH C4B-7
GR/BK-18A
31 E.D.C. REV
WH/BK C5-20
WH/BK C1B-5
36 STEER LEFT/AXLE RETRACT
BL C1B-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GEN. OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXT/RET SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
CB1
CB2
TS57
D42
ENGINE
CONTROLS
PLAT.
LEVEL
PLATFORM
ROTATE
WH/RD-6A
CR17
JIB UP/DOWN (JIB OPTION ONLY)
TS59
BL/WH C3B-12
OR/RD 16B
86
PLATFORM ROTATE SWITCH
TS58
GR/WH-S.P.
WH-4A
WH/BK-5A
RD/BK 2B
86
FUNCTION ENABLE SWITCH
TS57
GR/WH C4B-7
TS59
BL/RD C4B-1
CR20A
TS54
19 JIB VALVE
D13
OR/RD 42B
TB134A-A
GLOW PLUG SWITCH (DIESEL ONLY)
BL/WH C6-12
RD-24A
CR3
GROUND STUD
START ENGINE SWITCH
TS56
FROM
HIGH/LOW
RPM
TS54
WH-21C
86
TS52
CIRCUIT DESCRIPTION
D14
BK/RD C5-18
CR39
KEY SWITCH
AUXILIARY SWITCH
TS62
TS58
RD C6-27
7
KS1
TS51
12 DRIVE ENABLE
OR/RD 16C
BK 7B
BL/RD C6-13
WH C5-11
BOOM
UP/DOWN
BOOM EXTEND/
RETRACT
RD-1A
86
TB33AB
DESCRIPTION
EMERGENCY STOP BUTTON
RD-27A
BK-S.P.
D51
BK/WH-S.P.
BK/RD-S.P.
C1B
C2B
KSI
AUXILIARY PUMP
TS51
D2
CR5
FUNCTIONS
P1
NC
BK/WH C6-29
GR C2B-5
86
RD C4B-12
KEYSWITCH
CR38
86
G3
RD C23-6
WH-23A
BK-22A
RD-1B
86
(SPARE WIRE)
OPTION WIRE TO PBOX
WH/RD C5-16
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
IGN./START
MODULE
BATTERY
KEY PWR.
KEY BYPASS
U1
IGN./FUEL ON
ENG. FAULT
CR2
G2
WH/BK C5-14
OR-S.P.
OR/BK-S.P.
D34
GR-S.P.
GR/BK-S.P.
RD-B1-S.P.
WH S.P.
BK-S.P.
WH-S.P.-D2
RD-S.P.-CB1
RD-S.P.-CB3
RD-S.P.
RD-B2-S.P.
CR1
TB24AD
BRN GND
RD-24C
6
10 AMP FUSE
WATER TEMP.
RD C4B-11
A
RD-S.P.
RD/BK-S.P.
RD/WH-S.P.
WH-S.P.
WH/BK-S.P.
WH/RD-S.P.
BK-S.P.
BK/WH-S.P.
BK/RD-S.P.
BRN(GND)
5
OIL PRESSURE
CR23
BASE TERMINATION BLOCK
6 - 14
K
P1
H6
CE ONLY
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
5
6
7
8
12
D
RD C3B-1
RD/BK C6-19
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
PRI. BOOM UP
PRI. BOOM DOWN
PRI. BOOM F.C.
TURN. ROT. L
TURN. ROT. R
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
EXT./RET. F.C.
RD H6
BL/WH C1-12
BK-22D
1
3
4
C32 CONNECTOR
PLUG ANSI/CSA ONLY
BK/WH C5-22
RD TB23
+
1
2
8
J
NOTE: CE OPTION- LOADSENSE
MODULE CONNECTS TO C32.
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH-C6-34
Part No. 122149
R2
TO
N
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models (before serial number 5520)
6 - 16
6 - 15
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models (before serial number 5520)
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
COMPONENT INDEX
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
2
U13
ALC-500
P2
P3
TS1
TS2
TS4
TS6
3
J3
D12
1
TS7
TS8
TS9
GND STUD
J2
J1
11
9
TS14
TS15
TS16
TS47
TS48
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
HI-C133PLA GN/BL C3P-10
TS16-C61AX BL/BK C3P11
TS47-C45GEN GR/WH C2P-7
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
3
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
PLATFORM OVERLOAD LIMIT SWITCH
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
AXLE EXTENDED LED
TILT ALARM LED
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC2
JC1
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
U13 ALC500
CR13 JIB BOOM CUTOUT RELAY
CR26 AXLE CUTOUT RELAY
TILT ALARM
H1
BATGND C7P-3
D40
CR13 BRN
GR/WH C4P-7
GR/WH TS7
RD/BK JIB CABLE
C2P-9 & 10
GND
C4P(BR)
C3P(GR)
BRN
GND STUD
C2P(BK)
C1P(GY)
H1
TILT
ALARM
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
AXLE EXTEND/RETRACT TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
LS18
L1
L4
JC3
4
5
PLATFORM LEVEL TOGGLE SWITCH
TS49
L40
L48
C28TTA RD/BK C1P-2
D39
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
HIGH RPM SWITCH
GLOW PLUG OPTION
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
CE LIFT/DRIVE OPTION
BK LS CABLE CIP-12
19/18 CONTROL CABLE
JIB
C7P
C9
12V DC
BATTERY
FOOT SWITCH
LS18
REPLACE WIRE WITH THIS WIRING DIAGRAM
OPT.
(OPTION)
RD-H1
RD-P2
RD LS CABLE
BRN BATGND
GND STUD
CR27
+
WH-TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR/RD R40LS2
(SPLICE TO R40LS2)
+
3
L48
-
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
GN/BK H1 (D39)
TS15
DRIVE
ENABLE
BRN J1-14
4
OR J1-13
WH J1-5
BL J1-4
5
4
2
2
D12
JC3
DRIVE
1
CR26
AXLE CUTOUT
WH J3-2
RD/BK H1
6
5
1
DETAIL B: GENERATOR OPTION
+
+
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
RD WL2
L1
TS15
NO
TS9
PLATFORM
LEVEL
TS1
AUXILIARY
PUMP
TS14
DRIVE
SPEED
TS6
GLOW PLUG
OPTION
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
BK
NC
TS48/TS49
TS2
P2
EMERGENCY
STOP
CE MODELS (SEE DETAIL A)
S-80 • S-85
RD WL1
L4
TS8
JIB BOOM
GR/WH C2P-7
TS7
PLATFORM
ROTATE
P3
HORN
6 - 16
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
1
BL/WH J1-6
L40
BK/WH C1P-8
6
-
-
2
8
7
3
3
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
7
+
+
7
BL/BK J1-7
TS16
4
RD/WH J1-8
D2
BRN J1-10
JC1
BOOM
EXTEND/
RETRACT
JIB
CUTOUT
5
OR J1-9
YEL J1-3
RD C1P-1
6
GR/BK C4P-6
7
GR C4P-5
GR/WH JIB CABLE
CR13
J2-DIODE WH
BRN
AXLE
EX/RET
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
6
WH-TS7
Part No. 122149
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models (after serial number 5519)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
COMPONENT INDEX
PLATFORM CONTROL BOX
BK P2
D12
WH TS4
WH C9-2
WH CR26#85
BL TS16
JC3-4 BL(2)
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-3 OR
JC3-6 BL(1)
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD LS18
RD C2P-6
U13
ALC-500
3
1
GND STUD
J2
J1
11
9
1
1
CC132PLI BL/WH C3P-12
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
C133PLA BL C3P-10
TS16-C61AX BL/BK C3P11
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
TS47-C45GEN GR/WH C2P-7
C134PWR GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
TS3-C39LP BL/RD C2P-1
C40LS1 OR C2P-2
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-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
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
RD/BK H1
C28TTA RD/BK C1P-2
BATGND C7P-3
D40
C2P-9 & 10
C4P(BR)
TS2
START ENGINE SWITCH
TS6
GLOW PLUG
HIGH RPM SWITCH
TS7
PLATFORM ROTATE SWITCH
TS8
JIB UP/DOWN (JIB OPTION ONLY)
TS9
PLATFORM LEVEL SWITCH
TS14
DRIVE SPEED LOW/HIGH SWITCH
TS15
DRIVE ENABLE SWITCH
TS16
AXLE EXT/RET SWITCH
TS47
GENERATOR SWITCH ( OPTION )
TS48
WORK LIGHT RELAY (OPTION)
TS48
DRIVE LIGHT RELAY (OPTION)
2
3
L1
DRIVE ENABLE LED
L4
PLATFORM OVERLOAD LED (OPTION)
L40
AXLE EXTENDED LED
JC3
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC1
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
JC2
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
CR13
JIB CUTOUT RELAY ( JIB ONLY )
U13
ALC500
H1
TILT ALARM
4
LS18
PLATFORM OVERLOAD LIMIT SWITCH
L48
TILT ALARM LED
GR/WH TS7
BRN BATGND
C9
(GND STUD)
RD-H1
RD LS CABLE
F.S.
12V BATT
19/18 CONTROL CABLE
OPT.
Y
C7P
LS18
OPT.
Y
GND STUD
AUXILIARY SWITCH
BK LS CABLE CIP-12
JIB
BRN
H1
HORN SWITCH
TS1
GR/WH C2P-7
C3P(GR)
C2P(BK)
C1P(GY)
GND
Y
CR13 BRN
BK JIB CABLE
Y
GR/WH C4P-7
D39
P3
TS4
J3
D12
EMERGENCY STOP BUTTON
P2
RD-P2
CR27
WH TS7
WH TS1
TILT ALARM
WH/RD C32BRK
CR30
JC3-1
JC3-2
+
L48
RD WL1
+
+
TS48
OPTION WIRE TO GBOX
7
TS49
2
+
F18 10A
L4
L1
TS7
TS8
JIB
TS48 PIN2
E-STOP BK
TS4
NO
BK
DETAIL C: WORKLIGHT OPTION
DRIVELIGHT OPTION
NC
TS1
TS6
AUX. PUMP
TS14
D27
(SPARE WIRE)
RD WL2
DRIVE/STEER
PLATFORM
ROTATE
PLATFORM
LEVEL
6
DETAIL A: LIFT/DRIVE OPTION
JC1
TT ROTATE
HORN
DETAIL B:
GENERATOR OPTION
(SPLICE TO
R40LS2)
JC3
P3
TS47
REPLACE WIRE WITH THIS WIRING DIAGRAM
AXLE CUTOUT
TS9
TS2 RD
(SPLICE TO
C32BRK)
OR/RD R40LS2
D12
TS15
DRV.ENA
RD LS18
BK C7P-1
BK C9-1
WH C7P-2
BK J3-3
GN/BK H1 (D39)
J1-14 BRN
J1-5 BL/WH JC3-3
J1-13 OR
J1-5 BL/WH JC3-5
J1-4 WH/RD JC3-4
WH J3-2
RD/BK H1
BK/RD C1P-9
RD C9-3
BK C1P-7
BK/WH C1P-8
BL/WH J1-6
BL/BK J1-7
RD/WH J1-8
JC1-1
L40
J1-10 BRN
BOOM
EXT/RET
TS16
CR26
JC2
J1-3 WH/BK JC1-4
D2
UP/DOWN
J1-9 OR JC1-2
JIB
CUTOUT
PRI. BOOM
RD C1P-1
GR C4P-5
GR/BK C4P-6
J2-DIODE WH
JC2-1
JC2-2
CR13
GR/WH JIB CABLE
GND BRN
OR/RD C2P-4
BL/BK C3P-11
BL C1P-10
BL/RD C4P-1
J1-11 OR
J1-12 BRN
J1-2 RD/WH JC2-4
J1-1 WH/RD JC2-3
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
5
DRIVE
SPEED
GLOW PLUG
TS2
START
BK
RD
HIGH/LOW RPM
RD
8
RD
P2
E- STOP
CE SEE DETAIL A
Part No. 122149
S-80 • S-85
6 - 17
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Deutz BF4L 2011 Models (after serial number 5519)
6 - 17
6 - 18
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Perkins 804-33 Models (before serial number 5520)
6 - 20
6 - 19
C7P-1
ENGINE SPEED
HIGH (FS)
OFF
GENERATOR
ON
DRIVE LIGHT
WH
WH
WORKLIGHT
ON GLOW
PLUG
ENGINE
START
AUXILIARY
PUMP
C1-9
C2-7
C4-11/12
C1-8
C1-7
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C2P-5
P22BAT BK
C132PLI BL/WH
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
OPTION WIRE
BK
BK
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
RD
C7B-2
C1B-2
C3B-10
C2B-5
DLITE
GR
GR/BK
BK/RD
BL/RD
C6-28
C6-23
C5-12
C5-18
GR/WH
FUSE 10A
C34SA
C5-22
C27AUX RD
RD
RD
J144-3
J144-8
C26TSR WH/RD
J144-5
C25PSR WH/BK
J144-6
J144-4
BK/WH
J144-7
WH
R33STR BK
C21IGN
C24TPS WH
B2BAT RD
RD
C5-5
C5-11
C5-15
C6-27
C5-16
C5-14
WH
C43HRN BK
RD
C6-16
R21IGN WH
C28TTA RD/BK
P134TTS RD
C6-34
R116HYD OR
BK
HOUR METER
RPM RELAY
RPM RELAY
RPM SOLENOID
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
GLOW PLUG 1 RELAY
GLOW PLUG 1
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
POWER RELAY
FUEL PUMP
FUEL SOLENOID
IGN./START RELAY
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
OIL PRESSURE
SENDER (OPT.)
VOLT METER (OPT.)
WATER TEMP
SENDER (OPT.)
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
D12
P134BAT GR/BK
C6-33
FLASHING BEACONS
OPTION
ADD D40 ONLY IF UNIT HAS L4 AND L48.
3
HM
J144-1
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
L29
L29
TS4
C1P-12
C2B-6
RD
C41RPM OR/BK
J144-2
ALTERNATOR
START BATTERY
BATTERY
SEPARATOR (OPT.)
Part No. 122149
2
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
1
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
_
FUEL
PUMP
STARTER
CR4
CR4
NO
C6-24 P134FB RD
C5-2
C107AF WH
NC
B
+
PR2
NO
S2
FB
NO
S1
NO
IND.
REGULATOR
S-80 • S-85
+
6 - 20
EXCT.
PUMP
FAN
PR1
CR23
CR23
NO
TB25
TB26
P23 RD
L5
D52
CR3
D51
P20BAT RD
8
BK
RD
ALTERNATOR
M4
B1
BAT.
BAT.
+
12 V
DC
7
D22
H2
STA.
C
A
G2
G3
6
C21IGN WH
CR2
NO
TB21
CR3
NO
G1
CR5
NO
CR17
NO
FUSE 70A
TB33A
C41RPM OR/BK
P46 RD
5
CR1
NO
RD
20AMP.
C21IGN WH
TB24A
C5-3
CR39
NO
CB3
D6
TB24
D13
TB23
TB23
D42
D14
TB46
D7
TB27
D8
TB28
RD
15AMP.
TB34
TB41
C32-8
TB35
CB2
TB33
8
12
D2
WH
TS54
TS56
TS52
L30
OR/BK
RD
RD
RD
6
PBOX GND
7
C32
CONN.
PLUG
4
H1
TS48
TS49
TS1
TS47
FUSE 10A
C2P-6
GRD
P3
HORN
L30
2
TB134
TS51
5
4
PLAT
3
1
TB22
KS1
D40
3
3
L48
+
CE Option, See 6 - 60
P24FS WH
BK
F18
RD
P26ESTP BK
P26ESTP BK
P26ESTP BK
TS6
TS2
2
P24FS WH
FS1
P25FS RD
BK
P25FS RD
C9P-1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./
5 GROUND
START
6 BATTERY
MODULE
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
RD
15AMP.
RD
P1
CB1
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Perkins 804-33 Models (before serial number 5520)
1
C28TTA RD/BK
P134BAT RD
P2
C27AUX RD
B2BAT RD
BRN
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
YOUT 5
RKOUT 6
OR
BL
WH
BL
14
5
13
4
7
6
12
12
13
14
8
7
6
10
9
11
20
19
16
15
17
18
1
4
RETRACT
EXTEND
AXLE
AXLE
EXTEND
RETRACT
15
8
16
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
XOUT 4
BRN
1
2
7
PWR 3
GND 2
RD
BK
1
YOUT 5
XOUT 4
OR
BRN
1
11
PWR 3
GND 2
6
7
3
9
10
1
2
3
4
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C1P-6
C1P-5
C1P-4
C1P-10
C1P-11
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
C6-21
C6-22
C6-10
C6-40
C61AXRT BL
C40LS2 BK
C42LS2 GR
CR20 B
NO
C40LS1 OR
C6-13
C6-39
C6-11
C60AX OR/RD
S3LED BL/RD
C34-1
C34-2
C35-2
C25-2
C35-1
J3 WH
J1 WH
C25-1
C12-1
C16-1
C20-1
C21-1
C23-1
C22-1
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
D
A
C24-1
C42AXDP WH
J4 BK
J2 WH
WH
RD
J5 BK
C6-31
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C32BRK WH/RD C26-1
C6-32
C5-23
C14-1
C15-1
C28-1
C29MS RD/WH
OR/BK-15-M.H.
OR-14-M.H.
C23BAT RD
C8PBR BK/WH
R16PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH C17-1
C7PBE BK
C3PBF RD/WH C29-1
C2PBD RD/BK C13-1
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C4TRL WH
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
GR/BK-18-M.H.
GR-17-M.H.
2
NC
2AO
NOHC
2AS
C3P-11
C2P-4
C4P-4
C40LS1 OR
C1P-3
C5TRR WH/BK
C6TRF WH/RD
C2P-2
C3P-5
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
R2
5
LEFT
TURNTABLE ROTATE
RIGHT
C4TRL WH
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
BK
EXTEND
BOOM
RETRACT
BK/WH
BK/RD
C12DRE BL/WH
C14PLU OR
C15PLD OR/BK
DOWN
PLAT LEVEL
UP
C18JD/PRR GR/BK
C17JU/PRL GR
2
L5
OUT 5 YEL
4
OR
PWR 3
GND 2 BRN
1
BRN
P24FS WH
P26ESTP BK
C3P-12
C2P-3
C4P-2
C4P-3
C4P-5
C4P-6
1
1
C20-2
C21-2
C24-2
C22-2
GROUND
PLATFORM ROTATE RIGHT
/JIB DOWN
PLAT LEVEL DOWN
PLAT LEVEL UP
LIMIT SWITCH
DRIVE ENABLE
BOOM EXT/RET
FLOW CONTROL
PRI. BOOM RETRACT
PRI. BOOM EXTEND
PRI. BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRI. BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM RETRACT OP.
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS2AO-BOOM ANGLE OP.
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RLY
AXLE NOT EXT PRESSURE SW
OPEN WHEN AXLE FULLY EXT.
8
PLATFORM ROTATE LEFT
/JIB UP
6 - 21
S-80 • S-85
Part No. 122149
D41
P24FS WH
3
5
DOWN
PLAT LEVEL
UP
D27
DOWN
UP JIB BOOM
C6-18
C6-17
3
DESCENT ALARM
2
4
AMP
1
Deutsch
D28
DOWN
UP JIB BOOM
C6-19
5
2
S3
NC
CR8
D34
RIGHT
PLAT ROTATE
LEFT
7
4
4
3
7
U4
D57
14
13
CR38
H4
2
3
3
1
2
NC
1RO
NOHC
1RS
NOHC
LS3
BRN
2
1
4
6
3
NO
1
CR20 A
TB32
TB16
TB40
TB46
TB37
2
H3
TB42
C19JSV GR/WH
3
1
5
RIGHT
PLAT ROTATE
LEFT
C27AUX + FE RD
1
4
3
3
C4P-7
C41RPM OR/BK
P46 RD
P23 RD
4
NC
CR8
CR38
D41
D29
D37
D36
D35
5
TB4
TB1
TB8
NC
TB6
TB3
TB18
J2
CR29
NC
D15
TB7
TB15
TB5
TB2
TB9
TB14
TB17
TS62
TS61
TS63
J1
J1
J1
J1
J3
4
TS59
TS58
TS57
D38
C19JSV GR/WH
TS8
JOYSTICK CONTROL CARD
2
TS16
TS9
TS7
JIB VALVE
JIB VALVE
4
6
Joystick Adaptor Harness
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
CE Option, See 6 - 60
CR13
+
JC2
JC1
L1
CR26
NC
TS14
TS15
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
EXTEND/RETRACT
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Perkins 804-33 Models (before serial number 5520)
P134BAT RD
P26ESTP BK
1
C28TTA RD/BK
BRN
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Perkins 804-33 Models (before serial number 5520)
6 - 21
6 - 22
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Perkins 804-33 Models (after serial number 5519)
6 - 24
6 - 23
C7P-1
ENGINE SPEED
HIGH (FS)
OFF
GENERATOR
ON
DRIVE LIGHT
WORKLIGHT
WH
WH
C1-9
C2-7
C4-11/12
C1-8
C1-7
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
OPTION WIRE
BK
BK
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
RD
C7B-2
C1B-2
C3B-10
C2B-5
DLITE
C41RPM OR/BK
P46 RD
GR
GR/BK
BK/RD
C21IGN WH
BL/RD
C6-28
C6-23
C5-12
C5-18
GR/WH
FUSE 10A
C34SA
C5-22
C27AUX RD
RD
RD
J144-3
_
J144-8
C26TSR WH/RD
J144-5
C25PSR WH/BK
J144-6
J144-4
BK/WH
J144-7
WH
R33STR BK
C21IGN
C24TPS WH
B2BAT RD
RD
C5-5
C5-11
C5-15
C6-27
C5-16
C5-14
WH
C43HRN BK
RD
C6-16
R21IGN WH
C28TTA RD/BK
P134TTS RD
C6-34
BK
HOUR METER
RPM RELAY
RPM RELAY
RPM SOLENOID
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
GLOW PLUG 1 RELAY
GLOW PLUG 1
WATER TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
POWER RELAY
FUEL PUMP
FUEL SOLENOID
IGN./START RELAY
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
OIL PRESSURE
SENDER (OPT.)
VOLT METER (OPT.)
WATER TEMP
SENDER (OPT.)
TILT ALARM
LEVEL SENSOR
SERVICE HORN
RELAY
SERVICE HORN
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
ON GLOW
PLUG
ENGINE
START
AUXILIARY
PUMP
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C2P-5
P22BAT BK
C132PLI BL/WH
R116HYD OR
ADD D40 ONLY IF UNIT HAS L4 AND L48.
3
D12
P134BAT GR/BK
C6-33
FLASHING BEACONS
OPTION
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
HM
J144-1
ALTERNATOR
BATTERY
SEPARATOR (OPT.)
START BATTERY
2
SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.
1
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
TS4
C1P-12
C2B-6
RD
J144-2
C41RPM OR/BK
C6-24 P134FB RD
C5-2
C107AF WH
NC
B
CR4
CR4
NO
D52
CR3
D51
P20BAT RD
Part No. 122149
S-80 • S-85
+
6 - 24
BK
RD
8
L29
L29
S1
NO
IND.
REGULATOR
+
PR2
NO
S2
FB
G2
FUEL
PUMP
STARTER
PUMP
FAN
NO
CR23
CR23
NO
TB25
TB26
PR1
EXCT.
12 V
DC
H2
STA.
C
A
ALTERNATOR
M4
B1
BAT.
BAT.
+
7
D22
FUSE 70A
TB33A
CR3
NO
G1
CR5
NO
CR17
NO
CR1
NO
RD
20AMP.
C21IGN WH
TB24A
C5-3
P23 RD
L5
5
CR2
NO
TB21
CR39
NO
CB3
D6
TB24
D13
TB23
TB23
D42
D14
TB46
D7
TB27
D8
TB28
RD
15AMP.
TB34
TB41
C32-8
TS54
TS56
TS52
L30
L30
TB35
CB2
TB33
8
12
D2
WH
PBOX GND
7
C32
CONN.
PLUG
4
G3
6
P134BAT RD
1
OR/BK
RD
RD
RD
6
H1
TS48
TS49
TS1
TS47
FUSE 10A
C2P-6
GRD
3
L48
+
TS51
5
4
PLAT
3
1
TB22
KS1
D40
2
TB134
P3
HORN
CE Option, See 6 - 60
P24FS WH
BK
F18
RD
P26ESTP BK
P26ESTP BK
P26ESTP BK
TS6
TS2
2
P24FS WH
FS1
P25FS RD
BK
P25FS RD
C9P-1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./
5 GROUND
START
6 BATTERY
MODULE
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
RD
15AMP.
RD
P1
CB1
3
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Perkins 804-33 Models (after serial number 5519)
C28TTA RD/BK
P2
C27AUX RD
B2BAT RD
BRN
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
6
4
12
13
14
8
7
6
10
9
11
20
19
16
15
17
18
1
4
RETRACT
EXTEND
AXLE
EXTEND
RETRACT
15
8
16
5
13
5
3 BL/WH
4 WH/RD
14
BL/WH
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
RKOUT
XOUT
YOUT
OR
3
12
11
1
2
BRN
1
PWR
2
GND
6
5
YOUT 4 RD/WH
XOUT 3 WH/RD
OR
BRN
PWR 2
GND 1
6
3
5
OUT 4 WH/BK
9
10
1
2
3
4
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
R2
5
C6-21
C6-22
C6-10
C6-40
LEFT
TURNTABLE ROTATE
RIGHT
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
C2P-2
C1P-11
C1P-10
C1P-5
C1P-4
C1P-6
C1P-3
C3P-6
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
BK
EXTEND
BOOM
RETRACT
BK/WH
BK/RD
C12DRE BL/WH
C14PLU OR
C15PLD OR/BK
DOWN
PLAT LEVEL
UP
C18JD/PRR GR/BK
C17JU/PRL GR
D28
DOWN
UP JIB BOOM
C42LS2 GR
C61AXRT BL
C40LS2 BK
C40LS1 OR
C60AX OR/RD
S3LED BL/RD
C34-1
C6-13
C6-39
C35-1
C34-2
C35-2
C25-2
C42AXDP WH
J3 WH
J1 WH
C25-1
C12-1
C16-1
C20-1
C21-1
C23-1
C22-1
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
D
A
C24-1
C6-11
J4 BK
J2 WH
RD
J5 BK
C6-31
WH
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C32BRK WH/RD C26-1
C6-32
C5-23
C14-1
C15-1
C28-1
C29MS RD/WH
GR-17-M.H.
GR/BK-18-M.H.
OR/BK-15-M.H.
OR-14-M.H.
C23BAT RD
C8PBR BK/WH
R16PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH C17-1
C7PBE BK
C3PBF RD/WH C29-1
C2PBD RD/BK C13-1
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C4TRL WH
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
C6-18
C6-17
C6-19
U4
C20-2
C21-2
C24-2
C22-2
GROUND
PLATFORM ROTATE LEFT
/JIB UP
PLATFORM ROTATE RIGHT
/JIB DOWN
PLAT LEVEL DOWN
PLAT LEVEL UP
LIMIT SWITCH
DRIVE ENABLE
BOOM EXT/RET
FLOW CONTROL
PRI. BOOM RETRACT
PRI. BOOM EXTEND
PRI. BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRI. BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM RETRACT OP.
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS2AO-BOOM ANGLE OP.
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RLY
AXLE NOT EXT PRESSURE SW
OPEN WHEN AXLE FULLY EXT.
8
DESCENT ALARM
6 - 25
S-80 • S-85
2
NC
2AO
NOHC
2AS
L5
OR
PWR 2
GND 1 BRN
BRN
P24FS WH
P26ESTP BK
C3P-12
C2P-3
C4P-2
C4P-3
C4P-6
C4P-5
D34
RIGHT
PLAT ROTATE
LEFT
1
2
7
S3
NC
CR8
Part No. 122149
4
1
3
4
2
NC
1RO
2
1
3
3
2
H3
TB42
C19JSV GR/WH
2
1
D57
14
13
CR38
H4
6
3
CR20 B
NO
1
CR38
D41
D29
NC
CR8
4
4
CR20 A
TB32
1
4
3
3
5
DOWN
PLAT LEVEL
UP
D27
3
C4P-7
C27AUX + FE RD
TB16
TB40
TB46
TB37
NOHC
1RS
NOHC
LS3
BRN
DOWN
UP JIB BOOM
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
C41RPM OR/BK
P46 RD
P23 RD
NO
TB3
D37
D36
D35
5
TB4
TB1
TB8
NC
TB6
TB9
TB18
J2
CR29
NC
D15
TB7
TB15
TB5
TB2
TB14
TB17
TS62
TS61
TS63
J1
J1
J1
J1
4
TS59
TS58
TS57
D38
C19JSV GR/WH
TS8
J3
2
TS16
TS9
TS7
JOYSTICK CONTROL CARD
D41
P24FS WH
CE Option, See 6 - 60
CR13
+
JC2
JC1
L1
CR26
NC
TS14
TS15
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
EXTEND/RETRACT
WH
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Perkins 804-33 Models (after serial number 5519)
1
C28TTA RD/BK
P134BAT RD
P26ESTP BK
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Perkins 804-33 Models (after serial number 5519)
6 - 25
6 - 26
February 2012
Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models
6 - 28
6 - 27
Section 6 • Schematics
February 2012
Ground Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models
A
B
C
D
E
F
G
H
I
C23
RD H6
BL/WH C1-12
BK-22D2
L
5
6
7
8
12
P1
H6
CE ONLY
DRIVE LIGHT OPTION RELAY
VOLT METER
PLAT. LEVEL. UP
PLAT. LEVEL DN.
AXLE DUMP VALVE
PLAT. ROT. L.
PLAT. ROT. R.
12V BATT. SUPPLY
IGNITION PWR.
HORN
KEYSWITCH PWR/PWR TO PLAT
FUSED 12V
OIL COOLER FAN
AUX PUMP
BRAKE
START ENG
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
L.P.
LIMIT SW #1
ENG RPM
LIMIT SW #2
LIMIT SW PWR
KS POWER
KS POWER
B
1 RD CR38#86
RD/BK CR8#30
2 D15
3
4
5
6
D57
7 CR8#86+
GND STUD
8 BK/WH C6-38
9
10
11
OR C4B-2
OR C6-14
14
OR/BK C4B-3
OR/BK C6-15
D42 15
OR/RD CR20A#86 OR/RD CR38#87A
16 OR/RD CR8#87A
GR C6-17
GR C4B-5
17
GR/BK C6-18
GR/BK C4B-6
18
20
RD-B1-H1
RD-B1-H1
WH C5-3
WH CR3#86
21 WH CR17 #86
22 BK CR5#30
BK C23-4
RD C6-30
WH C7B-2
23 WH ISM#7
RD ISM#6
RD CR1#30
24 RD CR2#30
24A RD CR17#30 D6
RD CR39#86&C1B-1
27 RDISM#4
WH/RD C1B-6
WH/RD C5-23
32 WH/RD C6-32
BK C1B-7
33 BK ISM#3
BK C5-5
33A BK-CR1#87
34
BK/WH C1B-8
BK/RD C1B-9
35 BK/RD CR3#30
BL/BK C1B-11
37 BL/BK C6-20
BL/BK C6-37
38
BL/RD C2B-1
39
OR C2B-2
OR C6-40
40 OR C6-10
41 OR/BK ISM#2
OR/BK C2B-3
OR/BK C5-2
42 OR/RD C6-22
OR/RD C4B-4
OR/RD CR29#86
D7
RD C6-31
46B
RD C2B-6
RD C6-23
134 RD-H6
RD C6-24
134A
C
RD C6-1
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
5
G1
H1
C7B
12V TO PLAT
BK CR1#86
OR/BK-41B
BK-33B
RD-27B
BRN GND
RD-24D
WH-23B
BRN-GND STUD
3
BK-C23-5
1
WH-23D
2
1
2
3
4
5
6
7
8
9
10
WH-CR2#86
WH L2
RD-B1-20C
RD-B1-20D
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
DIESEL ENGINE: C2-1 BL/RD
C4B
C3B
CR38
AUXILIARY PUMP
TS51
KSI
P1
B
NC
D2
NC
3
E-STOP
RD-134A
1
B1
2
4
RD/WH-3A
RD/BK-2A
BK-S.P.
D51
BK/WH-S.P.
BK/RD-S.P.
GR/BK-H6
PLATFORM
OVERLOAD
LED L45
CHECK ENG +
LED L2
-
WH ISM #10
WH C5-15
+
-
BK-7A
D8
RD-KSI-SP
BK/WH-8A
WH-21A
+
G6
HOUR METER
TS61
BK/RD-9A
RD-C23-7
BK-33
TS52
TS56
CB3
BK/WH-34A
RD-24AA
OR/BK-15A
RD-B2-H1
BK/RD-35A
BK-22B
BK C6-16
GLOW PLUG SW
START
OIL COOLER/
OPTION
C1B
C2B
OR/RD 16C
BK 7B
BL/RD C6-13
C6
FUNCTIONS
86
CR3
BK/RD-35B
RD-27D
JIB
TURNTABLE
ROTATE
ENGINE
C5
GROUND STUD
TB16D OR/RD
OR C6-33
CR20A
WH-21B
86
RD-24AB
PLATFORM LEVEL SWITCH
TS61
PRIMARY BOOM UP/DOWN SWITCH
TS62
TURNTABLE ROTATE SWITCH
TS63
PRIMARY BOOM EXTEND/RETRACT SWITCH
CB1
CIRCUIT BREAKER, ENGINE, 15A
CB2
CIRCUIT BREAKER, CONTROLS, 15A
CB3
CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
G6
HOUR METER
G1
VOLT METER GAUGE (OPT.)
G2
OIL PRESSURE GAUGE (OPT.)
G3
WATER TEMP. GAUGE (OPT.)
L2
CHECK ENGINE LED
L45
PLATFORM OVERLOAD LED
CR1
IGNITION / START RELAY
CR2
IGNITION POWER RELAY
CR3
HIGH IDLE CUTOUT RELAY
CR5
SERVICE HORN RELAY
CR8
BOOM FUNCTION CUTOUT
CR17
HYDRAULIC COOLER FAN RELAY
CR20A
LOW VOLTAGE DROP RELAY
CR20B
LOW VOLTAGE DROP RELAY
CR23
DRIVE LIGHT RELAY OPTION
CR25
AXLE RET L/O RELAY
CR29
AXLE EXTEND LED RELAY
CR38
EXTEND FUNCTION CUTOUT
CR39
AUXILARY PUMP RELAY
R2
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
U1
IGNITION/START MODULE
U33
PLATFORM OVERLOAD MODULE
WH/RD C5-16
WH/RD-S.P
26 WATER TEMP SENDER
WH/BK C5-14
WH/BK-S.P.
28 TILT ALARM
RD/BK C1B-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
RD-B1-20A
30 E.D.C. FWD
WH C1B-4
WH C5-21
OR-14A
GR-17A
GR/WH C4B-7
GR/BK-18A
31 E.D.C. REV
WH/BK C5-20
WH/BK C1B-5
36 STEER LEFT/AXLE RETRACT
BL C1B-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GEN. OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXT/RET SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
OR/RD C6-11
S-80 • S-85
TS59
25 OIL PRESSEURE SENDER
WH-C6-34
CR20B
JIB UP/DOWN (JIB OPTION ONLY)
BL/WH C3B-12
CB1
CB2
TS57
D42
ENGINE
CONTROLS
PLAT.
LEVEL
PLATFORM
ROTATE
WH/RD-6A
CR17
PLATFORM ROTATE SWITCH
TS58
GR/WH-S.P.
WH-4A
WH/BK-5A
ALL BRN WIRES
86
FUNCTION ENABLE SWITCH
TS57
GR/WH C4B-7
TS59
OR/RD 16B
86
TS54
19 JIB VALVE
D13
BL/RD C4B-1
RD/BK 2B
TB134A-A
GLOW PLUG SWITCH (DIESEL ONLY)
FROM
OR/RD 42B
GROUND STUD
START ENGINE SWITCH
TS56
BL/WH C6-12
RD-24A
WH-21C
86
86
TS52
CIRCUIT DESCRIPTION
HIGH/LOW
RPM
TS54
BK/RD C5-18
CR39
CR29
86
KEY SWITCH
AUXILIARY SWITCH
TS62
TS58
RD C6-27
CR8
KS1
TS51
12 DRIVE ENABLE
D14
WH C5-11
BOOM
UP/DOWN
BOOM EXTEND/
RETRACT
RD-1A
86
TB33AB
TS63
BK/WH C6-29
GR C2B-5
CR5
DESCRIPTION
EMERGENCY STOP BUTTON
RD-27A
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
IGN./START
MODULE
BATTERY
KEY PWR.
KEY BYPASS
U1
IGN./FUEL ON
ENG. FAULT
86
RD C4B-12
KEYSWITCH
6
86
G3
RD C23-6
WH-23A
BK-22A
RD-1B
CR2
(SPARE WIRE)
OPTION WIRE TO PBOX
WH/RD C5-16
OR-S.P.
OR/BK-S.P.
D34
GR-S.P.
GR/BK-S.P.
RD-B1-S.P.
WH S.P.
BK-S.P.
WH-S.P.-D2
RD-S.P.-CB1
RD-S.P.-CB3
RD-S.P.
RD-B2-S.P.
86
G2
WH/BK C5-14
RD-24C
CR1
TB24AD
BRN GND
BRN(GND)
7
10 AMP FUSE
WATER TEMP.
RD C4B-11
A
RD-S.P.
RD/BK-S.P.
RD/WH-S.P.
WH-S.P.
WH/BK-S.P.
WH/RD-S.P.
BK-S.P.
BK/WH-S.P.
BK/RD-S.P.
BASE TERMINATION BLOCK
19/18 CABLES
OIL PRESSURE
CR23
D
RD C3B-1
RD/BK C6-19
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
PRI. BOOM UP
PRI. BOOM DOWN
PRI. BOOM F.C.
TURN. ROT. L
TURN. ROT. R
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
EXT./RET. F.C.
4
P134PWR RD-134B
GR/BK-C3B-10
GR/BK-L45
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
2
3
LABEL
+
1
3
4
6 - 28
K
NOTE: CE OPTION- LOADSENSE
MODULE CONNECTS TO C32.
1
8
J
Part No. 122149
R2
TO
M
N
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models (before serial number 5520)
6 - 30
6 - 29
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models (before serial number 5520)
A
B
C
D
E
F
G
H
I
J
K
L
1
M
N
COMPONENT INDEX
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
2
U13
ALC-500
P2
P3
TS1
TS2
TS4
TS6
3
J3
D12
1
TS7
TS8
TS9
GND STUD
J2
J1
11
9
TS14
TS15
TS16
TS47
TS48
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
HI-C133PLA GN/BL C3P-10
TS16-C61AX BL/BK C3P11
TS47-C45GEN GR/WH C2P-7
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
3
DRIVE LIGHT TOGGLE SWITCH (OPTION)
PLATFORM OVERLOAD LIMIT SWITCH
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
AXLE EXTENDED LED
TILT ALARM LED
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
U13 ALC500
CR13 JIB BOOM CUTOUT RELAY
CR26 AXLE CUTOUT RELAY
TILT ALARM
H1
CR13 BRN
GR/WH C4P-7
GR/WH TS7
RD/BK JIB CABLE
C2P-9 & 10
GND
C4P(BR)
GND STUD
C3P(GR)
BRN
C2P(BK)
C1P(GY)
5
WORK LIGHT TOGGLE SWITCH (OPTION)
JC2
JC1
BATGND C7P-3
H1
TILT
ALARM
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
AXLE EXTEND/RETRACT TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
LS18
L1
L4
JC3
D40
D39
PLATFORM LEVEL TOGGLE SWITCH
TS49
L40
L48
C28TTA RD/BK C1P-2
4
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START SWITCH
HIGH RPM SWITCH
GLOW PLUG OPTION
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
CE LIFT/DRIVE OPTION
BK LS CABLE CIP-12
19/18 CONTROL CABLE
JIB
C7P
C9
12V DC
BATTERY
FOOT SWITCH
LS18
REPLACE WIRE WITH THIS WIRING DIAGRAM
OPT.
(OPTION)
RD-H1
RD-P2
RD LS CABLE
BRN BATGND
GND STUD
CR27
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR/RD R40LS2
(SPLICE TO R40LS2)
+
+
3
-
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
GN/BK H1 (D39)
BRN J1-14
OR J1-13
WH-TS1
4
L48
2
D12
JC3
DRIVE
1
1
DETAIL B: GENERATOR OPTION
TS9
PLATFORM
LEVEL
RD WL2
L1
TS15
TS1
AUXILIARY
PUMP
S-80 • S-85
RD WL1
L4
TS8
JIB BOOM
GR/WH C2P-7
TS7
PLATFORM
ROTATE
+
+
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
TS14
DRIVE
SPEED
TS6
GLOW PLUG
OPTION
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
BK
NC
TS48/TS49
TS2
P2
EMERGENCY
STOP
CE MODELS (SEE DETAIL A)
6 - 30
WH J1-5
TS15
DRIVE
ENABLE
P3
HORN
BL J1-4
2
CR26
AXLE CUTOUT
WH J3-2
5
NO
8
RD/BK H1
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
1
BL/WH J1-6
6
5
-
-
L40
BK/WH C1P-8
6
+
+
2
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
7
3
3
7
7
4
4
BL/BK J1-7
TS16
RD/WH J1-8
D2
BRN J1-10
JC1
BOOM
EXTEND/
RETRACT
JIB
CUTOUT
5
OR J1-9
YEL J1-3
RD C1P-1
6
GR/BK C4P-6
7
GR C4P-5
GR/WH JIB CABLE
CR13
J2-DIODE WH
BRN
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
6
AXLE
EX/RET
WH-TS7
Part No. 122149
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models (after serial number 5519)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
COMPONENT INDEX
PLATFORM CONTROL BOX
BK P2
D12
WH TS4
WH C9-2
WH CR26#85
BL TS16
JC3-4 BL(2)
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-3 OR
JC3-6 BL(1)
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD LS18
RD C2P-6
U13
ALC-500
3
J3
D12
1
GND STUD
J2
J1
11
9
CC132PLI BL/WH C3P-12
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
C133PLA BL C3P-10
TS16-C61AX BL/BK C3P11
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
TS47-C45GEN GR/WH C2P-7
C134PWR GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
TS3-C39LP BL/RD C2P-1
C40LS1 OR C2P-2
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-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
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
RD/BK H1
C28TTA RD/BK C1P-2
BATGND C7P-3
C4P(BR)
GLOW PLUG
TS4
HIGH RPM SWITCH
TS7
PLATFORM ROTATE SWITCH
TS8
JIB UP/DOWN (JIB OPTION ONLY)
TS9
PLATFORM LEVEL SWITCH
TS14
DRIVE SPEED LOW/HIGH SWITCH
2
DRIVE ENABLE SWITCH
TS16
AXLE EXT/RET SWITCH
TS47
GENERATOR SWITCH ( OPTION )
TS48
WORK LIGHT RELAY (OPTION)
TS48
DRIVE LIGHT RELAY (OPTION)
L1
DRIVE ENABLE LED
L4
PLATFORM OVERLOAD LED (OPTION)
3
AXLE EXTENDED LED
JC3
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC1
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
JC2
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
CR13
JIB CUTOUT RELAY ( JIB ONLY )
U13
ALC500
H1
TILT ALARM
4
LS18
PLATFORM OVERLOAD LIMIT SWITCH
L48
TILT ALARM LED
GR/WH TS7
BRN BATGND
JIB
C9
LS18
OPT.
(GND STUD)
RD-H1
RD LS CABLE
F.S.
12V BATT
19/18 CONTROL CABLE
OPT.
Y
C7P
Y
GND STUD
START ENGINE SWITCH
TS6
BK LS CABLE CIP-12
BRN
H1
TS2
GR/WH C2P-7
C3P(GR)
C2P(BK)
C1P(GY)
GND
Y
BK JIB CABLE
C2P-9 & 10
Y
GR/WH C4P-7
CR13 BRN
HORN SWITCH
AUXILIARY SWITCH
L40
D40
D39
P3
TS1
TS15
1
1
EMERGENCY STOP BUTTON
P2
RD-P2
CR27
WH TS7
TILT ALARM
WH/RD C32BRK
CR30
JC3-1
JC3-2
6
DETAIL A: LIFT/DRIVE OPTION
+
L48
JC1
RD WL1
+
DRIVE/STEER
+
TS48
7
+
L4
L1
TS7
TS8
JIB
TS48 PIN2
E-STOP BK
TS4
NO
BK
DETAIL C: WORKLIGHT OPTION
DRIVELIGHT OPTION
NC
TS1
TS6
AUX. PUMP
TS14
D27
OPTION WIRE TO GBOX
TS49
2
F18 10A
PLATFORM
ROTATE
PLATFORM
LEVEL
(SPARE WIRE)
RD WL2
TT ROTATE
HORN
DETAIL B:
GENERATOR OPTION
(SPLICE TO
R40LS2)
JC3
P3
TS47
REPLACE WIRE WITH THIS WIRING DIAGRAM
AXLE CUTOUT
TS9
TS2 RD
(SPLICE TO
C32BRK)
OR/RD R40LS2
D12
TS15
DRV.ENA
RD LS18
BK C7P-1
BK C9-1
WH C7P-2
BK J3-3
GN/BK H1 (D39)
J1-14 BRN
J1-5 BL/WH JC3-3
J1-13 OR
J1-5 BL/WH JC3-5
J1-4 WH/RD JC3-4
WH J3-2
RD/BK H1
BK/RD C1P-9
RD C9-3
BK C1P-7
BK/WH C1P-8
BL/WH J1-6
BL/BK J1-7
RD/WH J1-8
JC1-1
TS16
L40
J1-10 BRN
BOOM
EXT/RET
CR26
JC2
J1-3 WH/BK JC1-4
D2
UP/DOWN
J1-9 OR JC1-2
JIB
CUTOUT
PRI. BOOM
RD C1P-1
GR C4P-5
GR/BK C4P-6
J2-DIODE WH
JC2-1
JC2-2
CR13
GR/WH JIB CABLE
GND BRN
OR/RD C2P-4
BL/BK C3P-11
BL C1P-10
BL/RD C4P-1
J1-11 OR
J1-12 BRN
J1-2 RD/WH JC2-4
J1-1 WH/RD JC2-3
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
5
WH TS1
DRIVE
SPEED
GLOW PLUG
TS2
START
BK
RD
HIGH/LOW RPM
RD
8
RD
P2
E- STOP
CE SEE DETAIL A
Part No. 122149
S-80 • S-85
6 - 31
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Perkins 804-33 Models (after serial number 5519)
6 - 31
6 - 32
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Continental TME27 Models (before serial number 5520)
6 - 34
6 - 33
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (before serial number 5520)
A
1
B
C
D
E
F
G
H
I
J
K
L
M
N
P134BAT RD
RD/BK
P26ESTP BK
BK
BK
FS1
P2
C9P-1
FUSE 10A
C9P-3
P25FS RD
C9P-2
P24FS WH
WH
RD
ENGINE SPEED
C1-9
C35RPM BK/RD
TB39
D14
TB46
D7
P23BAT
P20BAT RD
TB28
C6-28
C6-23
GR/BK
GR/BK
CB3
C27AUX RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C1B-2
TB33
C45GEN GR/WH
OPTION WIRE
PBOX GND
TB27
RD
HIGH (FS)
C2-7
C4-11/12
DRIVE LIGHT
WORK LIGHT
BK
TS54
OR/BK
RD
RD
RD
TB23
RD
20AMP.
WH
D11
BK
TS53
TB41
D2
RD
TB20
L30
C39LP BL/RD
C33STR BK
C27AUX RD
TS52
RD
C7B-2
WH
C3B-10
RD
C2B-5
BK
WH
8
TS51
P23BAT WH
7
CONN.
PLUG
12
5
WH
C2-1
C1-7
C1-1
C7P-2
6
CB2
15AMP.
C1P-2
5
C32
4
D12
WH
C28TTA RD/BK
GRD
5
C133PLA BL
4
B
3
D40
3
1
TB22
PLAT
L48
C46HRN GR
4
1
6
TS4
TS48
TS49
TS1
D10
H1
C3P-10
TB134
TS47
TS3
P3
HORN
C2P-5
RD
B1
RD
C7B-1
RD
BL/WH
2
P1
15AMP.
C1B-12
KS1
CB1
P22BAT BK
P134BAT GR/BK
C132PLI BL/WH
C2B-6
3
D43
C7P-1
CE Option, See 6 - 60
C1P-12
C2P-6
2
TS2
D42
D13
TB35
TB24
CR39A
NO
CR2
NO
CR39B
NC
CR1
NO
C41RPM OR/BK
P46 RD
D8
TB21
TB21
C21IGN WH
P23 RD
TB24A
C21IGN WH
RD
C5-8
C5-13
C5-11
C5-14
C5-19
C5-10
12
9
10
3
C38RET-BL
C38FP-BL/WH
C127TSW-GN
C108ESL-BL/WH
E21IGN-WH
2
C26TSR-GN/BK
C35RPM-BK/RD
VSW-RD
C41RPM-OR/BK
C39LP-BL/RD
R33STR-BK
C128RPM-OR/RD
1
L2
R1
TS64
4
PUMP
RD
RD
C25PSR BL/BK
VEHICLE INTERFACE 1
CONTINENTAL TME27 ENGINE
CR23
CR23
NO
GR/WH
11
HM
_
C5-12
8
G1
FUSE 10A
6
G3
C5-16
7
1K
BK-12GA
STARTER
+
-
M3
GENERATOR
OPTION
DRIVE LIGHT &
WORK LIGHTS
OPTION
HOUR METER
FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13
VOLT METER
(OPT.)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
7
OIL PRESSURE
SENDER &
GAUGE (OPT.)
ADD D40 ONLY IF UNIT HAS L4 AND L48.
6
WATER TEMP
GAUGE (OPT.)
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
5
CHECK ENGINE LED
FUEL PUMP
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
2
TEST SWITCH
Part No. 122149
L29
BRN
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
LEVEL SENSOR
TILT ALARM
SERVICE HORN
RELAY
SERVICE HORN
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
FLASHING BEACONS
OPTION
ALTERNATOR
START BATTERY
S-80 • S-85
C5-2
AUX
PUMP
B
REGULATOR IND.
6 - 34
5
G2
HARNESS
H2
AUX
FAN
BK
STA.
C5-18
C5-5
NO
RD-12GA
WH-14GA
WH
RD
PR1
FB
8
C5-9
C
BAT.
-
7
B1
+
C27AUX RD
A
C6-27
C28TTA RD/BK
P134TTS RD
C43HRN BK
BAT.
+
C6-16
EXCT.
12 V
DC
R21IGN WH
ALTERNATOR
CR5
NO
C6-34
RD
R116HYD OR
P134FB RD
GND BR
C6-33
C6-24
510
R16
RD
C21IGN WH
C5-3
6
CR17
NO
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
YOUT 5
RKOUT 6
OR
BL
WH
BL
14
5
13
4
7
6
12
12
13
14
8
7
6
10
9
11
20
19
16
15
17
18
1
4
RETRACT
EXTEND
AXLE
EXTEND
RETRACT
15
8
16
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
XOUT 4
BRN
1
2
7
PWR 3
GND 2
RD
BK
1
YOUT 5
XOUT 4
OR
BRN
1
11
PWR 3
GND 2
6
7
3
9
10
1
2
3
4
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C40LS OR/RD
C60AX OR/RD
C3P-11
C2P-4
C4P-4
C40LS1 OR
C1P-3
C1P-6
C1P-5
C1P-4
C1P-10
C1P-11
C5TRR WH/BK
C6TRF WH/RD
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
C2P-2
C3P-5
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
R2
5
C6-21
C6-22
C6-10
C6-40
LEFT
TURNTABLE ROTATE
RIGHT
C4TRL WH
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
BK
EXTEND
BOOM
RETRACT
BK/WH
BK/RD
C12DRE BL/WH
C14PLU OR
C15PLD OR/BK
DOWN
PLAT LEVEL
UP
C18JD/PRR GR/BK
C17JU/PRL GR
C61AXRT BL
C40LS2 BK
C42LS2 GR
CR20 B
NO
C40LS1 OR
C6-13
C6-39
C6-11
C60AX OR/RD
S3LED BL/RD
C34-1
C34-2
C35-2
C25-2
C12-1
C16-1
C20-1
C21-1
C23-1
C22-1
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C25-1
D
A
C24-2
C35-1
J3 WH
J1 WH
7
U4
C24-1
C42AXDP WH
J4 BK
J2 WH
WH
RD
J5 BK
C6-31
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C32BRK WH/RD C26-1
C6-32
C5-23
C14-1
C15-1
C28-1
C29MS RD/WH
OR/BK-15-M.H.
OR-14-M.H.
C23BAT RD
C8PBR BK/WH
R16PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH C17-1
C7PBE BK
C3PBF RD/WH C29-1
C2PBD RD/BK C13-1
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C4TRL WH
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
GR/BK-18-M.H.
GR-17-M.H.
2
NC
2AO
NOHC
2AS
L5
OUT 5 YEL
4
OR
PWR 3
GND 2 BRN
1
BRN
P24FS WH
P26ESTP BK
C3P-12
C2P-3
C4P-2
C4P-3
C4P-5
C4P-6
1
2
C20-2
C21-2
C24-2
C22-2
GROUND
PLATFORM ROTATE RIGHT
/JIB DOWN
PLAT LEVEL DOWN
PLAT LEVEL UP
LIMIT SWITCH
DRIVE ENABLE
BOOM EXT/RET
FLOW CONTROL
PRI. BOOM RETRACT
PRI. BOOM EXTEND
PRI. BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRI. BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM RETRACT OP.
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS2AO-BOOM ANGLE OP.
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RLY
AXLE NOT EXT PRESSURE SW
OPEN WHEN AXLE FULLY EXT.
8
PLATFORM ROTATE LEFT
/JIB UP
6 - 35
S-80 • S-85
Part No. 122149
D41
P24FS WH
3
5
DOWN
PLAT LEVEL
UP
D27
DOWN
UP JIB BOOM
C6-18
C6-17
3
DESCENT ALARM
2
4
AMP
1
Deutsch
D28
DOWN
UP JIB BOOM
C6-19
5
2
S3
NC
CR8
D34
RIGHT
PLAT ROTATE
LEFT
7
4
1
3
4
2
NC
1RO
2
1
3
3
2
H3
NOHC
1RS
NOHC
LS3
BRN
2
1
D57
14
13
CR38
H4
6
3
CR20 A
TB32
TB16
TB40
TB46
TB37
1
4
CR38
D41
D29
NC
CR8
TB42
C19JSV GR/WH
3
1
5
RIGHT
PLAT ROTATE
LEFT
C27AUX + FE RD
1
4
3
3
C4P-7
C41RPM OR/BK
P46 RD
P23 RD
4
NC
TB3
D36
5
TB4
TB1
TB8
D37
D35
NO
TB6
TB18
J2
CR29
NC
D15
TB7
TB15
TB5
TB2
TB9
TB14
TB17
TS62
TS61
TS63
J1
J1
J1
J1
J3
4
TS59
TS58
TS57
D38
C19JSV GR/WH
TS8
TS7
JOYSTICK CONTROL CARD
2
TS16
TS9
JIB VALVE
JIB VALVE
4
6
Joystick Adaptor Harness
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
CE Option, See 6 - 60
CR13
+
JC2
JC1
L1
CR26
NC
TS14
TS15
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
EXTEND/RETRACT
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (before serial number 5520)
P134BAT RD
P26ESTP BK
1
C28TTA RD/BK
BRN
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (before serial number 5520)
6 - 35
6 - 36
February 2012
Section 6 • Schematics
Electrical Schematic, S-80/85
Continental TME27 Models (after serial number 5519)
6 - 38
6 - 37
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (after serial number 5519)
A
1
B
C
D
E
F
G
H
I
J
K
L
M
N
P134BAT RD
RD/BK
P26ESTP BK
BK
FS1
P2
C9P-1
2
BK
FUSE 10A
C9P-3
P25FS RD
C9P-2
P24FS WH
WH
RD
C1P-12
C2P-6
C1-9
TB39
P20BAT RD
TB28
C6-28
C6-23
GR/BK
GR/BK
CB3
C35RPM BK/RD
D2
RD
C27AUX RD
LOW RPM
FUNC. ENABLE
HIGH RPM
TB33
C45GEN GR/WH
OPTION WIRE
PBOX GND
OR/BK
RD
RD
RD
TB23
TB27
RD
HIGH (FS)
ENGINE SPEED
C2-7
C4-11/12
DRIVE LIGHT
WORK LIGHT
BK
TS54
TB41
RD
20AMP.
WH
D11
BK
TS53
D14
TB46
D7
P23BAT
TB20
L30
C39LP BL/RD
C33STR BK
TS52
RD
C7B-2
WH
C1B-2
C2B-5
RD
C3B-10
BK
WH
8
CB2
C27AUX RD
7
CONN.
PLUG
TS51
P23BAT WH
6
12
5
WH
C2-1
C1-7
C1-1
5
C32
15AMP.
C7P-2
GRD
D12
WH
C28TTA RD/BK
3
5
C133PLA BL
4
B
4
D40
3
1
TB22
PLAT
C46HRN GR
4
1
L48
C1P-2
TB134
6
TS4
TS48
TS49
TS1
D10
H1
C3P-10
RD
B1
RD
TS47
TS3
P3
HORN
C2P-5
RD
C7B-1
P1
15AMP.
BL/WH
2
C1B-12
KS1
CB1
P22BAT BK
P134BAT GR/BK
C132PLI BL/WH
C2B-6
3
D43
C7P-1
CE Option, See 6 - 60
TS2
D42
D13
TB35
TB24
CR39A
NO
CR2
NO
CR39B
NC
CR1
NO
C41RPM OR/BK
P46 RD
D8
TB21
TB21
C21IGN WH
P23 RD
TB24A
C21IGN WH
RD
C5-8
C5-13
C5-11
C5-14
C5-19
C5-10
C5-2
12
9
10
3
C38RET-BL
C38FP-BL/WH
C127TSW-GN
C108ESL-BL/WH
E21IGN-WH
2
C26TSR-GN/BK
C35RPM-BK/RD
VSW-RD
C41RPM-OR/BK
C39LP-BL/RD
R33STR-BK
C128RPM-OR/RD
1
L2
R1
TS64
4
PUMP
RD
RD
C25PSR BL/BK
VEHICLE INTERFACE 1
CONTINENTAL TME27 ENGINE
CR23
CR23
NO
GR/WH
11
HM
_
C5-12
8
G1
FUSE 10A
6
G3
C5-16
7
1K
BK-12GA
STARTER
+
-
M3
GENERATOR
OPTION
DRIVE LIGHT &
WORK LIGHTS
OPTION
HOUR METER
FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13
VOLT METER
(OPT.)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
7
OIL PRESSURE
SENDER &
GAUGE (OPT.)
ADD D40 ONLY IF UNIT HAS L4 AND L48.
6
WATER TEMP
GAUGE (OPT.)
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
5
CHECK ENGINE LED
FUEL PUMP
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
2
TEST SWITCH
Part No. 122149
L29
BRN
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER
RELAY
TILT ALARM
LEVEL SENSOR
SERVICE HORN
SERVICE HORN
RELAY
HYD. OIL TEMP.
SWITCH (OPT.)
HYD. COOLING
FAN (OPT.)
FLASHING BEACONS
OPTION
ALTERNATOR
START BATTERY
S-80 • S-85
C5-18
C5-5
BK
AUX
PUMP
B
REGULATOR IND.
6 - 38
5
G2
HARNESS
H2
AUX
FAN
FB
8
C5-9
NO
RD-12GA
WH-14GA
RD
PR1
BAT.
STA.
B1
+
C27AUX RD
C
WH
C43HRN BK
A
C6-27
C28TTA RD/BK
P134TTS RD
C6-16
BAT.
+
R21IGN WH
7
CR5
NO
C6-34
EXCT.
12 V
DC
R116HYD OR
RD
ALTERNATOR
CR17
NO
C6-33
C6-24
P134FB RD
GND BR
510
R16
RD
C21IGN WH
C5-3
6
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
EXTEND
14
AXLE
4
1
18
17
15
16
20
19
9
11
10
6
8
7
14
13
12
C4P-4
C3P-11
C2P-4
C4P-1
C7-3
C40LS1 OR
C40LS OR/RD
C61AX BL/BK
C60AX OR/RD
S3LED BL/RD
BRN
D28
JIB
BK/WH
BK/RD
C61AXRT BL
C40LS1 OR
C40LS2 BK
C6-21
NO
C42LS2 GR
CR20 B
C6-22
C6-10
C6-40
TURN TABLE ROTATE
5
R2
PRIMARY BOOM
C8PBR BK/WH
BOOM
C7PBBE BK
UP
DOWN
DOWN
C17JU/PRL GR
C18JD/PRR GR/BK
PLATFORM LEVEL
C15PLD OR/BK
C14PLU OR
C12DRE BL/WH
RETRACT
EXTEND
BK
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
RIGHT
LEFT
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
C2P-2
C1P-11
C1P-10
C1P-5
C1P-4
C1P-6
C1P-3
C3P-5
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C3P-12
C2P-3
D34
RIGHT
PLAT ROTATE
LEFT
UP
CR29
NC
NO
C42AXDP WH
C35-1
S3LED BL/RD
C6-11
J3 WH
J2 WH
J1 WH
C21-1
C23-1
C22-1
C35-2
C34-2
C20-2
C21-2
C24-2
C22-2
GROUND
AXLE NOT EXT
PRESSURE SW
OPEN WHEN
AXLE FULLY EXT.
AXLE EXTEND RLY
AXLE DUMP RELAY
AXLE DUMP VALVE
AXLE EXT/RET
SELECT
JIB VALVES
DESCENT ALARM
PLATFORM ROTATE LEFT
/JIB UP
PLATFORM ROTATE RIGHT
/JIB DOWN
PLAT LEVEL DOWN
PLAT LEVEL UP
DRIVE ENABLE
LIMIT SWITCH
BOOM EXT/RET
FLOW CONTROL
PRI. BOOM RETRACT
PRI. BOOM EXTEND
PRI. BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRI. BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM
RETRACT OP.
DRIVE/ROTATE
SPD. LIMIT SWITCH
LS2AO BOOM
ANGLE OP.
DRIVE LIMIT SWITCH
8
LS2AS BOOM
ANGLE SAFETY
DRIVE LIMIT SWITCH
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C25-2
C15-1
C28-1
C26-1
D
A
C25-1
C34-1
J4 BK
J5 BK
WH
RD
C37STC BL/BK
C36STCC BL
C30EDC WH
C31EDC WH/BK
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C14-1
C12-1
C13-1
C29-1
C16-1
C17-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
GR-17-M.H.
C20-1
C8PBR BK/WH
C12DRE BL/WH
C9PERF BK/RD C27-1
C8PBR BK/WH
C7PBE BK
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
C6TTRF WH/RD C31-1
C5TRR WH/BK
C24-2
C60AX OR/RD
C6-20
C6-31
C6-37
C6-36
C5-21
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
C6-18
C6-17
H4
C24-1
C6-39
C6-13
6
C6-19
7
NC
U4
6 - 39
S-80 • S-85
2
NC
2AO
RETRACT
15
8
16
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
6
4
BR
1
2
5
13
RD/WH
3
11
9
12
WH/BK
10
OR
BR
3
4
2
1
OR
BR
WH/RD
5 BL/WH
4 WH/RD
3 BL/WH
OR
2
GND 1
RKOUT
YOUT
XOUT
PWR
6
5
YOUT 4
XOUT 3
GND 1
PWR 2
6
3
5
YOUT 4
PWR 2
GND 1
BRN
P24FS WH
P26ESTP BK
3
5
C4P-2
PLATFORM LEVEL
C4P-3
C4P-5
C4P-6
TB42
C19JSV GR/WH
S3
CR38
CR8
Part No. 122149
1
2
NOHC
2AS
NC
1RO
NOHC
LS3
4
1
3
4
2
H3
NOHC
1RS
1
2
1
D57
14
13
2
1
3
3
2
4
NC
TB16
TB40
TB37
1
4
CR38
D29
NC
CR8
3
3
P24FS WH
UP
DOWN
D27
JIB
C4P-7
C41RPM OR/BK
P46 RD
P23 RD
C27AUX RD
2
JIB VALVE
RIGHT
LEFT PLAT ROTATE
UP
DOWN
D38
5
TB1
D36
CR20 A
TB46
D15 D41
3
D37
D35
4
TB6
TB3
TB9
TB18
TB32
TB5
TB2
TB8
TB14
TB17
TB4
TB7
TB15
TS62
TS61
TS63
L1
4
TS59
TS58
TS57
J1
J1
J1
J1
J3
L5
CR13
NC
J2
JOYSTICK CONTROL CARD
TS16
TS9
TS8
TS7
TS15
D41
CE Option, See 6 - 60
CR13
+
CR26
NC
TS14
DRIVE & STEERING
JC3
PRI UP/DN & TT ROTATE
JC2
EXT/RET
JC1
WH
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (after serial number 5519)
P26ESTP BK
1
P134BAT RD
C28TTA RD/BK
BRN
Section 6 • Schematics
February 2012
Electrical Schematic, S-80/85
Continental TME27 Models (after serial number 5519)
6 - 39
6 - 40
February 2012
Section 6 • Schematics
Ground Control Box Wiring Diagram, S-80/85
Continental TME27 Models
6 - 42
6 - 41
Section 6 • Schematics
February 2012
Ground Control Box Wiring Diagram, S-80/85
Continental Models
A
1
B
C
D
E
F
G
H
I
J
K
L
LABEL
P1
DRIVE LIGHT OPTION RELAY
VOLT METER
OIL PRESSURE
WATER TEMP.
10 AMP FUSE
2
CR23
PRI. BOOM UP
PRI. BOOM DOWN
PRI. BOOM F.C.
TURN. ROT. L
TURN. ROT. R
TURN. ROT. F.C.
BOOM EXTEND
BOOM RETRACT
EXT./RET. F.C.
3
PLAT. LEVEL. UP
PLAT. LEVEL DN.
AXLE DUMP VALVE
PLAT. ROT. L.
PLAT. ROT. R.
12V BATT. SUPPLY
IGNITION PWR.
HORN
KEYSWITCH PWR/PWR TO PLAT
FUSED 12V
OIL COOLER FAN
AUX PUMP
BRAKE
START ENG
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
4
L.P.
LIMIT SW #1
ENG RPM
LIMIT SW #2
LIMIT SW PWR
KS POWER
KS POWER
5
TEST
TS64
RUN/TEST
SWITCH
C7B
12V TO PLAT
H1
6
G1
G2
BRN GND
(SPARE WIRE)
GAS ENGINE: C1-8 BK/WH
WH-23A
BK-22A
B
NC
D2
NC
3
E-STOP
RD-134A
RD/WH-3A
RD/BK-2A
R1
FUNCTION ENABLE SWITCH
TS57
PLATFORM ROTATE SWITCH
TS58
JIB UP/DOWN (JIB OPTION ONLY)
TS59
PLATFORM LEVEL SWITCH
TS61
PRIMARY BOOM UP/DOWN SWITCH
TS62
TURNTABLE ROTATE SWITCH
TS63
PRIMARY BOOM EXTEND/RETRACT SWITCH
CB1
CIRCUIT BREAKER, ENGINE, 15A
CB2
CIRCUIT BREAKER, CONTROLS, 15A
CB3
CIRCUIT BREAKER, OIL COOLER/OPTION, 20A
G6
HOUR METER
G1
VOLT METER GAUGE (OPT.)
G2
OIL PRESSURE GAUGE (OPT.)
G3
WATER TEMP. GAUGE (OPT.)
L2
CHECK ENGINE LED YELLOW (#110395)
R1
RESISTOR, 1K OHM/2W, CHECK ENGINE (#104333)
CR1
IGNITION / START RELAY
CR2
IGNITION POWER RELAY
CR3
HIGH IDLE CUTOUT RELAY
SERVICE HORN RELAY
CR5
CR8
BOOM FUNCTION CUTOUT
BK/WH-8A
WH-21A
CR17
HYDRAULIC COOLER FAN RELAY
CR20A
LOW VOLTAGE DROP RELAY
+
G6
HOUR METER
-
TS53
LP/GASSEL SW
TS61
TS63
D11
BK/RD-9A
WH-C5-11
TS52
RD-24C
START
CR1
CR2
86
86
CR38
86
CR5
BK-33
CR20B
LOW VOLTAGE DROP RELAY
CR23
DRIVE LIGHT RELAY OPTION
CR25
AXLE RET L/O RELAY
CR29
AXLE EXTEND LED RELAY
CR38
EXTEND FUNCTION CUTOUT
CB3
BK-22B
OIL COOLER/
OPTION
RD-24AA
OR/BK-15A
RD-B2-H1
BK/RD-35A
BK-C6-16
OR/RD-16C
BK-7B
BL/RD-C6-13
TS58
JIB
TURNTABLE
ROTATE
TS59
HIGH/LOWRPM
CB1
CB2
TS57
TS54
RD-C6-27
86
CR8
86
86
CR39
CR29
86
RD-24A
WH-23B
CR39B
RD-27D
D42
ENGINE
CONTROLS
PLAT.
LEVEL
PLATFORM
ROTATE
OR-C6-33
WH-21B
86
CR17
RD-24AB
FROM
TO
12 DRIVE ENABLE
BL/WH C6-12
BL/WH C3B-12
19 JIB VALVE
GR/WH C4B-7
GR/WH-S.P.
25 OIL PRESSEURE SENDER
WH/RD C5-16
WH/RD-S.P
26 WATER TEMP SENDER
WH/BK C5-14
WH/BK-S.P.
28 TILT ALARM
RD/BK C1B-2
RD/BK C6-28
RD/WH C1B-3
WH C5-21
OR-14A
GR-17A
GR/WH C4B-7
GR/BK-18A
31 E.D.C. REV
WH/BK C5-20
WH/BK C1B-5
36 STEER LEFT/AXLE RETRACT
BL C1B-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GEN. OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXT/RET SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
WH-C6-34
OR/RD-C6-11
RD-134AA
GROUND
STUD
S-80 • S-85
CIRCUIT DESCRIPTION
WH C1B-4
OR/RD -16D
ALL BRN WIRES
PLATFORM OVERLOAD MODULE
30 E.D.C. FWD
WH-4A
WH/BK-5A
C5
86
IGNITION/START MODULE
U33
RD/WH C5-24
WH/RD-6A
CR20B
TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS
29 2WD/4WD
OR/RD-16B
86
R2
U1
RD-B1-20A
OR/RD-42B
CR20A
AUXILARY PUMP RELAY
AUXILARY PUMP/ENGINE SHUT DOWN RELAY
TS62
D13
D14
WH C5-3
WH-21C
CR39
CR39A
D28
86
BK C5-5
BOOM
UP/DOWN
BOOM EXTEND/
RETRACT
RD-1A
RD-B2-S.P.
C4B
GAS/LP (DUAL FUEL OPTION)
TS54
BL/WH C5-13
RD-B1-20C
RD-B1-20D
C3B
START ENGINE SWITCH
TS53
BL/RD-39A
BRN-GND STUD
3
BK-22D
1
WH-23D
2
C6
TS52
BK-7A
BRN(GND)
WH-C5-19
ENGINE
KEY SWITCH
AUXILIARY SWITCH
CHECK ENGLED L2
GN C5-8
C2B
2
RD-27A
1
C1B
19/18 CABLES
1
B1
4
BK/WH-C6-29
GR C2B-5
FUNCTIONS
AUXILIARY PUMP
TS51
KSI
P1
BL/RD-C4B-1
6 - 42
KS1
TS51
DIESEL ENGINE: C2-1 BL/RD
KEYSWITCH
RD/BK-2B
8
DESCRIPTION
EMERGENCY STOP BUTTON
WH/BK C5-14
RD-1B
7
RD C4B-11
WH/RD C5-16
GND
BK-33C
G3
(SPARE WIRE)
OPTION WIRE TO PBOX
RD C4B-12
BASE TERMINATION BLOCK
3
2
RUN
B
A
1 RD CR38#86
RD C6-1
RD-S.P.
RD/BK CR8#30 RD/BK-S.P.
2 D15
RD/BK C3B-2&C6-2
RD/WH-S.P.
3
RD/WH C6-3
WH C6-4
WH-S.P.
4
WH/BK C6-5
WH/BK-S.P.
5
WH/RD C6-6
WH/RD-S.P.
6
D57
BK C6-7
GND STUD BK-S.P.
7 CR8#86+
BK/WH C6-8
BK/WH-S.P.
8 BK/WH C6-38
BK/RD C6-9
BK/RD-S.P.
9
10
11
OR-S.P.
OR C6-14
OR C4B-2
14
OR/BK C6-15
OR/BK-S.P.
OR/BK C4B-3
D42 15
D34
OR/RD CR20A/B #86 OR/RD CR38#87A
16 OR/RD CR8#87A
GR C6-17
GR-S.P.
GR C4B-5
17
GR/BK C6-18
GR/BK C4B-6
GR/BK-S.P.
18
20
RD-B1-H1
RD-B1-S.P.
RD-B1-H1
WH CR2#87
OR/RD C5-9
21 WH CR17 #86
WH S.P.
BK C7B-1
22 BK CR5#30
BK-S.P.
RD C6-30
WH C7B-2
WH-S.P.-D2
23 RD CR39#30
RD CR1#30
24 RD CR2#30
RD-S.P.-CB1
24A RD CR17#30
RD-S.P.-CB3
RD CR39#86&C1B-1
27 RD
RD-S.P.
WH/RD C1B-6
WH/RD C5-23
32 WH/RD C6-32
BK C1B-7
BK-S.P.
BK CR1#86
33
33A
34
BK/WH C1B-8
BK/RD-S.P.
BK/RD C1B-9
35
BK/RD C5-18
BL/BK C1B-11
37 BL/BK C6-20
BL/BK C6-37
38
BL/RD C2B-1
39
BL/RD TS53
BL/RD C5-10
OR C2B-2
OR C6-40
40 OR C6-10
41
OR/BK C2B-3
OR/BK C5-2
42 OR/RD C6-22
OR/RD C4B-4
OR/RD CR29#86
D8
RD C6-31
D7
46B
RD-KSI-SP
RD C2B-6
RD C6-23
134 RD-H6
RD CR20A #30
RD C6-24
134A
C
D
RD C3B-1
RD/BK C6-19
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
TB24AD
M
Part No. 122149
R2
N
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Continental models (before serial number 5520)
6 - 44
6 - 43
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Continental models (before serial number 5520)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
COMPONENT INDEX
PLATFORM CONTROL BOX
BK P2
D12
WH TS4
WH C9-2
WH CR26#85
BL TS16
JC3-4 BL(2)
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-3 OR
JC3-6 BL(1)
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK L4
GN/BK C3P-10
RD LS18
RD C2P-6
2
U13
ALC-500
3
1
GND STUD
J2
J1
11
9
1
1
CC132PLI BL/WH C3P-12
C28TTA RD/BK C1P-2
4
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
C133PLA BL C3P-10
TS16-C61AX BL/BK C3P11
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
TS47-C45GEN GR/WH C2P-7
C134PWR GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
TS3-C39LP BL/RD C2P-1
C40LS1 OR C2P-2
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-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
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
RD/BK H1
3
BATGND C7P-3
D40
C4P(BR)
START ENGINE SWITCH
TS3
FUEL SELECT SWITCH (FORD)
HIGH RPM SWITCH
TS7
PLATFORM ROTATE SWITCH
TS8
JIB UP/DOWN (JIB OPTION ONLY)
TS9
PLATFORM LEVEL SWITCH
TS14
DRIVE SPEED LOW/HIGH SWITCH
TS15
DRIVE ENABLE SWITCH
TS16
AXLE EXT/RET SWITCH
TS47
GENERATOR SWITCH ( OPTION )
TS48
WORK LIGHT RELAY (OPTION)
TS48
DRIVE LIGHT RELAY (OPTION)
L1
DRIVE ENABLE LED
L4
PLATFORM OVERLOAD LED (OPTION)
L40
AXLE EXTENDED LED
JC3
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC1
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
JC2
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
CR13
JIB CUTOUT RELAY ( JIB ONLY )
U13
ALC500
H1
TILT ALARM
LS18
PLATFORM OVERLOAD LIMIT SWITCH
L48
TILT ALARM LED
GR/WH TS7
BRN BATGND
JIB
C9
LS18
OPT.
(GND STUD)
RD-H1
RD LS CABLE
F.S.
12V BATT
19/18 CONTROL CABLE
OPT.
Y
C7P
RD-P2
Y
GND STUD
TS2
BK LS CABLE CIP-12
BRN
H1
HORN SWITCH
AUXILIARY SWITCH
GR/WH C2P-7
C3P(GR)
C2P(BK)
C1P(GY)
5
GND
Y
BK JIB CABLE
C2P-9 & 10
Y
GR/WH C4P-7
CR13 BRN
D39
P3
TS1
TS4
J3
D12
EMERGENCY STOP BUTTON
P2
CR27
WH TS7
WH TS1
TILT ALARM
WH/RD C32BRK
RD LS18
BK C7P-1
BK C9-1
WH C7P-2
BK J3-3
GN/BK H1 (D39)
BL/RD C2P-1
1
DETAIL A: LIFT/DRIVE OPTION
+
2
L48
1
RD WL1
+
DRIVE/STEER
TS48
+
D12
+
L4
L1
TS7
E-STOP BK
TS4
NO
P3
TS8
JIB
HORN
PLATFORM
LEVEL
AUX. PUMP
DRIVE
SPEED
CE SEE DETAIL A
S-80 • S-85
DETAIL C: WORKLIGHT OPTION
NC
TS2
START
BK
RD
6 - 44
BK
D10
TS1
TS14
D27
OPTION WIRE TO GBOX
TS49
2
F18 10A
PLATFORM
ROTATE
8
(SPARE WIRE)
RD WL2
AXLE CUTOUT
TS9
DETAIL B:
GENERATOR OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
3
TS15
DRV.ENA
TS47
-
L40
(SPLICE TO
R40LS2)
+
1
2
CR26
-
2
OR/RD R40LS2
6
4
D12
3
-
3
TS16
CR30
7
5
4
+
+
D2
BRN J1-14
JIB
CUTOUT
4
OR J1-13
5
WH J1-5
BL J1-4
WH J3-2
RD/BK H1
BK/RD C1P-9
BL/RD J1-16
RD C9-3
BK C1P-7
6
5
7
BL/WH J1-6
7
6
TT ROTATE
BL/BK J1-7
7
RD/WH J1-8
BOOM
EXT/RET
BRN J1-10
OR J1-9
YEL J1-3
RD C1P-1
GR C4P-5
GR/BK C4P-6
J2-DIODE WH
CR13
GR/WH JIB CABLE
GND BRN
OR/RD C2P-4
AXLE
EX/RET
PRI. BOOM
UP/DOWN
BL C1P-10
BL/RD C4P-1
BL/BK C3P-11
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
6
TS2 RD
(SPLICE TO
C32BRK)
Part No. 122149
TS3
HIGH/LOW
RPM
FUEL SELECT
RD
P2
E- STOP
RD
TS48 PIN2
DRIVELIGHT OPTION
February 2012
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-80/85
Continental models (after serial number 5519)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
COMPONENT INDEX
PLATFORM CONTROL BOX
BK P2
D12
WH TS4
WH C9-2
WH CR26#85
BL TS16
JC3-4 BL(2)
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-3 OR
JC3-6 BL(1)
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD LS18
RD C2P-6
U13
ALC-500
3
J3
D12
1
GND STUD
J2
J1
11
9
CC132PLI BL/WH C3P-12
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
C133PLA BL C3P-10
TS16-C61AX BL/BK C3P11
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
TS47-C45GEN GR/WH C2P-7
C134PWR GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
TS3-C39LP BL/RD C2P-1
C40LS1 OR C2P-2
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-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
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
RD/BK H1
C28TTA RD/BK C1P-2
D40
C4P(BR)
START ENGINE SWITCH
TS3
FUEL SELECT SWITCH (FORD)
TS4
HIGH RPM SWITCH
TS7
PLATFORM ROTATE SWITCH
TS8
JIB UP/DOWN (JIB OPTION ONLY)
TS9
PLATFORM LEVEL SWITCH
TS14
DRIVE SPEED LOW/HIGH SWITCH
2
DRIVE ENABLE SWITCH
TS16
AXLE EXT/RET SWITCH
TS47
GENERATOR SWITCH ( OPTION )
TS48
WORK LIGHT RELAY (OPTION)
TS48
DRIVE LIGHT RELAY (OPTION)
3
L1
DRIVE ENABLE LED
L4
PLATFORM OVERLOAD LED (OPTION)
AXLE EXTENDED LED
JC3
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC1
BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE
JC2
BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN
CR13
JIB CUTOUT RELAY ( JIB ONLY )
U13
ALC500
H1
TILT ALARM
4
LS18
PLATFORM OVERLOAD LIMIT SWITCH
L48
TILT ALARM LED
GR/WH TS7
BRN BATGND
JIB
C9
LS18
OPT.
(GND STUD)
RD-H1
RD LS CABLE
F.S.
12V BATT
19/18 CONTROL CABLE
OPT.
Y
C7P
Y
GND STUD
TS2
BK LS CABLE CIP-12
BRN
H1
AUXILIARY SWITCH
GR/WH C2P-7
C3P(GR)
C2P(BK)
C1P(GY)
GND
Y
BK JIB CABLE
C2P-9 & 10
Y
GR/WH C4P-7
CR13 BRN
HORN SWITCH
TS1
L40
BATGND C7P-3
D39
P3
TS15
1
1
EMERGENCY STOP BUTTON
P2
RD-P2
CR27
WH TS7
WH/RD C32BRK
RD LS18
BK C7P-1
BK C9-1
WH C7P-2
BK J3-3
GN/BK H1 (D39)
BL/RD C2P-1
J1 - 14 BRN JC3 - 1
J1 - 5 BL/WH JC3 - 3
J1 - 13 OR JC3 - 2
J1 - 5 BL/WH JC3 - 5
J1 - 4 WH/RD JC3 - 4
WH J3-2
RD/BK H1
BK C1P-7
BK/RD C1P-9
BL/RD J1-16
RD C9-3
BL/WH J1-6
BL/BK J1-7
RD/WH J1-8
CR30
+
L48
RD WL1
TS48
+
+
D12
OPTION WIRE TO GBOX
7
TS49
2
+
F18 10A
L4
L1
TS7
TS48 PIN2
E-STOP BK
TS4
NO
BK
D10
DETAIL C: WORKLIGHT OPTION
DRIVELIGHT OPTION
NC
TS1
AUX. PUMP
TS14
D27
(SPARE WIRE)
RD WL2
DRIVE/STEER
PLATFORM
ROTATE
PLATFORM
LEVEL
6
DETAIL A: LIFT/DRIVE OPTION
JC1
TT ROTATE
HORN
DETAIL B:
GENERATOR OPTION
(SPLICE TO
R40LS2)
JC3
P3
TS47
REPLACE WIRE WITH THIS WIRING DIAGRAM
AXLE CUTOUT
TS9
TS2 RD
(SPLICE TO
C32BRK)
OR/RD R40LS2
D12
TS15
DRV.ENA
CR26
L40
J1 - 10 BRN JC1 - 1
TS16
J1 - 9 OR JC1 - 2
BOOM
EXT/RET
J1 - 3 WH/BK JC1 - 4
RD C1P-1
GR C4P-5
GR/BK C4P-6
J2-DIODE WH
GR/WH JIB CABLE
GND BRN
JC1
OR/RD C2P-4
D2
UP/DOWN
BL C1P-10
BL/RD C4P-1
BL/BK C3P-11
J1 - 11 OR JC2 - 2
J1 - 12 BRN JC2 - 1
J1 - 1 WH/RD JC2 - 3
J1 - 2 RD/WH JC2 - 4
OR C4P-2
GR C2P-5
OR/BK C4P-3
PRI. BOOM
AXLE
EX/RET
5
WH TS1
TILT ALARM
DRIVE
SPEED
TS2
START
BK
RD
TS3
HIGH/LOW
RPM
FUEL SELECT
RD
8
RD
P2
E- STOP
CE SEE DETAIL A
Part No. 122149
S-80 • S-85
6 - 45
Section 6 • Schematics
February 2012
Platform Control Box Wiring Diagram, S-80/85
Continental models (after serial number 5519)
6 - 45
6 - 46
February 2012
Section 6 • Schematics
Continental TME27 Engine Harness
6 - 48
6 - 47
Section 6 • Schematics
February 2012
Continental TME27 Engine Harness
A
B
C
D
E
LT GREEN/BLACK 18
1
ORANGE 18
DK GREEN 18
LT GREEN/RED 18
BLK/LT GREEN 18
RX A
TX B
5V
C
RTN D
F
G
H
I
J
K
L
BLACK/LT GREEN 18 A
YELLOW/GRAY 18
B
M
ECT
OIL PRESSURE SWITCH
BLACK/LT GREEN 18
TAN 18
LT GREEN/RED 18
LT GREEN 18
1
2
3
4
TMAP
BLACK/LT GREEN 18
DK GREEN/ORANGE 18
PINK/DK GREEN 16
BLACK/WHITE 16
A
B
C
D
PRE CAT HEGO
BLACK/LT GREEN 18
TAN/DK GREEN 18
PINK/DK GREEN 16
BLACK/YELLOW 16
A
B
C
D
POST CAT HEGO
SPLICE WITHIN 6" OF CONNECTOR
COMM
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
4
5
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 -
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
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
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
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
6
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
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
COBRA EPR
PURPLE/WHITE 18
PURPLE/WHITE 18
WHITE/PURPLE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
WHITE/PURPLE 18 C
LT GREEN/RED 18
GRAY/BROWN 18
CRANK SENSOR
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
1
2
3
4
5
6
VEHICLE INTERFACE 2
DEUTSCH DT06 PLUG
DBW THROTTLE CONNECTOR
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
87A LT BLUE/PINK 14
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
B
C
D
COIL 2
COIL 3
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
BAT +
BROWN/YELLOW 16
20A
RED 14
S-80 • S-85
INJECTOR 4
INJECTOR 3
INJECTOR 2
NOTE: INECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER
Part No. 122149
INJECTOR 1
A
B
C
COIL 1
PINK/DK GREEN 16
BLACK/LT GREEN 18
PINK/YELLOW 16
FUEL PUMP RELAY
YELLOW 18
85
F4
15A
BLACK 16
TAN/BLACK 18
87 PINK/YELLOW 16
PINK/DK GREEN 16
86
BLACK/LT GREEN 18
PINK/TAN 18
STARTER RELAY
YELLOW/LT GREEN 18
30
BLACK 16
85
RED 14
PINK/DK GREEN 16
PINK/BLACK 18
BLUE/GREEN 14
YELLOW/BLACK 18
87
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 - 48
B
WHITE/RED 18 A
LT GREEN/RED 18
BLACK/LT GREEN 18
PURPLE/WHITE 18
WHITE/PURPLE 18
GRAY/BROWN 18
PURPLE/ORANGE 18
BLUE/WHITE 18
8
GROUND
BLK/LT GREEN 18
JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
WHITE 14
7
CAN +
VBAT
LT GREEN/RED 18 A
SPLICE WITHIN 6" FROM CONNECTOR
46 DK BLUE/YELLOW 18
47
48 LT GREEN/WHITE 18
49
50
51 GRAY/DK BLUE 18
52 GRAY/WHITE 18
53 LT GREEN/BLACK 18
54 WHITE/LT GREEN 18
55 DK GREEN 18
56 ORANGE 18
57
58 YELLOW/LT GREEN 18
59 PINK/YELLOW 16
60 RED/TAN 16
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
CAN CAN + TERM
BLUE/WHITE 18
WHITE/ORANGE 18
BLACK 16
3
N
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
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
6
15
8
16
4 WH/RD
5
13
4
5
3 BL/WH
14
BL/WH
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
XOUT
YOUT
RKOUT
OR
2
1
10
9
3
12
11
1
2
BRN
1
PWR
2
GND
6
5
YOUT 4 RD/WH
XOUT 3 WH/RD
OR
BRN
PWR 2
GND 1
6
5
YOUT 4 WH/BK
3
OR
PWR 2
GND 1 BRN
BRN
P24FS WH
P24FS WH
3
4
4
1
18
17
15
16
20
19
11
9
10
6
7
8
14
13
12
3
5
C4P-4
C2P-2
C1P-10
C1P-11
C1P-5
C1P-4
C1P-6
C1P-3
C3P-6
C3P-4
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C3P-12
C2P-3
4
Deutsch - 6 Pin Connector
H1 RD/BK
DRIVE MODE
LED BL/RD
C29MS RD/WH
15
8
16
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
7
OR
BL
14
5
13
4
XOUT 4
BRN
2
RKOUT 6 BL
YOUT 5 WH
PWR 3
GND 2
BK
12
6
7
1
5
RD
OR
BRN
1
2
3
3
4
2
1
10
9
3
11
1
4
YOUT
XOUT
PWR
GND
7
6
YOUT 5 YEL
4
OR
PWR 3
GND 2 BRN
1
BRN
P24FS WH
P26ESTP BK
P24FS WH
BRN J1-14
OR J1-13
WH J1-5
BL J1-4
BRN J1-10
OR J1-9
YEL J1-3
4
1
18
17
16
15
20
19
11
9
10
6
7
8
14
12
13
3
5
+
+
+
-
-
-
C3P-12
C3P-7
C3P-8
C3P-9
C3P-3
C3P-2
C3P-1
C3P-4
C3P-5
C3P-6
C1P-3
C1P-6
C1P-5
C1P-4
C1P-10
C1P-11
C2P-2
C4P-4
8
C2P-3
6 - 49
S-80 • S-85
Part No. 122149
6
BRN J1-12
OR J1-11
4
P26ESTP BK
J1-13 OR JC3-PIN 2
J1-14 BRN JC3-PIN 1
J1-5 BL/WH JC3-PIN 3
J1-5 BL/WH JC3-PIN 5
J1-4 WH/RD JC3-PIN 4
J1-9 OR JC1-PIN 2
J1-10 BRN JC1-PIN 1
J1-3 WH/BK JC1-PIN 4
J1-12 BRN JC2-PIN 1
RD J1-1
4
D36
D35
L1
7
4
1
Deutsch
J1
5
3
TS14
BK J1-2
1
1
2
1
JC3
DRIVE
2
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
2
3
3
3
J2
5
3
2
AMP
Joystick Adaptor Harness
5
2
5
J1
J1
J1
6
5
J3
7
6
4
4
Note: Production changed to Deutsch 6 pin connectors at serial number 5520.
TS15
JC2
PRI UP/DN & TT ROTATE
5
1
6
JC3
DRIVE & STEERING
JC1
EXTEND/RETRACT
P24FS WH
7
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
J1
J1-1 WH/RD JC2-PIN 3
TT ROTATE
3
JC3
2
J1-11 OR JC2-PIN 2
DRIVE/STEER
D36
D35
BOOM
L1
J1-2 RD/WH JC2-PIN 4
UP/DOWN
JOYSTICK CONTROL CARD
7
6
JC1
BOOM
EXTEND/
RETRACT
7
JC1
JC2
J2
JOYSTICK CONTROL CARD
J1
J1
J1
J3
PRI. BOOM
TS14
TS15
JC2
PRI UP/DN & TT ROTATE
JC3
DRIVE & STEERING
JC1
EXTEND/RETRACT
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
February 2012
Joystick Wiring Diagram
C28TTA RD/BK
1
P26ESTP BK
EXT/RET
C28TTA RD/BK
P26ESTP BK
AMP - 7 Pin Connector
Section 6 • Schematics
February 2012
Joystick Wiring Diagram
6 - 49
6 - 50
February 2012
Section 6 • Schematics
Connector Pin Legend - Sheet 1
6 - 52
6 - 51
Section 6 • Schematics
February 2012
Connector Pin Legend - Sheet 1
A
B
C
D
E
F
G
H
I
J
K
L
M
1
C7: DTP06-4S
C1 DT06-12SC
2
CKT # PIN #
C27AUX
1
RD/BK
C28TTA
2
BK
P22BAT
1
RD/WH
C29MS
3
WH
P23SWBAT
2
WH
C30EDC+
4
BRN
BATGND
3
WH/BK
C31EDC-
5
N/C
4
WH/RD
C32BRK
6
BK
C33STR
7
1
P24BAT
BK/WH
C34SA
8
2
BK/RD
C35RPM
9
3
BL
C36STCC
10
4
BL/BK
C37STC
11
5
BL/WH
C132PLI
12
6
3
6
C3
GRAY
CKT #
C5-ENGINE HARNESS
FORD
DEUTZ
PERKINS
3.0L GM
PIN
ENGINE
ENGINE
ENGINE
ENGINE
#
1
P24BAT
C41RPM
OR/BK
OR/BK
OR/BK
OR/BK
2
C107AF
WH
WH
WH
WH
3
#
C39LP
1
OR
C40LS1
2
OR/BK
C41RPM
3
OR/RD
C60AX
4
GR
C43HRN
5
GR/BK
C134BAT
6
GR/WH
C45GEN
7
CIRCUIT #
1
C2
BLACK
8
NC
R33STR
BK(14)
BK(14)
BK(14)
BK(14)
5
RD
6
COLOR
C1PBU
RD-3
GR
OR/RD
OR/RD
OR/RD
OR/RD
WH(14)
WH(14)
WH
10
11
BL/RD
WH
WH(14)
WH(14)
BL/RD
WH
12
C45GEN
GR/WH
GR/WH
GR/WH
GR/WH
12
C45GEN
GR/WH
GR/WH
GR/WH
13
14
C108ESL
BL/WH
C108ESL
BL/WH
WH/RD
BL/WH
WH/RD
13
14
15
C24SW
16
C25PSR OPT.
WH
WH/BK
10
11
2
C2PBD
RD/BK-3
3
C3PBF
RD/WH-3
4
C4TRL
WH-3
C26TSR OPT.
BL/WH
WH/RD
5
C5TRR
WH/BK-3
15
C24SW
WH
WH
6
C6TRF
WH/RD-3
16
C25PSR OPT.
WH/BK
WH/BK
BK/RD
BK/RD(14)
BK/RD(14)
RD
NC
11
9
C9PERF
BK/RD-3
RD
NC
12
10
C40LS2
OR
19
P23BAT
11
C42LD
WH
20
C31EDC-
WH(14)
WH/BK
WH/BK
12
C12DRE
BL/WH-3
21
C30EDC+
WH
13
S3LED
BL/RD-3
22
C34SA
14
C14PLU
OR-3
23
C32BRK
24
C29MS
COLOR
RD
CKT #
C1PBU
15
C15PLD
OR/BK-3
RD/BK
C2PBD
2
16
R43HRN
BK
RD/WH
C3PBF
3
17
C17JU
GR-3
WH
C4TRL
4
18
C18JD
GR/BK-3
WH/BK
C5TRR
5
19
C2DA
RD/BK
20
C37STC
BL/BK
21
C61AXRT
BL/BK
22
C42LS2
OR/RD-1
23
P23BATSR
RD
24
P23BAT
RD
25
C46BBR
RD
C3
WH/RD
C6TRF
6
BK
C7PBE
7
C3
BK/WH
C8PBR
8
GREEN
BK/RD
C9PERF
9
BL
C133PLA
10
BL/BK
C61AX
11
BL/WH
C12DRE
12
A
C4
26
C46BBR
GR
27
C27AUX
RD-1
WH/BK
WH/BK
WH
21
C30EDC
WH
WH
22
C34SA
WH
WH
BK/WH
WH/RD
WH/RD
WH/RD
WH/RD
RD/WH
RD/WH
RD/WH
RD/WH
C9 FS DT04-4P
COLOR
RD
C32TA
WH/RD-1
33
R116HYD
OR
34
R21IGN
WH
COLOR
P22BAT
1
2
DC
C9 FS DT04-4P
GR
C17JU
5
36
C36STCC
BL-1
BK
GR/BK
C18JD
6
37
C37STC
BL/BK-1
WH
P24BAT
GR/WH
C19JSV
7
RD
P25BAT
3
NC
8
N/C
4
CKT # PIN #
35
MARK NUMBER ON CABLE 3
BK/RD
BK/WH
C9
C46PWR
Part No. 122149
WH
WH/BK
AC
3
S-80 • S-85
WH(14)
WH/BK
WH
C31EDC
C29MS
4
11
P23BAT
20
C32BRK
C40LS2
12
19
24
32
OR-1
WH
WH/BK
23
31
C40LS1
WH
WH/BK
RD/WH
RD
40
BK/RD(14)
WH/RD
C46PWR
BK/WH
BK/RD(14)
RD/WH
30
WH
BK/RD
WH/RD
BK/WH
OR/RD
WH/BK
RD
RD/WH
RD/BK
C8PBR
WH/BK
C35RPM
WH/RD
R16PBR
C60AX
WH/RD
WH
P24BAT
RD/WH
C28TTA
39
WH/RD
WH
18
WH/RD
28
GR/WH
BL/RD
17
WH
29
38
GR
BK/RD
BK/WH
C15PLD
C4
C26TSR OPT.
WH
OR/BK
BROWN
WH
BK/WH
OR/RD
R2DRVLITE
RD
C128RPM(OPT)
C39LP
C21IGN
C35RPM
R1DRVLITE
BK(14)
C127TSW
P134BAT
RD
BK(14)
BK(14)
9
18
RD
BK(14)
8
17
9
R33STR
GR
BK/WH-3
10
WH
OR/RD
BL/RD
BK-3
NC
OR/BK
WH
OR/RD
C8PBR
NC
OR/BK
WH
OR/RD
C7PBE
8
OR/BK
WH
OR/RD
BL/RD
WH
8
1
OR/BK
C107AF
GR
7
2
C41RPM
C127TSW
9
C14PLU
ENGINE
C128RPM(OPT)
C39LP
C21IGN
10
OR
3.0L GM
ENGINE
9
NC
BL/RD
PERKINS
ENGINE
8
NC
CKT # PIN #
S3LED (AX)
DEUTZ
ENGINE
7
BRN
1
FORD
4
BRN
PIN #
CKT #
C6
C2
CKT # PIN #
BL/RD
COLOR
6 - 52
C5-GBOX
PIN
7
C4 DT06-12SB
7
C7
C1
C3 DT06-12SA
5
CKT # PIN #
COLOR
C2 DT06-12SD
COLOR
4
C1
COLOR
RD
CKT # PIN #
N/C
1
WH
NEUTRAL
2
GRN
CHASSIC
3
BK
LINE
4
XX
N
February 2012
Section 6 • Schematics
Connector Pin Legend - Sheet 2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
ALC500 JOYSTICKS/INPUT
PIN#
CKT#
GM PLUG
WIRE
PIN#
CKT#
HARN
GM ENGINE
1
JC2-4
RD
1
C39LP
BL/RD
YL
2
JC2-5
BK
2
C35RPM
BK/RD
LT BL
3
JC1-5
YL
3
C33STR
BK
RD/BL
4
JC3-5
WH
4
P23BATSA
RD
PU
5
JC3-6
BL
5
C27AUX
RD
GR/BK
6
DRE A
BL/WH
6
C21IGN
WH
RD
7
DRE B
BL/BK
7
C38ESL
BL/RD
WH/BL
8
C29MS
RD/WH
8
C41RPM
OR/BK
DK BL
9
JC1-3
OR
9
-----
BRN
YL/BK
10
JC1-2
BRN
10
-----
-----
-----
11
JC2-3
OR
11
PUMP+
BL/WH
PU/BK
12
JC2-2
BRN
12
GND1
BRN
BK
13
JC3-3
OR
14
JC3-2
BRN
15
H1
RD/BK
16
C13LED
BL/RD
J1
2
16
8
C1
GRAY
3
9
1
4
ALC500 OUTPUT
NC
3
C12DRE
BL/WH
4
C40LS1
OR
5
C41RPM
OR/BK
6
C1PBU
RD
7
C2PBD
RD/BK
8
C3PBF
RD/WH
9
C4TRL
WH
10
C5TRR
WH/BK
11
C6TRF
WH/RD
12
C7PBE
BK
13
C8PBR
BK/WH
14
C9PERF
BK/RD
15
C30EDC+
WH
16
17
C31EDCC36STCC
WH/BK
BL
18
C37STC
BL/BK
19
C32BRK
WH/RD
20
C29MS
RD/WH
5
J2
6
1
2
11
OR/RD
20
WIRE
R40LS2
PIN#
10
CKT#
1
7
8
Part No. 122149
S-80 • S-85
6 - 53
Section 6 • Schematics
February 2012
Connector Pin Legend - Sheet 2
6 - 53
6 - 54
February 2012
Section 6 • Schematics
Dual Battery Option
6 - 56
6 - 55
Section 6 • Schematics
February 2012
Dual Battery Option
A
B
C
CB2
15A
1
D
E
F
G
H
CB2
P1
RD
RD
KS1
P1
15A
RD
I
RD
RD
RD
KS1
TB22
PLAT
PLAT
GRD
GRD
2
RD
WH
WH
CB1
15A
3
CB1
15A
RD
CB3
20A
RD
CB3
RD
TB20
TB20
20A
RD
RD
4
ALTERNATOR
EXCT.
12V DC
BAT.
+
BAT.
-
BAT.
+
BAT.
-
+
STA.
+
+
STA.
-
B1
B1
REGULATOR
-
6
-
B2
IND.
DUAL BATTERY (OPTION)
S-80 • S-85
ALTERNATOR
START BATTERY
ALTERNATOR
BATTERY SEPARATOR (OPTION)
START BATTERY
6 - 56
CONTROL BATTERY (OPTION)
8
W
REGULATOR
IND.
7
C41RPM OR/BK
D22
EXCT.
12 V
DC
C5-2
C107AF WH
12 V
DC
C5-3
ALTERNATOR
P20BAT RD
D22
C41RPM OR/BK
C107AF WH
5
C5-2
C5-3
P20BAT RD
BATTERY
SEPARATOR
SINGLE BATTERY (STANDARD)
Part No. 122149
J
K
L
M
N
February 2012
Section 6 • Schematics
Belt Drive Generator Option
L
K
J
I
H
G
F
E
D
C
B
A
1
REGULATOR
VOLTAGE
R20BAT RD
NEUTRAL WH
GND BR
2
LINE BK
FIELD BK/WH
GENERATOR
BELT DRIVEN
120VAC / 60HZ
GENERATOR
OUTLET
CB2
TG2
LINE BK
LINE BK
LINE
15A
GND GR
NEUTRAL WH
TG4
3
VOLTAGE
REGULATOR
GND
TG1
FIELD GR
CR1
CB1
P20BAT
30A
87A
30
BAT
86
NEUTRAL WH
NEU
CB2
87
C45GEN
85
TO GBOX
12.5A- 220V
15A- 120V
A
B
C45GEN
B
-
TG3
GND BR
Y
BATTERY+
Y
A
BATTERY-
B
4
TG
CR1
120 VAC / 60 HZ with Regulator
1
2
Y
3
Y
4
OUTLET
5
Y
F
REGULATOR
VOLTAGE
R20BAT RD
NEUTRAL WH
GND BR
LINE BK
A
FIELD BK/WH
B
CB1
30A
GENERATOR
PIN# COLOR
1 WH
2 GR
3 BK
4
CKT#
NEUTRAL
FIELD
LINE
PLUG
6
BELT DRIVEN
220VAC / 50HZ
GENERATOR
OUTLET
CB2
TG2
LINE BK
LINE BK
1
TG4
GND
TG1
FIELD GR
CR1
CB1
P20BAT
30A
87A
30
NEUTRAL WH
NEU
87
85
4
5
C45GEN
CKT#
R20BAT
NEUTRAL
GND
LINE
FIELD
7
TO GBOX
-
BAT
86
3
VOLTAGE REGULATOR
PIN# COLOR
1 RD 12GA
2 WH 12GA
3 BR 12GA
4 BK 12GA
5 BK/WH 14GA
GND GR
NEUTRAL WH
2
LINE
12.5A
+
M
+
N
TG3
GND BR
220 VAC / 50 HZ with Regulator
8
Part No. 122149
S-80 • S-85
6 - 57
Section 6 • Schematics
February 2012
Belt Drive Generator Option
6 - 57
6 - 58
February 2012
Section 6 • Schematics
CE Option
6 - 60
6 - 59
H1
P22BAT BK
C7P-2
C7B-2
P23BAT WH
C1B-2
C2B-5
C3B-10
TB28
C6-28
C6-23
GR/BK
TO SERVICE HORN
H1 RD/BK
DRIVE MODE
NO
1
4
RETRACT
EXTEND
AXLE
EXTEND
RETRACT
15
8
16
18
17
15
16
20
19
11
9
10
6
7
8
14
12
13
+
L5
CR26
NC
L1
TS14
6
C7-3
C4P-1
C3P-11
C2P-4
C4P-4
C1P-11
C2P-2
C1P-10
C1P-4
C1P-5
C1P-3
C1P-6
C3P-6
C3P-4
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C3P-12
C2P-3
C4P-3
C4P-2
C4P-6
RIGHT
PLAT ROTATE C4P-5
LEFT
D27
D37
D36
C29MS RD/WH
LED BL/RD
CDE2 BL/BK
7
2
1
10
9
3
12
11
1
2
14
5
13
4
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
BRN
P24FS WH
P24FS WH
3
5
D38
DOWN
PLAT LEVEL
UP
3
4
J1
J1
J1
J1
D41
P26ESTP BK
J2
CR30
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
BK
GR/BK
TO FB OPT
TO GROUND
P20BAT RD
CR27 CE
C1P-2
C3P-10
C2P-5
C7B-1
TB24A
D35
8
C7P-1
BL/WH
RD
P2
BK
TS16
TS9
TS7
C1B-12
L45
L4
C132PLI BL/WH
BK
WH
H6
C9P-1
LS18
TB23
RD
CB3
TS15
NC
WH
P24FS WH
C1P-12
U33
D39
C2B-6
4
C40LS OR/RD
C32BRK WH/RD
Part No. 122149
S-80 • S-85
6 - 60
TO AUX PUMP
8
12
7
6
GRD
3
5
B
D2
CB1
TO TS51
PLAT
TO TS52, TS54
WH
3
1
TB22
4
1
J3
JOYSTICK CONTROL CARD
7
TB134
B1
P3
HORN
P134BAT GR/BK
KS1
D43
C2P-6
2
LOAD
SENSE
MODULE
4
TB24
RD
15AMP.
RD
20AMP.
TB20
5
P134BAT RD
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
2
P1
CB2
RD
RD
15AMP.
3
February 2012
Section 6 • Schematics
CE Option
P26ESTP BK
RD
P28TTA RD/BK
C28TTA RD/BK
P26ESTP BK
February 2012
Section 6 • Schematics
Platform Level Cutout, CTE Option
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 122149
S-80 • S-85
6 - 61
Section 6 • Schematics
February 2012
Platform Level Cutout, CTE Option
6 - 61
6 - 62
February 2012
Section 6 • Schematics
12kW Hydraulic Generator Option
6 - 64
6 - 63
Section 6 • Schematics
February 2012
12 kW Hydraulic Generator Option
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
FOOTSWITCH
P2
ALC-500
P25FS-RD
P26ESTP-BK
P22PWR-BK
P24FS-WH
19
RPM HI
RPM LO
2
D12
2 COM
OMRON
RELAY
CR66
5 SW INPUT
C1B-4
8
C5-21
C1B-5
TIME DELAY
MODULE 4S
C2B-7
C5-20
C5-4 WH
3 GND
TB24
C45GEN GR/WH
C1B-9
1 N.O.
4
C32BRK WH/RD
C35RPM BK/RD
C1B-3
C1B-4
C1B-5
8 N.C.
C2P-7
C1P-9
C29MS RD/WH
C30EDC WH
C31EDC WH/BK
3
C1P-3
C1P-4
C1P-6
C32BRK WH/RD
C1P-5
TS47
GENERATOR
ON
7
20
15
16
TS4
5
C5-21
C5-20
124 ohms
BK 16-2
NC
Y75
E1NOT USED
E2NOT USED
E3NOT USED
F1DIG IN 0
F2DIG IN 1 GENERATOR ON
F3DIG IN 2
SX Controller
C6-39
Part No. 122149
D1ANALOG 0 JOYSTICK
D2ANALOG 1 NC
D3C41 RPM
C41RPM OR/BK
DIVERTER MANIFOLD
C1TxD
C2RxD
C3/BOOT
BRAKE
RELEASE
BR-2
(16-2)
PILOT PRESSURE SIGNAL
FROM GENERATOR MANIFOLD
RS232TxD
RS232RxD
CR4
HIGH IDLE
RELAY
Y75
N.O.
A
B
C
MOTOR
STROKE
VALVE
S-80 • S-85
DRIVE EDC +
DRIVE EDC -
8
PS4
PRESSURE SWITCH
200 PSI
BYPASS COIL
C
B
A
D
U4
RD-1
7
6
BK-2
5
OMRON
RELAY
CR50
C57
C45GEN GR/WH
C57
2 4
6
5
TB41
C5-12 OR/BK
8
TB45
C5-12
4
TB21
C5-23
2
D65
C5-18
3
B1VALVE 0 FWD COIL
B2VALVE 1 NC
B3DIGITAL OUTPUT BYPASS
D98
C5-24
1
A1BATTERY +
A2SENSOR POWER +5 VDC
A3BATTERY-
TB32
TB35
3
1
V151HG GR
V150HG GR/BK
6
6 - 64
124 ohms
TB29
1
1k ohms
2
7
D99
3
February 2012
Section 6 • Schematics
Hydraulic Schematic, 12kW Generator
D
E
F
G
H
I
J
K
L
M
N
1
B
DRIVE PUMP
3.5 GPM / 13.25L/min
OIL COOLER
A
2
CASE
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
C
3
B
1
A
7
TANK
8
21CC
21 GPM / 79.5 L/min
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.
G2
G1
HS0166C
GENERATOR
12.5 KW
Part No. 122149
S-80 • S-85
6 - 65
Section 6 • Schematics
February 2012
Hydraulic Schematic, 12kW Generator
6 - 65
6 - 66
February 2012
Section 6 • Schematics
Hydraulic Schematic, 2WD Models
6 - 67
6 - 68
Section 6 • Schematics
February 2012
Hydraulic Schematic, 2WD Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
51 psi
3.5 bar
BRAKE/2 SPEED
MANIFOLD
F
1200 psi
82.7 bar
PRIMARY
T2
TT
UU
BRAKE
A
A
QQ
RR
(S-85 Models)
C
J2
F
PRIMARY LIFT
CYLINDER
M
1.7
AUXILIARY
PUMP
WW
B
BOOM EXTENSION CYLINDER
C
TEST
A
OPTIONAL
GENERATOR
MANIFOLD
2400 PSI
B
RETRACT
4 GPM
ACCUM
SW1
T3
G
V1
PL1
SW2
P1
P2
Q
2100 psi
145 bar
2500 psi
172 bar
V2
PL2
P
E
OPTIONAL
GENERATOR
30 psi
2 bar
30 psi
2 bar
B
C
9
13
HIGH
PRESSURE
FILTER
2
PTEST
DRIVE PUMP
RETURN
FILTER
T4
25 psi
1.7 bar
T1
Y
EE
CC
AA
W
0.6 gpm
2.27 L/min
150 psi
10.3 bar
0.6 gpm
2.27 L/min
BB
PLATFORM
ROTATE
DUMP
MANIFOLD
LIM SW
GG
KK
NN
PS
3.5 gpm
13.2 L/min
DD
S
30 psi
2 bar
0.1 gpm
0.38 L/min
150 psi
10.3 bar
HH
30 psi
2 bar
JJ
OIL COOLER
OPTION
Z
AUX
MM
II
T2
ST1
ST2
AXLE EXTEND
PRESSURE SWITCH
0.3 gpm
1.1 L/min
FF
150 psi
10.3 bar
3 psi
0.2 bar
D
V
TANK
3 psi
0.2 bar
N
O
H
U
FUNCTION
PUMP
J
K
T
PRESS
A
R
I
2900 psi
200 bar
PR2
JIB SELECT
MANIFOLD
X
F
102 psi
7 bar
L
M
E
D
PR1
PR2
PR1
E
OO
3
4
RET
EXT
D
VV
V2
FUNCTION
MANIFOLD
310 psi
21.4 bar
E
C
PP
S1 0.030 in
0.076 mm
450 psi
22 bar
ACCUMULATOR
PTEST
3625 psi
250 bar
J1
XX
C
MASTER
EXTEND
7 GPM (REGEN)
2 SPEED
TEST
0.030 in
0.76 mm
V1
SECONDARY
CP
2
PLATFORM LEVEL
CYLINDERS
SLAVE
B
B
SS
JIB BOOM
TURNTABLE
ROTATE
MEDIUM
PRESSURE
FILTER
OC2
OC1
LS TEST
AXLE
LL
CP
LIM SW
RESERVOIR
COUNTERBALANCE VALVE
RATIO
5
6
8
3
1
2
4
5
9
10
7
HYDRAULIC ROTARY COUPLER
TEST
6B
8B
8A
6A
2A
3
1
2D
6
2B
STEER
CYLINDERS
CP
X
A
5
10
V1
V2
PILOT
2C
9A
7
9B
RIGHT
B
3:1
2000 PSI
C
3:1
3000 PSI
D
3:1
3300 PSI
E
F
3:1
3500 PSI
5:1
3500 PSI
A
FA
FD
M3
1000 PSI
B
B
IN
OUT
REAR
FRONT
3:1
850 psi
58.6 bar
FRR
REAR
RIGHT
4
C
FC
C
C
C
OSCILLATE VALVE
FRB
C
C
C
BI
FLB
BF
7
M2
LEFT
FLR
50%
BG
BH
280 psi
19.3 bar
0.070 in
1.77 mm
FAR
RAE
AXLE SELECT
MANIFOLD
LEFT
TEST
RIGHT
FAE
FE
RAR
1000 psi
68.9 bar
FB
50%
AXLE EXTEND
CYLINDERS
OSCILLATE CYLINDERS
TE
M4
8
TIE ROD
CYLINDER
T
REAR
LEFT
C
M1
2WD DRIVE MANIFOLD
T1
6 - 68
S-80 • S-85
Part No. 122149
C
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.
PRESSURE
A
C
February 2012
Section 6 • Schematics
Hydraulic Schematic, 4WD Models
A
B
51 psi
3.5 bar
C
D
E
1200 psi
82.7 bar
PRIMARY
T2
I
J
A
A
QQ
RR
K
TT
UU
M
AUXILIARY
PUMP
F
PRIMARY LIFT
CYLINDER
1.7
A
OPTIONAL
GENERATOR
MANIFOLD
2400 PSI
B
ACCUMULATOR
310 psi
21.4 bar
V2
ACCUM
RET
EXT
2
V1
SW1
T3
G
OPTIONAL
GENERATOR
3625 psi
250 bar
PL1
SW2
P1
P2
P
E
PTEST
RETURN
FILTER
T4
25 psi
1.7 bar
T1
CC AA
EE
C
PR2
JIB SELECT
MANIFOLD
D
A
0.6 gpm
2.27 L/min
W
0.6 gpm
2.27 L/min
BB
150 psi
10.3 bar
LIM SW
GG
KK
NN
PS
3.5 gpm
13.2 L/min
Y
3
PLATFORM
ROTATE
DUMP
MANIFOLD
V
DD
S
30 psi
2 bar
0.1 gpm
0.38 L/min
150 psi
10.3 bar
30 psi
2 bar
TANK
AUX
JJ
4
Z
OIL COOLER
OPTION
MM
II
T2
ST1
ST2
AXLE EXTEND
PRESSURE SWITCH
0.3 gpm
1.1 L/min
HH
FF
150 psi
10.3 bar
3 psi
0.2 bar
B
N
O
H
U
FUNCTION
PUMP
J
K
T
30 psi
2 bar
R
I
PRESS
L
30 psi
2 bar
X
F
HIGH
PRESSURE
FILTER
2
M
PR1
PR2
PR1
E
E
2900 psi
200 bar
D
V2
PL2
Q
2100 psi
145 bar
2500 psi
172 bar
D
102 psi
7 bar
3 psi
0.2 bar
C
VV
OO
DRIVE PUMP
J1
XX
PP
FUNCTION
MANIFOLD
13
0.030 in
0.76 mm
C
S1 0.030 in
0.076 mm
450 psi
22 bar
PTEST
9
1
C
MASTER
TEST
E
OC2
OC1
LS TEST
AXLE
LL
CP
LIM SW
RESERVOIR
COUNTERBALANCE VALVE
RATIO
6
8
3
2
1
4
5
9
10
7
HYDRAULIC ROTARY COUPLER
8B
6B
6A
8A
3
1
2A
2B
2D
STEERING
CYLINDERS
A
TEST
REAR
RIGHT
5
10
V2
PILOT
2C
9A
9B
7
C
C
C
C
AXLE EXTEND
CYLINDERS
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
6
C
C
FLB
LEFT
CL
CH
CE
50%
LEFT
CP
50%
CJ
FE
C
RIGHT
7
OSCILLATE CYLINDERS
FB
1000 psi
69 bar
50%
TEST
M4
CM
FLR
0.040 in/
1 mm
FAE
FAR
RAE
RAR
50%
M3
0.040 in/
1 mm
TE
TIEROD
CYLINDER
CDL
DRIVE MANIFOLD
D
E
F
5
M6
280 psi
19.3 bar
CN
CQ
3000 PSI
OSCILLATE VALVE
50%
M2
M1
3:1
FA
FC
50%
REAR
LEFT
2000 PSI
C
A
C
CD
CI
3:1
850 psi
58.6 bar
FRB
CO
CK
1000 PSI
B
B
OUT
FD
FRONT
RIGHT
CF
M5
0.040 in/
1 mm
3:1
TEST
IN
REAR
FRONT
AXLE SELECT
MANIFOLD
FRR
M8
CDR
4
V1
PRESSURE
A
RIGHT
B
M7
CG
N
J2
F
WW
C
RETRACT
4 GPM
EXTEND
7 GPM (REGEN)
2 SPEED
TEST
M
(S-85 Models)
V1
B
BOOM EXTENSION CYLINDER
L
JIB BOOM
PLATFORM LEVEL
CYLINDERS
SLAVE
SECONDARY
CP
BRAKE
H
B
B
SS
G
TURNTABLE
ROTATE
MEDIUM
PRESSURE
FILTER
BRAKE/2 SPEED
MANIFOLD
F
8
FRONT
LEFT
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.
T
C
C
Part No. 122149
S-80 • S-85
6 - 69
Section 6 • Schematics
February 2012
Hydraulic Schematic, 4WD Models
6 - 69
6 - 70