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Service Manual Serial Number Range S-80 S-85 S-80X from S8008-8000 to S8013-11875 from S8508-8001 to S8513-11875 from S80X10-8500 to S80X13-11875 Part No. 122985 Rev D1 September 2015 Introduction September 2015 Introduction Important Serial Number Information Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. Genie offers the following Service Manuals for these models: This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Compliance Title Part No. Genie S-80 and S-85 Service Manual (from serial number 101 to 785) .......... 34032 Genie S-80 and S-85 Service Manual (from serial number 786 to 965) .......... 52270 Genie S-80 and S-85 Service Manual (from serial number 966 to 3081) ........ 72062 Genie S-80 and S-85 Service Manual (from serial number 3082 to 3737) ...... 77832 Genie S-80 and S-85 Service Manual (from serial number 3738 to 5380) ... 111165 Machine Classification Group B/Type 3 as defined by ISO 16368 Genie S-80 and S-85 Service Manual (from serial number 5381 to 7999) ... 122149 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Copyright © 2011 Terex Corporation 122985 Rev D February 2012 Seventh Edition, Fourth Printing "Genie" and "S" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper Contact Us: Printed in U.S.A. http://www.genielift.com e-mail: [email protected] ii S-80 • S-85 • S-80X Part No. 122985 September 2015 Revision History Revision Date Section Procedure / Schematic Page / Description D 2/2012 2 - Spec. 2-1 3 - Maint. 3-1, 3-51 4 - Repair 4-3 to 4-6, 4-18 3 - Maint. E-4 D1 9/2015 REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Part No. 122985 Electronic Version Click on any procedure or page number highlighted in blue to view the update. S-80 • S-85 • S-80X September 2015 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. S-80 • S-85 • S-80X Part No. 122985 September 2015 Serial Number Legend Model: S-80 S8008-12345 Serial number: Model year: 2006 Manufacture date: 01/05/06 Electrical schematic number: ES503 Machine unladen weight: Rated work load (including occupants): 500 lb / 227 kg Maximum number of platfrm occupants: 2 Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg S80 Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 80 ft/ 24.4 m 08 - 12345 Sequence number Model Maximum platform reach : 71 ft 6 in/ 21.8 m Gradeability: N/A Model year Country of manufacture: USA This machine complies with: Terex South Dakota 500 Oak Wood road PO Box 1150 Watertown, SD 57201 USA Sequence number (stamped on chassis) Serial label (located under cover) PN - 77055 Part No. 122985 S-80 • S-85 • S-80X iii September 2015 This page intentionally left blank. iv S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-80 and Genie S-85 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 122985 S-80 • S-85 • S-80X v Section 1 - Safety Rules September 2015 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Note: Used to indicate operation or maintenance information. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. vi S-80 • S-85 • S-80X Part No. 122985 September 2015 Table of Contents Introduction Important Information ................................................................................................... ii Serial Number Information ............................................................................................ ii Serial Number Legend ................................................................................................. iii Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 2 Hydraulic Oil Specifications ................................................................................... 2 - 2 Hydraulic Component Specifications ...................................................................... 2 - 3 Valve Coil Resistance Specifications ..................................................................... 2 - 4 Continental TME27 Engine Specifications ............................................................. 2 - 5 Deutz TD2011L04i Engine Specifications ............................................................... 2 - 6 Perkins 804D-33 Engine Specifications ................................................................. 2 - 7 Machine Torque Specifications .............................................................................. 2 - 8 Manifold Component Specifications ....................................................................... 2 - 8 Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 9 SAE and Metric Torque Specifications ................................................................. 2 - 10 Part No. 122985 S-80 • S-85 • S-80X vii September 2015 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 Checklist A Procedures A-1 Inspect the Manuals and Decals .................................................................. 3 - 7 A-2 Perform Pre-operation Inspection ................................................................. 3 - 8 A-3 Perform Engine Maintenance ....................................................................... 3 - 8 A-4 Perform Function Tests ................................................................................ 3 - 9 A-5 Test the Oscillate Axle ................................................................................. 3 - 9 A-6 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10 A-7 Perform 30 Day Service ............................................................................. 3 - 10 A-8 Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 11 A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11 A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13 A-11 Perform Engine Maintenance ..................................................................... 3 - 14 A-12 Replace the Drive Hub Oil .......................................................................... 3 - 15 A-13 Perform Engine Maintenance - Perkins Models .......................................... 3 - 17 Checklist B Procedures viii B-1 Inspect the Battery(s) ................................................................................. 3 - 18 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19 B-3 Test the Key Switch ................................................................................... 3 - 21 B-4 Check the Exhaust System ....................................................................... 3 - 21 S-80 • S-85 • S-80X Part No. 122985 September 2015 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued B-5 Inspect the Engine Air Filter ....................................................................... 3 - 22 B-6 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 23 B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 24 B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 24 B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 25 B-10 Check and Adjust the Engine RPM ............................................................ 3 - 26 B-11 Perform Engine Maintenance ..................................................................... 3 - 28 B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 28 B-13 Test the Ground Control Override ............................................................... 3 - 29 B-14 Test the Platform Self-leveling ................................................................... 3 - 29 B-15 Test the Engine Idle Select Operation ........................................................ 3 - 30 B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 31 B-17 Test the Drive Enable System ................................................................... 3 - 32 B-18 Test the Drive Brakes ................................................................................ 3 - 33 B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 33 B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 34 B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 35 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 36 B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 37 B-24 Inspect the Boom Extend/Retract Cables ................................................... 3 - 37 Checklist C Procedures Part No. 122985 C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 39 C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 39 C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 40 C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 43 C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 43 C-6 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X ....... 3 - 45 S-80 • S-85 • S-80X ix September 2015 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued Checklist D Procedures A Section 4 Rev D-1 Check the Boom Wear Pads ...................................................................... 3 - 48 D-2 Check the Free-wheel Configuration ........................................................... 3 - 49 D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 50 D-4 Inspect the Turntable Bearing Wear ........................................................... 3 - 51 D-5 Perform Engine Maintenance ..................................................................... 3 - 53 D-6 Replace the Hydraulic Filter Elements ........................................................ 3 - 53 D-7 Replace the Drive Hub Oil .......................................................................... 3 - 54 D-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56 Checklist E Procedures E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 57 E-2 Perform Engine Maintenance - Perkins Models .......................................... 3 - 59 E-3 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 59 E-4 Remove and Replace the Boom Extend/Retract Cables ............................. 3 - 60 Repair Procedures Introduction ............................................................................................................ 4 - 1 Platform Controls 1-1 ALC-500 Circuit Board .................................................................................. 4 - 2 1-2 Joysticks ..................................................................................................... 4 - 3 Platform Components x 2-1 Platform ....................................................................................................... 4 - 9 2-2 Platform Leveling Slave Cylinder ................................................................ 4 - 10 S-80 • S-85 • S-80X Part No. 122985 September 2015 TABLE OF CONTENTS Section 4 Rev Repair Procedures, continued 2-3 Platform Rotator ......................................................................................... 4 - 11 2-4 Calibrate the Platform Overload System .................................................... 4 - 13 Jib Boom Components, S-85 3-1 Jib Boom .................................................................................................... 4 - 16 3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 17 Boom Components 4-1 Cable Track ................................................................................................ 4 - 18 4-2 Boom ......................................................................................................... 4 - 21 4-3 Boom Lift Cylinder ...................................................................................... 4 - 24 4-4 Boom Extension Cylinders ......................................................................... 4 - 25 4-5 Boom Extend/Retract Cables ..................................................................... 4 - 28 4-6 Platform Leveling Master Cylinder .............................................................. 4 - 32 Engines 5-1 RPM Adjustment ........................................................................................ 4 - 33 5-2 Flex Plate ................................................................................................... 4 - 33 Ground Controls 6-1 Control Relays ............................................................................................ 4 - 38 Hydraulic Pumps Part No. 122985 7-1 Function Pump ........................................................................................... 4 - 39 7-2 Drive Pump ................................................................................................ 4 - 40 S-80 • S-85 • S-80X xi September 2015 TABLE OF CONTENTS Section 4 Rev Repair Procedures, continued Manifolds 8-1 Function Manifold Components .................................................................. 4 - 42 8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 44 8-3 Brake/Two-speed Manifold Components .................................................... 4 - 46 8-4 Turntable Rotation Manifold Components ................................................... 4 - 47 8-5 Platform Rotate Manifold Components ....................................................... 4 - 48 8-6 Platform Manifold Components, S-80 ......................................................... 4 - 49 8-7 Platform Manifold Components, S-85 ......................................................... 4 - 50 8-8 2WD Traction Manifold Components .......................................................... 4 - 51 8-9 4WD Traction Manifold Components (before serial number 8581) ............... 4 - 53 8-10 4WD Traction Manifold Components (after serial number 8580) .................. 4 - 55 8-11 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 57 8-12 Valve Adjustments - Traction Manifold ....................................................... 4 - 58 8-13 Valve Coils ................................................................................................. 4 - 59 Fuel and Hydraulic Tanks 9-1 Fuel Tank ................................................................................................... 4 - 61 9-2 Hydraulic Tank ........................................................................................... 4 - 62 Turntable Rotation Components 10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 64 2WD Steer Axle Components 11-1 Yoke and Hub ............................................................................................ 4 - 67 11-2 Steer Cylinder ............................................................................................ 4 - 68 xii S-80 • S-85 • S-80X Part No. 122985 September 2015 TABLE OF CONTENTS Section 4 Rev Repair Procedures, continued 4WD Steer Axle Components 12-1 Yoke and Drive Hub ................................................................................... 4 - 69 12-2 Drive Motor ................................................................................................ 4 - 70 12-3 Drive Hub ................................................................................................... 4 - 70 12-4 Steer Cylinders ........................................................................................... 4 - 71 Non-steer Axle Components 13-1 Drive Motor ................................................................................................ 4 - 72 13-2 Drive Hub ................................................................................................... 4 - 72 Oscillating Axle Components 14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73 14-2 Oscillate Directional Valve ......................................................................... 4 - 74 Section 5 Rev Fault Codes Introduction ............................................................................................................ 5 - 1 Fault Codes - Control System ................................................................................ 5 - 2 Engine Fault Codes - Continental Models ............................................................... 5 - 7 Section 6 Rev Schematics Introduction ............................................................................................................ 6 - 1 Electrical Symbols Legend .................................................................................... 6 - 2 Hydraulic Symbols Legend .................................................................................... 6 - 3 Connector Pin Legend - View 1 .............................................................................. 6 - 6 Connector Pin Legend - View 2 .............................................................................. 6 - 7 Part No. 122985 S-80 • S-85 • S-80X xiii September 2015 TABLE OF CONTENTS Section 6 Rev Schematics, continued Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ......................................................................... 6 - 10 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 14 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 15 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ......................................................................... 6 - 18 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 19 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 22 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 26 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 27 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 30 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 31 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 34 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 38 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 39 xiv S-80 • S-85 • S-80X Part No. 122985 September 2015 TABLE OF CONTENTS Section 6 Rev Schematics, continued Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 42 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 43 Electrical Schematic, S-80X Deutz TD2011L04i Models ......................................................................... 6 - 46 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Deutz TD2011L04i Models ......................................................................... 6 - 50 Ground Control Box Switch panel Wiring Diagram, S-80X, Deutz TD2011L04i Models ......................................................................... 6 - 51 Platform Control Box Wiring Diagram, S-80X, Deutz TD2011L04i Models ......................................................................... 6 - 54 Platform Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04i Models ......................................................................... 6 - 55 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ............................................................................ 6 - 58 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 62 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 63 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ............................................................................ 6 - 66 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 67 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 70 Part No. 122985 S-80 • S-85 • S-80X xv September 2015 TABLE OF CONTENTS Section 6 Rev Schematics, continued Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 74 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 75 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 78 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 79 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 82 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 86 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 87 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 90 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 91 Electrical Schematic, S-80X, Perkins 804D-33 Models ............................................................................ 6 - 94 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Perkins 804D-33 Models ............................................................................ 6 - 98 Ground Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models ............................................................................ 6 - 99 Platform Control Box Wiring Diagram, S80X, Perkins 804D-33 Models ........................................................................... 6 - 102 Platform Control Box Switch Panel Wiring Diagram, S80X, Perkins 804D-33 Models ........................................................................... 6 - 103 xvi S-80 • S-85 • S-80X Part No. 122985 September 2015 TABLE OF CONTENTS Section 6 Rev Schematics, continued Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ....................................................................... 6 - 106 Ground Control Box Terminal Strip Wiring Diagram S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 110 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 111 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ....................................................................... 6 - 114 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ................. 6 - 115 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ............................ 6 - 118 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ............................ 6 - 122 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ............................ 6 - 123 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ............................ 6 - 126 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ............................ 6 - 127 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ............................... 6 - 130 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ............................... 6 - 134 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ............................... 6 - 135 Part No. 122985 S-80 • S-85 • S-80X xvii September 2015 TABLE OF CONTENTS Section 6 Rev Schematics, continued ................................................................................................. Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ............................... 6 - 138 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ............................... 6 - 139 Electrical Schematic, S-80X, Continental TME27 Models ....................................................................... 6 - 142 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Continental TME27 Models ....................................................................... 6 - 146 Ground Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models ....................................................................... 6 - 147 Platform Control Box Wiring Diagram, S-80X, Continental TME27 Models ....................................................................... 6 - 150 Platform Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models ....................................................................... 6 - 151 Continental TME27 Engine Harness .................................................................... 6 - 154 Platform Level Cutout, CTE Option ..................................................................... 6 - 155 Continental Options Schematic ........................................................................... 6 - 158 Deutz and Perkins Options Schematic ................................................................ 6 - 159 12 kW Hydraulic Generator Wiring Diagram ......................................................... 6 - 162 12 kW Hydraulic Generator Electrical Schematic ................................................ 6 - 163 Belt Driven Generator Option .............................................................................. 6 - 166 Relay and Fuse Panel Legend ............................................................................ 6 - 167 Hydraulic Schematic, 2WD Models ..................................................................... 6 - 170 Hydraulic Schematic, 4WD Models ..................................................................... 6 - 171 12 kW Hydraulic Generator Hydraulic Schematic ................................................ 6 - 173 xviii S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 2 • Specifications Specifications Machine Specifications Fluid capacities Rough Terrain and Non Marking Tires and Wheels Fuel tank, (Deutz and Perkins models) 35 gallons 132.5 liters (Continental models) 30 gallons 113.5 liters Tire size Tire ply rating Overall tire diameter Tire pressure Wheel diameter Wheel width Tire weight, new foam-filled (minimum) 18-625 FF 16 40.7 in 103.3 cm Foam filled 24.5 in 62.2 cm 15 in 38.1 cm 622 lbs 282 kg 41/18LLx22.5 Tire ply rating 14 Tire pressure 70 psi 4.8 bar Wheel diameter 22.5 in 57 cm Wheel width 33.5 pounds 15.2 kg Hydraulic tank 40 gallons 151.4 liters Hydraulic system (including tank) 50 gallons 189.3 liters Turntable rotation drive hub (single fill port) Turntable rotation drive hub (Dual fill ports) Four wheel drive hubs High Floatation Tires and Wheels Tire size LPG tank Two wheel drive hubs 40 fl oz 1.2 liters 43 fl oz 1.3 liters 30.5 fl oz 0.90 liters 23 fl oz 0.68 liters Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 For operational specifications, refer to the Operator's Manual. 14 in 35.6 cm Lugs and Lug Nut Torque Wheel lugs 10 @ 3/4 -16 Lug nut torque, dry 420 ft-lbs 569 Nm Lug nut torque, lubricated 320 ft-lbs 434 Nm Part No. 122985 S-80 • S-85 • S-80X 2-1 September 2015 Section 2 • Specifications SPECIFICATIONS Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Oil Specifications Stowed position RT Tires 40 ft / 7.9-8.5 sec 12.2 m / 7.9-8.5 sec Stowed position Flotation Tires 40 ft / 11-13 sec 12.2 m / 11-13 sec Raised or extended position 40 ft / 40-45 sec 12.2 m / 40-45 sec Braking distance, maximum High range on paved surface Gradeability 3 ft 90 cm Refer to the Operator’s Manual Boom function speeds, maximum from platform controls Hydraulic oil type Viscosity grade Viscosity index Cleanliness level, minimum Water content, maximum 25 to 35 seconds Optional fluids Jib boom down (S-85) 15 to 25 seconds Biodegradable Boom up (ANSI, CSA, AS models) 57 to 65 seconds Boom up (CE models) 75 to 83 seconds Fire resistant Boom down (ANSI, CSA, AS models) 61 to 69 seconds 75 to 83 seconds Boom extend 59 to 67 seconds Boom retract 57 to 65 seconds Turntable rotate, 360° boom fully stowed Turntable rotate, 360° boom raised or extended Platform rotate, 160° 200 ppm Mineral based Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S UCON Hydrolube HP-5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A 95 to 103 seconds 210 to 250 seconds 8 to 12 seconds Platform level up 50 to 60 seconds Platform level down 40 to 50 seconds 2-2 15/13 Chevron Rando HD MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Jib boom up (S-85) Boom down (CE models) Chevron Rando HD MV equivalent Multi-viscosity 200 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 2 • Specifications SPECIFICATIONS Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32°F / 0°C may result in component damage. Hydraulic Component Specifications Drive pump Note: Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below 0°F / -18°C. Type: bi-directional variable displacement piston pump Note: Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C. Flow rate @ 2300 rpm Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use. Drive pressure, maximum Displacement 0 to 2.8 cu in 0 to 46 cc 0 to 30.3 gpm 0 to 114.7 L/min 3750 psi 259 bar Charge pump Type: gerotor Displacement 0.85 cu in 13.9 cc Flow rate @ 2300 rpm 9 gpm 34.1 L/min Charge pressure @ 2300 rpm Neutral position 310 psi 21.4 bar Function pump Type: variable displacement piston pump Displacement 0 to 2.3 cu in 0 to 38 cc Flow rate @ 2300 rpm 0 to 23 gpm 0 to 87 L/min Auxiliary pump Type: Displacement - static Part No. 122985 S-80 • S-85 • S-80X fixed displacement gear pump 0.151 cu in 2.47 cc 2-3 September 2015 Section 2 • Specifications SPECIFICATIONS Function manifold System relief pressure (measured at PTEST port) 3200 psi 221 bar Boom down relief pressure (measured at PTEST port) 2400 psi 165 bar Boom extend relief pressure (measured at PTEST port) 2400 psi 165 bar Steer/axle extend flow regulator 3.5 gpm 13.2 L/min Oscillate relief pressure 950 psi 65.5 bar Drive manifold Hot oil relief pressure 280 psi 19.3 bar Brake release pressure Wheel drive hubs 240 psi 16.5 bar Drive motors Displacement per revolution, variable (2 speed motor) 0.9 to 2.7 cu in 14.7 to 45 cc Hydraulic filters High pressure filter Beta 3 ≥ 200 High pressure filter bypass pressure 102 psi 7 bar Medium pressure filter Beta 3 ≥ 200 Medium pressure filter bypass pressure 51 psi 3.5 bar Hydraulic tank return filter 2-4 Valve Coil Resistance Specifications Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / -7.8°C that your air temperature increases or decreases from 68°F / 20°C. Valve coil resistance specifications Proportional solenoid valve (schematic items SE) 3.7 Ω Proportional solenoid valve (schematic items SR and SF) 4.8 Ω 2 position 3 way solenoid valve (schematic items SJ) 4.1 Ω 2 position 3 way solenoid valve (schematic items SK) 9Ω 3 position 4 way solenoid valve (schematic items SI and SL) 7.2 Ω Solenoid valve, NO, Poppet (schematic items SP and SQ) 5.6 Ω 10 micron with 25 psi / 1.7 bar bypass S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 2 • Specifications SPECIFICATIONS Continental TME27 Engine Displacement Fuel Requirement 164 cu in 2.68 liters 4 Number of cylinders Bore and stroke Horsepower Firing order Compression ratio 3.58 x 4.06 inches 91 x 103.2 mm 59.03 @ 2500 rpm 44 kW @ 2500 rpm 1-3-4-2 8.2:1 Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Low idle - computer controlled Frequency 1600 rpm 53.33 Hz High idle - computer controlled Frequency 2500 rpm 83.33 Hz For fuel requirements, refer to the engine Operator's Manual on your machine. Electronic fuel pump Fuel pressure, static Fuel flow rate Type Exhaust 0.018 in 0.46 mm 12V DC Group 31 Quantity Cold cranking ampere Reserve capacity @ 25A rate Alternator output Fan belt deflection 0.014 in 0.36 mm 0.42 gpm 1.59 L/min Batteries Valve clearance, warm Intake 55 psi 3.8 bar 1 1000A 200 minutes 65A @ 13.8V DC 1 /2 inch 12 mm Lubrication system Oil pressure Oil capacity (including filter) 40-60 psi 2.8-4.1 bar 7 quarts 6.65 liters Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Part No. 122985 S-80 • S-85 • S-80X 2-5 September 2015 Section 2 • Specifications SPECIFICATIONS Deutz TD2011L04i Engine Displacement Oil viscosity requirements 189.6 cu in 3.1 liters 4 Number of cylinders Bore and stroke 3.7 x 4.409 inches 94 x 112 mm Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil temperature switch Oil temperature switch point 284°F 140°C Horsepower Continuous Net intermittent Continuous Net intermittent Firing order 69.1 @ 2500 rpm 72.8 @ 2500 rpm 51.5 KW @ 2500 rpm 54.3 KW @ 2500 rpm 1-3-4-2 Oil pressure switch Oil pressure switch point Fuel injection system Low idle Frequency 1300 rpm 331.5 Hz Injection pump make High idle Frequency 2350 rpm 599.3 Hz Injector opening pressure Compression ratio 17.5:1 Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor centrifugal mechanical Exhaust 0.012 in 0.3 mm 0.020 in 0.5 mm Oil capacity (including filter) 2-6 Injection pump pressure, maximum15,000 psi/1034 bar 3046 psi 210 bar Fuel Requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Batteries 21.8 psi 1.5 bar 12V DC Group 31 Quantity 1 Cold cranking ampere Reserve capacity @ 25A rate Lubrication system Minimum oil pressure, hot (at 1300 rpm) Bosch Type Valve clearance, cold Intake 22 psi 1.5 bar Alternator output Fan belt deflection 12.8 quarts 12.1 liters S-80 • S-85 • S-80X 1000A 200 minutes 80A @ 14V DC 3 /8 to 1/2 inch 9 to 12 mm Part No. 122985 September 2015 Section 2 • Specifications SPECIFICATIONS Perkins 804D-33 Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Injection system 201 cu in 3.3 liters Injection pump make Injection pump pressure 4 3.70 x 4.72 inches 94 x 120 mm 63 @ 2600 rpm 47 KW @ 2600 rpm 1-3-4-2 22:1 300 to 500 psi 20.7 to 34.5 bar Pressure (psi or bar) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder Compression pressure Low idle Frequency 1650 rpm 335.5 Hz High idle Frequency 2300 rpm 467.7 Hz Injector opening pressure 1707 to 1849 psi 117.7 to 127.5 bar ~2000 psi ~138 bar Fuel Requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Engine coolant Capacity 12.5 quarts 11.8 liters Batteries Type Group Quantity Cold cranking ampere Governor Zexel 12V DC 31 1 1000A mechanical all speed Reserve capacity @ 25A rate 200 minutes Valve clearance, cold Alternator output Intake Exhaust 0.0098 in 0.25 mm Fan belt deflection 90A, 12V DC 3/8 to 1/2 in 9 to 12 mm 0.0098 in 0.25 mm Lubrication system Oil pressure @ 2000 rpm 40-60 psi 2.8-4.1 bar Oil capacity (including filter) 10.6 quarts 10 liters Oil viscosity requirements Units ship with 15W-40. Extreme operating temperatures my require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Part No. 122985 S-80 • S-85 • S-80X 2-7 September 2015 Section 2 • Specifications SPECIFICATIONS Machine Torque Specifications Platform rotator 1-8 center bolt, GR 5, lubricated 3 /8 -16 bolts, GR 8 *(use blue thread locking compound) 480 ft-lbs 651 Nm 35 ft-lbs* 47 Nm* Turntable rotate assembly Rotate bearing mounting bolts, lubricated Rotate drive hub mounting bolts, lubricated Backlash plate mounting bolts, lubricated 180 ft-lbs 244 Nm 80 ft-lbs 108 Nm Manifold Component Specifications Plug torque SAE No. 2 50 in-lbs / 6 Nm SAE No. 4 14 ft-lbs / 18.9 Nm SAE No. 6 23 ft-lbs / 31.2 Nm SAE No. 8 36 ft-lbs / 48.8 Nm SAE No. 10 62 ft-lbs / 84.1 Nm SAE No. 12 84 ft-lbs / 113.9 Nm 280 ft-lbs 379 Nm Drive motor and hubs Drive hub mounting bolts, dry Drive hub mounting bolts, lubricated *(use blue thread locking compound) 210 ft-lbs 284 Nm 160 ft-lbs* 217 Nm Drive motor mounting bolts, dry 110 ft-lbs 149 Nm Drive motor mounting bolts, lubricated *(use blue thread locking compound) 80 ft-lbs* 108 Nm Drive hub oil plug, O-ring seal 13 ft-lbs 18 Nm 2-8 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 2 • Specifications SPECIFICATIONS Seal-Lok® fittings Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok® fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. SAE O-ring Boss Port (tube fitting - installed into Aluminum) 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-rings used in the Parker Seal Lok® fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. SAE Dash size Torque -4 14 ft-lbs / 18.9 Nm -6 23 ft-lbs / 31.2 Nm -8 36 ft-lbs / 48.8 Nm -10 62 ft-lbs / 84.1 Nm -12 84 ft-lbs / 113.9 Nm -16 125 ft-lbs / 169.5 Nm -20 151 ft-lbs / 204.7 Nm -24 184 ft-lbs / 250 Nm 3 Be sure that the face seal O-ring is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table. 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. SAE O-ring Boss Port Seal-Lok® Fittings (tube fitting - installed into Steel) (hose end) SAE Dash size Torque SAE Dash size Torque -4 15 ft-lbs / 20.3 Nm -4 18 ft-lbs / 24.4 Nm -6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm -8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm -10 100 ft-lbs / 135.6 Nm -10 60 ft-lbs / 80 Nm -12 135 ft-lbs / 183 Nm -12 85 ft-lbs / 115 Nm -16 200 ft-lbs / 271 Nm -16 110 ft-lbs / 150 Nm -20 250 ft-lbs / 334 Nm -20 140 ft-lbs / 190 Nm -24 305 ft-lbs / 414 Nm -24 180 ft-lbs / 245 Nm Part No. 122985 S-80 • S-85 • S-80X 2-9 September 2015 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • SIZE Grade 5 THREAD LUBED 20 28 1/4 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 1/2 LUBED DRY DRY in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm 80 90 9 10.1 100 120 11.3 13.5 110 120 12.4 13.5 140 160 15.8 18 130 140 14.7 15.8 LUBED 5/16 A574 High Strength Black Oxide Bolts LUBED Grade 8 DRY LUBED DRY LUBED ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm 13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190 23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560 33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826 21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000 28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067 METRIC FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • Size (mm) 5 6 7 4.6 Class 4.6 LUBED 2 - 10 Class 8.8 LUBED DRY 10.9 DRY Class 10.9 LUBED 12.9 DRY Class 12.9 LUBED DRY in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm 16 19 45 1.8 3.05 5.12 21 36 60 2.4 4.07 6.83 41 69 116 4.63 7.87 13.2 54 93 155 6.18 10.5 17.6 58 100 167 6.63 11.3 18.9 78 132 223 8.84 15 25.2 68 116 1.95 7.75 13.2 22.1 91 155 260 10.3 17.6 29.4 LUBED 8 10 12 14 16 18 20 22 24 8.8 DRY LUBED DRY LUBED DRY LUBED DRY ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm 5.4 10.8 18.9 30.1 46.9 64.5 91 124 157 7.41 14.7 25.6 40.8 63.6 87.5 124 169 214 7.2 14.4 25.1 40 62.5 86.2 121 166 210 9.88 19.6 34.1 54.3 84.8 117 165 225 285 14 27.9 48.6 77.4 125 171 243 331 420 19.1 37.8 66 105 170 233 330 450 570 18.8 37.2 64.9 103 166 229 325 442 562 25.5 50.5 88 140 226 311 441 600 762 20.1 39.9 69.7 110 173 238 337 458 583 27.3 54.1 94.5 150 235 323 458 622 791 26.9 53.2 92.2 147 230 317 450 612 778 36.5 72.2 125 200 313 430 610 830 1055 23.6 46.7 81 129 202 278 394 536 682 32 63.3 110 175 274 377 535 727 925 31.4 62.3 108 172 269 371 525 715 909 42.6 84.4 147 234 365 503 713 970 1233 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Each procedure includes a description, safety warnings and step-by-step instructions. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every two years as specified on the Maintenance Inspection Report. The frequency and extent of periodic examinations and tests may also depend on national regulations. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial machine damage. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Immediately tag and remove from service a damaged or malfunctioning machine. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Repair any machine damage or malfunction before operating machine. Use only Genie approved replacement parts. Machines that have been out of service for a period longer than three months must complete the quarterly inspection. Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Boom in the stowed position • Turntable rotated with the boom between the non-steer (yellow arrow) wheels • Turntable secured with the turntable rotation lock pin • Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 122985 Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Note: Used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. S-80 • S-85 • S-80X 3-1 Section 3 • Scheduled Maintenance Procedures September 2015 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below. The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies of the Pre-delivery Preparation Report to use for each inspection. Store completed forms as required. Maintenance Schedule Indicates that tools will be required to perform this procedure. Indicates that new parts will be required to perform this procedure. Indicates that a cold engine will be required to perform this procedure. Indicates that a warm engine will be required to perform this procedure. There are five types of maintenance inspections that must be performed according to a schedule— daily, quarterly, six months, annual, and two year. To account for repeated procedures, the Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection Daily or every 8 hours Quarterly or every 250 hours Indicates that dealer service is required to perform this procedure. Checklist Six month or every 500 hours Annual or every 1000 hours Two year or every 2000 hours A A+B A+B+C A+B+C+D A+B+C+D+E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of four years or in compliance with employer, jobsite and governmental regulations and requirements. 3-2 S-80 • S-85 • S-80X Part No. 122985 Pre-Deliver Pre-Deliveryy Preparation Fundamentals Instructions It is the responsibility of the dealer to perform the Pre-delivery Preparation. Use the operator’s manual on your machine. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual. If any inspection receives an N, remove the machine from service, repair and reinspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments Pre-Delivery Preparation Pre-operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 (605) 882-4000 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D Y N R Section 3 • Scheduled Maintenance Procedures September 2015 This page intentionally left blank. 3-4 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Serial number A-1 Inspect the manuals and decals B-1 Battery(s) Date A-2 Pre-operation inspection B-3 Key switch Hour meter A-3 Engine maintenance Y N R A-4 Function tests Checklist B B-2 Electrical wiring B-4 Exhaust system B-5 Engine air filter Machine owner A-5 Oscillate axle B-6 Oil cooler and finsDeutz models Inspected by (print) A-6 Filter condition indicator B-7 Brake configuration Perform after 40 hours: A-7 30 day service B-8 Tires, wheels and lug nut torque Perform after 50 hours: B-9 Drive hub maintenance A-8 Engine maintenance Deutz and Continental models B-10 Engine RPM Inspector signature Inspector title Inspector company B-11 Engine maintenance Instructions • Make copies of this report to use for each inspection. Perform every 100 hours: B-12 Oscillate directional Control A-9 Inspect filter/separator Diesel models B-13 Ground control override • Select the appropriate checklist(s) for the type of inspection to be performed. A-10 Grease rotation bearing B-14 Platform self-leveling Perform after 150 hours: Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: A-11 Engine maintenance A A-12 Replace Drive Hub oil Perform every 200 hours: A+B Six Month or 500 hour Inspection: A+B+C A-13 Engine maintenance Perkins models B-15 Engine idle select B-16 Fuel select operation B-17 Drive enable system B-18 Drive brakes B-19 Drive speed-stowed B-20 Drive speed-raised or extended B-21 Alarm package and descent alarm Annual or 1000 hour Inspection: A+B+C+D B-22 Fuel and hydraulic tank venting systems 2 Year or 2000 hour Inspection: A+B+C+D+E • Place a check in the appropriate box after each inspection procedure is completed. • Use the step-by-step procedures in this section to learn how to perform these inspections. Y N R B-23 Hydraulic oil analysis B-24 Inspect the Boom Extend/Retract Cables Comments • If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 122985 S-80 • S-85 • S-80X 3-5 Section 3 • Scheduled Maintenance Procedures September 2015 MAINTENANCE INSPECTION REPORT Model Checklist C Y N R Checklist E Y N R C-1 Engine maintenance E-1 Hydraulic oil Date C-2 Grease platform overload (if equipped) E-2 Engine maintenance Perkins models C-3 Test the platform overload (if equipped) Perform every 3000 hours: Hour meter Serial number E-3 Engine maintenance Deutz and Perkins models C-4 Air filter element Machine owner C-5 Replace filter/separator Deutz and Perkins models Inspected by (print) Inspector signature C-6 Safety envelope S-80X Inspector title Checklist D Perform every 10 years: E-4 Replace the Boom Extend/Retract Cables Y N R D-1 Boom wear pads Inspector company D-2 Free-wheel configuration Instructions • Make copies of this report to use for each inspection. D-3 Turntable rotation bearing bolts D-4 Turntable bearing wear • Select the appropriate checklist(s) for the type of inspection to be performed. D-5 Engine maintenance D-6 Replace hydraulic filters D-7 Drive hub oil Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: A A+B Perform every 1500 hours: D-8 Engine maintenance Deutz models Six Month or 500 hour Inspection: A+B+C Annual or 1000 hour Inspection: A+B+C+D Comments 2 Year or 2000 hour Inspection: A+B+C+D+E • Place a check in the appropriate box after each inspection procedure is completed. • Use the step-by-step procedures in this section to learn how to perform these inspections. • If any inspection receives an “N”, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3-6 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures Checklist A Procedures A-1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed daily. Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage. Result: The machine is equipped with all required decals, and all decals are legible and in good condition. Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced. 4 Always return the manuals to the storage container after use. Note: Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed. 1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform. 2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced. Part No. 122985 S-80 • S-85 • S-80X 3-7 Section 3 • Scheduled Maintenance Procedures CHECKLIST A September 2015 PROCEDURES A-2 Perform Pre-operation Inspection A-3 Perform Engine Maintenance Genie specifications require that this procedure be performed daily. Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number 111901 To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3-8 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-4 Perform Function Tests A-5 Test the Oscillate Axle Genie specifications require that this procedure be performed daily. Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Genie specifications require that this procedure be performed daily. Proper axle oscillation is essential to safe machine operation. If the axle oscillation system is not operating correctly, the stability of the machine is compromised and it may tip over. Tip-over hazard. Failure to perform this procedure on a firm, level surface will compromise the stability of the machine and could result in the machine tipping over. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 1 Start the engine from the platform controls. 2 Drive the right steer tire up onto a 6 inch / 15 cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. 3 Drive the left steer tire up onto a 6 inch / 15 cm block or curb. Result: The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times. 4 Drive both steer tires up onto a 6 inch / 15 cm block or curb. Result: The non-steer tires should stay in firm contact with the ground. Note: If the chassis does not remain level during the test, refer to Repair Procedure 14-2, How to Set Up the Directional Valve Linkage. Part No. 122985 S-80 • S-85 • S-80X 3-9 Section 3 • Scheduled Maintenance Procedures CHECKLIST A September 2015 PROCEDURES A-6 Check the High Pressure Hydraulic Filter Condition Indicator A-7 Perform 30 Day Service Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage, whichever comes first. After this interval, refer to the maintenance tables for continued scheduled maintenance. Maintaining the high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation. The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. If the filter is not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. 1 Perform the following maintenance procedures: • A-10 Grease the Turntable Rotation Bearing and Rotate Gear • B-8 Inspect the Tires, Wheels and Lug Nut Torque 2 Start the engine from the ground controls. • B-9 3 Change the engine idle to high rpm (rabbit symbol). Check the Drive Hub Oil Level and Fastener Torque • B-24 Inspect the Boom Extend/Retract Cables • D-4 Check the Turnable Rotation Bearing Bolts • D-7 Replace the Hydraulic Filter Elements 1 Open the engine side turntable cover. 4 Visually inspect the filter condition indicator. Result: The filter condition indicator should be operating with the plunger in the green area. Result: If the indicator displays the plunger in the red area, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. See D-6, Replace the Hydraulic Filters. 3 - 10 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-8 Perform Engine Maintenance Deutz and Continental Models A-9 Inspect the Fuel Filter/Water Separator - Diesel Models Engine specifications require that this one-time procedure be performed after the first 50 hours of operation. Genie specifications require that this procedure be performed every 100 hours or monthly, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and/or hard starting, and continued use may result in component damge. Extremely dirty conditions may require this procedure be performed more often. Required maintenance procedures for commissioning new and overhauled engines and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number 139320 Continental TME27 Owner's Manual Genie part number 111901 Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. To access the engine: Perkins Models: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 1 Put on protective clothing and eye wear. 2 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. 3 Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps 4 through 8. S-80 • S-85 • S-80X 3 - 11 Section 3 • Scheduled Maintenance Procedures CHECKLIST A September 2015 PROCEDURES 4 Loosen the vent plug located on the fuel filter/ water separator head. 8 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. a d c Deutz Models: b 1 Put on protective clothing and eye wear. a b c d 2 Remove the engine tray retaining fastener located under the engine tray.Swing the engine tray out and away from the machine. vent plug drain plug filter bowl separator head 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. 5 Loosen the drain plug located at the bottom of the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 6 Tighten the vent plug. Note: If the fuel filter/water separator is completely drained, you must prime the fuel filter/water separator before starting the engine. See C-6, Replace The Fuel Filter/Water Separator Element Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 4 Locate the fuel filter/water separator next to the oil filter. Clean up any fuel that may have spilled. 3 - 12 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 5 Loosen the drain plug located at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. A-10 Grease the Turntable Rotation Bearing and Rotate Gear Note: Do not completely drain the filter. Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. a b Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Locate the grease fitting on the platform end of the tank side bulkhead. a b fuel filter/water separator drain valve 6 Clean up any fuel that may have spilled. 7 Start the engine from the ground controls and check the fuel filter/water separator for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 122985 2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased. 3 Apply grease to each tooth of the drive gear, located under the turntable. Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent S-80 • S-85 • S-80X 3 - 13 Section 3 • Scheduled Maintenance Procedures CHECKLIST A September 2015 PROCEDURES A-11 Perform Engine Maintenance To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Engine specifications require that this procedure be performed every 100 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Required maintenance procedures and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number 3 - 14 111901 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole. Install the plugs. A-12 Replace the Drive Hub Oil Manufacturer specifications require that this one-time procedure be performed after the first 150 hours. Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil after the initial 150 hours of use may cause the machine to perform poorly and continued use may cause component damage. Drive hubs: 1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point. 5 Install the plugs into the drive hub. Torque to Specification. Refer to Section 2, Specifications. 6 Repeat steps 1 through 4 for the other drive hub. 7 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications. Turntable rotate drive hub: Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Remove both plugs and drain the oil into a suitable container. Note: The turntable rotation lock pin is located next 3 Drive the machine until one plug is at the top and the other is at 90 degrees. a to the boom rest pad. 2 Tag, disconnect and plug the hydraulic hoses from the turntable rotate drive motor. Cap the fittings on the drive motor. 3 Attach a suitable lifting device to the lifting eyes located near the drive motor. a. Part No. 122985 models with o-ring plugs S-80 • S-85 • S-80X 3 - 15 Section 3 • Scheduled Maintenance Procedures CHECKLIST A September 2015 PROCEDURES 4 Remove the drive hub mounting bolts. Carefully remove the turntable rotate drive hub assembly from the machine. Crushing hazard. The turntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device. a B 5 Remove the plug the drive hub. Drain the oil from the hub into a suitable container. c a B A b A d b Dual fill port rotator a motor b drive hub c drive hub mounting bolts d fill ports 6 Install the drive hub assembly onto the machine. Torque the drive hub mounting bolts to specification. Refer to Section 2, Specifications. d Single fill port rotator a motor b fill port c drive hub mounting bolts d drive hub 3 - 16 c 7 Fill the drive hub with oil. Refer to Section 2, Specifications. Apply pipe thread sealant to the plug. Install the plug. 8 Adjust turntable rotation gear backlash. Refer to Repair Procedure 10-1, How to Adjust the Turntable Rotation Gear Backlash. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-13 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 200 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Perkins 804D-33 Operation and Maintenance Manual Genie part number To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 S-80 • S-85 • S-80X 3 - 17 Section 3 • Scheduled Maintenance Procedures September 2015 Checklist B Procedures 3 Be sure that the battery hold downs and cable connections are tight. B-1 Inspect the Battery(s) 4 Be sure that the battery separator wire connections are tight (if equipped). Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. A single battery configuraton is standard. A dual battery option is available, where one battery is used to start the engine and the other is used to power the control system and auxiliary power unit. The two batteries are charged by the alternator through a battery separator. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. 1 Put on protective clothing and eye wear. 5 Fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 11. Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 8. 8 Perform an equalizing charge, OR fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 2 Be sure that the battery cable connections are free of corrosion. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 - 18 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: B-2 Inspect the Electrical Wiring • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display a specific gravity of 1.277 or greater. The battery is fully charged. Proceed to step 11. Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is less than 1.177. Replace the battery. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution/ burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 11 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 12 Install the vent caps and neutralize any electrolyte that may have spilled. 1 Open the turntable cover at the engine side of the machine. 2 Remove the engine tray retaining fastener. Swing the engine tray out away from the machine. a b a b Part No. 122985 S-80 • S-85 • S-80X engine tray anchor hole engine tray retaining fastener 3 - 19 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 3 Locate the engine tray anchor hole on the turntable. 4 Install the bolt that was just removed into the anchor hole to secure the engine tray from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 5 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: • September 2015 13 Inspect for a liberal coating of dielectric grease in the following location: • All wire harness connectors to platform control box 14 Remove the engine tray retaining fastener from the engine tray anchor hole at the pivot end of the engine tray. 15 Swing the engine tray in towards the machine. 16 Install the engine tray retaining fasteners. Engine wiring harness 6 Open the turntable cover at the ground controls side of the machine. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 7 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: • Battery area wiring • Inside the ground control box • Hydraulic manifold wiring • Hydraulic oil cooler wiring 8 Inspect for a liberal coating of dielectric grease in the following locations: • All wire harness connectors to ground control box 9 Start the engine from the ground controls and raise the boom above the turntable covers. 10 Inspect the turntable area for burnt, chafed and pinched cables. 11 Lower the boom to the stowed position and turn the engine off. 12 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: • Cable track on the boom • Cables on the boom and jib boom • Jib, rotate, level manifold • Inside of the platform control box 3 - 20 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-3 Test the Key Switch B-4 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. 2 Turn the key switch to ground control, start the engine and then turn the key switch to platform control. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 3 Check all machine function from the ground controls. Result: All machine functions should not operate. 4 Turn the key switch to ground control. 5 Check all machine function from the platform controls. To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Result: All machine functions should not operate. 6 Turn the key switch to the off position. Result: The engine should stop and no functions should operate. Part No. 122985 S-80 • S-85 • S-80X Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 21 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES 2 Be sure that all nuts and bolts are tight. 3 Inspect all welds for cracks. 4 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. B-5 Inspect the Engine Air Filter Continental, Deutz and Perkins Models 5 Swing the engine pivot plate in towards the machine. 6 Install the bolts that were just removed into the original holes to secure the engine pivot plate. Crushing hazard. Failure to install the bolts into the engine pivot plate to secure it from moving could result in death or serious injury. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Note: Perform this procedure with the engine off. 1 Locate the engine air filter assembly. 2 Release the latches from the air cleaner canister end cap. Remove the end cap. 3 Remove the filter element. 4 Clean the inside of the canister and the end cap with a damp cloth. 5 Inspect the air filter element. If needed, blow from the inside out using low pressure dry compressed air, or carefully tap out dust. Replace the filter if needed. 6 Install the filter element. 7 Install the air filter canister end cap and secure the end cap latches. Note: Be sure the discharge valve is pointing down when the cap is instaled. 3 - 22 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-6 Check the Oil Cooler and Cooling Fins - Deutz Models 3 Remove the fasteners from the engine side cover, then remove the cover. 4 Inspect the oil cooler for leaks and physical damage. a b c Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the oil cooler in good condition is essential for good engine performance. Operating a machine with a damaged oil cooler may result in engine damage. Also, restricting air flow through the oil cooler will affect the performance of the cooling system. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. Oil cooler: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 a b c oil cooler cylinder head cooling fins fan blower fins 5 Clean the oil cooler of debris and foreign material. Cooling and fan blower fins: 6 Inspect the fan blower fins for physical damage. 7 Clean the fan blower fins of debris and foreign material. 8 Inspect the head cooling passages and fins for physical damage or foreign material, using a flashlight. 9 Clean the cylinder head cooling passages of debris and foreign material. 10 Install the engine side cover. 11 Swing the engine back to its original position and install the engine pivot plate retaining fastener. S-80 • S-85 • S-80X 3 - 23 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES B-7 Confirm the Proper Brake Configuration B-8 Inspect the Tires, Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake configuration is essential to safe operation and good machine performance. Hydrostatic brakes and hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. Maintaining the tires and wheels in good condition, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. 1 Check each drive hub disconnect cap to be sure it is in the engaged position. Bodily injury hazard. An overinflated tire can explode and could result in death or serious injury. disengaged position engaged position Tip-over hazard. Do not use temporary flat tire repair products. Note: The tires on some machines are foam filled and do not need air added to them. 1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. 4 Check the pressure in each air-filled tire. Add air as necessary. Refer to Section 2, Specifications. 3 - 24 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-9 Check Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. Drive hubs: 1 Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees. 4 Install the plugs into the drive hub. Torque to Specification. Refer to Section 2, Specifications. 5 Check the torque of the drive hub mounting fasteners. Refer to Section 2, Specifications. 6 Repeat steps 1 through 5 for the other drive hubs. Turntable rotate drive hub: Single fill port rotator: 1 Remove the plug located on the top of the hub and check the oil level. Result: The oil level should be visible below the bottom of the fill port. a a B a A b models with o-ring plugs 2 Remove the plug located at 90 degrees and check the oil level. Result: The oil level should be even with the bottom of the side plug hole. 3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. Part No. 122985 S-80 • S-85 • S-80X d c Single fill port rotator a motor b fill port c drive hub mounting bolts d drive hub 3 - 25 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES Dual fill port rotator: 2 Remove one of the plugs located on the side of the hub and check the oil level. B-10 Check and Adjust the Engine RPM Result: The oil level should be even with the bottom of the plug hole. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. a B b A c Continental models: Note: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact the Genie Industries Service Department. Deutz TD2011L04i models: 1 Connect a tachometer to the engine. Start the engine from the ground controls and check the rpm. Refer to Section 2, Specifications. d Dual fill port rotator a motor b drive hub c drive hub mounting bolts d fill ports 3 If necessary, add oil. Refer to Section 2, Specifications. 4 Apply pipe thread sealant to the plug, and install the plug in the drive hub. 5 Check the torque of the turntable rotate drive hub mounting fasteners. Refer to Section 2, Specifications. 3 - 26 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Perkins models: 1 Connect a tachometer to the engine. Start the engine from the ground controls and check the rpm. Refer to Section 2, Specifications. Skip to step 3 if the low idle rpm is correct. 2 Loosen the low idle lock nut. Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the low idle lock nut and confirm the rpm. a a c b b Deutz models a high idle adjustment b low idle adjustment Skip to step 4 if the low idle rpm is correct. 2 Loosen the locknut on the low idle adjustment screw. f 3 Adjust the low idle adjustment screw until low idle meets specification. Tighten the locknut. 5 Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. d Perkins models a solenoid boot b yoke lock nut c low idle adjustment screw d low idle lock nut e yoke f high idle adjustment nut 4 Push and hold the function enable/high speed button. Note the engine rpm on the display. Refer to Section 2, Specifications. If the high idle is correct, disregard adjustment step 5. e 3 Move the function enable/rpm select toggle switch to the high idle (rabbit symbol) position. Refer to Section 2, Specifications. If high idle rpm is correct, disregard adjustment step 4. 4 Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. Part No. 122985 S-80 • S-85 • S-80X 3 - 27 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES B-11 Perform Engine Maintenance Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number 111901 B-12 Check the Oscillate Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper axle oscillation is essential to safe machine operation. If the oscillate directional valve linkage is not operating correctly, the stability of the machine is compromised and it may tip over. 1 Remove the drive chassis cover from the non-steer end of the machine. 2 Locate the oscillate directional valve inside of the non-steer axle and inspect the linkage for the following: • Lock nut is tight against yoke • Yoke clevis pins are installed • Cotter pins are installed through clevis pins • Linkage is properly attached to directional valve To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 28 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-13 Test the Ground Control Override B-14 Test the Platform Self-leveling Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button at the platform controls is in the on or off position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the red Emergency Stop button at the platform controls to the off position. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 1 Start the engine from the ground controls. 2 Start the engine from the ground controls. 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch. 3 At the ground controls, operate each boom function through a partial cycle. 3 Raise and lower the boom through a full cycle. Result: All boom functions should operate. Part No. 122985 Result: The platform should remain level at all times to within ±5 degrees. S-80 • S-85 • S-80X 3 - 29 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES 5 Release the function enable button. B-15 Test the Engine Idle Select Operation Result: The engine rpm should change to low idle. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol) allows the operator to control individual boom functions only. Functon enable button high idle (rabbit symbol) allows the operator to control multiple boom functions simultaneously. This setting maintains a consistent high idle. Foot switch activated high idle (rabbit and foot switch symbols) should be used for normal machine operation. This setting activates high idle only when the foot switch is pressed down. 1 Turn the key switch to ground control. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 6 Turn the key switch to platform controls. 7 Move the engine idle select toggle switch to low idle (turtle symbol). Result: The engine rpm should remain at low idle. 8 Move the engine idle select toggle switch to foot switch activated high idle (rabbit and foot switch symbol). Result: The engine rpm should not change to high idle. 9 Press down the foot switch. Result: The engine rpm should change to high idle. high idle. 10 Press down the foot switch. Result: The engine rpm should change to high idle. 3 Start the engine from the ground controls. 4 Move and hold the function button in and move the idle switch to the high idle (rabbit symbol) position. Result: The engine rpm should change to high idle. 3 - 30 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-16 Test the Fuel Select Operation Gasoline/LPG Models 4 Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position. 5 Move the fuel select toggle switch to LPG. 6 Start the engine and allow it to run at low idle. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation. A fuel selection can be made whether the engine is running or not. Switching malfunctions and/or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation. 7 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. Note: The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running. Note: Perform this test after checking the gasoline and LPG fuel levels, and warming the engine to normal operating temperature. 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle (rabbit and foot switch symbol). 2 Start the engine from the platform controls and allow it to run at low idle. 3 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. Part No. 122985 S-80 • S-85 • S-80X 3 - 31 CHECKLIST B PROCEDURES B-17 Test the Drive Enable System Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive enable system operation is essential to safe machine operation. When the boom is past the non-steering wheels, drive movement is stopped and the indicator light turns on. The drive enable switch must be held to either side to reactivate the drive function and should alert the operator that the machine may move in the opposite direction that the drive and steer controls are moved. An improperly functioning drive enable system may allow the machine to be moved into an unsafe position. 5 Rotate the turntable until the boom moves past the other non-steer wheel. Result: The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown. 6 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. Result: The drive function should operate. Collision hazard. Always use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction of travel. Note: When the drive enable system is in use, the machine may drive in the opposite direction that the drive and steer control handle is moved. Note: Perform this procedure with the boom in the stowed position. 1 Start the engine from the platform controls. Blue 2 Press down the foot switch. 3 Rotate the turntable until the boom moves past one of the the non-steer wheels. Result: The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown. 4 Slowly move the drive control handle off center. Result: The drive function should not operate. Yellow CHECKLIST B PROCEDURES B-18 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. See B-7, Confirm the Proper Brake Configuration. Note: Select a test area that is firm, level and free of obstructions. Note; Perform this procedure with the boom in the stowed position. 1 Mark a test line on the ground for reference. 2 Start the engine from the platform controls. 3 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the test line. 4 Bring the machine to top drive speed before reaching the test line. Release the drive controller when your reference point on the machine crosses the test line. 5 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. Note: The brakes must be able to hold the machine on any slope it is able to climb. B-19 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Note: Select a test area that is firm, level and free of obstructions. Note: Perform this procedure with the boom in the stowed position. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Start the engine from the platform controls. 3 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the start and finish lines. 4 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 5 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Performance Specifications. Note: To adjust the speed, refer to Repair procedure 1-2, How to Adjust the Joystick Max-out Setting. Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES B-20 Test the Drive Speed Raised or Extended Position 7 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Performance Specifications. Note: To adjust the speed, refer to Repair procedure 1-2, How to Adjust the Joystick Max-out Setting. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 8 Press down the foot switch and lower the boom to the stowed position. 9 Extend the boom 3 feet / 90 cm. 10 Choose a point on the machine (i.e., contact patch of a tire), as a visual reference for use when crossing the start and finish lines. 11 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 2 Start the engine from the platform controls. 12 Continue at top speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Performance Specifications. 3 Move the engine idle select toggle switch to foot switch activated high idle (rabbit and foot switch symbol). Note: To adjust the speed, refer to Repair procedure 1-2, How to Adjust the Joystick Max-out Setting. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 4 Press down the foot switch and raise the boom 10° above horizontal. 5 Choose a point on the machine (i.e. contact patch of a tire), as a visual reference for use when crossing the start and finish lines. 6 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 3 - 34 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-21 Test the Alarm Package (if equipped) and the Descent Alarm Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. The alarm package includes: • Travel alarm • Flashing beacons Alarms and beacons are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the turntable rear cover. Beacons are installed on both turntable covers. 3 Turn the key switch to platform controls. Result: The flashing beacons should be on and flashing. 4 Press down the foot switch. Move the boom controller to the down position, hold for a moment and then release it. Result: The descent alarm should sound when the controller is held down. 5 Press down the foot switch. Move the drive controller off center, hold for a moment and then release it. Move the drive controller off center in the opposite direction, hold for a moment and then release it. Result: The travel alarm should sound when the drive controller is moved off center in either direction. Note: The alarms and beacons will operate with the engine running or not running. 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Result: Both flashing beacons should be on and flashing. 2 Move and hold the function enable button to either side and activate the boom toggle switch in the down position, hold for a moment and then release it. Result: The descent alarm should sound when the toggle switch is held down. Part No. 122985 S-80 • S-85 • S-80X 3 - 35 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. 4 Install the fuel tank cap onto the fuel tank. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the caps be inspected more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. 5 Remove the breather cap from the hydraulic tank. 6 Check for proper venting. Result: Air passes through the hydraulic tank cap. Procced to step 8. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7. Note: When checking for positive tank cap venting, air should pass freely through the cap. 7 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank. Note: Perform this procedure with the engine off. Note: This procedure applies to diesel equipped machines only. 1 Remove the cap from the fuel tank. 2 Check for proper venting. Result: Air passes through the fuel tank cap. Procced to step 4. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. When checking for positive tank cap venting, air should pass freely through the cap. 3 - 36 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES B-23 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more frequently. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. B-24 Inspect the Boom Extend/Retract Cables Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Inspecting for foreign objects, damage and/or improper adjustment of the boom extend/retract cables and related components on a regular basis is essential to good machine performance and safe machine operation. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. 1 Raise the boom to horizontal and fully extend the boom. 2 After the boom is fully extended, lower the boom until the platform is at chest height. Turn the machine off. 3 Remove the boom end cover retaining fasteners and remove the cover. 4 Remove the retaining fasteners from the access covers located on the side of the boom at the platform end of the machine. Remove the covers. Part No. 122985 S-80 • S-85 • S-80X 3 - 37 Section 3 • Scheduled Maintenance Procedures CHECKLIST B September 2015 PROCEDURES 5 Visually inspect the cables and components through both inspection holes for the following: 6 Install the cover at the pivot end of the boom. 7 Install the access panels on the sides of the boom. • Frayed or broken wire strands • Kinks in the cables • Corrosion • Paint or foreign materials on the cable • Split or cracked cable ends 9 Turn the key switch to the platform controls. • Cables are on all pulleys 10 Extend the boom approximately 2 feet / 0.6 m. • Extend cable break limit switch arm is centered in the pivot plate • Cables have equal tension 11 Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 boom tubes. • Cables at end of adjustment range • No broken or damaged pulleys • No unusual or excessive pulley wear • All fasteners in place and secure 8 Start the engine from the ground controls and fully retract and lower the boom to the stowed position. Result: The number 2 boom tube should not move more than 1/2 inch / 13 mm before the number 3 boom tube begins to retract. Note: A flashlight and inspection mirror may be necessary to thoroughly inspect the above items. Note: A pulley groove gauge should be used to check the condition of the pulleys. 3 - 38 Note: If the number 2 boom tube moves more than 1 /2 inch / 13 mm before the number 3 boom tube begins to retract, the boom extend/retract cables need to be adjusted. See Repair Procedure 4-5, How to Adjust the Boom Extend/Retract Cables. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures Checklist C Procedures C-1 Perform Engine Maintenance C-2 Grease the Platform Overload Mechanism (if equipped) Engine specifications require that this procedure be performed every 500 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number 111901 Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Perform this procedure more often if dusty conditions exist. Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage. 1 Locate the grease fittings on each pivot pin of the platform overload assembly. 2 Thoroughly pump grease into each grease fitting. Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 S-80 • S-85 • S-80X 3 - 39 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES C-3 Test the Platform Overload System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over. Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test. 4 Using a suitable lifting device, place a test weight equal to that of the available capacity at one of the locations shown. Refer to Illustration 1. Result: The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). 3 - 40 Illustration 1 5 Carefully move the test weight to each remaining location. Refer to Illustration 1. Result: The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound. Result: The platform overload indicator lights are on and the alarm is sounding. Calibrate the platform overload system. Refer to Repair Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). 6 Using a suitable lifting device, place an additional 50 lbs / 23 kg of weight onto the platform. Result: The alarm should sound and the engine should shut off. The platform overload indicator lights should be flashing at both the ground and platform controls. Result: The alarm does not sound, the engine does not shut off and the platform overload indicator lights are not flashing. Calibrate the platform overload system. Refer to Repair Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). Note: There may be a 2 second delay before the overload indicator lights flash, the alarm sounds and the engine shuts off. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 7 Using a suitable lifting device, remove the test weights, restart the engine and carefully move the test weights to each remaining location on the platform. Refer to Illustration 1. Result: The alarm should sound, the engine should shut off and the platform overload indicator lights should be flashing at both the ground and platform controls. Result: The alarm does not sound and the platform overload indicator lights are not flashing. Calibrate the platform overload system. Refer to Repair Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). 14 Start the engine and test all machine functions from the ground controls. Result: All ground control functions should operate normally. 15 Turn the key switch to platform control. 16 Test all machine functions from the platform controls. Result: All platform control functions should operate. Note: If the platform overload system is not operating properly, Refer to Repair Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). Note: There may be a 2 second delay before the overload indicator lights flash, the alarm sounds and the engine shuts off. 17 Push in the red Emergency stop button at the platform to shut off engine. 8 Test all machine functions from the platform controls. 18 Using a suitable lifting device, remove all test weights from the platform. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 19 Pull out the red Emergency stop button to the on position at the platform controls. 20 Remove the fasteners securing the lid to the platform controls. Using Illustration 2 as a guide, locate the timer relay inside the platform control box. Tag and disconnect the red wire from terminal 5 on the timer relay. 11 Activate the auxiliary power toggle switch. 12 Using auxiliary power, test all machine functions from the ground controls. Timer Relay Result: All ground control functions should operate. 13 Using a suitable lifting device, lift the additional test weight from the platform. Result: The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound. Orange Wire Terminal 5 Illustration 2 Part No. 122985 S-80 • S-85 • S-80X 3 - 41 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 21 Using Illustration 3 as a guide, locate D31 Valve Power LED on the ALC500 printed circuit board. Valve Power LED 26 Using a suitable lifting device, place an additional 50 lbs / 23 kg of weight onto the platform. Result: The alarm should sound and the Valve Power LED should not light. The platform overload indicator lights should be flashing at both the ground and platform controls. ALC 500 Board 27 Working from outside the platform and standing next to the platform rotator, locate the orange wire, which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire. Tag and disconnect the connectors. Refer to Illustration 2. 28 Using a multimeter set to read resistance (ohms), securely install a lead from the multimeter to the connector on the orange wire, and securely connect the other multimeter lead to a ground point in the control box. Illustration 3 22 Step on the footswitch at the platform. Result: The Valve Power LED should not illuminate. Result: The readout on the multimeter should indicate zero resistance. Result: The Valve Power LED is illuminated. Remove the machine from service and contact the Genie Service Department. Result: The readout on the multimeter shows resistance. Remove the machine from service and contact the Genie Service Department. 23 Securely install the red wire, disconnected in step 20, onto terminal 5 of the relay timer. 24 Step on the footswitch at the platform. Result: The Valve Power LED should illuminate. Result: The Valve Power LED is not illuminated. Remove the machine from service and contact the Genie Service Department. 25 Using a suitable lifting device, place a test weight equal to that of the available capacity at the center location shown in Illustration 1. 29 Using a suitable lifting device, remove all weight from the platform. Note the result on the multimeter. Result: The readout on the multimeter should indicate infinite resistance. Result: The readout on the multimeter shows zero resistance. Remove the machine from service and contact the Genie Service Department. 31 Turn off the multimeter and remove the leads from the machine. Securely connect the wires disconnected in step 27. 32 Close the platform control box. Install and securely tighten the fasteners. Do not overtighten. 3 - 42 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES C-4 Replace the Engine Air Filter Element Engine specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Note: Perform this procedure with the engine off. 1 Release the latches on the air cleaner cap. Remove the end cap from the air cleaner canister. C-5 Replace the Fuel Filter/Water Separator Element Diesel Models Note: Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Regular replacement of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and/or hard starting, and continued use may result in component damge. Extremely dirty conditions may require this procedure be performed more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. 2 Remove the filter element. 3 Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube. Make sure that all contaminant is removed before the filter is inserted. 4 Check new filter element gasket for damage before installing. Note: Perform this procedure with the engine off. 5 Install the new filter element. Perkins Models: 6 Install the end cap on the canister and secure. 1 Put on protective clothing and eye wear. Note: Be sure the discharge slot is pointing down. 2 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. 3 Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps 4 through 8. Part No. 122985 S-80 • S-85 • S-80X 3 - 43 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 8 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. 4 Loosen the vent plug located on the fuel filter/ water separator head. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. a d c Deutz Models: b 1 Put on protective clothing and eye wear. a b c d 2 Remove the engine tray retaining fastener located under the engine tray.Swing the engine tray out and away from the machine. vent plug drain plug filter bowl separator head 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. 5 Loosen the drain plug located at the bottom of the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 6 Tighten the vent plug. Note: If the fuel filter/water separator is completely drained, you must prime the fuel filter/water separator before starting the engine. See C-6, Replace The Fuel Filter/Water Separator Element Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 4 Locate the fuel filter/water separator next to the oil filter. for leaks. Clean up any fuel that may have spilled. 3 - 44 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 5 Loosen the drain plug located at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Note: Do not completely drain the filter. C-6 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X Note: Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. a b a b Testing the safety envelope system regularly is essential to safe machine operation. Continued use of an improperly operating safety envelope could result in the system not restricting the range of motion. Machine stablity could be compromised resulting in the machine tipping over. Note: Perform this procedure with the machine on a firm, level surface with all weight, tools and equipment removed from the platform. fuel filter/water separator drain valve Note: Start this procedure with the boom fully retracted and in the stowed position. 6 Clean up any fuel that may have spilled. 7 Start the engine from the ground controls and check the fuel filter/water separator for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. Ground controls: 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position. 2 Start the engine from the ground controls. 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 122985 S-80 • S-85 • S-80X 3 - 45 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST C PROCEDURES 3 Turn and hold the function enable switch to the restricted maximum platform capacity and raise the primary boom until it is fully elevated. a b 7 Measuring Tape: Measure the distance between the center of the pivot pins as shown, 201.75 inches / 512 cm ± 2.0 inch / 5 cm. Digital Protractor: 1000 lbs / 454 kg 500 lbs / 227 kg Place the digital protractor on the turntable chassis and reset the protractor to 0°. Place the protractor on top of the primary boom. The protractor should display 58° ± 2°. Result: The primary boom angle is not within specifications.Consult Genie Industries Service Department. a b restricted maximum platform capacity unrestricted maximum platform capacity Measure between the centers of these pivot pins 4 Extend the primary boom until it is fully extended. 5 Lower the primary boom until it stops. Result: The boom will automatically stop after 10 degrees. Result: The primary boom does not stop after 10 degrees. Check limit switches LST3O and LST3S. 6 Turn the key switch to the off position and push in the red Emergency Stop button. Note: The follwing step can be done using a measuring tape or a digital protractor (Genie part number 58377). 3 - 46 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES Platform controls: Note: Start this procedure with the boom fully retracted and in the stowed position. 1 Pull out the red Emergency Stop button to the on position and start the engine. 2 Select the restricted maximum platform capacity with the toggle switch. a b 1000 lbs / 454 kg 500 lbs / 227 kg 6 Move the primary boom down joystick off center and retract the primary boom until the unrestricted platform capacity light stops flashing. Result: Primary boom down should return to normal operation. 7 Lower the primary boom 5 feet / 1.5 m and activate primary boom extend. Result: Primary boom extend will stop and the unrestricated platform capacity light will start flashing. 8 Activate primary boom extend and raise the primary boom until the unrestricated platform capacity light stops flashing. Result: Primary boom extend should return to normal operation. 9 Return the machine to the fully stowed position. a b restricted maximum platform capacity unrestricted maximum platform capacity 3 Raise the primary boom until it is fully elevated. 4 Extend the primary boom until it is fully extended. 5 Lower the primary boom until it stops. Result: The boom will automatically stop after 10 degrees and the unrestricted platform capacity light will flash. Result: The primary boom does not stop after 10 degrees. Calibrate the boom angle sensor. Refer to Repair Procedure 1-2, How to Calibrate the Boom angle Sensor. Part No. 122985 S-80 • S-85 • S-80X 3 - 47 Section 3 • Scheduled Maintenance Procedures September 2015 Checklist D Procedures 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom. D-1 Check the Boom Wear Pads Note: Always maintain squareness between the outer and inner boom tubes. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Boom wear pad specifications Boom number one Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions. 5 /8 Top and side wear pads (extension end of boom) inch 15.9 mm Boom number two 1/2 inch 12.7 mm Top, bottom and side wear pads (extension end of boom) 1 Start the engine from the ground controls. 2 Raise the end of the boom to a comfortable working height (chest high), then extend the boom 1 foot / 30 cm. 1 /2 Bottom wear pads (pivot end of boom) inch 12.7 mm Top and side wear pads (pivot end of boom) 5/8 inch 15.9 mm Boom number three 1/2 inch 12.7 mm Top, bottom and side wear pads (pivot end of boom) 3 Measure each wear pad. Replace the wear pad if it is less than specification. If the wear pad is still within specification, shim as necessary to obtain zero clearance and zero drag. a 3 - 48 1/2 inch 12.7 mm Bottom wear pads (extension end of boom) Note: If the wear pads are still within specification, refer to Repair Procedure 4-2, How to Shim the Boom. a b c Minimum b c boom 1 boom 2 boom 3 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 5 Manually rotate each non-steer wheel. D-2 Check the Free-wheel Configuration Result: Each non-steer wheel should rotate with minimum effort. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge could result in death or serious injury and property damage. 6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. Steer wheels: 4WD models 7 Chock the non-steer wheels to prevent the machine from rolling. Collision hazard. Select a work site that is firm and level. 8 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the steer wheels. Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. 9 Lift the wheels off the ground and then place blocks under the drive chassis for support. Non-steer wheels: All models 1 Chock the steer wheels to prevent the machine from rolling. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub. disengaged position 2 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the non-steer wheels. 3 Lift the wheels off the ground and place blocks under the drive chassis for support. engaged position 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub. disengaged position engaged position Part No. 122985 S-80 • S-85 • S-80X 3 - 49 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel. D-3 Check the Turntable Rotation Bearing Bolts Result: Each steer wheel should rotate with minimum effort. 12 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. All models: 13 Turn the valve in a clockwise direction to be sure it is fully closed. Note: The free-wheel valve is located on the bottom of the drive pump, and should always remain closed. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Start the engine from the platform controls and extend the axles. 2 Turn the key switch to ground controls. 3 Raise the boom and place a safety chock on the lift cylinder rod. Carefully lower the boom onto the lift cylinder safety chock. Crushing hazard. Keep hands away from cylinder and all moving parts when lowering the boom. b c a d a b c d 3 - 50 drive pump screwdriver lift pump free-wheel valve Note: The lift cylinder safety chock is available through Genie Service Parts. 4 Remove the center turntable cover retaining fasteners. Remove the cover. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 5 Confirm that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications. D-4 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage. Note: Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 1 Grease the turntable bearing. See A-12, Grease the Turntable Rotation Bearing and Rotate Gear. Bolt torque sequence 6 Install the center turntable cover and tighten the retaining fasteners. 7 Raise the boom and remove the safety chock. 8 Lower the boom to the stowed position. 2 Torque the turntable bearing bolts to specification. See D-4, Check the Turntable Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the boom to full height. Do not extend the boom. 9 Confirm that each bearing mounting bolt under the drive chassis is torqued in sequence to specification. Refer to Section 2, Specifications. Part No. 122985 S-80 • S-85 • S-80X 3 - 51 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing. Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing. 7 Note the reading on the dial indicator. Result: The measurement is less than 0.063 inch / 1.6 mm. The bearing is good. Result: The measurement is more than 0.063 inch / 1.6 mm. The bearing is worn and needs to be replaced. 8 Fully retract the boom and raise the boom to full height. Visually inspect the the dial indicator to be sure the needle returns to the "zero" position. a 9 Remove the dial indicator and rotate the turntable 90°. 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart. b 11 Lower the boom to the stowed position and turn the machine off. c 12 Remove the dial indicator from the machine. d a b c d turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 3 - 52 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES D-5 Perform Engine Maintenance D-6 Replace the Hydraulic Filters Engine specifications require that this procedure be performed every 1000 hours. Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Perform this procedure more often if dusty conditions exist. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Deutz TD2011 Operation Manual Genie part number Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number Replacement of the hydraulic filters is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filters be replaced more often. Note: Perform this procedure with the engine off. Hydraulic return filter: 111901 To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 1 Open the ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank. 2 Remove the cap from the filter housing. 3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing. 4 Remove the filter element from the filter housing. 5 Install the new filter element into the filter housing. 6 Push the filter element down to be sure the O-ring on the element is fully seated into the housing. 7 Rotate the filter element clockwise to lock it in place. Part No. 122985 S-80 • S-85 • S-80X 3 - 53 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES 8 Install the filter housing cap. 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing. D-7 Replace the Drive Hub Oil Medium and high pressure filters: Note: The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit. 10 Open the engine side turntable cover and locate the two filters. Note: The high pressure filter is located toward the bulkhead with a condition indicator. The medium pressure filter is located nearest the operator. 11 Place a suitable container under the filters. 12 Remove the filter housing by using a wrench on the nut provided on the bottom of the housings. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. Drive hubs: 1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point. 13 Remove the filter element from the housings. 2 Remove both plugs and drain the oil into a suitable container. 14 Inspect the housing seals and replace them if necessary. 3 Drive the machine until one plug is at the top and the other is at 90 degrees. 15 Install the new medium and high pressure filter elements into the housings and tighten them securely. a 16 Clean up any oil that may have spilled during the installation procedure. 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings. 18 Start the engine from the ground controls. 19 Inspect the filter housings and related components to be sure that there are no leaks. a. models with o-ring plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole. Install the plugs. 5 Install the plugs into the drive hub. Torque to Specification. Refer to Section 2, Specifications. 3 - 54 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 6 Repeat steps 1 through 4 for the other drive hub. 7 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications. 5 Remove the plug the drive hub. Drain the oil from the hub into a suitable container. Turntable rotate drive hub: Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. a B A b Note: The turntable rotation lock pin is located next to the boom rest pad. 2 Tag, disconnect and plug the hydraulic hoses from the turntable rotate drive motor. Cap the fittings on the drive motor. 3 Attach a suitable lifting device to the lifting eyes located near the drive motor. 4 Remove the drive hub mounting bolts. Carefully remove the turntable rotate drive hub assembly from the machine. Crushing hazard. The turntable rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device. Part No. 122985 S-80 • S-85 • S-80X d c Single fill port rotator a motor b fill port c drive hub mounting bolts d drive hub 3 - 55 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST D PROCEDURES D-8 Perform Engine Maintenance Deutz Models a B A b c Engine specifications require that this procedure be performed every 1500 hours of operation. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: d Deutz TD2011 Operation Manual Genie part number Dual fill port rotator a motor b drive hub c drive hub mounting bolts d fill ports 139320 To access the engine: 6 Install the drive hub assembly onto the machine. Torque the drive hub mounting bolts to specification. Refer to Section 2, Specifications. 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure. 7 Fill the drive hub with oil. Refer to Section 2, Specifications. Apply pipe thread sealant to the plug. Install the plug. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 8 Adjust turntable rotation gear backlash. Refer to Repair Procedure 10-1, How to Adjust the Turntable Rotation Gear Backlash. 3 - 56 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures Checklist E Procedures 2 Models without hydraulic tank shutoff valves: Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container. Refer to Section 2, Specifications. E-1 Test or Replace the Hydraulic Oil Models with hydraulic tank shutoff valves: Close the two hydraulic tank valves located at the hydraulic tank. Genie specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more frequently. Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 3 Remove the drain plug from the hydraulic tank Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the fuel tank. Refer to Repair Procedure 9-1, How to Remove the Fuel Tank. open closed and completely drain the tank into a suitable container. Refer to Section 2, Specifications. 4 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. 5 Disconnect and plug the T-fitting located at the return filter with the two hoses connected to it. Cap the fitting on the return filter housing. 6 Disconnect and plug the supply hose for the auxiliary power unit. Cap the fitting on the hydraulic tank. Part No. 122985 S-80 • S-85 • S-80X 3 - 57 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST E PROCEDURES 7 Remove the retaining fasteners from the hydraulic tank hold down straps. Remove the hold down straps from the hydraulic tank. 18 Open the hydraulic tank shutoff valves (if equipped). Component damage hazard. Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank. Refer to Repair Procedure 7-2, How to Prime the Pump. 8 Support the hydraulic tank with 2 lifting straps. Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device. 9 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank may become unbalanced and fall if it is not properly supported and secured to the lifting device. 10 Remove the suction strainers from the tank and clean them using a mild solvent. 11 Rinse out the inside of the tank using a mild solvent. Note: Always use pipe thread sealant when installing the drain plug and strainers. 19 Operate all machine functions through a full cycle and check for leaks. Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use. 12 Install the suction strainers using pipe thread sealant on the threads. 13 Install the drain plug using pipe thread sealant on the threads. 14 Install the hydraulic tank onto the machine. 15 Install the two suction hoses and the supply hose for the auxiliary power unit. 16 Fill the tank with hydraulic oil until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. 17 Clean up any oil that may have spilled. 3 - 58 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES E-2 Perform Engine Maintenance Perkins Models E-3 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performed every 2000 hours. Engine specifications require that this procedure be performed every 3000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the: Required maintenance procedures and additional engine information are available in the: Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Deutz TD2011 Operation Manual Genie part number To access the engine: Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 139320 To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out away from the machine and secure it from moving. S-80 • S-85 • S-80X Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 59 Section 3 • Scheduled Maintenance Procedures September 2015 CHECKLIST E PROCEDURES E-4 Replace the Boom Extend/ Retract Cables Genie specifications require that this procedure be performed every 10 years. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Replacement of the boom extend/retract cables is essential to good machine performance and safe machine operation. The boom extend/ retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. 1 Replace the boom extend/retract cables. See Repair Procedure 4-5, How to Replace the Boom Extend/Retract Cables. 3 - 60 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Be sure that all necessary tools and parts are available and ready for use. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Boom in the stowed position • Turntable rotated with the boom between the non-steering wheels • Turntable secured with the turntable rotation lock pin • Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 122985 Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Note: Used to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. S-80 • S-85 • S-80X 4-1 Section 4 • Repair Procedures September 2015 Platform Controls The platform control box contains one printed circuit board. The ALC-500 circuit board inside the platform control box controls all proportional machine functions from the platform. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls. If a joystick error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. See 1-2, How to Calibrate a Joystick. Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. a 1-1 ALC-500 Circuit Board Note: When the ALC-500 circuit board is replaced, the joystick controllers will need to be calibrated. See 1-2, How to Calibrate a Joystick. How to Remove the ALC-500 Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box lid retaining fasteners. Open the control box lid. 3 Locate the ALC-500 circuit board mounted to the inside of the platform control box. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 4 Attach a grounded wrist strap to the ground screw inside the platform control box. c Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. b a b c ALC-500 circuit board drive/steer joystick controller primary boom up/down, extend/retract and turntable rotate right/left joystick controller 5 Carefully disconnect the wire connectors from the circuit board. 6 Remove the ALC-500 circuit board mounting fasteners. 7 Carefully remove the ALC-500 circuit board from the platform control box. 4-2 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM CONTROLS 1-2 Joysticks 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. How to Calibrate a Joystick Note: No machine fuction should operate while performing the joystick calibration procedure. The joysticks on this machine utilize digital Hall Effect technology for proportional control. If a joystick is disconnected or replaced, it must be calibrated before that particular machine function will operate. Note: The joystick must be calibrated before the threshold, max-out or ramping can be set. How to Adjust the Joystick Max-out Setting 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. The max-out setting of a joystick controls the maximum speed of a joystick-controlled machine function. Whenever a hydraulic cylinder, drive motor or hydraulic pump is replaced, the max-out setting should be adjusted to maintain optimum performance. The max-out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. 3 Turn the key switch to platform control. Do not start the engine. Note: Perform this procedure with the boom in the stowed position. Note: Perform this procedure with the engine off. 1 Open the platform control box. 4 Select a joystick to calibrate. 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds. Connect the wire harness connector to the joystick. 6 Move the joystick full stroke in either direction and hold for 5 seconds. 7 Return the joystick to the neutral position, pause for a moment, then move the joystick full stroke in the opposite direction. Hold for 5 seconds. Result: The alarm should sound indicating successful joystick calibration. Result: The alarm does not sound. Check the electrical connections or replace the joystick. Part No. 122985 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 Turn the key switch to platform control. Do not start the engine. 3 Push in the platform controls red Emergency Stop button to the off position. 4 Do not press down the foot switch. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. 6 When the alarm sounds, release the drive enable toggle switch. S-80 • S-85 • S-80X 4-3 Section 4 • Repair Procedures September 2015 PLATFORM CONTROLS 7 Momentarily activate the drive enable toggle switch in the right direction 4 times. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. 8 Start the engine from the platform controls and press down the foot switch. 9 Start a timer and activate the machine function that needs to be adjusted. Record the time it takes for that function to complete a full cycle (ie; boom up). 10 Compare the machine function time with the function times listed in Section 2, Specifications. Determine whether the function time needs to increase or decrease. 11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle time. Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed. Note: Each time the drive enable toggle switch is momentarily moved, the function speed will change in 2% increments. 12 Repeat steps 9 through 11 for each joystick controlled machine function. 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. Result: The alarm should sound indicating that the settings have been saved in memory. Result: The alarm does not sound. The minimum or maximum adjustment has been obtained. No changes can be saved. Note: Do not operate any machine function during the 10 second waiting time. 14 Cycle the red Emergency Stop button off, then back on. How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Note: Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 2 Turn the key switch to platform control. Do not start the engine. 3 Push in the platform controls red Emergency Stop button to the off position. 4-4 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM CONTROLS 4 Do not press down the foot switch. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. 6 When the alarm sounds, release the drive enable toggle switch. 7 Momentarily activate the drive enable toggle switch in the right direction 6 times. Result: There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. 13 Repeat steps 9 through 11 for each joystick controlled machine function. 14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. Result: The alarm should sound indicating that the settings have been saved in memory. Note: Do not operate any machine function during the 10 second waiting time. 15 Cycle the red Emergency Stop button off, then back on. Ramp rate (factory settings) 8 Start the engine from the platform controls and press down the foot switch. Turntable rotate accelerate decelerate 3 seconds 2 second 9 Start a timer and simultaneously move the joystick in either direction full stroke. Note how long it takes the function to reach maximum speed. This is the ramp rate. Boom up/down accelerate decelerate 3 seconds 1 second 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease. 11 Release the foot switch. 12 While the joystick is activated, set the ramp rate. Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time. Boom extend/retract accelerate decelerate 2.5 seconds 1 second Drive accelerate decelerate to neutral decelerate, change of direction decelerate, coasting decelerate, braking decelerate, shift from low to high speed decelerate, shift from high to low speed 4 seconds 0.5 second 0.75 second 1 second 1 second 1 second 4 seconds Note: Each time the drive enable toggle switch is momentarily moved, the time will change in 5% increments. Part No. 122985 S-80 • S-85 • S-80X 4-5 Section 4 • Repair Procedures September 2015 1234567890 1234567890 1234567890 1234567890 1234567890 1234567890 PLATFORM CONTROLS How to Adjust the Joystick Threshold Setting 10 Slowly move the joystick off center in either direction just until the function begins to move. The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate. 11 Slowly move the joystick back to the neutral position. Just before the function stops moving, move the drive enable toggle switch to either side to set the threshold. Note: Perform this procedure with the boom in the stowed position. Result: The alarm should sound indicating a successful calibration. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 12 Repeat steps 9 through 11 for each boom joystick-controlled machine function (boom up/ down, boom extend/retract and turntable rotate). 2 Turn the key switch to platform control. Do not start the engine. 13 Return the joystick to the neutral position and wait for approximately 10 seconds. 3 Push in the red Emergency Stop button to the off position at the platform controls. 4 Do not press down the foot switch. 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position. 6 When the alarm sounds, release the drive enable toggle switch. Result: The alarm should sound indicating that the settings have been saved in memory. Note: Do not operate any machine function during the 10 second waiting time. 14 Cycle the red Emergency Stop button off, then back on. Function speeds (factory settings) Boom up 89 to 93 seconds Boom down 90 to 94 seconds Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. Boom extend 73 to 79 seconds Boom retract 79 to 84 seconds Result: The alarm does not sound. Repeat steps 3 through 7. Turntable rotate, 360° boom fully stowed 7 Momentarily activate the drive enable toggle switch in the right direction 8 times. 8 Start the engine from the platform controls and press down the foot switch. 9 Select a boom function joystick to set the threshold. 4-6 95 to 103 seconds Drive speeds (factory settings) Stowed- high speed Non-stowed S-80 • S-85 • S-80X 7.9 to 8.5 seconds 40 to 45 seconds Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM CONTROLS How to Calibrate the Boom Angle Sensor Note: Manually reduce the boom speed as it reaches the fully elevated position. The boom angle sensor controls the maximum angle that the boom can attain. 9 Momentarily activate the drive enable toggle switch to the right 1 time to set the elevated position. Note: Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at the ground controls. 2 Turn the key switch to platform controls. 3 Move and hold the drive enable toggle switch to the right and pull out the red Emergency Stop button to the on position. 4 When the alarm sounds, release the drive enable toggle switch. Result: The alarm will sound indicating that the angle sensor has been calibrated. 10 Release the joystick and the foot switch and wait for 10 seconds. Result: The alarm will sound indicating that the settings have been saved and is leaving calibration mode. 11 Cycle the red Emergency Stop button off, then back on. Start the machine and return to the stowed position. 5 Momentarily activate the drive enable toggle switch to the right 12 times. Result: There should be a pause and the alarm should sound 12 times indicating that the machine is in Angle Sensor calibration mode. 6 Start the engine from the platform controls and press down the foot switch. 7 Momentarily activate the drive enable toggle switch to the right 1 time to set the stowed position. Note: The alarm will not sound indicating the setting. 8 Raise the primary boom to the fully elevated position. Part No. 122985 S-80 • S-85 • S-80X 4-7 Section 4 • Repair Procedures September 2015 This page intentionally left blank. 4-8 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Platform Components 7 Support and secure the platform to an appropriate lifting device. 2-1 Platform How to Remove the Platform 8 Remove the platform mounting fasteners and remove the platform from the machine. 1 Remove the cable clamp from the top of the platform mounting weldment. 2 Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side. Do not disconnect the wiring. Crushing hazard. The platform could become unstable and fall when it is removed from the machine if not properly supported. 3 Remove the foot switch mounting fasteners. 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals. 5 Tag and disconnect the foot switch wiring from the foot switch. Remove the cable from the back of the platform. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 6 Remove the platform control box mounting fasteners. Lower the control box and set it aside. Component damage hazard. Cables can be damaged if they are kinked or pinched. Note: If your machine is equipped with an airline to platform option, the airline must be disconnected from the platform before removal. Part No. 122985 S-80 • S-85 • S-80X 4-9 Section 4 • Repair Procedures September 2015 PLATFORM COMPONENTS 2-2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. 4 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to drive the rod-end pivot pin out. Crushing hazard. The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly supported. 5 Remove the external snap rings from the barrelend pivot pin. 6 Use a soft metal drift to drive the barrel-end pivot pin out. How to Remove the Platform Leveling Slave Cylinder 7 Carefully pull the cylinder out of the primary boom to access the hydraulic hoses. Note: Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop. 8 Tag, disconnect and plug the hydraulic hoses from the slave cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. How to Bleed the Slave Cylinder 2 Raise the primary boom slightly and place blocks under the platform for support. Note: Do not start the engine. Use auxiliary power for this procedure. 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform. 1 Raise the primary boom to a horizontal position. Note: Do not rest the entire weight of the boom on the blocks. 4 - 10 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM COMPONENTS 2 Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the fittings on the rotator. 2-3 Platform Rotator Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees. How to Remove the Platform Rotator Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. Part No. 122985 3 S-85: Support the jib boom leveling arms and the platform mounting weldment with an appropriate lifting device. Do not apply any lifting pressure. 4 Remove the mounting bolts from the platform mounting weldment. Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment could become unbalanced and fall if not properly supported when removed from the machine. 5 Support the platform rotator with an appropriate lifting device. Do not apply any lifting pressure. S-80: 6 Support the rod end of the platform leveling slave cylinder. Protect the cylinder rod from damage. 7 Remove the pivot pin retaining fasteners from both the slave cylinder rod-end pivot pin and the rotator pivot pin. S-80 • S-85 • S-80X 4 - 11 Section 4 • Repair Procedures September 2015 PLATFORM COMPONENTS 8 Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the machine. Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported. Note: When installing the platform rotator fasteners, torque the fasteners to specifications. Refer to Section 2, Specifications. S-85: 9 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins. Do not remove the pins. How to Bleed the Platform Rotator Note: This procedure will require two people. Do not start the engine. Use auxiliary power for this procedure. 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right. 10 Support the jib boom leveling arms. 2 Place a suitable container underneath the platform rotator. 11 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine. 3 Open the top bleed screw on the rotator, but do not remove it. Bodily injury hazard. The jib boom leveling arms may fall if not properly supported. 12 Lower the jib boom leveling arms. Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Note: When installing the platform rotator fasteners, torque the fasteners to specifications. Refer to Section 2, Specifications. 4 - 12 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM COMPONENTS 4 Move the function enable button to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. 2-4 Platform Overload System How to Calibrate the Platform Overload System (if equipped) Crushing hazard. Keep clear of the platform during rotation. 5 Open the bottom bleed screw on the rotator, but do not remove it. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. 7 Clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks. Part No. 122985 Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over. Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine and level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an incorrect calibration. 4 Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor. S-80 • S-85 • S-80X 4 - 13 Section 4 • Repair Procedures September 2015 PLATFORM COMPONENTS 5 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. 7 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 6. Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 8. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Slowly tighten the load spring adjustment nut in a clockwise direction in 10° increments until the overload indicator light turns off, and the alarm does not sound. Proceed to step 8. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5. Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 6 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle. Result: The overload indicator lights are off at the platform and ground controls, and the alarm does not sound. Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10° increments until the overload indicator light flashes at both the platform and ground controls, and the alarm sounds. Proceed to step 7. Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 8 Add an additional 10 lb / 4.5 kg test weight to the platform. Result: The overload indicator light is flashing at both the ground and platform controls, and the alarm is sounding. Proceed to step 9. Result: The overload indicator light is off at both the ground and platform controls, and the alarm does not sound. Remove the additional 10 lb / 4.5 kg test weight. Repeat this procedure beginning with step 6. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator lights and alarm responds. 4 - 14 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures PLATFORM COMPONENTS 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 12 Using a suitable lifting device, lift the test weight off the platform floor. Result: The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound. Note: There may be a 2 second delay before the overload indicator lights and alarm turn off. 13 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 14 Turn the key switch to platform control. 15 Test all machine functions from the platform controls. Result: All platform control functions should operate normally. Part No. 122985 S-80 • S-85 • S-80X 4 - 15 Section 4 • Repair Procedures September 2015 Jib Boom Components, S-85 5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 3-1 Jib Boom Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove the Jib Boom Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. Note: Models equipped with platform overoad system: If the platform overload components are disassembled and/or removed from the platform support, the platform overload system will need to be calibrated. See 2-4, How to Calibrate the Platform Overload System. 2 Models equipped with platform overload system: Tag and disconnect the electrical connector from the platform load sense module. 3 Remove the hose and cable cover from the side of the jib boom. 4 Remove the hose and cable clamp from the jib boom pivot pin. Lay all hoses and cables to the side. 6 Attach a lifting strap from an overhead crane to the jib boom assembly. 7 Place blocks under the platform leveling cylinder for support. Protect the cylinder rod from damage. 8 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly attached to the overhead crane. 9 Remove the pin retaining fastener from the jib boom bellcrank to primary boom pivot pin. 10 Use a soft metal drift to remove the pin and carefully remove the jib boom assembly from the primary boom. Component damage hazard. Hoses and cables can become damaged if they are kinked or pinched. 4 - 16 S-80 • S-85 • S-80X Crushing hazard. The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Part No. 122985 September 2015 Section 4 • Repair Procedures JIB BOOM COMPONENTS, S-85 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 3-2 Jib Boom Lift Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove the Jib Boom Lift Cylinder Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 5 Attach a lifting strap from an overhead crane to the lug at the rod end of the jib boom lift cylinder. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. 7 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine. Part No. 122985 S-80 • S-85 • S-80X 4 - 17 Section 4 • Repair Procedures September 2015 Boom Components 4-1 Cable Track The boom cable track guides cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom. 6 S-80: Tag, disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove the Cable Track Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 7 Tag, disconnect and plug the hydraulic hoses from the platform leveling slave cylinder at the platform manifold and cap the fittings. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 1 Open the platform control box. 2 Tag and disconnect the foot switch wiring from the terminal strip inside the platform control box. 3 Loosen the squeeze connector and remove the foot switch cable from the control box. 8 Remove the timing link/timing link cam pin and gently rest the timing link against the counterweight. 4 Disconnect the wire connectors from the bottom of the platform control box. 9 S-85:Remove the hose and cable cover from the side of the jib boom. Note: When installing the wire connectors to the bottom of the platform control box, match the color of the connectors to those on the control box to be sure they are installed in the correct location. 10 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate select manifold. Cap the fittings on the manifold. 5 Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side. 4 - 18 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 11 Tag, disconnect and plug the wiring from the jib boom/platform rotate select manifold. 12 Tag, disconnect and plug the hydraulic hoses from the jib boom lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. All models: 13 From the ground controls, raise the boom to a horizontal position. 18 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 19 Attach a lifting strap from an overhead crane to the cable track. 20 Remove the mounting fasteners that attach the lower cable track to the boom. 21 Remove the cable track from the machine and place it on a structure capable of supporting it. 14 Remove the fasteners from the drive speed limit switch bracket (LS1RS) mounted on the side of the boom at the platform end of the boom. Do not remove the limit switch from the bracket. 15 Remove the cotter pin from the upper cable track at the platform end of the boom. Note: Always replace the cotter pin with a new one. 16 Remove the cable track guide fasteners from the cable track guides at the platform end of the boom. Remove the cable track guides from the boom. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Component damage hazard. The cable track can be damaged if it is twisted. 17 Remove the cable clamp from the pivot end of the boom. Part No. 122985 S-80 • S-85 • S-80X 4 - 19 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS How to Repair the Cable Track Component damage hazard. The boom cable track can be damaged if it is twisted. 5 Remove the upper rollers from the replacement section of cable track. 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. Note: A cable track repair kit is available through the Genie Industries Service Parts Department, part no. 77896. The kit includes a 4-link section of cable track. 1 Visually inspect the cable track and determine which 4 link section needs to be replaced. 2 Carefully remove the snap rings from each end of the damaged section of cable track. 3 Remove the retaining fasteners from the upper black rollers from the 4-link section of cable track to be replaced. Remove the rollers. 7 Connect the ends of the replacement cable track section to the existing cable track using the snap rings. 8 Install the rollers onto the new section of cable track. 9 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track. 4 Lift up the hoses and cables and carefully remove the damaged 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 4 - 20 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 4-2 Boom How to Remove the Boom TIp-over hazard. This procedure requires the removal of the turntable counterweight. Failure to remove the counterweight before removing the boom assembly will result in the machine tipping over. Do not remove the boom without first removing the counterweight. How to Shim the Boom 1 Measure each wear pad. Note: Replace the pad if thickness is less than minimum specification. If thickness is more than minimum specification, perform the following procedure. Refer to Section 3, D-1, Check the Boom Wear Pads. TIp-over hazard. When installing the boom onto the machine, the boom assembly must be first installed prior to the installation of the counterweight. If the counterweight is installed before the boom assembly, the machine will tip over resulting in death or serious injury. 2 Extend the boom until the wear pads are accessible. 3 Loosen the wear pad mounting fasteners. 4 Install the new shims under the wear pad to obtain zero clearance and zero drag. 5 Tighten the mounting fasteners. TIp-over hazard. The turntable counterweight is essential for machine stability. Failure to install the counterweight after installing the boom assembly will compromise machine stability resulting in the machine tipping over. Death or serious injury will result. 6 Extend and retract the boom through an entire cycle. Check for tight spots that could cause binding or scraping. Note: Always maintain squareness between the outer and inner boom tubes. Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 1 Remove the jib boom. See 3-1, How to Remove the Jib Boom. 2 Remove the cable track. See 4-1, How to Remove the Cable Track. Part No. 122985 S-80 • S-85 • S-80X 4 - 21 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers. 9 Slowly operate the overhead crane to apply tension to the lifting straps. Do not attempt to lift the machine with the overhead crane. 4 Place a block of wood measuring 4 x 4 x 60 inches / 10 x 10 x 152 cm under the long link arm, across the turntable covers. 10 Locate and remove the counterweight retaining fastener at the center of the counterweight. Carefully lift the counterweight upwards and remove the counterweight from the machine. Set the counterweight on the ground. Do not leave the counterweight suspended above the ground. 5 Slowly lower the boom until the long link arm contacts the wood block. Do not rest the entire weight of the boom on the block. Turn the machine off. Crushing hazard. The turntable counterweight will fall if not properly supported by the overhead crane resulting in death or serious injury. Keep personnel away from the area when removing the counterweight. Component damage hazard. The turntable covers can become damaged if the weight of the boom is allowed to rest on the block. 6 Place wood blocks between the short link arm and the turntable weldment for support. 7 Insert a 1.125 x 12 inches / 32 x 300 mm eye-bolt through each hole located on the top surface of the counterweight. Secure the eyebolts in position with flat washers and nuts. 11 Attach lifting straps from a 5 ton / 5000 kg overhead crane to each end of the boom. Support the boom. Do not apply any lifting pressure. 8 Securely attach lifting straps or chains with a minimum rating of 5 tons / 5000 kg to the lifting points on the top of the turntable counterweight. Attach the lifting straps or chains to a 5 ton / 5000 kg overhead crane. 12 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device. Note: A spreader bar and other hardware may be needed to safely remove the counterweight. 4 - 22 13 Remove the lift cylinder rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin. S-80 • S-85 • S-80X Crushing hazard. The boom could fall if not properly supported when the lift cylinder rod-end pivot pin is removed. Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 14 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off. 17 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Crushing hazard. The boom lift cylinder could fall if not properly supported and secured to the lifting device. 15 Using the overhead crane, carefully lower the boom lift cylinder and allow it to rest on the boom rest pad. Protect the cylinder rod from damage. 16 Remove the boom end cover retaining fasteners and remove the cover. 18 Tag and disconnect the electrical connector for the cable break limit switch. 19 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom. 20 Support the platform leveling master cylinder. Remove the master cylinder rod-end pivot pin retaining fasteners. Place a rod through the pin and twist to remove. Carefully lower the master cylinder down. 21 Tag, disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom. Cap the bulkhead fittings. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 22 Remove the external snap rings from both boom pivot pins at the short and long link arms. Do not remove the pins. Part No. 122985 S-80 • S-85 • S-80X 4 - 23 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 23 Using the overhead crane, adjust the boom as necessary to relieve pressure from the pivot pins. 4-3 Boom Lift Cylinder 24 Use a soft metal drift to remove each boom pivot pin. Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it. The boom lift cylinder raises and lowers the boom. The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. Crushing hazard. The boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed. How to Remove the Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Crushing hazard. The long and short link arms may fall if not properly supported when the boom pivot pins are removed. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom to a horizontal position. 2 Attach a 5 ton / 5000 kg overhead crane to the boom at the platform end for support. Do not lift the boom. 3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device. 4 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom will fall if not properly supported when the primary boom rod-end pivot pin is removed. 4 - 24 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 5 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off. 6 Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4-4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube. The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. How to Remove the Boom Extension Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 7 Remove the pin retaining fasteners from the boom lift cylinder barrel-end pivot pins. Do not remove the pins. 8 Use a slide hammer to remove the barrel-end pivot pins. Crushing hazard. The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. 9 Move the boom lift cylinder towards the counterweight end of the machine. Rotate the boom lift cylinder until the barrel-end pivot pin bores will clear the boom linkage. 10 Carefully remove the boom lift cylinder from the machine. Crushing hazard. The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 122985 Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom fully retracted. 1 Raise the boom to a horizontal position. S-80 • S-85 • S-80X 4 - 25 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 2 Remove the boom end cover retaining fasteners and remove the cover. 3 Remove the access covers from both sides of the boom at the pivot end. 4 Fully loosen the lock nuts on the extend cables. Do not remove the nuts. 5 Loosen the retract cable nut at the platform end of the boom. Pull the cable rod from the support and let it hang down. 6 Remove the cable guard fasteners and remove the cable guard. 7 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube. 8 Remove the cable retaining plates and pull the retract cables off of the pulleys. Lay the cables flat and out of the way. 9 Remove the fasteners from the retaining blocks from the extension cylinder saddle. Remove the blocks. Note: Access the fasteners through the access hole in the outer boom tube at the pivot end. 10 Disconnect the wire connector to the extend cable break limit switch. 11 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube. b a a b 4 - 26 cable guard retaining block S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 13 Lift up the extend cable mounting plate and push the extend cables towards the platform to create slack in the cables. Rest the cable and bracket assembly on top of the extend cylinder. 14 Locate the lower extend cable bracket on the bottom of the number 3 boom tube. 15 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube. 16 While pushing the lower extend cable bracket towards the platform, pull the extend cable mounting plate towards the pivot end of the boom. 17 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder. a b a b c d c 18 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom. d extend extend extend extend cable lock nuts cable mounting plate cable mounting plate fastener cable bracket 12 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube. Part No. 122985 19 Use a soft metal drift to remove the pin. 20 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. S-80 • S-85 • S-80X Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 27 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 21 Attach a lifting strap from a 5 ton / 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder. 4-5 Boom Extend/Retract Cables 22 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube. How to Adjust the Boom Extend/ Retract Cables 23 Carefully support and slide the extension cylinder out of the boom. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Proper adjustment of the boom extend/retract cables and related components on a regular basis is essential to good machine performance and safe machine operation. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. Crushing hazard. The extension cylinder could fall when removed from the boom if not properly supported. Component damage hazard. Be careful not to damage the cable break limit switch. Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the boom. Note: During removal of the extension cylinder, the overhead crane strap will need to be carefully adjusted for proper balancing. Note: Perform this procedure with the boom in a horizontal position. 1 Start the engine from the Ground Controls. 2 Raise the boom to a horizontal position 3 Fully retract the boom. 4 Stop the engine. 5 Remove the boom end cover retaining fasteners and remove the cover. 6 Inspect the threaded ends of the boom extend cables. The threads must be clean and in good condition with no damaged threads. 4 - 28 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 7 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom. Loosen the nut, but do not remove the nut. 13 Retract and extend the boom approximately 3 feet / 1 m two times and stop during the extension cycle. This will create slack in the retract cables. 8 Locate the extend cable adjustment nuts on the counterweight end of boom tube #1. Refer to Illustration 2. Loosen the nylock nuts and jam nuts on the cable tension equalizer bracket. Do not remove the nuts. Note: Be sure to not fully extend the boom. Stop when there is approximately 3 feet / 1 m of travel left. 9 Adjust the extend cable adjustment nut to obtain 6 3/8 inches/16.2 cm to 6 1/2 inches/16.5 cm between the platform end of boom tube #2 and boom tube #3. Refer to illustration 1. There should be approximately 1/2 inch of exposed threads on the adjustment bolts. Refer to Illustration 2. 15 Fully extend the boom then retract the boom approximately 12 inches / 30 cm. Note: If the cables have been replaced, be sure the adjustment nuts have been replaced. Do not reuse the existing nuts. 14 Repeat steps 12 and 13 two to three times. 16 At the pivot end of the boom, visually inspect the boom extend cables for even cable droop or sag. Note: If the boom extend cables are uneven, tighten the boom extend cable adjustment nut at the pivot end of the boom for the appropriate cable. 10 Extend the boom until there is approximately 3 feet / 1 m of travel left. Do not fully extend the boom. 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom. 12 Using a dial type torque wrench, torque the retract cable adjustment nut to 32-36 ft lbs / 43-49 Nm using gentle and steady torque. 6.375 inches / 16.2 cm Illustration 1 Part No. 122985 S-80 • S-85 • S-80X 4 - 29 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 17 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm is centered in the notch of the pivot plate. How to Replace the Boom Extend/Retract Cables Note: If the boom extend cables are adjusted evenly, the wheel of the limit switch arm should be centered in the notch of the pivot plate. Note: The cable pulleys must also be replaced when replacing the cables. 1 Remove the boom extension cylinder. See Section 4-4, How to Remove the Boom Extension Cylinder. Boom extend cables: a 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube. 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch. 4 Remove the external snap rings from the boom extend cable pulley pivot pin. Use a soft metal drift to remove the pin. Note: When driving the pivot pin out, be sure to drive it from the shaped end of the pin. b 5 Remove the pulley and boom extend cables from the extension cylinder assembly. Discard the old cables and pulleys. c Illustration 2 a cable break limit switch b extend cable adjustment nut c extend cable pivot plate 18 Install the boom end cover at the pivot end of the boom. 19 Fully retract and lower the boom to the stowed position. 4 - 30 6 Route the new boom extend cables through the boom extend pulley bracket. 7 Install the new boom extend cable pulley, pivot pin and snap rings. Note: Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures BOOM COMPONENTS 8 Install the boom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch. 18 At the platform end of the boom, install the retract cables, clevis pins and rue rings to the adjustment plate. 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. 19 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder. Boom retract cables: 20 Install the new boom retract pulleys to the pivot end of the boom extension cylinder. 10 Remove the rue rings and clevis pins from the boom retract cables at the platform end of the boom. 21 Install the boom extension cylinder assembly into the boom. 11 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom. Note: Before lowering the extension cylinder into the saddles of the number 1 boom tube, wrap the boom retract cables around the pulleys. Note: A cable pulling tool is available through Genie Service Parts Department (Genie part no. 94510) 22 Adjust the boom extend/retract cables. See Section 4-5, How to Adjust the Boom Extend/Retract Cables. 12 At the platform end of the boom, pull on the boom retract cable that has the rope attached to it. 13 Pull the old cable completely out of the boom tube. Remove the rope. Discard the old boom retract cable. 14 Securely attach the rope to the same end of the new boom retract cable. 15 At the pivot end of the boom, carefully pull the rope with the new retract cable attached. 16 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube. Remove the rope. 17 Repeat steps 14 through 19 for the other boom retract cable. Part No. 122985 S-80 • S-85 • S-80X 4 - 31 Section 4 • Repair Procedures September 2015 BOOM COMPONENTS 4 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. 4-6 Platform Leveling Master Cylinder 5 Place a rod through the barel-end pivot pin and twist to remove the pin. The master cylinder acts as a pump for the slave cylinder. It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion. The master cylinder is located inside the pivot end of the boom. How to Remove the Platform Leveling Master Cylinder Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until the master cylinder rod-end pivot pin is accessible. 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder. 7 Remove the pin retaining fastener from the rod-end pivot pin. 8 Place a rod through the rod-end pivot pin and twist to remove the pin. 9 Remove the master cylinder from the machine. 2 Remove the turntable end cover to access the master cylinder. 3 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder. Crushing hazard. The master cylinder could become unbalanced and fall if it is not properly supported by the lifting device when removed from the machine. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 32 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Engines 5-1 RPM Adjustment 5-2 Flex Plate Refer to Maintenance Procedure B-10, Check and Adjust the Engine RPM. The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. Type "B" flex plates combines the pump coupler, as part of the flex plate, which is installed onto the engine flywheel. Type "B" (flexplate with coupler combined) Part No. 122985 S-80 • S-85 • S-80X 4 - 33 Section 4 • Repair Procedures September 2015 ENGINES How to Remove the Flex Plate Deutz model: Note: Perform this procedure with the engine off and cool to the touch. 5 Tag and disconnect the wiring from the bell housing. 1 Open the engine side turntable cover. 6 Remove the U-bolt from the exhaust flex pipe at the muffler. 2 Tag and disconnect the battery cables from the battery(s). Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the engine tray retaining fastener. Swing the engine tray out away from the machine. Burn hazard. Hot engine parts can cause severe burns. 7 Remove the muffler bracket retaining fasteners from bell housing. Remove the muffler and bracket assembly from the engine. 8 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners. 9 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched a 10 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel. b a b engine tray anchor hole engine tray retaining fastener 4 Tag and disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 4 - 34 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures ENGINES Perkins model: 11 Tag and disconnect the wiring from the bell housing. 12 Remove the exhaust pipe clamp at the muffler. Burn hazard. Hot engine parts can cause severe burns. 13 Remove the muffler mounting bracket fasteners. Remove the muffler and bracket assembly from the engine. 14 Remove the hose clamps from the air cleaner elbow and the engine intake manifold. 15 Remove the air cleaner mounting bracket fasteners. Remove the air cleaner and bracket assembly from the engine. 16 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing to engine fasteners. 21 Remove the relay housing from the muffler mount. Do not disconnect the relays. 22 Disconnect and remove the ECM from the muffler mount. 23 Close the shutoff valve on the Liquid Petroleum Gas (LPG) tank by turning it clockwise (if equipped). 24 Unbolt the EPR valve from the muffler mount. Leave the hoses attached to the EPR valve. 25 Remove the muffler mount. 26 Support the drive pump with an appropriate lifting device. Remove all of pump plate mounting fasteners. 27 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched. Continental model: 17 Tag and disconnect the wire harness from the oxygen sensor. 28 Remove the flex plate mounting fasteners. Remove the flex plate from the engine flywheel. 18 Remove the exhaust pipe heat shield fasteners from the top of the muffler. Burn Hazard. Hot engine parts can cause severe burns. 19 Remove the muffler retainer bracket fasteners. 20 Remove the muffler fasteners securing the muffler to the exhaust manifold. Remove the muffler from the bracket. Part No. 122985 S-80 • S-85 • S-80X 4 - 35 Section 4 • Repair Procedures September 2015 ENGINES How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. Apply Loctite® removable thread sealant to the mounting screws. Note: Torque the flex plate mounting bolts in two stages. Continental model: Torque the flex plate mounting bolts in sequence to 20.8 ft-lbs / 28 Nm. Deutz model: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Perkins model: Torque the flex plate mounting bolts in sequence to 46.7 ft-lbs / 63.3 Nm. 2 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine. 3 Apply Loctite® removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. Apply Loctite® removable thread sealant to the pump retaining fasteners. Torque the pump retaining fasteners to 57 ft-lbs / 77 Nm. Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 5 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine. 6 Install the pump and pump mounting plate assembly onto the engine. Apply Loctite® removable thread sealant to the mounting screws. Perkins model: Torque the pump mounting plate fasteners in sequence to 28 ft-lbs / 38 Nm. Deutz model: Torque the pump mounting plate fasteners in sequence to 46.7 ft-lbs / 63.3 Nm. Continental model: Torque the pump mounting plate fasteners in sequence to 23 ft-lbs / 31.2 Nm. 4 Install the pump onto the pump mounting plate. Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur. Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 4 - 36 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures ENGINES 6 1 1 8 10 3 6 4 3 11 12 5 4 5 7 2 2 Perkins 804C-33 Pump Mounting Plate Perkins, Deutz and Continental Flex Plate 6 6 1 4 3 11 1 8 10 8 10 9 12 4 3 11 12 5 7 5 7 2 2 9 9 Continental Pump Mounting Plate Deutz BF4L-2011 Pump Mounting Plate Part No. 122985 S-80 • S-85 • S-80X 4 - 37 Section 4 • Repair Procedures September 2015 Ground Controls 6-1 Control Relays Relays used for single function switching are single pole double throw (SPDT) relays. How to Test a Single Pole Double Throw Relay Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Tag and disconnect all the wiring from the relay to be tested. terminal no. 87a - N.C. terminal no. 85 - coil negative (-) terminal no. 30 - common terminal no. 86 - coil positive (+) terminal no. 87 - N.O. Control Relay Schematic 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination. Test terminal 85 to 86 with resistor terminal 87 to 87a and 30 terminal 87a to 30 Desired result 75 to 85Ω no continuity (infinite Ω) continuity (zero Ω) 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86, then test the following terminal combinations. Test terminal 87 to 87a and 30 terminal 87 to 30 4 - 38 Desired result no continuity (infinite Ω) continuity (zero Ω) S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Hydraulic Pumps 2 Tag, disconnect and plug the hydraulic hoses from the function pump. Cap the fittings on the pump. 7-1 Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove the Function Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 3 Remove the pump mounting fasteners. Carefully remove the pump. 1 Close the two hydraulic tank valves located at the hydraulic tank. Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. open Part No. 122985 Component damage hazard. Be sure to open the two hydraulic tank valves (if equipped) and prime the pump after installing the pump. See 7-2, How to Prime the Pump. closed S-80 • S-85 • S-80X 4 - 39 Section 4 • Repair Procedures September 2015 HYDRAULIC PUMPS 2 Close the two hydraulic tank valves located at the hydraulic tank. 7-2 Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Sundstrand-Sauer service center. Call Genie Industries Service Department to locate your local authorized service center. Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. How to Remove the Drive Pump Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. open closed Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Disconnect the wire harness at the electronic displacement controller (EDC), located on the drive pump. 4 - 40 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures HYDRAULIC PUMPS 3 Tag, disconnect and plug the hydraulic hoses from the drive and function pumps. Cap the fittings on the pumps. How to Prime the Pump Component damage hazard. Be sure that the hydraulic tank shutoff valves (if equipped) are in the open position before priming the pump. The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners. 1 Connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump. 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 2 Continental models: If equipped, close the valve on the LPG tank, then disconnect the hose from the tank. Move the fuel select toggle switch to the LPG position. Deutz and Perkins models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump. 6 Remove the drive pump assembly from the machine. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. Note: Before installing the pump, verify proper pump coupler spacing. See 5-2, Flex Plate. 3 Crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 300 psi / 20.7 bar. 4 Continental models: If equipped, connect the LPG hose to the LPG tank and open the valve on the tank. Deutz and Perkins models: Connect the engine wiring harness to the fuel solenoid. 5 Start the engine from the ground controls and check for hydraulic leaks. Part No. 122985 S-80 • S-85 • S-80X 4 - 41 Section 4 • Repair Procedures September 2015 Manifolds 8-1 Function Manifold Components The function manifold assembly is located on the tank side tray, behind the ground control box. Index No. Description 1 Solenoid valve, 2 position 3 way ...... SJ ......... Boom up ........................................... 50-55 ft-lbs / 68-75 Nm Schematic Item Function Torque 2 Solenoid valve, 2 position 3 way ...... SK ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm 3 Solenoid valve, NO, Poppet .............. SP ......... Extend ............................................... 33-37 ft-lbs / 45-50 Nm 4 Solenoid valve, NO, Poppet .............. SQ ........ Retract .............................................. 33-37 ft-lbs / 45-50 Nm 5 Proportional valve ............................. SR ........ Extend proportional .......................... 20-25 ft-lbs / 27-34 Nm 6 Differential sensing valve .................. SS ......... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm 7 Proportional valve ............................. SF ......... Boom up/down proportional ............. 33-37 ft-lbs / 45-50 Nm 8 Solenoid valve, 3 position, 4 way ..... SL ......... Steering directional .......................... 20-25 ft-lbs / 27-34 Nm 9 Proportional valve ............................. SE ......... Swing proportional ........................... 20-25 ft-lbs / 27-34 Nm 10 Solenoid valve, 3 position, 4 way ..... SI .......... Swing directional .............................. 26-30 ft-lbs / 35-41 Nm 11 Flow regulator valve .......................... SD ........ Oscillate flow control ........................ 20-25 ft-lbs / 27-34 Nm 12 Relief valve, 2400 psi / 165 bar ........ SN ........ Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm 13 Relief valve, 2400 psi / 165 bar ........ SO ........ Boom extend relief ........................... 20-25 ft-lbs / 27-34 Nm 14 Check valve, 30 psi / 2.1 bar ............. ST ......... Return check valve ........................... 30-35 ft-lbs / 41-47 Nm 15 Differential sensing valve .................. SH ........ Primary lift ......................................... 30-35 ft-lbs / 41-47 Nm 16 Check valve ....................................... SA ......... Back flow / check function pump ...... 30-35 ft-lbs / 41-47 Nm 17 Relief valve, 3200 psi / 221 bar ........ SB ......... System relief ..................................... 20-25 ft-lbs / 27-34 Nm 18 Pressure reducing valve ................... SC ........ Oscillate pressure control ................. 30-35 ft-lbs / 41-47 Nm 19 Differential sensing valve .................. SG ........ Differential sensing/turntable rotate . 30-35 ft-lbs / 41-47 Nm 20 Flow regulator valve .......................... SM ........ Steering flow control ......................... 20-25 ft-lbs / 27-34 Nm 4 - 42 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS SJ SK SP 20 19 18 17 16 15 SQ SM SC SR SB SS 4 5 6 SH SE 12 3 SA SL 13 2 SG SF 14 1 ST SI 7 8 9 10 SO SN SD Part No. 122985 S-80 • S-85 • S-80X 11 4 - 43 Section 4 • Repair Procedures September 2015 MANIFOLDS How to Adjust the Boom Down Relief Valve 8-2 Valve Adjustments Function Manifold Note: Perform this procedure with the boom in the stowed position. How to Adjust the System Relief Valve 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the diagnostic nipple located next to the auxiliary pump. Note: Perform this procedure with the boom in the stowed position. 2 Start the engine from the ground controls. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the diagnostic nipple (PTEST) located next to the auxiliary pump. 2 Simultaneously activate and hold the auxiliary power toggle switch and the primary boom retract toggle switch with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 3 Locate the system relief valve on the function manifold (item SB). Use a wrench to hold the relief valve and remove the cap using an allen wrench. 4 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counter clockwise to reduce the pressure. Install the relief valve cap. 3 Hold the function enable/rpm select toggle switch to the high idle position and activate and hold the boom down toggle switch with the boom fully lowered. Observe the pressure reading on the pressure gauge. Refer to Section 2, Hydraulic Specifications. 4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item SN) on the function manifold. 5 Adjust the internal hex socket. Turn it clockwise to increase pressure or counterclockwise to decrease pressure. Install the relief valve cap. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 through 5 and confirm relief valve pressure. Component damage hazard. Do not adjust the relief valve higher than specified. 5 Repeat step 2 to confirm relief valve pressure. 6 Remove the pressure gauge. 4 - 44 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS How to Adjust the Boom Extend Relief Valve Note: Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 3000 psi / 0 to 200 bar pressure gauge to the diagnostic nipple (PTEST port) on the function manifold. 2 Start the engine from the ground controls. 3 Hold the function enable/rpm select toggle switch to the high idle position and activate and hold the boom extend toggle switch with the boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Section 2, Hydraulic Specifications. 4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item SO) on the function manifold. 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 through 5 to confirm relief valve pressure. Part No. 122985 S-80 • S-85 • S-80X 4 - 45 Section 4 • Repair Procedures September 2015 MANIFOLDS 8-3 Brake/Two-Speed Manifold Components The brake/two speed manifold is mounted inside the drive chassis. Index Schematic No. Description Item Function Torque 1 Solenoid valve, 2 position 3 way .... BA ........... Brake release .................................... 20-25 ft-lbs / 27-34 Nm 2 Solenoid valve, 2 position 3 way .... BC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm 3 Check valve .................................... BB ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm 4 Orifice, 0.025 inch / 0.63 mm ......... BD ........... Turntable rotation brake release 1 BA 4 3 2 BC BD BB 4 - 46 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-4 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine. Index No. Description Schematic Item 1 Counterbalance valve, 1000 psi ....... RA ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm 2 Counterbalance valve, 1000 psi ....... RB ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm 3 Shuttle valve, 2 position 3 way ......... RD ........ Turntable rotation brake release ........ 8-10 ft-lbs / 10-15 Nm 4 Orifice, 0.030 inch / 0.8 mm ............... RC ........ Brake release circuit Function 2 1 RA Torque RB RD 4 Part No. 122985 RC S-80 • S-85 • S-80X 3 4 - 47 Section 4 • Repair Procedures September 2015 MANIFOLDS 8-5 Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator. Index No. Description Schematic Item Function Torque 1 Counterbalance valve, 3300 psi ........ PA ......... Platform rotate right .......................... 37-44 ft-lbs / 50-60 Nm 2 Counterbalance valve, 3300 psi ........ PB ......... Platform rotate left ............................. 37-44 ft-lbs / 50-60 Nm 2 1 PB PA 4 - 48 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-6 Platform Manifold Components, S-80 The jib boom/platform rotate manifold is mounted on the platform end of the boom. Index No. Description Schematic Item 1 Solenoid valve, 3 position 4 way ...... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm 2 Solenoid valve, 3 position 4 way ...... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm 3 Counterbalance valve, 3500 psi ....... EC ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm 4 Counterbalance valve, 3500 psi ....... ED ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm 5 Needle valve ..................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm 6 Pressure comp., flow control valve ... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm Function Torque EF EB 6 EE EC ED 5 1 2 3 4 EA Part No. 122985 S-80 • S-85 • S-80X 4 - 49 Section 4 • Repair Procedures September 2015 MANIFOLDS 8-7 Platform Manifold Components, S-85 The jib boom/platform rotate manifold is mounted on the platform end of the boom. Index No. Description Schematic Item 1 Solenoid valve, 3 position 4 way ....... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm 2 Solenoid valve, 3 position 4 way ....... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm 3 Solenoid valve, 3 position 4 way ....... EH ........ Jib Up/Down ...................................... 30-35 ft-lbs / 41-47 Nm 4 Counterbalance valve, 3500 psi ........ EC ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm 5 Counterbalance valve, 3500 psi ........ ED ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm Function Torque 6 Needle valve ...................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm 7 Pressure comp., flow control valve .... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm 8 Pressure comp., flow control valve .... EG ........ Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm EH EF EB 8 6 2 3 EG EC 7 1 EE ED 4 5 EA 4 - 50 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-8 2WD Traction Manifold Components The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description 1 Relief Valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm 2 Flow Divider / Combiner Valve ......... DB ........ Controls flow to drive motors in .......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm 3 Check Valve ...................................... DC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm 4 Check Valve ...................................... DD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm 5 Shuttle Valve, 3 position 3 way ......... DF ......... Controls flow to drive motors in .......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm 6 Orifice Plug, 0.070 inch / 1.8 mm ...... DA ........ Equalizes flow across flow divider/ .......................................................................... combiner valve BY Part No. 122985 Schematic Item Function S-80 • S-85 • S-80X Torque 4 - 51 Section 4 • Repair Procedures September 2015 MANIFOLDS 1 DE DB DC DD DF DA 4 - 52 S-80 • S-85 • S-80X 2 3 4 5 6 Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-9 4WD Traction Manifold Components (before serial number 8581) The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description 1 Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm 2 Flow divider/combiner valve ............. DB ........ Controls flow to non-steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 3 Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm 4 Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm 5 Flow divider/combiner valve ............. CK ........ Controls flow to flow divider/combiner valves 2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm 6 Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm 7 Orifice, 0.040 inch / 1 mm .................. DL ......... Equalizes pressure on both sides of flow divider/combiner valve 5 8 Orifice, 0.040 inch / 1 mm .................. DA ........ Equalizes pressure on both sides of flow divider/combiner valve 2 9 Orifice, 0.040 inch / 1 mm .................. DN ........ Equalizes pressure on both sides of flow divider/combiner valve 13 10 Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm 11 Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm 12 Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit that directs hot oil out of low pressure side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm 13 Flow divider/combiner valve ............. DM ........ Controls flow to steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 14 Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm Part No. 122985 Schematic Item Function S-80 • S-85 • S-80X Torque 4 - 53 Section 4 • Repair Procedures September 2015 MANIFOLDS DE DB DF 14 13 DP DC DM DK DD 12 11 10 1 2 3 4 5 6 DJ DH DG DN 9 4 - 54 DL DA 8 7 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-10 4WD Traction Manifold Components (after serial number 8580) The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description 1 Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm 2 Flow divider/combiner valve ............. DB ........ Controls flow to non-steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 3 Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm 4 Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm 5 Flow divider/combiner valve ............. CK ........ Controls flow to flow divider/combiner valves 2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm 6 Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm 7 Orifice, 0.040 inch / 1 mm .................. DL ......... Equalizes pressure on both sides of flow divider/combiner valve 5 8 Orifice, 0.040 inch / 1 mm .................. DA ........ Equalizes pressure on both sides of flow divider/combiner valve 2 9 Orifice, 0.040 inch / 1 mm .................. DN ........ Equalizes pressure on both sides of flow divider/combiner valve 13 10 Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm 11 Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm 12 Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit that directs hot oil out of low pressure side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm 13 Flow divider/combiner valve ............. DM ........ Controls flow to steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 14 Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm Part No. 122985 Schematic Item Function S-80 • S-85 • S-80X Torque 4 - 55 Section 4 • Repair Procedures September 2015 MANIFOLDS DE DB DF 14 13 DC DP DD DM DK 12 11 10 1 2 3 4 5 6 DJ DH DG DN 9 4 - 56 DL DA 8 7 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-11 Drive Oil Diverter Manifold Components (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index No. Description 1 Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm 2 Orifice disc, 0.031 inch / 0.8 mm .... CV ........... Delays shift to drive 3 Solenoid valve ............................... CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm 4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm 5 Pressure switch .............................. CZ ........... Power to relay .............................................. 16 ft-lbs / 22 Nm 6 Connector ........................................ --- ............ For pressure switch ..................................... 11 ft-lbs / 15 Nm 7 Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm 7 Schematic Item Function Torque CY CU CV CW CX 6 5 1 2 3 4 CZ Part No. 122985 S-80 • S-85 • S-80X 4 - 57 Section 4 • Repair Procedures September 2015 MANIFOLDS 4 Start the engine from the platform controls and drive the machine slowly in the forward direction. Note the pressure reading on the pressure gauge. 8-12 Valve Adjustments Traction Manifold How to Adjust the Hot Oil Shuttle Relief Valve Note: The pressure differential between the charge pump relief valve (located in the drive pump) and the hot oil shuttle relief valve (located in the traction manifold) is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling. This pressure differential must be maintained at 40 psi / 14.5 bar. 5 Turn the engine off, and remove the hot oil shuttle relief valve cap (item BJ). Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 6 Repeat steps 4 and 5 until a pressure differential (between the charge pump reading and the hot oil shuttle relief valve) of 40 psi / 14.5 bar is obtained. Note: The following procedure will require two people. 1 Open the engine side turntable cover and connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump. 2 Start the engine from the platform controls and allow the engine to run at low idle. Note the pressure reading on the pressure gauge. 3 Turn the engine off and connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the diagnostic nipple located on the traction manifold. 4 - 58 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures MANIFOLDS 8-13 Valve Coils Valve Coil Resistance Specifications How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance or infinite resistance indicates the coil has failed. Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases. While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / -7.8°C that your air temperature increases or decreases from 68°F / 20°C. Proportional solenoid valve (schematic items K and W) 4.8 Ω 2 position 3 way solenoid valve (schematic items D, R, X, TT and UU) 6.3 Ω 2 position 3 way solenoid valve (schematic items G) 3.3 Ω 3 position 4 way solenoid valve (schematic items A, E, N and S) 6.3 Ω 2 position 3 way solenoid valve (schematic items AK, AM, VV and WW) 6.3 Ω 2 position 3 way solenoid valve (schematic item G) 3.3 Ω Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance using a multimeter set to resistance (Ω). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. Part No. 122985 S-80 • S-85 • S-80X 4 - 59 Section 4 • Repair Procedures September 2015 MANIFOLDS How to Test a Coil Diode a AMMETER COIL d - b + c 10 W RESISTOR c 9V BATTERY b + Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. - Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. a b c d multimeter 9V DC battery 10Ω resistor coil 1 Test the coil for resistance. Refer to, How to Test a Coil. Note: Dotted lines in illustration indicate a reversed connection as specified in step 6. 2 Connect a 10Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. 4 Connect the negative lead to the other terminal on the coil. Note: The battery should read 9V DC or more when measured across the terminals. 3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. 4 - 60 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Fuel and Hydraulic Tanks 9-1 Fuel Tank 4 Tag, disconnect, drain and plug the supply and return fuel hoses. Cap the fittings on the fuel tank. How to Remove the Fuel Tank 5 Remove the fuel tank retaining fasteners. Explosion and fire hazard. Engine fuels are combustible. Remove the fuel tank in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. 6 Remove the fuel tank from the machine. Component damage hazard. The fuel tank is plastic and may become damaged if allowed to fall. Component damage hazard. When installing the plastic fuel tank, do not overtighten the retaining fasteners. Note: Clean the fuel tank and inspect for damage before installing it onto the machine. 1 Turn the manual fuel shutoff valve to the closed position (if equipped). 2 Remove the fuel filler cap from the tank. 3 Using an approved hand-operated pump, drain the fuel tank into a suitable container. Refer to capacity specifications. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. Note: Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel. Part No. 122985 S-80 • S-85 • S-80X 4 - 61 Section 4 • Repair Procedures September 2015 FUEL AND HYDRAULIC TANKS 2 Close the two hydraulic tank valves located at the hydraulic tank (if equipped). 9-2 Hydraulic Tank Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. The primary functions of the hydraulic tank are to cool, clean and de-aerate the hydraulic fluid during operation. The tank utilizes internal suction strainers for the pump supply hoses and has an external return filter equipped with a filter condition indicator. How to Remove the Hydraulic Tank Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the fuel tank. See 9-1, How to Remove the Fuel Tank. open closed 3 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container. Refer to Section 2, Specifications. 4 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank. 5 Tag and disconnect and plug the hose from the return filter. Cap the fitting on the return filter housing. 6 Tag and disconnect and plug the supply hose for the auxiliary power unit. Cap the fitting on the hydraulic tank. 4 - 62 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures FUEL AND HYDRAULIC TANKS 7 Remove the retaining fasteners from the hydraulic tank hold down straps. Remove the hold down straps from the hydraulic tank. 17 Clean up any oil that may have spilled. 18 Open the hydraulic tank shutoff valves (if equipped). 8 Support the hydraulic tank with 2 lifting straps. Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane. Component damage hazard. Be sure to open the two hydraulic tank shutoff valves (if equipped) and prime the pump after installing the hydraulic tank. 9 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if not properly supported and secured to the overhead crane. Note: Always use pipe thread sealant when installing the drain plug and strainers. 10 Remove the suction strainers from the tank and clean them using a mild solvent. 11 Rinse out the inside of the tank using a mild solvent. 12 Install the suction strainers using pipe thread sealant on the threads. 13 Install the drain plug using pipe thread sealant on the threads. 14 Install the hydraulic tank onto the machine. 15 Install the two suction hoses and the supply hose for the auxiliary power unit. 16 Fill the tank with hydraulic oil until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. Part No. 122985 S-80 • S-85 • S-80X 4 - 63 Section 4 • Repair Procedures September 2015 Turntable Rotation Components 10-1 Turntable Rotation Drive Hub Assembly How to Remove the Turntable Rotation Drive Hub Assembly B Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. A a b 1 Secure the turntable from rotating with the turntable rotation lock pin. c a b c backlash pivot plate adjustment bolt with lock nut backlash pivot plate mounting bolts 5 Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub assembly from the machine. unlocked Crushing hazard. The turntable rotation drive hub assembly could become unbalanced and fall when it is removed from the machine if not properly supported. locked 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Loosen the backlash pivot plate and adjustment bolts. 4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly. 4 - 64 When installing the drive hub assembly: 6 Install the drive hub. Apply removable thread locking compound to fastener threads.Torque the backlash pivot plate mounting fasteners to specification. Refer to Section 2, Machine Torque Specifications. 7 Install the brake and then the motor onto the drive hub. Apply removable thread locking compound to fastener threads.Torque the motor/brake mounting fasteners to specification. Refer to Section 2, Machine Torque Specifications. 8 Adjust turntable rotation gear backlash. See 10-1, How to Adjust the Turntable Rotation Gear Backlash. S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures TURNTABLE ROTATION COMPONENTS How to Remove the Turntable Rotation Hydraulic Motor Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. a B A 1 Secure the turntable from rotating with the turntable rotation lock pin. Note: The turntable rotation lock pin is located next to the boom rest pad. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. c a b c b motor drive hub mounting bolts drive hub with brake 3 Remove the hydraulic tube that connects from the counterbalance manifold to the brake. Cap the fittings on the brake and manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the motor/brake mounting fasteners. Carefully remove the motor from the brake. 5 Clean up any oil that may have spilled. Part No. 122985 S-80 • S-85 • S-80X 4 - 65 Section 4 • Repair Procedures September 2015 TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear. Note: Perform this procedure with the boom between the non-steer end tires and with the machine on a firm and level surface. 1 Secure the turntable from rotating with the turntable rotation lock pin. Note: The turntable rotation lock pin is located next to the boom rest pad. 2 Loosen the backlash pivot plate mounting fasteners. B A 3 Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation gear into the turntable bearing ring gear). 4 Loosen the lock nut on the adjustment bolt. 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate. 6 Turn the adjustment bolt one half turn counterclockwise. Tighten the lock nut on the adjustment bolt. 7 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt. Then torque the mounting fasteners on the backlash pivot plate. Refer to Section 2, Specifications. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. a b c a b c 4 - 66 backlash pivot plate adjustment bolt with lock nut backlash pivot plate mounting bolts S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures 2WD Steer Axle Components 11-1 Yoke and Hub How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts. Do not remove them. How to Remove the Yoke and Hub 1 Remove the pin retaining fasteners from both the steering cylinder and the tie rod cylinder pivot pins. Use a soft metal drift to remove the pins. 2 Block the non-steer wheels and center a lifting jack of ample capacity under the steer axle. 3 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 2 Loosen the wheel lug nuts. Do not remove them. 4 Remove the lug nuts. Remove the tire and wheel assembly. 3 Block the non-steer wheels and center a lifting jack of ample capacity under the steer axle. 5 Remove the dust cap, cotter pin and castle nut. 4 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 5 Remove the lug nuts. Remove the tire and wheel assembly. 6 Remove the pin retaining fasteners from the yoke pivot pins. Note: Always replace the cotter pin with a new one when installing the castle nut. 6 Pull the hub off the spindle. The washer and outer bearing should fall loose from the hub. 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing. 7 Support and secure the yoke and hub assembly to a lifting jack. 8 Use a slide hammer to remove the upper yoke pivot pin, then use a soft metal drift to drive the lower yoke pivot pin down and out. 9 Remove the yoke and hub assembly from the machine. Crushing hazard. The yoke and hub assembly may become unbalanced and fall if not properly supported and secured to the lifting jack when it is removed from the machine. Part No. 122985 S-80 • S-85 • S-80X 4 - 67 Section 4 • Repair Procedures September 2015 2WD STEER AXLE COMPONENTS How to Install the Hub and Bearings, 2WD Models 11-2 Steer Cylinder Note: When replacing a wheel bearing, both the inner and outer bearings including the pressed-in races must be replaced. How to Remove a Steer Cylinder 1 Be sure that both bearings are packed with clean, fresh grease. 2 Place the large inner bearing into the rear of the hub. 3 Press the bearing seal evenly into the hub until it is flush. 4 Slide the hub onto the yoke spindle. Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur. 5 Place the outer bearing into the hub. 6 Install the washer and castle nut. There are two identical steer cylinders that work in parallel. They are part of the same hydraulic circuit, but move in opposite directions. The tie rod cylinder maintains equal movement of the tires. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Tighten the castle nut to 158 ft-lbs / 214 Nm to seat the bearing. Note: Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly. 8 Loosen the castle nut one turn, and then torque to 35 ft-lbs / 47 Nm. 9 Install a new cotter pin. Bend the cotter pin to secure the castle nut. Note: Always use a new cotter pin when installing a castle nut. 2 Remove the pin retaining fasteners from the steer cylinder pivot pins. Remove the pivot pin from each end of the steer cylinder. 3 Remove the steer cylinder from the machine. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 4 - 68 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures 4WD Steer Axle Components 6 Remove the lug nuts. Remove the tire and wheel assembly. 12-1 Yoke and Drive Hub 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin. How to Remove the Yoke and Drive Hub Assembly 8 Remove the drive motor mounting fasteners. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the pin retaining fasteners from both the steer cylinder and the tie rod cylinder pivot pins. Remove the pins. 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine. 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. 11 Support and secure the yoke and drive hub assembly to a lifting jack. 12 Use a slide hammer to remove the upper yoke pivot pin. Use a soft metal drift to drive the lower yoke pivot pin down and out. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Loosen the wheel lug nuts. Do not remove them. 4 Block the non-steer wheels, and center a lifting jack of ample capacity under the steer axle. Crushing hazard. The yoke and drive hub assembly could become unbalanced and fall when the yoke pivot pins are removed if not properly supported and secured to the lifting jack. 13 Place the yoke and drive hub assembly on a flat surface with the drive hub facing down. 14 Remove the drive hub mounting fasteners that attach the drive hub to the yoke. Remove the yoke from the drive hub. Refer to Section 2, Specifications. Note: Replace the thrust washer when installing the yoke and drive hub assembly onto the axle. 5 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. Part No. 122985 S-80 • S-85 • S-80X 4 - 69 Section 4 • Repair Procedures September 2015 4WD STEER AXLE COMPONENTS 3 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. 12-2 Drive Motor Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Remove a Drive Motor Component damage hazard. Repairs to the motor should only be performed by an authorized Sauer dealer. Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. 4 Remove the drive motor mounting fasteners. 5 Slide the drive motor shaft out of the drive hub, and remove the drive motor from the machine. Refer to Section 2, Specifications. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Extend the axles. 2 Remove the drive motor access covers from both sides of the inner axle. 4 - 70 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures 4WD STEER AXLE COMPONENTS 12-3 Drive Hub 12-4 Steer Cylinders How to Remove a Drive Hub How to Remove a Steer Cylinder Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. There are two identical steer cylinders that work in parallel. They are part of the same hydraulic circuit, but move in opposite directions. The tie rod cylinder maintains equal movement of the tires. 1 Remove the drive motor. See 12-2, How to Remove a Drive Motor. 2 Loosen the wheel lug nuts. Do not remove them. 3 Center a lifting jack of ample capacity under the non-steer axle. 4 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the wheel lug nuts, then the tire and wheel assembly. 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack. 7 Remove the drive hub mounting fasteners that attach the drive hub to the axle. Remove the drive hub. Crushing hazard. The drive hub could become unbalanced and fall if not properly supported and secured to the lifting jack when removed from the machine. 2 Remove the hose bracket mounting fastener on the steer cylinder barrel-end pivot pin. 3 Remove the pin retaining fasteners from the steer cylinder pivot pins. Remove the pivot pin from each end of the steer cylinder. 4 Remove the steer cylinder from the machine. Note: Do not re-use the drive hub mounting fasteners. Genie specifications require the use of new fasteners. Part No. 122985 S-80 • S-85 • S-80X 4 - 71 Section 4 • Repair Procedures September 2015 Non-steer Axle Components 13-1 Drive Motor 13-2 Drive Hub How to Remove a Drive Motor How to Remove a Drive Hub This procedure is the same as the steer axle procedure. See 12-2, How to Remove a Drive Motor. This procedure is the same as the steer axle procedure. See 12-3, How to Remove a Drive Hub. 4 - 72 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures Oscillating Axle Components 3 Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on the cylinder. 14-1 Oscillate Axle Cylinders Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain a level chassis while driving over uneven terrain. The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure. How to Remove an Oscillate Axle Cylinder Note: Perform this procedure on firm, level surface with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or the hose end must be replaced. All connections must be torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 4 Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to remove the pin. 5 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. 6 Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to remove the pin. 7 Remove the cylinder from the machine. 1 Rotate the turntable until the boom is between the steer tires. 2 Remove the fasteners from the drive chassis cover at the steer end. Remove the cover. Part No. 122985 S-80 • S-85 • S-80X Crushing hazard. The oscillate cylinder could become unbalanced and fall if not properly attached to the overhead crane when removed from the machine. 4 - 73 Section 4 • Repair Procedures September 2015 OSCILLATING AXLE COMPONENTS 4 Start the engine from the ground control. 14-2 Oscillate Directional Valve 5 With the engine running, manually activate the valve and observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. How to Adjust the Oscillate Relief Valve Pressure 6 Turn the engine off. 1 Connect a 0 to 2000 psi / 0 to 150 bar pressure gauge to the diagnostic nipple located on the function manifold. 2 Remove the drive chassis cover from the nonsteer end of the machine. 3 Disconnect the directional valve linkage, by removing the clevis yoke from the drive chassis. Refer to illustration 1. 7 Locate the relief valve on the function manifold (item SC). 8 Loosen the jam nut on the relief valve. 9 Turn the valve clockwise to increase the pressure or counterclockwise to decrease the pressure. Tip-over hazard. Do not adjust the relief valve higher than specified. 10 Tighten the jam nut. 11 Repeat steps 4 through 10 to confirm the oscillate relief valve pressure. Note: The oscillate pressure required is while the oscillate cylinders are in motion. Do not dead head the cylinders to either side. a 12 Turn the engine off, remove the pressure gauge and assemble the directional valve linkage. 13 Install the cover on the non-steer end of the drive chassis. b c a b c 4 - 74 oscillate valve clevis yoke drive chassis S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 4 • Repair Procedures OSCILLATING AXLE COMPONENTS How to Set Up the Directional Valve Linkage 8 Verify that the ground and drive chassis are completely level. Note: Perform this procedure on a firm, level surface. 9 Loosen the jamb nuts and adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the axle. 1 Lower the boom to the stowed position. 10 Install the cotter pin and tighten the jamb nuts. 2 Use a "bubble type" level to be sure the surface the machine is on is completely level. 11 Measure the gap between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis). Tip-over hazard. Failure to perform this procedure on a firm, level surface will compromise the stability of the machine and could result in the machine tipping over. 3 Check the tire pressure in all four tires and add air if needed to meet specification. Result: The measurements should be equal. Note: The gap on both sides should be between 0.150 inch / 0.381 cm and 0.170 inch / 0.432 cm. 12 Add or remove shims between the oscillation stop bar and the drive chassis to achieve the proper gap. 4 Remove the drive chassis cover from the non-steer end of the machine. 5 Disconnect the linkage clevis yoke from the axle. 6 Place a "bubble type" level on the turntable rotate bearing plate at the non-steer end. Confirm whether the drive chassis is completely level. 7 If the drive chassis is not level, start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level. Part No. 122985 S-80 • S-85 • S-80X 4 - 75 Section 4 • Repair Procedures September 2015 This page intentionally left blank. 4 - 76 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Be sure that all necessary tools and test equipment are available and ready for use. Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. • Boom in stowed position • Turntable rotated with the boom between the non-steer wheels • Turntable secured with the turntable rotation lock Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Note: Two persons will be required to safely perform some troubleshooting procedures. Part No. 122985 S-80 • S-85 • S-80X 5-1 Section 5 • Fault Codes September 2015 FAULT CODES Fault Codes - Control System How to Retrieve Control System Fault Codes Note: At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes. Note: Perform this procedure with the engine off, the key switch turned to platform controls and both red Emergency Stop button pulled out to the on position at both the ground and platform controls. 1 Open the platform control box lid. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 2 Locate the red and yellow fault LEDs on the ALC-500 circuit board inside the platform control box. Do not touch the circuit board. 3 Determine the error source: The red LED indidates the error source and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second. Note: When the red LED is flashing the code, the yellow LED will be on solid. 4 Determine the error type: The yellow LED indidates the error type and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second. Note: When the yellow LED is flashing the code, the red LED will be on solid. 5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. If the circuit board does need to be handled, maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap. 5-2 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 5 • Fault Codes FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 21 Primary Up / Down Joystick 11 12 15 16 17 Value at 5V Value too high Value too low Value at 0V Not calibrated Function is inoperative. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. Calibrate joystick. 22 Primary Up / Down Directional Valves 21 Fault Valve is operating outside of limits. Alarm sounds indicating a fault. Cycle power off, then on after problem has been correted. 23 Primary Up / Down Flow Valve 12 15 Value too high Value too low 17 Not calibrated Valve is operating outside of limits. Alarm sounds indicating a fault. Normal function except threshold for one or both directions is zero. Cycle power off, then on after problem has been corrected. Calibrate valve threshold. Reduced speed function. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. Calibrate angle sensor. 24 Angle sensor 11 12 15 16 17 31 Value at 5V Value too high Value too low Value at 0V Not calibrated Invalid setup 26 Angle sensor cross check (S-80X) 19 Out of range Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5-3 Section 5 • Fault Codes September 2015 FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 31 Primary Ext. / Ret. Joystick 11 12 15 16 17 Value at 5V Value too high Value too low Value at 0V Not calibrated Function is inoperative. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. Calibrate joystick. 32 Primary Ext. / Ret. Directional Valves 21 Fault Valve is operating outside of limits. Alarm sounds indicating a fault. Cycle power off, then on after problem has been correted. 33 Primary Ext. / Ret. Flow Valve 12 15 Value too high Value too low 17 Not calibrated Valve is operating outside of limits. Alarm sounds indicating a fault. Normal function except threshold for one or both directions is zero. Cycle power off, then on after problem has been corrected. Calibrate valve threshold. Limited speed and direction frozen at zero and neutral. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. 34 Ext. Ret. Limit Switch Cross Check 31 Invalid setup 41 Turntable Rotate Joystick 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 5-4 S-80 • S-85 • S-80X Calibrate joystick. Part No. 122985 September 2015 Section 5 • Fault Codes FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 42 Turntable Rotate Directional Valves 21 Fault Limited direction. Frozen at zero and neutral. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. 43 Turntable Rotate Flow Valve 12 15 Value too high Value too low Cycle power off, then on after problem has been correted. 17 Not calibrated Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault. Normal function except threshold for one or both directions is zero. Calibrate valve threshold. 44 Drive Enable Override Switch 21 Fault Drive enable override direction is frozen at neutral. Cycle power off, then on after problem has been corrected. 51 Drive Joystick 11 12 15 16 Value at 5V Value too high Value too low Value at 0V Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault. Cylcle power off, then on after problem has been corrected. 17 Not calibrated Calibrate joystick. Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5-5 Section 5 • Fault Codes September 2015 FAULT CODES Error Source Error Type ID Name ID Name 53 Drive Flow Valve (EDC) 12 15 Value too high Value too low Frozen at zero and neutral. 17 Not calibrated Condition Solution Limited speed and direction. problem has been corrected. Alarm sounds indicating a fault. Normal function except threshold for one or both directions is zero. Cycle power off, then on after Calibrate valve threshold. 54 Drive Brake Valve 21 Fault Drive frozen at zero and neutral. Alarm sounds indicating a fault. Cycle power off, then on after problem has been correted. 55 High Drive Motor Speed Valve 21 Fault Motor speed in the low state. Alarm sounds indicating a fault. Cycle power off, then on after problem has been corrected. 61 Steer Joystick 11 12 15 16 Value at 5V Value too high Value too low Value at 0V Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault. Cylcle power off, then on after problem has been corrected. 17 Not calibrated 21 Fault 62 5-6 Steer Directional Valve Calibrate joystick. Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault. S-80 • S-85 • S-80X Cycle power off, then on after problem has been corrected. Part No. 122985 September 2015 Section 5 • Fault Codes FAULT CODES Continental Engine Models 5 Continue to hold the run/test toggle switch in the test position and count the blinks. How to Retrieve Continental Engine Fault Codes Note: Before the fault codes are displayed, the check engine light will blink a code 1654 three times. After the fault codes, the check engine light will blink a code 1654 three times again indicating the end of the stored codes. The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. Note: Perform this procedure with the key switch in the off position. 1 Open the ground controls side cover and locate the run/test toggle switch on the side of the ground control box. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Quickly activate and release the start toggle switch/button. Do not start the engine. 4 Move and hold the run/test toggle switch to the test position. Note: If any fault codes are present, the ECM will blink a three or four digit code three times for each code stored in memory. It will blink the first digit of a three digit code, pause, blink the second digit, pause, blink the third digit, then pause and possibly a fourth digit. For example: the check engine light blinks 5 consecutive times, blinks 3 times and then 1 time. That would indicate code 531. Note: Once a fault code has been retrieved and the repair has been completed, the ECM memory must be reset to clear the fault code from the ECM. See How to Clear Engine Fault Codes from the ECM. How to Clear Engine Fault Codes from the ECM Note: Perform this procedure with the engine off and the key switch in the off position. 1 Open the engine side turntable cover and locate the battery. 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes. Result: The check engine light should turn on. The check engine light should begin to blink. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. Part No. 122985 S-80 • S-85 • S-80X 5-7 Section 5 • Fault Codes September 2015 IAT BP 118 117 116 217 ECT Voltage High ECT Voltage Low ECT higher than expected 1 ECT higher than expected 2 113 112 111 127 IAT Voltage High IAT Voltage Low IAT higher than expected 1 IAT higher than expected 2 Low Rev Limit Power Derate 2 Power Derate 1 Y Y 107 MAP Voltage Low ECT/ CHT Adaptive Learn KC* Code Fault Name 108 MAP Pressure High Adaptive Learn System MAP Shutdown FAULT CODES Y Y Fault Conditions MAP pressure > 16 psi and TPS < 10% and RPM > 1800 To Unlatch, MAP pressure must be < 10 psi MAP voltage < 0.05 vdc and TPS > 2% and RPM < 7000 To Unlatch, MAP voltage must be > 0.5 vdc Y Y Y Y Y ECT voltage > 4.95 vdc ECT voltage < 0.05 vdc ECT > 210° F and RPM > 600 ECT > 230° F and RPM > 600 Y Y Y IAT voltage > 4.95 vdc IAT voltage < 0.05 vdc IAT > 200° F and RPM > 1000 IAT > 210° F and RPM > 1000 Y Y Y 2229 BP Pressure High 129 BP Pressure Low Y Y Y Y BP pressure > 16 psi BP pressure < 8.3 psi Battery Voltage 563 Voltage High 562 Voltage Low Y Y Y Y Voltage > 18 vdc Voltage < 9.5 vdc and RPM > 1500 5V External 643 5VE1 High Voltage 642 5VE1 Low Voltage Y Y 5VE1 > 5.4 vdc 5VE1 < 4.6 vdc TPS 123 122 223 222 221 121 2112 2111 2135 TPS1 High Voltage TPS1 Low Voltage TPS2 High Voltage TPS2 Low Voltage TPS1 > than TPS2 TPS1 < than TPS2 Unable to reach > TPS Unable to reach < TPS TPS1/2 simultaneous voltages out of range Y Y Y Y Y Y Y Y Y TPS1 voltage > 4.8 vdc TPS1 voltage < 0.2 vdc TPS2 voltage > 4.8 vdc TPS2 voltage < 0.2 vdc (TPS1 percent - TPS2 percent) > 20% (TPS1 percent - TPS2 percent) < -20% (target TPS - actual TPS) > 20% (target TPS - actual TPS) < -20% Uses same parameters as individual TPS1/2 voltage fault detection above * Adaptive Learn Key Cycle 5-8 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 5 • Fault Codes 219 Max Govern Speed Override 1111 Rev Fuel Limit 1112 Spark Rev Limit Y Oil Pressure 524 Oil Pressure Low Y Adaptive Learn 171 AL High Gasoline Bank 1 Engine Speed Oil pressure pulled-up input with a threshold voltage of 2.5 vdc and RPM > 500 and run-time > 30 s AL_BM > 30% and RPM between 0-9999 and MAP between 0-99 psi AL_BM < -30% and RPM between 0-9999 and MAP between 0-99 psi AL_BM > 30% and RPM between 0-9999 and MAP between 0-99 psi AL_BM < -30% and RPM between 0-9999 and MAP between 0-99 psi 1161 AL High LPG 1162 AL Low LPG 1155 CL High Gasoline Bank 1 CL_BM > 40% and RPM between 0-9999 and MAP between 0-99 psi CL_BM <-40% and RPM between 0-9999 and MAP between 0-99 psi CL_BM > 35% and RPM between 0-9999 and MAP between 0-99 psi CL_BM < -35% and RPM between 0-9999 and MAP between 0-99 psi 1156 CL Low Gasoline Bank 1 1151 CL High LPG 1152 CL Low LPG Catalyst Monitor Fault Conditions Y FPP1 voltage > 4.8 vdc Y FPP1 voltage < 0.2 vdc RPM > 3400 RPM > 3600 RPM > 3800 172 AL Low Gasoline Bank 1 Closed Loop Low Rev Limit Power Derate 2 Power Derate 1 Adaptive Learn KC* Code Fault Name 2122 FPP1 High Voltage 2123 FPP1 Low Voltage Adaptive Learn System FPP Shutdown FAULT CODES 420 Gasoline Cat Monitor Y Y 1165 LPG Cat Monitor Y Y EGO2 RMS > 0.005 phi and EGO2 RMS > EGO1 RMS* 50% and EGO2 RMS > CL waveform RMS* 50% EGO2 RMS > 0.005 phi and EGO2 RMS > EGO1 RMS* 50% and EGO2 RMS > CL waveform RMS* 50% * Adaptive Learn Key Cycle Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5-9 Section 5 • Fault Codes September 2015 Injectors 261 Injector Loop Open or Low-Side Short to Ground 262 Injector Coil Shorted Power Relay Control Coil 686 Relay Control Ground Short 685 Relay Coil Short 687 Relay Coil Short to Pwr Tach Output 2618 Tach Output Ground Short 2619 Tach Output Short to Pwr EPR 1171 EPR Delivery Pressure > than expected 1172 EPR Delivery Pressure < than expected 1173 EPR Comm Lost 1174 EPR Voltage Supply High 1175 EPR Voltage Supply Low 1176 EPR Internal Actuator fault detection 1177 EPR Internal Circuitry fault detection 1178 EPR Internal Comm fault detection Diagnostics LPG Low Rev Limit Power Derate 2 Power Derate 1 Adaptive Learn KC* Adaptive Learn System Code Fault Name EGO 134 EGO Open/Lazy Pre-cat 1 Sensors 154 EGO Open/Lazy Post-cat 1 Shutdown FAULT CODES Y Y Y Y Fault Conditions EGO cold persistently > 120 seconds EGO cold persistently > 120 seconds Injector off-state low-side < 4 vdc and battery voltage > 9 vdc Injector on-state low-side > 4 vdc and battery voltage < 16 vdc Y Y Y Y Y Y Does not turn on MIL Does not turn on MIL Y Y MJ actual-commanded press > 4 in. H20 Y Y MJ actual-commanded press < 4 in. H20 Y Y Y Y Y Y Y Y No MJ packets received within 500 ms Y Y Y Y * Adaptive Learn Key Cycle 5 - 10 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 5 • Fault Codes 336 Crank Sync Noise 16 Internal 606 Processor 1612 Diagnostics 1613 1614 1615 1616 601 604 J1939 Network 1625 1626 1627 1628 Y Y Y Y Y Y Never Crank Synced at Start COP Failure RTI 1 Loss RTI 2 Loss RTI 3 Loss A/D Loss Invalid Interrupt Flash Checksum Invalid RAM Failure Y Y Y Y Y Y Y Y Low Rev Limit Power Derate 2 Power Derate 1 Adaptive Learn KC* Adaptive Learn System Code Fault Name Cam 342 Cam Loss Crank 337 Crank Loss Sensors 341 Cam Sync Noise Shutdown FAULT CODES Fault Conditions No cam pulse in 4 cycles and RPM > 1000 Cam pulses without crank activity > 6 cam pulses Number of invalid cam re-syncs = 1 within a time window of <= 700 ms Number of invalid crank re-syncs = 1 within a time window of <= 800 ms Cranking revs without sync < 4 revs and RPM > 90 rpm Y Y Y Y Y Y Y Y Shutdown Request CAN Tx Failure CAN Rx Failure Number of shutdown requests >= 1 TX error counter > 100 Rx error counter > 100 Address conflict counter > 5 CAN Address Conflict Failure * Adaptive Learn Key Cycle Part No. 122985 S-80 • S-85 • S-80X 5 - 11 Section 5 • Fault Codes September 2015 This page intentionally left blank. 5 - 12 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Hydraulic Schematics Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. Be sure that all necessary tools and test equipment are available and ready for use. Part No. 122985 S-80 • S-85 • S-80X 6-1 Section 6 • Schematics September 2015 Electrical Symbols Legend FS1 BLK BLK P3 WHT Quick disconnect terminal N.O.H.C Coil solenoid or relay N.C.H.O Limit switch Horn button normally open P1 KS1 TB21 WHT #21 Foot switch LS3 PLATFORM OTS2 N.O. GROUND T-circuits connect at terminal H1 Horn or alarm Key switch Oil temperature switch normally open T-circuits connect Emergency Stop button normally closed FAN FB PR1 CTS1 N.O. Flashing beacon Power relay Coolant temperature switch normally open Connection no terminal G1 TS2 START ENGINE Gauge Aux Pump Auxiliary pump OPS1 N.C. Circuits crossing no connection 510 HM Diode Hydraulic oil cooling fan Toggle switch SPDT Oil pressure switch normally closed Resistor with ohm value Hour meter TS6 + PLATFORM LEVEL - LED 25A AUX MAIN Fuse with amperage Battery separator Tilt sensor Toggle switch DPDT A CR4 N.O. Control relay contact normally open B C HOLD F1 Gauge sending unit PULL IN Battery UP DOWN L3 Fuel or RPM solenoid CB1 15A Circuit breaker with amperage 6-2 Starting aid: glow plug or flame ignitor Coil S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 6 • Schematics Hydraulic Symbols Legend 25 psi (1.7 bar) Accumulator .035" (0.89 mm) Filter with bypass valve relief setting Solenoid operated proportional valve Orifice with size Shut off valve Solenoid operated 3 position, 4 way, directional valve 2 position, 3 way, shuttle valve Pump fixed displacement Priority flow regulator valve Check valve 200 psi (13.8 bar) Hydraulic oil cooler Pump bi-directional, variable displacement Solenoid operated 2 position, 3 way, directional valve Relief valve with pressure setting 3000 psi (206.8 bar) 3:1 o Brake Motor bi-directional Directional valve (mechanically activated) Counterbalance valve with pressure and pilot ratio Pilot operated 3 position, 3 way, shuttle valve Motor 2-speed, bi-directional E Pump prime mover (engine or motor) 2 position, 2 way solenoid valve 50% 50% Flow divider/combiner valve with pressure balancing orifice and flow percentages Directional valve pilot operated 2 position, 2 way Double acting cylinder Differential sensing valve Part No. 122985 S-80 • S-85 • S-80X 6-3 Section 6 • Schematics September 2015 This page intentionally left blank. 6-4 S-80 • S-85 • S-80X Part No. 122985 Section 6 • Schematics September 2015 Connector Pin Legend - View 1 6-5 6-6 Section 6 • Schematics September 2015 Connector Pin Legend - View 1 A B C C1 DT06-12SA 1 2 COLOR RD RD/BK RD/WH WH WH/BK WH/RD BK BK/WH BK/RD BL BL/BK BL/WH BL/WH CIRCUIT # C27AUX C28TTA C29MS C30EDC+ C31EDCC32BRK C33STR C34SA C35RPM C36STC C37STCC C132PLI1 C177LS D E F G C1 GRAY (CE MODEL) (S-80X MODEL) C2 DT06-12SB 4 5 CIRCUIT # C39LP C40LS C41RPM C42LS C46HRN P134PWR C45GEN C123PBS P109ANG SNSR GND PLUG PLUG I J C3 DT06-12SC PIN # 1 2 3 4 5 6 7 8 9 10 11 12 12 COLOR RD RD/BK RD/WH WH WH/BK WH/RD BK BK/WH BK/RD BL BL/BK BL/WH BL/WH CIRCUIT # C1PBU C2PBD C3PBF C4TRL C5TRR C6TRF C7PBE C8PBR C9PERF C132PLI2 C59CNK C133PLA P109LS PIN # 1 2 3 4 5 6 7 8 9 10 11 12 12 C6 FUNCTION MANIFOLD C3 GREEN (CE MODEL) (CE MODEL) (S-80X MODEL) C4 DT06-12SD PIN # 1 2 3 4 5 6 7 8 9 10 11 12 C2 BLACK COLOR BL/RD OR OR/BK OR/RD GR GR/BK GR/WH RD/OR OR/GR LT BR - CIRCUIT # C13DRE C14PLU C15PLD V155PCE C17PRL C18PRR C43JU C44JD C49DLITE SPARE PLUG PLUG K L M N C5 ENGINE 3 COLOR BL/RD OR OR/BK OR/RD GR GR/BK GR/WH GR/RD OR/WH LT BR - H PIN # 1 2 3 4 5 6 7 8 9 10 11 12 6 7 8 C4 BROWN DEUTZ 2011L04i CONTINENTAL TME27 PERKINS 804 PIN# CIRCUIT # COLOR CIRCUIT # COLOR CIRCUIT # COLOR PIN# CIRCUIT # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 C1PBU C2PBD C3PBF C4TRL C5TRR C6TRF C7PBE C8PBR C9PERF COLOR RD RD/BK RD/WH WH WH/BK WH/RD BK BK/WH BK/RD C59CNK P210PWR C13DRE BL/BK BK BL/RD (S-80X MODEL) C109LS GR/WH (S-80X MODEL) C177LS C42LS P134PWR(A) P134PWR(B) P134PWR(C) BL/RD OR/RD RD RD RD C28TTA RD/BK C211LO C118LSR BL/BK OR C123PBS SNSR GND P109ANG C36STC C37STCC C212LO C45GEN C40LS RD/BK BR GR/WH BL BL/BK GR/BK GR/WH OR (S-80X MODEL) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 P24PWR C41RPM C21IGN RD OR/BK WH P24PWR C41RPM C21IGN RD OR/BK WH C33STR BK C27AUX RD C46HRN GR C33STR C27AUX C46HRN BK RD GR R21IGN R21IGN WH(14) P23PWR C41RPM C33STR C27AUX C46HRN C127TSW C35RPM C39LP WH(14) R21IGN C24TSPS WH C24TSPS WH C35RPM BK/RD V155PCE OR/RD C31EDC- WH/BK C30EDC+ WH C34SA BK/WH C32BRK WH/RD C29MS RD/WH C35RPM V155PCE C31EDCC30EDC+ C34SA C32BRK C29MS BK/RD OR/RD WH/BK WH BK/WH WH/RD RD/WH WH OR/BK BK RD GR GR BK/RD BL/RD WH(14) C108ESL BL/WH P24PWR RD R24PWR RD V155PCE OR/RD C31EDC- WH/BK C30EDC+ WH C32BRK C29MS WH/RD RD/WH (S-80X MODEL) C7 C9 (S-80X MODEL) 12V POWER TO PLAT FOOTSWITCH C7 DTP06-4S C9 FS DT04-4P COLOR CIRCUIT # PIN # COLOR CKT # BK WH BR BK WH RD P22PWR P23PWR BATGND PLUG 1 2 3 4 P26ESTP P24FS P25FS PLUG PIN # 1 2 3 4 ES0507C 6-6 S-80 • S-85 • S-80X Part No. 122985 September 2015 Section 6 • Schematics Connector Pin Legend - View 2 N M L K J I ALC500 POWER/VALVE INPUT CIRCUIT # GND P24FS P26ESTP P24FS COLOR BR WH BK WH J3 ALC500 INPUT C DEUTZ 2011LO4i ENGINE PLUG CIRCUIT # R23PWR C21RET C38RET C38FP R33STR C41RPM R21IGN C35RPM C108ESL C127TSW C39LP C26TSR PIN# CIRCUIT # 1 C41RPM 2 C107AF C26TSR 3 C24TS 4 5 C25PSR 6 C24PS R21IGN 7 8 GND 9 10 COLOR WH WH BL BL/WH BK(14) OR/BK WH BK/RD BL/WH GN BL/RD WH/RD C14 GRAY B A 1 COLOR OR/BK WH WH/RD WH WH/BK WH WH(14) BR - J144 2 (GAUGE OPTION) 3 1 PLATFORM MANIFOLD S-80X MODEL WIRE J8 1 GR/WH WH BL GR/WH BL/RD BR GR 6 CIRCUIT # P109LS C184PL NC NC C169LED2 P109LS C177LS SNSR GND NC C169LED1 5 PIN# 1 2 3 4 5 6 7 8 9 10 10 J2 20 J22 PIN # 1 2 3 4 5 6 7 8 9 10 11 12 DT04-12PA CIRCUIT # GND GND C18PRR C17PRL C43JU C44JD C14PLU C15PLD GND GND GND GND COLOR BR BR GR/BK GR GR GR/BK OR OR/BK BR BR BR BR 5 J22 6 7 8 1 11 COLOR OR RD/BK BL/RD OR/RD OR/BK RD RD/BK RD/WH WH WH/BK WH/RD BK BK/WH BK/RD WH WH/BK BL BL/BK WH/RD RD/WH D 4 10 CIRCUIT # C40LS C123PBS C13DRE C42LS C41RPM C1PBU C2PBD C3PBF C4TRL C5TRR C6TRF C7PBE C8PBR C9PERF C30EDC+ C31EDCC36STC C37STCC C32BRK C29MS E J1 ALC500 OUTPUT PIN# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 F 8 COLOR WH/RD RD/WH WH/BK WH/RD BL/WH BL/WH BL/BK RD/WH GR/WH BR OR BR OR BR RD/BK BL/RD 9 CIRCUIT # C165TRS C164PES C163PLS C160JPL C159STC C144DER C143DEL C29MS P109ANG SNSR GND P162JPW2 JSGND2 P162JPW1 JSGND1 C28TTA C13DRE(A) 16 PIN# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 G CONTINENTAL TME27 ENGINE PLUG PIN# 1 2 3 4 5 6 7 8 9 10 11 12 2 1 4 3 PIN# 1 2 3 4 H ES0507C Part No. 122985 S-80 • S-85 • S-80X 6-7 September 2015 Section 6 • Schematics Connector Pin Legend - View 2 6-7 6-8 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models 6-9 6 - 10 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models A B C D E F G H I J K P2 FS1 C9P-1 BK C28TTA RD/BK P26ESTP BK P26ESTP BK LOW P22PWR BK + H1 - V155PCE OR/RD TS4 ENGINE RPM HIGH C7-1 D12 L48 C4-4 C1-9 C1-8 C1-7 C1-1 C7-2 C1-2 C3-12 C2-5 TB132 1 D64 C35RPM BK/RD U16 NO LOW TIMER 30 RD TB33 D67 D2 P134PWR RD C41RPM OR/BK C27AUX + FE RD C27AUX RD D13 TB155 TB35 TB27 TB23 D68 D4 TB34 WH C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK RD GR/BK GBOX GROUND TS54 ENG. RPM P4 FUNC. ENABLE HIGH TB28 C34SA BK/WH 8 C32 TS56 GLOW PLUG C33STR BK 12 TS52 ENGINE START C27AUX RD TB133 WH 7 AUXILIARY PUMP TB20 TS51 P23PWR WH 6 C28TTA RD/BK 5 C46HRN GR 1 3 4 PLAT GND C133PLS GR/BK TB22 3 B 4 TS6 GLOW PLUG 4 KS1 3 P24FS WH TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 D40 TB134 RD 2 B1 RD C132PLI BL/WH P134PWR RD P1 RD C1-12 C2-6 CB2 15AMP P24FS WH P25FS RD P25FS RD BK P24FS WH P3 HORN TB46 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING WH C24TSPS WH C5-11 V155PCE OR/RD CB7 15A Y74 HOLD ES0504D CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM CONTROL RELAY RPM SOLENOID RPM MODULE GLOW PLUG TIME DELAY 30 SECONDS GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR S-80 • S-85 • S-80X BR -COM MOM N.O. S-613 S1 NO S2 NC B IND WH RD PULL IN M2 +BAT +AUX J144-4 J144-6 J144-8 REGULATOR R34SA BK/WH J144-7 M3 H2 CR15 NO C24TSPS WH R21ING WH R27AUX RD R33STR BK RD WH PR1 NO PR2 BK FB SW4 NO NO C RD B1 TB21 + HM - CR3 NO CR2 CR39A NO D51 FB - START BATTERY CONTROL BATTERY 6 - 10 A STA M1 8 P134PWR RD 7 C28TTA RD/BK BAT- R46HRN GR BAT+ + J144-1 12 VDC C116HYD WH EXCT CR5 NO CR17 NO R116HYD OR P134FB RD P134FB RD J144-2 C41RPM OR/BK AUX MAIN D22 F20 20A F22 60A CR1 NO 6 B2 C5-19 B1BAT RD F7 20A - L2 R21ING WH BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12 VDC START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT BL/RD F17 20A 5 N C9P-3 RD 2 M C28TTA RD/BK P26ESTP BK 1 L WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH LED BL/RD 9 6 7 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK P134PWR RD C3PBF RD/WH C8PBR BK/WH C9PER BK/RD PRIMARY BOOM C7PBE BK EXTEND RETRACT P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP SNSR-GND BR C123PBS RD/BK C6-7 C6-8 C6-9 C6-11 J114 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C6-31 C118LS OR C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C1PUB RD C2PBD RD/BK C3PBF RD/WH C129DA RD/BK C7PBE BK C8PBR BK/WH C9PERF BK/RD C30EDC WH C31EDC WH/BK C130TA WH/RD C32BRK WH/RD C29MS RD/WH 4 3 2 1 RD RD BR BK WH BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP GROUND L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 11 S-80 • S-85 • S-80X 10 15 8 C144DER BL/WH RIGHT 16 LEFT C143DEL BL/BK 4 5 13 14 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C17PRL GR PLAT. ROTATE 4 3 2 1 3 C4-5 CCW CW 24 Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 23 NO 14 13 NO U4 7 22 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 P24FS WH P26ESTP BK J22-11 UP PLATFORM DOWN LEVEL UP DOWN J22-12 14 LSB2S NC 21 14 21 NC 13 NO 22 13 NO 24 23 NO NO 4 3 2 1 3 6 4 3 2 1 2 TB118 14 14 CR34 TB37 TB36 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W TB42 TB13 5 TB3 TB14 TB44 CR34 13 NO 24 23 NO 13 TB5 4 R14 10W TB4 TB1 TB7 TB8 TB17 TS62 TB30 TB31 TB29 J1 J1 J1 J1 TB40 TB32 TS61 TS63 TB59 TS59 TS58 TS57 TB15 TB43 TB18 CCW CW J22-7 J22-9 J22-10 Y20 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y19 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y72 Y73 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 7.5W C27AUX RD J2 J2 Y70 Y71 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models 6 - 11 6 - 12 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 13 6 - 14 6 - 14 8 RD-44C WH/BK-32C OR-134A(D) WH-134A(D) BK-GND BL-GND GR-GND 5 BR GND 6 ES504D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 16/22 CABLE 18/22 CABLE C4B C2B C3B WH-C5-3 WH L2(-) U1 C7B START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT 12V TO PLAT 1 2 3 4 5 6 7 8 9 10 H BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C WH-TB23B CABLE RESTRAINT BK-C32-5 G BASE TERMINATION BLOCK CR23 BR-GND STUD RD-TB20A F BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ TB21C RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 F19 POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP 1 RD U16-2 E WH/12 C7B-2 DRIVE LIGHT OPTION RELAY RD-TB20B D BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-9 BR GND2 LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR JIB BOOM DOWN S-85 (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS (UNUSED) STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER C OR/RD C6-22 OR/BK C5-2 OR C6-40 3 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 RD DL2 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER (UNUSED) B BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 A OR/RD C5-19 RD C6-23 RD C6-24 BK GND1 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 WH DL1 155 134A 134 133 132 118 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 OR/BK ISM #2 41 40 39 37 36 BK/RD TS54-1(D13) 35 BK/WH U16-5 34 BK/WH TS56-3 BK ISM-3 BK TS52-3 33 WH/RD-TRAVEL ALARM 32 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH ISM #7 WH KS1-1(D2) 23 BK/12 KS1-3 BK C32-4 22 WH HM(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 WH/BK C4B-9 C D OR/RD TS62-5(D68) OR & WH-BEACONS RD C32-1 RD KS1-2 GR/BK C32-8 BL/WH C32-3 OR CR34 #86 BL/BK L46(+) A C32 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK- TB133C BR-GND RD - TB134C BL/WH-TB132C BK-TB22C 10 AMP FUSE BK/WH TB34C 5 6 7 8 12 1 3 4 5 3 7 BK/WH C5-22 4 RD TB23A 2 2 1 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models I J K C1B LABEL L FUNCTIONS ENGINE C6 C5 TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH M GROUND STUD 3 1 2 CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 IGNITION START MODULE U16 GLOW PLUG TIME DELAY RELAY NOTE: DASHED LINES INDICATE OPTIONS U16 HARNESS TO SWITCH PANEL N Part No. 122985 1 2 TS62 6 3 5 2 4 1 L46 4 2 CB2 4 5 TS61 6 2 1 1 1 2 3 P4 3 2 1 5 4 2 3 TS51 4 3 6 NO D64 1 BR-L46(-) RD-TB20D S-80 • S-85 • S-80X BR-GND STUD GR/BK-TB18D BL/BK-TB59D TO GROUND CONTROL BOX CONNECTIONS C BR-HM(-) D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34#85 E D68 6 1 3 - F 3 1 2 TS56 G6 G TS57 1 2 TS63 3 3 + H 3 B B1 4 WH-TB21D BK-TB22D RD-TB134D BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 I 3 1 D13 TS58 2 D2 1 2 KS1 R16 OR-TB118D RD/WH-TB3D J TS59 3 TS54 R14(A) R14 RD/WH-TS61-1 BR-HM(-) K L2 NC NC 2A 2B E-STOP 1B CR34 1A P1 87 L + M + N 87A 85 86 30 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models B A 1 2 3 4 5 6 7 8 ES0504D 6 - 15 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 15 6 - 16 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 17 6 - 18 1 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS GR/WH C3P-12 L47-C59CNK BL/BK C3P-11 J22 ES0505D C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 OPTION 12V BATTERY J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 TS3-C39LP BL/RD C2P-1 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C177LS BL/RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK 4 BK P2 1 WH L1 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH 1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH RD C2P-6 Part No. 122985 S-80 • S-85 • S-80X 6 - 18 6 1 2 OPTION C9 H1 6 J1 C7P + J22-1,2,9,10,11 AND 12 D40 J2 2 9 3 RD LS18 3 CONTROL HARNESS TO PLATFORM SWITCH PANEL 11 J8 J7 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND BR BATGND (GROUND STUD) CR27 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 8 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 BL/RD J1-16 TS15 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 GR/BK C4P-8 / J22-6 GR C4P-7 / J22-5 BR GND STUD GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 L47 D12 JC3 JC7 TS2 TS6 3 6 + 1 6 1 L1 4 TS9 TS8 TS1 TS14 TS7 + NO P3 NC L48 P2 RD 5 BK RD RD ES0504D 6 COMPONENT INDEX H1 TILT ALARM TS8 JIB BOOM UP/DOWN TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS14 DRIVE SPEED TOGGLE SWITCH L1 LED - DRIVE ENABLE TS15 DRIVE ENABLE TOGGLE SWITCH L47 LED - CABLE TENSION U13 ALC500 JOYSTICK CONTROLLER CARD L48 LED - TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 19 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 19 6 - 20 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) 6 - 21 6 - 22 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) A B C D E F G H I J K L M N C132PLI BK C28TTA RD/BK P26ESTP BK P24FS WH LS18A 1 FS1 P2 LS18 C9P-1 BK V155PCE OR/RD LOW HIGH 9 2 SEC. NO 30A 5 2 U34 U35 C4-10 PBOX GROUND 8 C4-10 C4-4 C1-9 C1-8 C1-7 C1-1 C7-2 C1-2 C3-12 PBOX GROUND 9 NO 10A 3 D12 8 2 SEC. RD U16 NO TB33 - TB23 C41RPM OR/BK C27AUX + FE RD C27AUX RD TB155 TB35 TB27 TB46 L45 P134PWR RD D4 D13 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK GR/BK RD + D67 D68 TB34 D2 H6 C35RPM BK/RD HIGH 30 SEC LOW C34SA BK/WH TS54 ENG. RPM P4 FUNC. ENABLE D64 TB28 WH GBOX GROUND TS56 GLOW PLUG C33STR BK 8 12 AUXILIARY PUMP TB133 WH 7 P23PWR WH U33 TS51 C28TTA RD/BK 6 TB20 TS52 ENGINE START C27AUX RD 5 C46HRN GR 1 4 PLAT GND C133PLS GR/BK 3 3 1 TB22 B 4 2 3 TB132 TS4 ENGINE RPM 4 KS1 3 5 + H1 L4 D39 D40 TB134 RD 2 TS6 GLOW PLUG P26ESTP BK R14 4.7KW C2-5 B1 RD P22PWR BK C132PLI BL/WH P134PWR RD P1 RD R26ESTP BK P3 HORN TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 C7-1 C1-12 C2-6 CB2 15AMP P24FS WH RD 2 P25FS RD P25FS RD BK D88 PBOX GROUND C9P-3 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING(A) WH C24TSPS WH C5-19 C5-11 V155PCE OR/RD CB7 15A Y74 HOLD ES0504A CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM CONTROL RELAY RPM SOLENOID RPM MODULE GLOW PLUG TIME DELAY 30 SECONDS GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY S-80 • S-85 • S-80X BR -COM MOM N.O. S-613 S1 NO S2 NC B WH RD PULL IN M2 +BAT +AUX J144-4 J144-6 J144-8 M3 IND R34SA BK/WH J144-7 FB H2 CR15 NO C24TSPS WH R21ING WH R27AUX RD R33STR BK FB REGULATOR RD WH D51 SW4 NO NO BK - B1 PR1 NO PR2 + G6 - CR3 NO CR2 CR39A NO C RD - CONTROL BATTERY 6 - 22 A STA M1 8 P134PWR RD 7 C28TTA RD/BK BAT- R46HRN GR BAT+ + J144-1 12V DC C116HYD WH EXCT CR5 NO CR17 NO R116HYD OR P134FB RD J144-2 P134FB RD D22 C41RPM OR/BK AUX MAIN 6 F20 20A F22 60A CR1 NO F7 20A B2 TB21 R21ING WH B1BAT RD BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12V DC L2 BL/RD F17 20A 5 START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH 9 10 15 8 6 7 16 C144DER BL/WH RIGHT 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH C8PBR BK/WH C9PER BK/RD PRIMARY BOOM C7PBE BK EXTEND RETRACT C118LS OR P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP C17PRL GR PLAT. ROTATE SNSR-GND BR C123PBS RD/BK C6-31 C6-9 C6-8 C6-7 C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 3 C6-11 YL BR OR BL BK RD BR BK WH RD BR BK WH RD BR BK WH RD 4 3 2 1 3 C4-5 CCW CW C29MS RD/WH C32BRK WH/RD C130TA WH/RD C31EDC WH/BK C30EDC WH C9PERF BK/RD C8PBR BK/WH C7PBE BK C129DA RD/BK C3PBF RD/WH C2PBD RD/BK C1PUB RD C6TRF WH/RD C5TRR WH/BK C4TRL WH C36STC BL C37STCC BL/BK 14 LED BL/RD LEFT C143DEL BL/BK 14 4 5 13 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 P24FS WH P26ESTP BK J22-11 UP PLATFORM DOWN LEVEL UP DOWN J22-12 4 3 2 1 2 6 4 3 2 1 RD BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND GROUND DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 23 S-80 • S-85 • S-80X Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 7 22 14 22 LSB2S NC 21 14 22 21 NC 13 NO NO TB37 TB36 13 NO 24 23 NO NC HO 21 14 TB5 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W 13 NO 24 23 NO 13 CR34 TB13 5 TB3 TB118 TB14 TB44 CR34 TB4 TB1 4 R14 10W TB42 TB40 TB32 TB7 TB8 TB17 TB30 TB31 TB29 J1 J1 J1 J1 TS62 TS61 TS63 TB59 TS59 TS58 TS57 TB15 TB43 TB18 CCW CW J22-7 J22-9 J22-10 Y20 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y19 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y72 Y73 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 5W C27AUX RD J2 J2 Y70 Y71 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD J114 U4 September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) 6 - 23 6 - 24 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 25 6 - 26 8 6 - 26 BR GND 7 ES0504A S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 I C7B 16/24 CABLE 18/22 CABLE C4B C2B C3B WH-C4-10 WH L2(-) 2 1 12V TO PLAT U1 WH-TB23B 3 H START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT BR-GND STUD CABLE RESTRAINT BK-C32-5 G 1 2 3 4 5 6 7 8 9 10 BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ F BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 RD-TB20A E RD U16-2 RD-TB20B H6 BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER PLATFORM LOAD ALARM PLATFORM LOAD INPUT LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR S-85 JIB BOOM DOWN (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS UNUSED STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER UNUSED POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP D WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 A OR/RD C5-19 RD C6-23 RD C6-24 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND C BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C 5 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 5 6 7 8 12 RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) B 155 134A WH-BEACON (LEFT) 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34 #86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 OR/BK ISM #2 40 39 37 36 BK/RD TS54-1(D13) 35 34 BK/WH U16-5 BK/WH TS56-3 BK ISM #3 BK TS52-3 33 WH/RD-TRAVEL ALARM 32 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH KS1-1(D2) 23 WH ISM #7 BK/12 KS1-3 BK C32-4 22 WH G6(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34 #30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 C U33 4 D OR/RD TS62-5(D68) OR-BEACON (RIGHT) RD L45(+) BK/WH TB34C RD DL2 BK GND1 BR GND2 WH DL1 WH/BK C4B-9 RD-H6(+) BL/WH-TB132C BK-TB22C A RD-44C WH/BK-32C OR-134A(D) WH-134A (D) BK-GND BL-GND GR-GND 5 3 U16 1 3 4 3 CR23 2 RD TB23A C32 1 2 1 BK/WH C5-22 6 DRIVE LIGHT RELAY (OPTION) F19 TB21C 10 AMP Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) J K C1B L LABEL M FUNCTIONS ENGINE C6 C5 H6 PLATFORM OVERLOAD ALARM KS1 KEY SWITCH L2 LED - CHECK ENGINE TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH GROUND STUD CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 U16 IGNITION START MODULE TIME DELAY, GLOW PLUG, 30 SECONDS U33 LOAD SENSE MODULE HARNESS TO SWITCH PANEL N 3 Part No. 122985 2 TS62 6 3 5 2 4 1 L46 4 1 2 1 CB2 4 5 TS61 6 2 1 1 2 3 P4 D64 4 5 6 NO 3 L45 TS51 4 3 2 3 1 2 1 BR-L46(-) S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD BR-G6(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D GR-TB17D WH-TB4D WH/BK-TB5D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D OR-TB14D GR/BK-TB44D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34 #85 E D68 6 TS63 3 3 - F 1 1 2 3 D13 TS56 G6 G TS57 1 1 TS58 2 B 3 + H 2 3 TS54 D2 B1 4 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 I 3 2B 2A 1 2 KS1 R16 J TS59 NC NC R14(A) RD-TS61-2 RD/WH-TB3D OR-TB118D RD/WH-TS61-1 K L2 1B 1A P1 CR34 R14 BR-G6(-) L + M + N + 87 87A 85 86 30 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) B A 1 2 3 4 5 6 7 8 ES0504A 6 - 27 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 27 6 - 28 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 29 6 - 30 7 CR27 8 RD LS18 CABLE WH TS14 WH TS7 R20 BR BATGND (GROUND STUD) ES0504A RD-E-STOP P134PWR RD P134PWR RD RD-H1+ C4P(BR) C3P(GN) C2P(BK) C1P(GY) LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) CR30 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) R26ESTP BK C9P-1 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 LS18-C132PLI2 BK C3P-10 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C2P-10 J1-P109ANG GR/WH C2P-9 P3-C46HRN GR C2P-5 TS47 C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C3-10 C4-10 BATGND J3-1 U35 LS18-C132PLI1 BK C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK F.S. P26ESTP BK E-STOP BR GND BK P2 WH L1 WH C9P-2 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH 1 5 JC3-5 C159STC BL/WH 1 GR/BK C3P-12 12V BATT H1 Part No. 122985 CONTROL HARNESS TO PLATFORM SWITCH PANEL OPT. LS18 C9 J22 C7P + S-80 • S-85 • S-80X 6 - 30 RD C2P-6 D40 BATGND C7P-3 5 1 U34 J2 2 BRN GND STUD 6 GR/BK L4 RD LS18 4 J3 COM NO 2 3 5 3 11 J1 9 COM NO 2 3 3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 1 C1P-2 C28TTA RD/BK D39 J22-1, 2, 9, 10, 11 & 12 D88 C132PLI BK C3P-12 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFROM BOX + RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 WH C9P-2 BL/RD J1-16 BL/BK J1-7 RD C1P-1 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD/WH J1-8 GR/BK C4P-8/J22-6 GR C4P-7/J22-5 BR GND STUD GR/BK H1 (D39) BL/BK C3P-11 GR C4P-5/J22-4 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 TS15 1 D12 L4 JC3 3 JC7 TS6 + TS2 6 L47 L1 + 1 4 1 TS9 TS1 TS8 TS7 TS14 5 L48 + NO 6 NC P3 P2 RD BK RD RD 6 RD ES0504A COMPONENT INDEX CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) LS18 PLATFORM OVERLOAD LIMIT SWITCH TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) P2 EMERGENCY STOP BUTTON TS14 DRIVE SPEED TOGGLE SWITCH H1 J22 TILT ALARM PLATFORM MANIFOLD P3 HORN BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER R20 TS1 RESISTOR - 4700W AUXILIARY TOGGLE SWITCH U13 U34 ALC500 JOYSTICK CONTROLLER CARD TIME DELAY RELAY - 2 SECONDS, 10A JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS2 ENGINE START TOGGLE SWITCH U35 TIME DELAY RELAY - 2 SECONDS, 30A L1 LED - DRIVE ENABLE RPM SELECT TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS 1 L4 LED - PLATFORM OVERLOAD TS4 TS6 L47 LED - CABLE TENSION TS7 PLATFORM ROTATE TOGGLE SWITCH L48 LED - TILT ALARM TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) 7 8 ROCKER / STEER OPTION Part No. 122985 S-80 • S-85 • S-80X 6 - 31 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 31 6 - 32 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 33 6 - 34 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) A B C D E F G H I J K L M N D89 C28TTA RD/BK P26ESTP BK P24FS WH LS18A 1 FS1 P2 LS18 C9P-1 BK PBOX GROUND 2 SEC. NO D12 8 C3-10 C4-4 C1-9 C1-8 PBOX GROUND C7-2 C1-2 C3-12 C2-5 C1-7 U35 30A C1-1 D40 C132PLI2 BK 9 V155PCE OR/RD HIGH LOW 5 HIGH RD U16 NO TB33 - P134PWR RD 2 5 TB23 2 SEC. C27AUX + FE RD 9 NO 3 C27AUX RD 8 TB155 TB35 TB27 C41RPM OR/BK D4 U34 10A D13 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK GR/BK RD + D67 D68 TB34 D2 H6 LOW TIMER 30 C35RPM BK/RD TS54 ENG. RPM P4 FUNC. ENABLE D64 TB28 WH GBOX GROUND C34SA BK/WH 8 12 TS56 GLOW PLUG C33STR BK TB133 WH 7 AUXILIARY PUMP U33 TS51 P23PWR WH 6 TB20 TS52 ENGINE START C27AUX RD 5 C28TTA RD/BK C133PLA GR/BK 4 PLAT GND C46HRN GR 1 3 1 TB22 3 B 4 2 + H1 L4 D39 3 TB132 TS4 ENGINE RPM P26ESTP BK R14 4.7KW P3 HORN TS6 GLOW PLUG 4 KS1 3 R26ESTP BK TB134 RD 2 B1 RD P22PWR BK C132PLI BL/WH P134PWR RD P1 RD P24FS WH TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 C7-1 C1-12 C2-6 CB2 15AMP P25FS RD P24FS WH RD 2 C9P-3 P25FS RD BK D88 TB46 L45 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING(A) WH C24TSPS WH C5-19 C5-11 V155PCE OR/RD CB7 15A Y74 HOLD ES0504D CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM CONTROL RELAY RPM SOLENOID RPM MODULE GLOW PLUG TIME DELAY 30 SECONDS GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR S-80 • S-85 • S-80X BR -COM MOM N.O. S-613 S1 NO S2 NC B IND WH RD PULL IN M2 +BAT +AUX J144-4 J144-6 J144-8 M3 REGULATOR R34SA BK/WH J144-7 FB H2 CR15 NO C24TSPS WH R21ING WH R27AUX RD R33STR BK PR1 NO PR2 BK - B1 RD WH RD - FB SW4 NO NO C + G6 - CR3 NO CR2 CR39A NO D51 M1 START BATTERY 6 - 34 A STA CONTROL BATTERY 8 P134PWR RD 7 C28TTA RD/BK BAT- R46HRN GR BAT+ + J144-1 12V DC C116HYD WH EXCT CR5 NO CR17 NO R116HYD OR P134FB RD J144-2 P134FB RD D22 C41RPM OR/BK AUX MAIN 6 F20 20A F22 60A CR1 NO F7 20A B2 TB21 R21ING WH B1BAT RD BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12V DC L2 BL/RD F17 20A 5 START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH LED BL/RD 7 2 4 1 3 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH P134PWR RD C9PER BK/RD C8PBR BK/WH PRIMARY BOOM C7PBE BK EXTEND RETRACT SNSR-GND BR C123PBS RD/BK C6-7 C6-8 C6-9 C6-11 J114 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C6-31 C118LS OR C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 C37STCC BL/BK C36STC BL C4TRL WH C5TRR WH/BK C6TRF WH/RD C1PUB RD C2PBD RD/BK C3PBF RD/WH C129DA RD/BK C7PBE BK C8PBR BK/WH C9PERF BK/RD C30EDC WH C31EDC WH/BK C130TA WH/RD C32BRK WH/RD C29MS RD/WH 4 3 2 1 RD RD BR BK WH BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP GROUND L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 35 S-80 • S-85 • S-80X 9 6 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 P134PWR RD C59CNK BL/BK C14PLU OR 4 3 2 1 3 6 4 3 2 1 10 15 8 C144DER BL/WH RIGHT 16 LEFT C143DEL BL/BK 4 5 13 14 1 3 1 2 11 12 GND BR 2 4 P24FS WH P24FS WH 3 C4-2 PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP C17PRL GR PLAT. ROTATE U4 23 NO 14 13 NO Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 24 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 3 C3-11 C4-3 C4-8 C4-7 C4-6 C4-5 CCW CW 7 LSB2S 22 NC 21 14 21 NC 13 NO 22 14 14 CR34 4 3 2 1 5 2 TB118 13 NO 24 23 NO NO P26ESTP BK J22-11 14 TB9 TB37 TB36 TB42 TB13 1 D29 D30 L46 R14(A) 5W 13 NO 24 23 NO 13 CR34 TB4 TB5 4 R14 10W TB6 TB2 TB15 TB1 TB7 TB8 TB17 TS62 TB30 TB31 TB29 TB40 TB32 TS61 TS63 TB59 TS59 TB3 TB14 TB44 UP PLATFORM DOWN LEVEL DOWN UP CCW J22-7 J22-12 J22-2 S-85 (OPTION) CW J22-8 J22-9 J22-5 J22-3 J22-10 Y20 J22-6 Y19 J22-1 TB134A P134PWR RD J1 J1 J1 J1 Y72 Y73 TB43 TB18 TS8 TS9 JIB BOOM (S-85 OPTION) J22-4 R16 7.5W C27AUX RD J2 J2 2 TS7 PLATFORM ROTATE Y70 Y71 TS58 TS57 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 35 6 - 36 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 37 6 - 38 6 - 38 3 U34 C 6 U16 ES0504D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT U1 H 12V TO PLAT WH-U34 #9 WH L2(-) 1 2 3 4 5 6 7 8 9 10 C7B BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C WH-TB23B CABLE RESTRAINT BASE TERMINATION BLOCK 3 1 2 G BK-C32-5 BR-GND STUD RD-TB20A F BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP E WH C5-1 RD-TB20B H6 BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER PLATFORM LOAD ALARM PLATFORM LOAD INPUT LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR S-85 JIB BOOM DOWN (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS (UNUSED) STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) D RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 5 6 7 8 12 A OR/RD C5-19 RD C6-23 RD C6-24 U33 RD-H6(+) BL/WH-TB132C BK-TB22C C WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 BR GND2 BK GND1 RD DL2 WH DL1 WH/BK C4B-9 1 3 4 C32 B 155 RD U34-2 134A 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34 #86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 OR/BK ISM #2 40 39 37 36 BK/RD TS54-1(D13) 35 34 BK/WH U16-5 BK/WH TS56-3 BK TS52-3 BK ISM #3 33 32 WH/RD-TRAVEL ALARM 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH KS1-1(D2) 23 WH ISM #7 BK/12 KS1-3 BK C32-4 22 WH G6(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34 #30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 D OR/RD TS62-5(D68) OR & WH-BEACONS RD L45(+) BK C3B-10 CR23 TB21C A RD-44C WH/BK-32C OR-134A(D) WH-134A (D) BK-GND BL-GND GR-GND 3 5 BR GND RD TB134C (A) F19 10 AMP FUSE 4 BK/WH TB34C BR GND 2 WH ISM-#9 DRIVE LIGHT OPTION RELAY 5 9 7 WH C5-3 3 RD TB23A 8 1 5 8 BK/WH C5-22 2 2 1 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) I J 16/22 CABLE 18/22 CABLE C4B C2B C3B K C1B L LABEL TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH U1 IGNITION START MODULE U16 GLOW PLUG TIME DELAY U33 LOAD SENSE MODULE U34 LOAD SENSE TIME DELAY M FUNCTIONS ENGINE C6 C5 TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH GROUND STUD CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER H6 PLATFORM OVERLOAD ALARM KS1 KEY SWITCH L2 LED - CHECK ENGINE L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH HARNESS TO SWITCH PANEL N 3 TS62 Part No. 122985 6 3 5 2 4 1 L46 4 1 3 2 1 CB2 4 5 TS61 6 2 1 1 2 3 P4 D64 - 3 4 5 6 NO L45 TS51 4 3 2 3 1 2 1 BR-L46(-) S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD BR-G6(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34 #85 E D68 6 TS63 3 TS56 G6 F 2 1 2 3 D13 B 3 + G TS57 1 2 1 TS58 2 TS54 D2 B1 4 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 H 1 2B 2A 1 2 KS1 R16 OR-TB118D RD/WH-TB3D I 3 NC NC R14(A) R14 RD/WH-TS61-1 BR-G6(-) J TS59 L2 1B 3 86 CR34 85 30 1A P1 87 K + L + M + N 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) B A 1 2 3 4 5 6 7 8 ES0504D 6 - 39 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 39 6 - 40 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 41 6 - 42 RD LS18 CABLE 8 RD-E-STOP P134PWR RD CR30 R20 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) 4700W R26ESTP BK C9P-1 J22 CR27 CONTROL HARNESS TO PLATFORM SWITCH PANEL BR BATGND (GROUND STUD) P134PWR RD RD-H1+ P26ESTP BK E-STOP BR GND TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH ES0504D 12V BATTERY P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C132PLI2 BK C3P-10 D39 BK P2 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 C132PLI1 BL/WH C1P-12 D88 5 U35 J1 C28TTA RD/BK 4 WH L1 1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH GR/BK C3P-12 GR/BK L4 RD C2P-6 RD LS18 Part No. 122985 S-80 • S-85 • S-80X 6 - 42 1 C1P-2 C28TTA RD/BK BATGND J3-1 OPTION C9 H1 6 6 1 LS18 C7P + J22-1,2,9,10,11 AND 12 D40 J1 1 2 1 3 COM NO 2 3 5 3 J2 2 9 11 J8 J7 J3 U13 - JOYSTICK CONTROL CARD N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 1 BATGND C7P-3 GROUND D89 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 BL/RD J1-16 TS15 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 GR/BK C4P-8 / J22-6 GR C4P-7 / J22-5 BR GND STUD GR/BK H1 (D39) GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 L4 D12 JC3 JC7 + TS2 3 TS6 6 L47 + 1 6 1 L1 4 TS9 TS8 TS1 TS14 TS7 + NO P3 NC P2 L48 RD 5 BK RD RD ES0504D 6 COMPONENT INDEX CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) H1 TILT ALARM TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS14 DRIVE SPEED TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS15 DRIVE ENABLE TOGGLE SWITCH L1 LED - DRIVE ENABLE U13 ALC500 JOYSTICK CONTROLLER CARD L4 LED - PLATFORM OVERLOAD U35 TIME DELAY RELAY L47 LED - CABLE TENSION L48 LED - TILT ALARM LS18 PLATFORM OVERLOAD LIMIT SWITCH P2 EMERGENCY STOP BUTTON P3 HORN BUTTON R20 TS1 RESISTOR - 4700W AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 43 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 43 6 - 44 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Deutz TD2011L04I Models 6 - 45 6 - 46 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Deutz TD2011L04I Models A B C D E F G H I J K P26ESTP BK 1 P2 C9P-3 P25FS RD P24FS WH V155PCE OR/RD C1-9 B1BAT RD D2 P134PWR RD C41RPM OR/BK C27AUX + FE RD C27AUX RD TB155 TB35 GR/BK TB46 P210PWR BK D68 D4 TB34 TB23 GROUND D67 D13 TB33 TB27 LOW RPM D64 C35RPM BK/RD 500 LB (A & B) P4 TS54 FUNCTION ENGINE ENABLE RPM HIGH RPM TB28 TS56 GLOW PLUG C34SA BK/WH C32 C33STR BK 8 TS52 ENGINE START C27AUX RD TB133 12 TS51 AUXILIARY PUMP 7 LOW RPM HIGH RPM (FS) C1-8 C1-1 1000 LB (A) P23PWR WH 6 C28TTA RD/BK GRD TB20 4 OFF ZONE B C7-2 C1-2 1 5 P26ESTP BK D12 ZONE A 3 4 PLAT C46HRN GR 3 1 TB22 3 C28TTA RD/BK P26ESTP BK TS4 ENGINE RPM D101 4 KS1 B P24FS WH TS6 GLOW PLUG TS2 ENGINE START L48 C2-5 TB132 2 B1 TS1 AUXILIARY PUMP C1-7 P22PWR BK P134PWR RD 15 AMP C28TTA RD/BK H1 D40 TB134 P1 C9P-2 + - D6 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21IGN WH C24TSPS WH 30 85 CR2 87 + HM - 85 NO CR15 86 CR4 85 R34SA BK/WH V155PCE OR/RD 87 C24TSPS WH C 85 CB20 10A 86 30 PR2 PR1 NO M3 M2 BK H2 30 NO 87 WH RD FB SW4 NO CR39A R21IGN WH A NO R27AUX RD 85 86 R33STR BK 86 R46HRN GR C116HYD WH CR5 87 C28TTA RD/BK 30 NO CR1 86 S2 S1 NC NO M4 Y74 REGULATOR IND B HOUR METER PRESSURE COMP VALVE (FUNCTION ENABLE) POWER RELAY RPM RELAY RPM SOLENOID FUEL PUMP GLOW PLUG RELAY GLOW PLUG WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH IGNITION POWER RELAY FUEL SOLENOID AUXILIARY PUMP RELAY AUXILIARY PUMP POWER RELAY Part No. 122985 AUXILIARY PUMP IGNITION / START RELAY POWER RELAY STARTER MOTOR TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN S-80 • S-85 • S-80X OIL COOLER TEMPERATURE SWITCH (OPTION) OIL COOLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY 6 - 46 CONTROL BATTERY 8 HYD FAN FB - 85 87 D51 STA B1 87 86 BAT - 7 - CR17 R116HYD OR + P134FB RD BAT + P134FB RD EXCT 12V DC C41RPM OR/BK ALTERNATOR NO P134PWR RD AUX. MAIN 30 D22 NO CR3 TB21 NO F22 60A 30 6 B2 C5-19 B1BAT RD 20A + C5-11 R21IGN WH BAT2 APU RD 12V DC C5-18 B1BAT RD 20A C5-22 C5-15 P24PWR RD F7 START RELAY TACHOMETER START INPUT AUXILIARY IGN / START GROUND MODULE BATTERY KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT BL/RD F17 5 N P25FS RD C7-1 C2-6 CB2 P3 HORN M P24FS WH FS1 C9P-1 2 L ES504D L2 H1 RD/BK C29MS RD/WH 9 10 2 4 1 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C3-6 C3-5 C3-4 C3-9 C3-8 C3-7 C3-12 C2-3 GR/WH C1-12 D23 BL/RD CW GND BR C123PBS RD/BK SNSR-GND BR P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6TRF WH/RD C5TRR WH/BK C4TRL WH CCW C9PER BK/RD C8PBR BK/WH C7PBE BK EXTEND C177LS BL/RD P109LS GR/WH RETRACT UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C37STCC BL/BK C36STC BL C6-33 C6-34 C6-35 C6-22 C6-40 C6-23 C6-25 C6-13 C123PBS RD/BK SNSR-GND BR BL/RD C6-5 C6-6 C6-7 C6-8 C6-9 C6-31 C6-3 C6-2 C6-1 C6-12 C211PLO BL/BK S212PLO GR/BK GR/WH C6-4 P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6-16 C6-38 C6-30 C6-21 P134PWR RD P210PWR BK C118LS OR C5-21 C5-20 C6-37 C6-36 C5-23 C5-24 OR BR YL RD OR WH BK WH BR RD BK WH BR RD BK WH BR RD RD BK BL 6 BK C29MS RD/WH C32BRK WH/RD C36STC BL C37STCC BL/BK C31EDC WH/BK C30EDC WH C3PBF RD/WH C2PBD RD/BK C1PBU RD BL BR C9PERF BK/RD C8PBR BK/WH C7PBE BK C6TRF WH/RD C5TRR WH/BK C4TRL WH 14 4 3 9 11 10 14 13 12 5 1 7 C3-1 C3-2 C3-3 C1-4 C1-5 C1-11 C1-10 C1-6 C1-3 14 13 NO NO 13 NO 5 13 14 15 8 7 16 6 LED BL/RD C144DER BL/WH RIGHT 5 10 8 6 2 6 7 8 15 16 18 17 19 20 C6-24 WH RD RD BL BR BK BK/WH BL BR BK BK/WH BK WH BR RD NC BR BK WH BR BK Y23 Y24 Y13 Y26 Y25 7 22 PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DESCENT ALARM LOOSE CABLE LED’S LSB2S LOOSE CABLE LIMIT SWITCH MOTOR STROKE BRAKE RELEASE STEER CW STEER CCW DRIVE EDC REVERSE DRIVE EDC FORWARD GROUND CR34 - PRIMARY BOOM SPEED REDUCTION RELAY PRIMARY BOOM FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP LST3O - BOOM UP/DOWN GROUND BOX - ZONE A OPERATION AND SPEED REDUCTION LIMIT SWITCH LSB1EO - BOOM EXTEND CAPACITY OPERATIONAL LIMIT SWITCH LSB1ES - BOOM EXTEND CAPACITY SAFETY LIMIT SWITCH LST3S - BOOM ANGLE STOWED GROUND BOX - ZONE A SAFETY LIMIT SWITCH PRIMARY BOOM EXTEND/RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CCW TURNTABLE ROTATE CW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O ANGLE STOWED DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CCW 6 - 47 S-80 • S-85 • S-80X Part No. 122985 LEFT C143DEL BL/BK C209LED BL C208LED GR SNSR BR ZONE SELECT P109TS GR/WH C184PL WH 3 1 2 11 1 12 GND BR 4 2 P24FS WH 3 J114 C6-11 13 NO 14 13 NO 14 14 13 NO NO U4 1 NC 13 NO 14 5 6 C129DA RD/BK 14 21 24 2 1 1 2 3 4 1 3 4 2 22 23 NO BK Y15 NC NC 21 22 21 22 21 22 23 24 NC Y22 1 2 3 4 J134 1 2 3 4 TB9 23 24 GR 6 J133 3 BL 2 1 2 3 4 NO TB7 2 1 J133 2 5 21 13 NO 14 13 H4 TB118 4 1 TB8 D29 Y21 Y12 Y6 Y5 Y3 Y4 Y2 Y27 P24FS WH P26ESTP BK P134PWR RD C59CNK BL/BK C14PLU OR PLATFORM LEVEL C15PLD OR/BK UP C43JU GR DOWN C44JD GR/BK C17PRL GR C18PRR GR/BK CW CCW TB3 TB4 TB1 TB37 TB36 TB44 CR68 CR34 4 CR53 R14 10W TB5 TB18 R14(A) 5W CR52 L46 TB42 TB13 TB30 TB31 TB32 TB29 TS62 TURNTABLE ROTATE TS63 PRI. BOOM EXT. / RET. TS61 PRI. BOOM UP / DOWN C27AUX RD 3 C3-11 C4-2 TB134A P210PWR BK 2 J1 J1 J1 D24 C59CNK BL/BK C4-3 C4-7 C4-8 C4-5 C4-6 TB59 TS59 P162JPW2-OR CR69 TB2 TB15 TB17 UP DOWN J22-11 J22-12 J22-9 J22-10 J22-2 J22-1 P134PWR RD P134PWR RD P162JPW1-OR 2 5 TB14 TB43 D30 CW CCW J22-7 J22-8 J22-5 J22-6 J22-4 J22-3 Y20 Y19 Y70 R16 7.5W TS57 PLATFORM ROTATE J2 J2 Y71 C159STC-BL/WH 2 C164PES-RD/WH J8 3 C165TRS-WH/RD 3 J8 CR30 J1 JSGND1-BR 1 J25 JSGND2-BR 1 J127 NO JOYSTICK CONTROL CARD J3 C160JPL-WH/RD 4 4 TS9 PLATFORM LEVEL TS7 PLATFORM ROTATE LIFT / DRIVE (OPTION) C159STC-BL/WH 5 C163PLS-WH/BK 6 L50 L51 6 JC3 DRIVE / STEER 5 JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 L47 TS14 DRIVE SELECT L1 TS15 DRIVE ENABLE TS75 ZONE SELECT NC 1 ZONE B ZONE A P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Deutz TD2011L04I Models GND BR C28TTA RD/BK P24FS WH C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80X, Deutz TD2011L04I Models 6 - 47 6 - 48 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 49 6 - 50 8 6 - 50 7 U16 ES0504D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 I 16/22 CABLE 18/22 CABLE C4B C2B C3B WH-C5-3 WH L2(-) U1 C7B START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT 12V TO PLAT 1 2 3 4 5 6 7 8 9 10 H BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C 3 WH-TB23B CABLE RESTRAINT BK-C32-5 BR-GND STUD TB21C BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ G BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 RD U16-2 RD-TB20A F WH/12 C7B-2 DRIVE LIGHT OPTION RELAY RD-TB20B 1 BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-18 E BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER (UNUSED) (UNUSED) LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR (OPTION) (UNUSED) (UNUSED) LIMIT SWITCH - LST20 RPM / TACH SIGNAL LIMIT SWITCH - LSB1RO (UNUSED) STEER CCW STEER CW ENGINE RPM GLOW PLUG ENGINE START BRAKE RELEASE REVERSE / EDCFORWARD / EDC+ DRIVE SPEED PLATFORM LEVEL ALARM AUXILIARY POWER 12V POWER POWER TO PLATFORM KEYSWITCH PWR TO PLATFORM 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP D OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 A OR/RD C5-19 RD C6-23 RD C6-24 BR GND2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 BK GND1 155 134A 134 133 132 118 59 46 45 D29 TB2C-DESC. ALARM 44 43 42 OR/BK ISM#2 41 40 39 37 36 35 BK/RD TS54-1(D13) BK/WH TS56-3 34 BK/WH U16-5 33 BK TS52-3 BK ISM#3 32 31 30 29 28 RD TS51-4 D6 27 RD ISM#4 24 WH KS1-1(D2) 23 WH ISM#7 BK C32-4 BK/12 KS1-3 22 WH HM(+) 21 RD/12 CB2-2 20 18 GR/BK TS57-1 17 GR TS57-3 OR/BK TS59-3 15 OR TS59-1 14 13 BK/RD R14(A) 9 BK/WH TS63-3 8 BK CR69-87A 7 6 WH/RD R14(A) 5 WH/BK TS62-1 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TB44C 2 RD/BK CR68-87A D30 1 RD TS61-4 RD DL2 C6-30 C211LO BL/BK C C D OR/RD TS62-5(D68) OR-BEACON (RIGHT) WH-BEACON (LEFT) RD C32-1 KS1-2 GR/BK C32-8 BL/WH C32-3 OR CR34#86 BL/BK L46(+) WH DL1 C6-38 C212LO GR/BK WH/BK C4B-9 TB2D R2PBD RD/BK CR69 CR23 TB7D R7PBE BK 5 CR68 B GND BR CR53 4 CR52 RD/BK 3 TS61-6 C2PBD RD/BK BK F19 C32 10 AMP FUSE TS63-1 C7PBE BK BK/WH TB34C BK-C7B-1 WH-TS51-5 RD-TS56-2 GN/BK-TB133C BR-GND RD - TB134C BL/WH-TB132C BK-TB22C A RD-44C WH/BK-32C OR-134A(D) WH-134A(C) BK-GND BL-GND GR-GND 5 BR GND STUD 5 6 7 8 12 1 3 4 2 3 BK/WH C5-22 RD TB23A 6 2 1 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Deutz TD2011L04I Models J K L C1B LABEL M FUNCTIONS ENGINE C6 C5 N GROUND STUD 1 2 CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY CR52 CR53 PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL CR68 PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY CR69 PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 R14 FUNCTION ENABLE TOGGLE SWITCH RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 TS51 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 IGNITION START MODULE U16 GLOW PLUG TIME DELAY RELAY HARNESS TO SWITCH PANEL Part No. 122985 1 D13 TS62 6 3 5 2 1 L46 4 1 4 5 6 2 CB2 TS61 2 1 1 3 1 2 3 4 4 5 6 NO D101 NO 3 P4 TS51 4 D64 3 2 1 2 3 1 S-80 • S-85 • S-80X GN/BK-TB18D BL/BK-TB59D BR-GND STUD TO GROUND CONTROL BOX CONNECTIONS C BR-HM(-) RD-TB20D RD-P1-2 D WH-C32-6 RD-TB27D RD-TS61-2 WH-KS1-1 D4 OR/RD-TB155D WH/BK-TB5D WH/RD-R14(A) WH-TB4D GN-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-CR52-30 BK-CR53-30 RD-R16 BK/WH-TB8D BK/RD-TB9D BK C6-12 OR-TB14D OR/BK-TB15D WH-ISM#10 BK-TB33D RD-C32-7 E D68 4 3 6 TS63 3 TS56 TS52 BL/WH-TB34D WH-TB23D RD-CB2-1 BK/RD-TB35D WH-TS51-2 BR-CR34#85 BR-L46(-) F 2 1 - G6 G TS57 1 2 2 B 3 H 3 3 TS54 D2 B1 + I 3 2B 2A 1 4 J TS59 NC NC 2 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 K L2 1B KS1 R16 OR-TB118D RD/WH-TB3D L 1A R14(A) R14 M P1 CR34 86 BR-HM(-) RD/WH-TS61-1 N 85 30 87 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models B A 1 2 3 4 5 6 7 8 ES0504D 6 - 51 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 51 6 - 52 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 53 6 - 54 BK P2 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS GR/WH C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C177LS BL/RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J22 C4P(BR) C3P(GR) C2P(BK) C1P(GY) LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 WH L1 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH J1 C28TTA RD/BK FOOT SWITCH ES0504D 12V BATTERY WH C9P-2 JC3-5 C159STC BL/WH CAN HI CAN LOW L51(-) C169LED1 GR L50(-) C169LED2 GR TS75-1 P109TS GR/WH C3P-12 P109LS BL/WH C1P-12 C177LS BL/WH TS75-2 C184PL WH TS75-3 SNSR BR 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH Part No. 122985 S-80 • S-85 • S-80X 6 - 54 RD C2P-6 4 BR BATGND (GROUND STUD) CR27 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 8 OPTION C9 H1 6 1 OPTION C7P + J22-1,2,9,10,11 AND 12 D40 CONTROL HARNESS TO PLATFORM SWITCH PANEL 6 1 11 J8 J7 J1 1 2 1 3 RD LS18 3 J2 2 9 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80X, Deutz TD2011L04I Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 GR J8-5 BR J8-8 GR/WH J8-6 WH J8-2 GR J8-10 TS15 BL/RD J1-16 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 BR GND STUD GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 L47 D12 JC3 JC7 TS2 3 TS6 6 + 1 6 1 L1 4 TS9 TS1 TS7 P3 + + TS14 + NO L48 L51 TS75 NC P2 L50 RD BK RD BK 5 BK RD ES0504D 6 COMPONENT INDEX H1 TILT ALARM TS6 GLOW PLUG TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH L1 LED - DRIVE ENABLE TS14 DRIVE SPEED TOGGLE SWITCH L47 LED - CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH L48 LED - TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH (OPTION) L50 LED - ZONE B, 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD L51 LED - ZONE A, 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 55 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 55 6 - 56 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 57 6 - 58 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models A B C D E F G H I J K P2 FS1 C9P-1 BK C28TTA RD/BK P26ESTP BK P26ESTP BK LOW P22PWR BK + H1 - V155PCE OR/RD TS4 ENGINE RPM HIGH C7-1 D12 L48 C4-4 C1-9 C1-8 C1-7 C1-1 C7-2 C1-2 C3-12 C2-5 TB132 1 C35RPM BK/RD LOW D64 D67 D68 P134PWR RD C41RPM OR/BK D4 C27AUX + FE RD C27AUX RD D13 TB34 RD TB33 TB155 D2 WH TB35 TB27 TB23 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK RD GR/BK GBOX GROUND HIGH TB28 TS54 ENG. RPM P4 FUNC. ENABLE C34SA BK/WH 8 C32 TS56 GLOW PLUG C33STR BK 12 TS52 ENGINE START C27AUX RD TB133 WH 7 AUXILIARY PUMP TB20 TS51 P23PWR WH 6 C28TTA RD/BK 5 C46HRN GR 1 3 4 PLAT GND P109LS GR/WH TB22 3 B 4 TS6 GLOW PLUG 4 KS1 3 P24FS WH TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 D40 TB134 RD 2 B1 RD C177LS BL/RD P134PWR RD P1 RD C1-12 C2-6 CB2 15AMP P24FS WH P25FS RD P25FS RD BK P24FS WH P3 HORN TB46 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING WH C24TSPS WH CB20 10A CR15 NO CR4 NO PR1 NO PR2 V155PCE OR/RD R35RPM BK/RD RD WH R34SA BK/WH C24TSPS WH R21ING WH R27AUX RD R33STR BK RD C + G6 - CR3 NO NO D51 FB M3 SW4 NO Y74 M2 H2 BK FB - REGULATOR ES0503D CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM POWER RELAY RPM CONTROL RELAY RPM SOLENOID FUEL PUMP GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN SERVICE HORN RELAY OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR S-80 • S-85 • S-80X M4 S1 NO S2 NC B IND START BATTERY CONTROL BATTERY 6 - 58 A STA M1 8 P134PWR RD 7 C28TTA RD/BK BAT- R46HRN GR BAT+ + C116HYD WH 12V DC CR5 NO CR17 NO R116HYD OR P134FB RD C41RPM OR/BK P134FB RD AUX MAIN D22 EXCT B1 TB21 C5-11 F22 60A CR2 CR39A NO CR1 NO 6 B2 C5-19 B1BAT RD F7 20A - L2 R21ING WH BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12V DC START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT BL/RD F17 20A 5 N C9P-3 RD 2 M C28TTA RD/BK P26ESTP BK 1 L WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH LED BL/RD 9 6 7 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW UP DOWN PRIMARY BOOM C1PBU RD C2PBD RD/BK P134PWR RD C3PBF RD/WH C8PBR BK/WH C9PER BK/RD PRIMARY BOOM C7PBE BK EXTEND RETRACT P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP SNSR-GND BR C123PBS RD/BK C6-7 C6-8 C6-9 C6-11 J114 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C6-31 C118LS OR C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C1PUB RD C2PBD RD/BK C3PBF RD/WH C129DA RD/BK C7PBE BK C8PBR BK/WH C9PERF BK/RD C30EDC WH C31EDC WH/BK C130TA WH/RD C32BRK WH/RD C29MS RD/WH 4 3 2 1 RD RD BR BK WH BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP GROUND L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 59 S-80 • S-85 • S-80X 10 15 8 C144DER BL/WH RIGHT 16 LEFT C143DEL BL/BK 4 5 13 14 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C17PRL GR PLAT. ROTATE 4 3 2 1 3 C4-5 CCW CW 24 Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 23 NO 14 13 NO U4 7 22 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 P24FS WH P26ESTP BK UP PLATFORM DOWN LEVEL UP DOWN J22-11 14 LSB2S NC 21 14 21 NC 13 NO 22 13 NO 24 23 NO NO 4 3 2 1 3 6 4 3 2 1 2 TB118 14 14 CR34 TB37 TB36 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W TB42 TB13 5 TB3 TB14 TB44 CR34 13 NO 24 23 NO 13 TB5 4 R14 10W TB4 TB1 TB7 TB17 TS62 TB30 TB31 TB29 J1 J1 J1 J1 ROCKER / STEER OPTION TB40 TB32 TS61 TS63 TB59 TS59 TB8 TB15 TB43 TB18 CCW CW J22-7 J22-12 J22-10 J22-9 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y20 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y19 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 7.5W C27AUX RD J2 J2 Y72 Y73 TS58 TS57 C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) Y70 Y71 JC3 DRIVE / STEER J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 59 6 - 60 Section 6 • Schematics September 2015 Ground Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 61 6 - 62 8 RD-44C WH/BK-32C OR-134A(D) WH-134A(D) BK-GND BL-GND GR-GND 7 6 - 62 ES503D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 16/22 CABLE 18/22 CABLE C4B C2B C3B WH-C5-3 WH L2(-) U1 C7B START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT 12V TO PLAT 1 2 3 4 5 6 7 8 9 10 WH-TB23B CABLE RESTRAINT H BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C CR23 BR-GND STUD G BK-C32-5 F BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ TB21C RD-TB20A E RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 F19 POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP DRIVE LIGHT OPTION RELAY RD-TB20B 1 WH/12 C7B-2 BR GND2 D BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 3 BL/BK C6-37 BL C6-36 BK/RD C5-9 RD DL2 LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR JIB BOOM DOWN S-85 (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS (UNUSED) STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER C OR/RD C6-22 OR/BK C5-2 OR C6-40 BK GND1 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 WH DL1 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER (UNUSED) B BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 A OR/RD C5-19 RD C6-23 RD C6-24 WH/BK C4B-9 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 10 AMP FUSE C32 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK- TB133C BR-GND 2 5 6 7 8 12 4 RD - TB134C BL/WH-TB132C BK-TB22C A BASE TERMINATION BLOCK 155 134A 134 133 132 118 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 OR/BK ISM #2 41 40 39 37 36 BK/RD TS54-1(D13) 35 34 BK/WH TS56-3 BK ISM-3 BK TS52-3 33 WH/RD-TRAVEL ALARM 32 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH ISM #7 WH KS1-1(D2) 23 BK/12 KS1-3 BK C32-4 22 WH HM(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 6 C D OR/RD TS62-5(D68) OR & WH-BEACONS RD C32-1 RD KS1-2 GR/BK C32-8 BL/WH C32-3 OR CR34 #86 BL/BK L46(+) 5 1 3 4 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models I J K C1B LABEL L FUNCTIONS ENGINE C6 C5 TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH M GROUND STUD 3 1 2 CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 IGNITION START MODULE NOTE: DASHED LINES INDICATE OPTIONS HARNESS TO SWITCH PANEL N Part No. 122985 2 1 TS62 6 3 5 2 4 1 L46 4 2 CB2 4 5 TS61 6 1 1 1 2 3 P4 3 2 1 5 4 2 3 TS51 4 3 6 NO D64 1 WH-TS51-2 RD-TB20D S-80 • S-85 • S-80X BR-GND STUD GR/BK-TB18D BL/BK-TB59D TO GROUND CONTROL BOX CONNECTIONS C BR-HM(-) D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 E D68 6 1 2 BR-L46(-) BR-CR34#85 F 3 1 2 3 - G TS57 1 2 TS63 3 TS56 G6 H 3 3 + I 3 1 D13 TS58 2 B B1 4 WH-TB21D BK-TB22D RD-TB134D BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 J TS59 3 TS54 D2 1 2 KS1 R16 OR-TB118D RD/WH-TB3D K L2 NC NC 2A 2B E-STOP 1B 1A R14(A) R14 RD/WH-TS61-1 L P1 CR34 87A 85 86 30 BR-HM(-) M + N + 87 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models B A 1 2 3 4 5 6 7 8 ES0503D 6 - 63 September 2015 Section 6 • Schematics Ground Control Switch Panel Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 63 6 - 64 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 65 6 - 66 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS GR/WH C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C177LS BL/RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J22 C4P(BR) C3P(GR) C2P(BK) C1P(GY) LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) CR30 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) WH TS14 WH TS7 7 BK P2 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH J1 C28TTA RD/BK FOOT SWITCH WH L1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH Part No. 122985 S-80 • S-85 • S-80X 6 - 66 RD C2P-6 4 ES0503D 12V BATTERY 6 1 BR BATGND (GROUND STUD) CR27 8 OPTION C9 H1 CONTROL HARNESS TO PLATFORM SWITCH PANEL 6 1 OPTION C7P + J22-1,2,9,10,11 AND 12 D40 J1 1 2 1 3 RD LS18 3 J2 2 9 11 J8 J7 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX 1 D12 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 BL/RD J1-16 TS15 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 GR/BK C4P-8 / J22-6 GR C4P-7 / J22-5 BR GND STUD GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 JC3 JC7 3 TS6 + TS2 6 L47 + 1 6 1 L1 4 TS9 TS8 TS1 TS14 TS7 + NO P3 NC P2 L48 RD 5 BK RD RD ES0503D 6 COMPONENT INDEX H1 TILT ALARM TS8 JC3 JOYSTICK - DRIVE / STEER TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS14 DRIVE SPEED TOGGLE SWITCH L1 LED - DRIVE ENABLE TS15 DRIVE ENABLE TOGGLE SWITCH L47 LED - CABLE TENSION U13 ALC500 JOYSTICK CONTROLLER CARD L48 LED - TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 67 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 67 6 - 68 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 69 6 - 70 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) A B C D E F G H I J K L M N C132PLI BK C28TTA RD/BK P26ESTP BK P24FS WH LS18A 1 FS1 P2 LS18 C9P-1 BK PBOX GROUND V155PCE OR/RD 2 LOW HIGH + H1 L4 D39 9 2 SEC. NO 30A 5 2 U34 U35 C4-10 PBOX GROUND 8 C4-10 C4-4 C1-9 C1-8 C1-7 PBOX GROUND C7-2 C1-2 C3-12 C2-5 C1-1 D40 9 NO 10A 3 D12 8 2 SEC. H6 - D67 D68 P134PWR RD C41RPM OR/BK D4 C27AUX + FE RD C27AUX RD D13 TB34 TB155 TB35 TB27 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK GR/BK RD + C35RPM BK/RD TB23 HIGH D2 LOW RD TB28 WH GBOX GROUND D64 TB33 TS54 ENG. RPM P4 FUNC. ENABLE C34SA BK/WH 8 12 TS56 GLOW PLUG C33STR BK TB133 WH 7 AUXILIARY PUMP U33 TS51 P23PWR WH TB20 TS52 ENGINE START C27AUX RD 5 6 C28TTA RD/BK C133PLS GR/BK 4 PLAT GND C46HRN GR 1 3 1 TB22 3 B 4 TS4 ENGINE RPM 4 KS1 3 5 3 TB132 TS6 GLOW PLUG P26ESTP BK R14 4.7KW TB134 RD 2 B1 RD P22PWR BK C132PLI BL/WH P134PWR RD P1 RD R26ESTP BK P3 HORN TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 C7-1 C1-12 C2-6 CB2 15AMP P25FS RD P24FS WH RD 2 C9P-3 P25FS RD BK D88 TB46 L45 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING(A) WH C24TSPS WH C5-11 F22 60A Y74 S1 NO S2 NC ES0503A CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM POWER RELAY RPM CONTROL RELAY RPM SOLENOID FUEL PUMP GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR S-80 • S-85 • S-80X V155PCE OR/RD M4 M2 B IND R35RPM BK/RD REGULATOR R34SA BK/WH C24TSPS WH R21ING WH R27AUX RD R33STR BK RD B1 FB CR4 NO M3 H2 BK FB - START BATTERY CONTROL BATTERY 6 - 70 WH D51 SW4 NO CR15 NO PR1 NO PR2 + G6 - CR3 NO NO C STA M1 8 A RD 7 P134PWR RD BAT- C28TTA RD/BK BAT+ + R46HRN GR 12V DC C116HYD WH EXCT CR5 NO CR17 NO R116HYD OR P134FB RD C41RPM OR/BK P134FB RD AUX MAIN D22 CB20 10A CR2 CR39A NO CR1 NO 6 B2 C5-19 B1BAT RD F7 20A - TB21 R21ING WH BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12V DC L2 BL/RD F17 20A 5 START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH 9 7 2 4 1 3 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C4-2 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH C9PER BK/RD C8PBR BK/WH PRIMARY BOOM C7PBE BK EXTEND RETRACT C118LS OR P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP C17PRL GR PLAT. ROTATE SNSR-GND BR C123PBS RD/BK C6-31 C6-9 C6-8 C6-7 C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 3 C6-11 YL BR OR BL BK RD BR BK WH RD BR BK WH RD BR BK WH RD 4 3 2 1 10 15 8 6 16 C144DER BL/WH RIGHT 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 3 C3-11 C4-3 C4-8 C4-7 C4-6 C4-5 CCW CW C29MS RD/WH C32BRK WH/RD C130TA WH/RD C31EDC WH/BK C30EDC WH C9PERF BK/RD C8PBR BK/WH C7PBE BK C129DA RD/BK C3PBF RD/WH C2PBD RD/BK C1PUB RD C6TRF WH/RD C5TRR WH/BK C4TRL WH C36STC BL C37STCC BL/BK 14 LED BL/RD LEFT C143DEL BL/BK 14 4 5 13 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 P24FS WH P26ESTP BK J22-11 4 3 2 1 5 2 6 4 3 2 1 RD BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND GROUND DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 71 S-80 • S-85 • S-80X Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 7 22 14 22 LSB2S NC 21 14 22 21 NC 13 NO NO TB37 TB36 13 NO 24 23 NO NC HO 21 14 TB9 TB4 TB5 TB42 TB13 1 D29 D30 L46 R14(A) 5W 13 NO 24 23 NO 13 CR34 TB6 TB2 TB15 TB1 TB7 TB8 TB17 4 R14 10W CR34 TS62 TB30 TB31 TB29 TB40 TB32 TS61 TS63 TB59 TS59 TB3 TB118 TB14 TB44 UP PLATFORM DOWN LEVEL DOWN UP CCW J22-7 J22-12 J22-2 S-85 (OPTION) CW J22-8 J22-9 J22-5 J22-3 J22-10 Y20 J22-6 Y19 J22-1 TB134A P134PWR RD J1 J1 J1 J1 Y72 Y73 TB43 TB18 TS8 TS9 JIB BOOM (S-85 OPTION) J22-4 R16 5W C27AUX RD J2 J2 2 TS7 PLATFORM ROTATE Y70 Y71 TS58 TS57 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD J114 U4 September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 71 6 - 72 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 73 6 - 74 8 RD-44C WH/BK-32C OR-134A(D) WH-134A (D) BK-GND BL-GND GR-GND 7 6 - 74 C RD DL2 BK GND1 BR GND2 WH DL1 WH/BK C4B-9 ES0503A S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 I 16/24 CABLE 18/22 CABLE C4B C2B C3B WH-C4-10 WH L2(-) C7B U1 12V TO PLAT START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT 2 1 H 1 2 3 4 5 6 7 8 9 10 WH-TB23B 3 CABLE RESTRAINT BASE TERMINATION BLOCK BR-GND STUD G BK-C32-5 F BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ H6 RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 E RD-TB20A RD-TB20B D BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER PLATFORM LOAD ALARM PLATFORM LOAD INPUT LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR S-85 JIB BOOM DOWN (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS UNUSED STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER UNUSED POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND C WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 4 A OR/RD C5-19 RD C6-23 RD C6-24 5 6 7 8 12 RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) B BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C 5 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 U33 3 RD-H6(+) BL/WH-TB132C BK-TB22C 2 1 3 4 1 CR23 C32 A 155 134A WH-BEACON (LEFT) 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34 #86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 OR/BK ISM #2 40 39 37 36 BK/RD TS54-1(D13) 35 34 BK/WH TS56-3 BK ISM #3 BK TS52-3 33 WH/RD-TRAVEL ALARM 32 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH KS1-1(D2) 23 WH ISM #7 BK/12 KS1-3 BK C32-4 22 WH G6(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34 #30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 D OR/RD TS62-5(D68) OR-BEACON (RIGHT) RD L45(+) 6 DRIVE LIGHT RELAY (OPTION) F19 TB21C 10 AMP Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) J K C1B L LABEL M FUNCTIONS ENGINE C6 C5 TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH GROUND STUD CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER H6 PLATFORM OVERLOAD ALARM KS1 KEY SWITCH L2 LED - CHECK ENGINE L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 IGNITION START MODULE U33 LOAD SENSE MODULE HARNESS TO SWITCH PANEL N 3 Part No. 122985 2 TS62 6 3 5 2 4 1 L46 4 1 3 2 1 CB2 4 5 TS61 6 2 1 1 2 3 P4 D64 4 5 6 NO 3 L45 TS51 4 3 2 3 1 2 1 BR-L46(-) S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD BR-G6(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D GR-TB17D WH-TB4D WH/BK-TB5D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D OR-TB14D GR/BK-TB44D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34 #85 E D68 6 TS63 3 TS56 - F 1 1 2 3 D13 G6 G TS57 1 1 TS58 2 B 3 + H 2 3 TS54 D2 B1 4 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 I 3 2B 2A 1 2 KS1 R16 RD-TS61-2 J TS59 NC NC R14(A) OR-TB118D RD/WH-TB3D K L2 1B 1A P1 CR34 R14 RD/WH-TS61-1 BR-G6(-) L + M + N + 87 87A 85 86 30 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) B A 1 2 3 4 5 6 7 8 ES0503A 6 - 75 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 75 6 - 76 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 77 6 - 78 7 CR27 8 RD LS18 CABLE WH TS14 WH TS7 R20 BR BATGND (GROUND STUD) ES0503A RD-E-STOP P134PWR RD P134PWR RD RD-H1+ C4P(BR) C3P(GN) C2P(BK) C1P(GY) LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) CR30 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) R26ESTP BK C9P-1 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 LS18-C132PLI2 BK C3P-10 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C2P-10 J1-P109ANG GR/WH C2P-9 P3-C46HRN GR C2P-5 TS47 C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 C3-10 C4-10 BATGND J3-1 U35 LS18-C132PLI1 BK C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK F.S. P26ESTP BK E-STOP BR GND BK P2 WH L1 WH C9P-2 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH 1 5 JC3-5 C159STC BL/WH 1 GR/BK C3P-12 12V BATT H1 Part No. 122985 CONTROL HARNESS TO PLATFORM SWITCH PANEL OPT. LS18 C9 J22 C7P + S-80 • S-85 • S-80X 6 - 78 RD C2P-6 D40 BATGND C7P-3 5 1 U34 J2 2 BRN GND STUD 6 GR/BK L4 RD LS18 4 J3 COM NO 2 3 5 3 11 J1 9 COM NO 2 3 3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 1 C1P-2 C28TTA RD/BK D39 J22-1, 2, 9, 10, 11 & 12 D88 C132PLI BK C3P-12 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFROM BOX + RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 WH C9P-2 BL/RD J1-16 BL/BK J1-7 BL/WH J1-6 RD C1P-1 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD/WH J1-8 GR/BK C4P-8/J22-6 GR C4P-7/J22-5 BR GND STUD GR/BK H1 (D39) BL/BK C3P-11 GR C4P-5/J22-4 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 TS15 1 D12 L4 JC3 3 JC7 TS6 + TS2 6 L47 L1 + 1 4 1 TS9 TS1 TS8 TS7 TS14 5 L48 + NO 6 NC P3 P2 RD BK RD RD 6 RD ES0503A COMPONENT INDEX CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) LS18 PLATFORM OVERLOAD LIMIT SWITCH TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) P2 EMERGENCY STOP BUTTON TS14 DRIVE SPEED TOGGLE SWITCH H1 J22 TILT ALARM PLATFORM MANIFOLD P3 HORN BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER R20 TS1 RESISTOR - 4700W AUXILIARY TOGGLE SWITCH U13 U34 ALC500 JOYSTICK CONTROLLER CARD TIME DELAY RELAY - 2 SECONDS, 10A JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS2 ENGINE START TOGGLE SWITCH U35 TIME DELAY RELAY - 2 SECONDS, 30A L1 LED - DRIVE ENABLE RPM SELECT TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS 1 L4 LED - PLATFORM OVERLOAD TS4 TS6 L47 LED - CABLE TENSION TS7 PLATFORM ROTATE TOGGLE SWITCH L48 LED - TILT ALARM TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) 7 8 ROCKER / STEER OPTION Part No. 122985 S-80 • S-85 • S-80X 6 - 79 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 79 6 - 80 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 81 6 - 82 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) A B C D E F G H I J K L M N D89 C28TTA RD/BK P26ESTP BK P24FS WH LS18A 1 FS1 P2 LS18 C9P-1 BK PBOX GROUND 2 SEC. NO D12 8 C3-10 C4-4 C1-9 C1-8 PBOX GROUND C7-2 C1-2 C3-12 C2-5 C1-7 U35 30A C1-1 D40 C132PLI2 BK V155PCE OR/RD 9 LOW HIGH 5 C35RPM BK/RD HIGH - 5 2 SEC. 3 TB23 C27AUX + FE RD 9 C27AUX RD 8 TB155 TB35 TB27 C41RPM OR/BK D4 U34 10A C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK GR/BK RD + H6 LOW RD D2 P134PWR RD 2 D13 TB34 TB33 WH GBOX GROUND D67 D68 NO D64 TB28 TS54 ENG. RPM P4 FUNC. ENABLE C34SA BK/WH 8 12 TS56 GLOW PLUG C33STR BK TB133 WH 7 AUXILIARY PUMP U33 TS51 P23PWR WH 6 TB20 TS52 ENGINE START C27AUX RD 5 C28TTA RD/BK C133PLS GR/BK 4 PLAT GND C46HRN GR 1 3 1 TB22 3 B 4 2 + H1 L4 D39 3 TB132 TS4 ENGINE RPM P26ESTP BK R14 4.7KW P3 HORN TS6 GLOW PLUG 4 KS1 3 R26ESTP BK TB134 RD 2 B1 RD P22PWR BK C132PLI BL/WH P134PWR RD P1 RD P24FS WH TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 C7-1 C1-12 C2-6 CB2 15AMP P25FS RD P24FS WH RD 2 C9P-3 P25FS RD BK D88 TB46 L45 TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD D6 P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21ING(A) WH C24TSPS WH C5-11 R35RPM BK/RD WH FB M4 M3 SW4 NO ES0503D CHECK ENGINE LED HOURMETER PRESSURE COMP. VALVE (FUNCTION ENABLE) RPM POWER RELAY RPM CONTROL RELAY RPM SOLENOID FUEL PUMP GLOW PLUG CONTROL RELAY GLOW PLUG OLI TEMPERATURE SWITCH OIL PRESSURE SWITCH FUEL SOLENOID FUEL SOLENOID CONTROL RELAY AUXILIARY PUMP CONTROL RELAY AUXILIARY PUMP Part No. 122985 AUXILIARY PUMP POWER RELAY IGNITION / STARTER RELAY STARTER POWER RELAY STARTER TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN OIL COOLER TEMP. SWITCH (OPTION) OIL COLLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR S-80 • S-85 • S-80X S1 NO S2 NC B IND Y74 M2 H2 REGULATOR V155PCE OR/RD CR4 NO R34SA BK/WH C24TSPS WH R21ING WH R27AUX RD R33STR BK RD CR15 NO PR1 NO PR2 + G6 - CR3 NO NO BK FB - START BATTERY 6 - 82 CR39A NO D51 M1 B1 CB20 10A CR2 C STA CONTROL BATTERY 8 A RD 7 P134PWR RD BAT- C28TTA RD/BK BAT+ + R46HRN GR 12V DC C116HYD WH EXCT CR5 NO CR17 NO R116HYD OR P134FB RD C41RPM OR/BK D22 P134FB RD AUX MAIN 6 - C5-19 F22 60A CR1 NO F7 20A B2 TB21 R21ING WH B1BAT RD BAT2 APU + C5-18 B1BAT RD C5-22 C5-15 P24PWR RD 12V DC L2 BL/RD F17 20A 5 START RELAY TACHOMETER START INPUT AUXILIARY ON GROUND IGN / START BATTERY MODULE KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH LED BL/RD 7 2 4 1 3 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH P134PWR RD C9PER BK/RD C8PBR BK/WH PRIMARY BOOM C7PBE BK EXTEND RETRACT SNSR-GND BR C123PBS RD/BK C6-7 C6-8 C6-9 C6-11 J114 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C6-31 C118LS OR C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 C37STCC BL/BK C36STC BL C4TRL WH C5TRR WH/BK C6TRF WH/RD C1PUB RD C2PBD RD/BK C3PBF RD/WH C129DA RD/BK C7PBE BK C8PBR BK/WH C9PERF BK/RD C30EDC WH C31EDC WH/BK C130TA WH/RD C32BRK WH/RD C29MS RD/WH 4 3 2 1 RD RD BR BK WH BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP GROUND L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 83 S-80 • S-85 • S-80X 9 6 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 P134PWR RD C59CNK BL/BK C14PLU OR 4 3 2 1 3 6 4 3 2 1 10 15 8 C144DER BL/WH RIGHT 16 LEFT C143DEL BL/BK 4 5 13 14 1 3 1 2 11 12 GND BR 2 4 P24FS WH P24FS WH 3 C4-2 PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP C17PRL GR PLAT. ROTATE U4 23 NO 14 13 NO Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 24 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 3 C3-11 C4-3 C4-8 C4-7 C4-6 C4-5 CCW CW 7 LSB2S 22 NC 21 14 21 NC 13 NO 22 14 14 CR34 4 3 2 1 5 2 TB118 13 NO 24 23 NO NO P26ESTP BK J22-11 14 TB9 TB37 TB36 TB42 TB13 1 D29 D30 L46 R14(A) 5W 13 NO 24 23 NO 13 CR34 TB4 TB5 4 R14 10W TB6 TB2 TB15 TB1 TB7 TB8 TB17 TS62 TB30 TB31 TB29 TB40 TB32 TS61 TS63 TB59 TS59 TB3 TB14 TB44 UP PLATFORM DOWN LEVEL DOWN UP CCW J22-7 J22-12 J22-2 S-85 (OPTION) CW J22-8 J22-9 J22-5 J22-3 J22-10 Y20 J22-6 Y19 J22-1 TB134A P134PWR RD J1 J1 J1 J1 Y72 Y73 TB43 TB18 TS8 TS9 JIB BOOM (S-85 OPTION) J22-4 R16 7.5W C27AUX RD J2 J2 2 TS7 PLATFORM ROTATE Y70 Y71 TS58 TS57 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE) Perkins 804D-33 Models (after serial number 8110) 6 - 83 6 - 84 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 85 6 - 86 6 - 86 3 7 U34 ES0503D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT U1 WH-TB23B 3 1 2 C7B 1 2 3 4 5 6 7 8 9 10 BR-GND STUD CABLE RESTRAINT BK-C32-5 G H 12V TO PLAT WH-U34 #9 WH L2(-) BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ F BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 RD-TB20A RD-TB20B E POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER PLATFORM LOAD ALARM PLATFORM LOAD INPUT LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR S-85 JIB BOOM DOWN (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS (UNUSED) STEER CCW STEER CW ENGINE SPEED GLOW PLUG START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER H6 BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 A OR/RD C5-19 RD C6-23 RD C6-24 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND D WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 BR GND2 5 6 7 8 12 RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) C BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C RD DL2 BK GND1 U33 RD-H6(+) BL/WH-TB132C BK-TB22C B 155 RD U34-2 134A 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34 #86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 OR/BK ISM #2 40 39 37 36 BK/RD TS54-1(D13) 35 34 BK/WH TS56-3 BK TS52-3 BK ISM #3 33 32 WH/RD-TRAVEL ALARM 31 30 29 28 RD TS51-4 27 RD ISM #4 D6 24 WH KS1-1(D2) 23 WH ISM #7 BK/12 KS1-3 BK C32-4 22 WH G6(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34 #30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 C 6 D OR/RD TS62-5(D68) OR & WH-BEACONS RD L45(+) BK C3B-10 WH DL1 WH/BK C4B-9 1 3 4 C32 A RD-44C WH/BK-32C OR-134A(D) WH-134A (D) BK-GND BL-GND GR-GND 5 CR23 TB21C 4 BR GND RD TB134C (A) F19 10 AMP FUSE 3 WH ISM-#9 5 DRIVE LIGHT OPTION RELAY 1 2 8 WH C5-3 2 9 8 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) I J 16/22 CABLE 18/22 CABLE C4B C2B C3B K C1B L LABEL TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH U1 IGNITION START MODULE U33 LOAD SENSE MODULE U34 LOAD SENSE TIME DELAY M FUNCTIONS ENGINE C6 C5 CB2 CONTROLS CIRCUIT BREAKER, 15A TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH GROUND STUD DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER H6 PLATFORM OVERLOAD ALARM KS1 KEY SWITCH L2 LED - CHECK ENGINE L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH HARNESS TO SWITCH PANEL N 3 TS57 1 2 3 1 1 2 3 TS58 2 TS54 D13 D2 TS62 5 2 Part No. 122985 L46 4 1 TS56 3 2 1 CB2 4 5 TS61 6 2 1 P4 2 3 1 - D64 G6 3 4 5 6 NO L45 TS51 4 3 2 3 1 2 1 S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD BR-G6(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D RD-C32-7 WH-ISM #10 TS52 BK/WH-TB34D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34 #85 BR-L46(-) E D68 4 1 3 F 6 3 6 TS63 3 B B1 + G 2 2B 2A 1 4 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 H 1 NC NC 2 KS1 R16 OR-TB118D RD/WH-TB3D I 3 1B R14(A) R14 RD/WH-TS61-1 BR-G6(-) J TS59 L2 86 CR34 85 30 1A P1 87 K + L + M + N 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) B A 1 2 3 4 5 6 7 8 ES0503D 6 - 87 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 87 6 - 88 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 89 6 - 90 RD LS18 CABLE 8 RD-E-STOP P134PWR RD CR30 R20 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) 4700W R26ESTP BK C9P-1 J22 CR27 CONTROL HARNESS TO PLATFORM SWITCH PANEL BR BATGND (GROUND STUD) P134PWR RD RD-H1+ P26ESTP BK E-STOP BR GND TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH ES0503D 12V BATTERY P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C132PLI2 BK C3P-10 D39 BK P2 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 C132PLI1 BL/WH C1P-12 D88 5 U35 J1 C28TTA RD/BK 4 WH L1 1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH GR/BK C3P-12 GR/BK L4 RD C2P-6 RD LS18 Part No. 122985 S-80 • S-85 • S-80X 6 - 90 1 C1P-2 C28TTA RD/BK BATGND J3-1 OPTION C9 H1 6 6 1 LS18 C7P + J22-1,2,9,10,11 AND 12 D40 J1 1 2 1 3 COM NO 2 3 5 3 J2 2 9 11 J8 J7 J3 U13 - JOYSTICK CONTROL CARD N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 1 BATGND C7P-3 GROUND D89 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 BL/RD J1-16 TS15 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 GR/BK C4P-8 / J22-6 GR C4P-7 / J22-5 BR GND STUD GR/BK H1 (D39) GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 L4 D12 JC3 JC7 + TS2 3 TS6 6 L47 + 1 6 1 L1 4 TS9 TS8 TS1 TS14 TS7 + NO P3 NC P2 L48 RD 5 BK RD RD ES0503D 6 COMPONENT INDEX CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) H1 TILT ALARM TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS14 DRIVE SPEED TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS15 DRIVE ENABLE TOGGLE SWITCH L1 LED - DRIVE ENABLE U13 ALC500 JOYSTICK CONTROLLER CARD L4 LED - PLATFORM OVERLOAD U35 TIME DELAY RELAY L47 LED - CABLE TENSION L48 LED - TILT ALARM LS18 PLATFORM OVERLOAD LIMIT SWITCH P2 EMERGENCY STOP BUTTON P3 HORN BUTTON R20 TS1 RESISTOR - 4700W AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 91 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 91 6 - 92 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Perkins 804D-33 Models 6 - 93 6 - 94 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Perkins 804D-33 Models A B C D E F G H I J K P26ESTP BK 1 P2 C9P-3 P25FS RD P24FS WH V155PCE OR/RD C1-9 B1BAT RD D2 P134PWR RD C41RPM OR/BK C27AUX + FE RD C27AUX RD TB155 TB35 TB46 P210PWR BK D68 D4 TB34 TB23 GROUND D67 D13 TB33 TB27 LOW RPM D64 C35RPM BK/RD 500 LB (A & B) P4 TS54 FUNCTION ENGINE ENABLE RPM HIGH RPM TB28 TS56 GLOW PLUG C34SA BK/WH C32 C33STR BK 8 TS52 ENGINE START C27AUX RD TB133 12 TS51 AUXILIARY PUMP 7 LOW RPM HIGH RPM (FS) C1-8 C1-1 1000 LB (A) P23PWR WH 6 C28TTA RD/BK GRD TB20 4 OFF ZONE B C7-2 C1-2 1 5 P26ESTP BK D12 ZONE A 3 4 PLAT C46HRN GR 3 1 TB22 3 C28TTA RD/BK P26ESTP BK TS4 ENGINE RPM D101 4 KS1 B P24FS WH TS6 GLOW PLUG TS2 ENGINE START L48 C2-5 TB132 2 B1 TS1 AUXILIARY PUMP C1-7 P22PWR BK P134PWR RD 15 AMP C28TTA RD/BK H1 D40 TB134 P1 C9P-2 + - D6 C27AUX RD C41RPM OR/BK P23PWR WH C33STR BK TB41 1 2 3 4 5 6 7 8 9 10 C33STR BK C27AUX RD P24PWR RD C5-3 C5-1 C5-6 C5-5 C6-28 C6-24 C5-7 C5-2 C21IGN WH C24TSPS WH 30 30 NO 87 CR2 87 + HM - 85 NO CR15 86 CR4 85 R34SA BK/WH V155PCE OR/RD 87 C24TSPS WH R21IGN WH C 85 CB20 10A 86 30 PR2 PR1 NO M3 M2 BK H2 CR39A 85 WH RD FB SW4 NO NO R27AUX RD A R46HRN GR C116HYD WH 85 86 R33STR BK 86 CR5 87 C28TTA RD/BK 30 NO CR1 86 S2 S1 NC NO M4 Y74 REGULATOR IND B HOUR METER PRESSURE COMP VALVE (FUNCTION ENABLE) POWER RELAY RPM RELAY RPM SOLENOID FUEL PUMP GLOW PLUG RELAY GLOW PLUG WATER TEMPERATURE SWITCH OIL PRESSURE SWITCH IGNITION POWER RELAY FUEL SOLENOID AUXILIARY PUMP RELAY AUXILIARY PUMP POWER RELAY Part No. 122985 AUXILIARY PUMP IGNITION / START RELAY POWER RELAY STARTER MOTOR TILT ALARM LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN S-80 • S-85 • S-80X OIL COOLER TEMPERATURE SWITCH (OPTION) OIL COOLER FAN (OPTION) FLASHING BEACONS (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY 6 - 94 CONTROL BATTERY 8 HYD FAN FB - 85 87 D51 STA B1 87 86 BAT - 7 - CR17 R116HYD OR + P134FB RD BAT + P134FB RD EXCT 12V DC C41RPM OR/BK ALTERNATOR NO P134PWR RD AUX. MAIN 30 D22 NO CR3 TB21 NO F22 60A 30 6 B2 C5-19 B1BAT RD 20A + C5-11 R21IGN WH BAT2 APU RD 12V DC C5-18 B1BAT RD 20A C5-22 C5-15 P24PWR RD F7 START RELAY TACHOMETER START INPUT AUXILIARY IGN / START GROUND MODULE BATTERY KEY POWER KEY BYPASS IGN / FUEL ON ENGINE FAULT BL/RD F17 5 N P25FS RD C7-1 C2-6 CB2 P3 HORN M P24FS WH FS1 C9P-1 2 L ES0503D L2 H1 RD/BK C29MS RD/WH 9 10 2 4 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C3-6 C3-5 C3-4 C3-9 C3-8 C3-7 C3-12 C2-3 GR/WH C1-12 D23 BL/RD CW GND BR C123PBS RD/BK SNSR-GND BR P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6TRF WH/RD C5TRR WH/BK C4TRL WH CCW C9PER BK/RD C8PBR BK/WH C7PBE BK EXTEND C177LS BL/RD P109LS GR/WH RETRACT UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C37STCC BL/BK C36STC BL C6-33 C6-34 C6-35 C6-22 C6-40 C6-23 C6-25 C6-13 C123PBS RD/BK SNSR-GND BR BL/RD C6-5 C6-6 C6-7 C6-8 C6-9 C6-31 C6-3 C6-2 C6-1 C6-12 C211PLO BL/BK S212PLO GR/BK GR/WH C6-4 P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6-16 C6-38 C6-30 C6-21 P134PWR RD P210PWR BK C118LS OR C5-21 C5-20 C6-37 C6-36 C5-23 C5-24 6 OR BR YL RD OR WH BK WH BR RD BK WH BR RD BK WH BR RD RD BK BL 5 BK C29MS RD/WH C32BRK WH/RD C36STC BL C37STCC BL/BK C31EDC WH/BK C30EDC WH C3PBF RD/WH C2PBD RD/BK C1PBU RD BL BR C9PERF BK/RD C8PBR BK/WH C7PBE BK C6TRF WH/RD C5TRR WH/BK C4TRL WH 14 4 1 3 9 11 10 14 13 12 5 1 7 C3-1 C3-2 C3-3 C1-4 C1-5 C1-11 C1-10 C1-6 C1-3 14 13 NO NO 13 NO 5 13 14 15 8 7 16 6 LED BL/RD C144DER BL/WH RIGHT 5 10 8 6 2 6 7 8 15 16 18 17 19 20 C6-24 WH RD RD BL BR BK BK/WH BL BR BK BK/WH BK WH BR RD NC BR BK WH BR BK Y23 Y24 Y13 Y26 Y25 7 22 PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DESCENT ALARM LOOSE CABLE LED’S LSB2S LOOSE CABLE LIMIT SWITCH MOTOR STROKE BRAKE RELEASE STEER CW STEER CCW DRIVE EDC REVERSE DRIVE EDC FORWARD GROUND CR34 - PRIMARY BOOM SPEED REDUCTION RELAY PRIMARY BOOM FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP LST3O - BOOM UP/DOWN GROUND BOX - ZONE A OPERATION AND SPEED REDUCTION LIMIT SWITCH LSB1EO - BOOM EXTEND CAPACITY OPERATIONAL LIMIT SWITCH LSB1ES - BOOM EXTEND CAPACITY SAFETY LIMIT SWITCH LST3S - BOOM ANGLE STOWED GROUND BOX - ZONE A SAFETY LIMIT SWITCH PRIMARY BOOM EXTEND/RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CCW TURNTABLE ROTATE CW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O ANGLE STOWED DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CCW 6 - 95 S-80 • S-85 • S-80X Part No. 122985 LEFT C143DEL BL/BK C209LED BL C208LED GR SNSR BR ZONE SELECT P109TS GR/WH C184PL WH 3 1 2 11 1 12 GND BR 4 2 P24FS WH 3 J114 C6-11 13 NO 14 13 NO 14 14 13 NO NO U4 1 NC 13 NO 14 6 C129DA RD/BK 14 21 24 2 1 1 2 3 4 1 3 4 2 22 23 NO BK Y15 NC NC 21 22 21 22 21 22 23 24 NC Y22 1 2 3 4 J134 1 2 3 4 TB9 23 24 GR 6 J133 3 BL 2 1 2 3 4 NO TB7 2 1 J133 2 5 21 13 NO 14 13 H4 TB118 4 1 TB8 D29 Y21 Y12 Y6 Y5 Y3 Y4 Y2 Y27 P24FS WH P26ESTP BK P134PWR RD C59CNK BL/BK C14PLU OR PLATFORM LEVEL C15PLD OR/BK UP C43JU GR DOWN C44JD GR/BK C17PRL GR C18PRR GR/BK CW CCW TB3 TB4 TB1 TB37 TB36 TB44 CR68 CR34 4 CR53 R16 10W TB5 TB18 R14(A) 5W CR52 L46 TB42 TB13 TB30 TB31 TB32 TB29 TS62 TURNTABLE ROTATE TS63 PRI. BOOM EXT. / RET. TS61 PRI. BOOM UP / DOWN C27AUX RD 3 C3-11 C4-2 TB134A P210PWR BK 2 J1 J1 J1 D24 C59CNK BL/BK C4-3 C4-7 C4-8 C4-5 C4-6 TB59 TS59 P162JPW2-OR CR69 TB2 TB15 TB17 UP DOWN J22-11 J22-12 J22-9 J22-10 J22-2 J22-1 P134PWR RD P134PWR RD P162JPW1-OR 2 5 TB14 TB43 D30 CW CCW J22-7 J22-8 J22-5 J22-6 J22-4 J22-3 Y20 Y19 Y70 R16 7.5W TS57 PLATFORM ROTATE J2 J2 Y71 C159STC-BL/WH 2 C164PES-RD/WH J8 3 C165TRS-WH/RD 3 J8 CR30 J1 JSGND1-BR 1 J25 JSGND2-BR 1 J127 NO JOYSTICK CONTROL CARD J3 C160JPL-WH/RD 4 4 TS9 PLATFORM LEVEL TS7 PLATFORM ROTATE LIFT / DRIVE (OPTION) C159STC-BL/WH 5 C163PLS-WH/BK 6 L50 L51 6 JC3 DRIVE / STEER 5 JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 L47 TS14 DRIVE SELECT L1 TS15 DRIVE ENABLE TS75 ZONE SELECT NC 1 ZONE B ZONE A P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Perkins 804D-33 Models GND BR C28TTA RD/BK P24FS WH C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80X, Perkins 804D-33 Models 6 - 95 6 - 96 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 97 6 - 98 8 6 - 98 RD-44C WH/BK-32C OR-134A(D) WH-134A(C) BK-GND BL-GND GR-GND 7 ES0503D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 I 16/22 CABLE 18/22 CABLE C4B C2B C3B WH-C5-3 WH L2(-) 1 U1 C7B START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT 12V TO PLAT 1 2 3 4 5 6 7 8 9 10 3 WH-TB23B CABLE RESTRAINT BK-C32-5 BR-GND STUD H BK-C5-5 OR/BK-TB41C BK-TB33C RD-TB27C BR GND RD-C5-1 WH-TB23C BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ G BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 TB21C RD-TB20A F WH/12 C7B-2 DRIVE LIGHT OPTION RELAY RD-TB20B 1 BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 BL/BK C6-37 BL C6-36 BK/RD C5-18 E BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER (UNUSED) (UNUSED) LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR (OPTION) (UNUSED) (UNUSED) LIMIT SWITCH - LST20 RPM / TACH SIGNAL LIMIT SWITCH - LSB1RO (UNUSED) STEER CCW STEER CW ENGINE RPM GLOW PLUG ENGINE START BRAKE RELEASE REVERSE / EDCFORWARD / EDC+ DRIVE SPEED PLATFORM LEVEL ALARM AUXILIARY POWER 12V POWER POWER TO PLATFORM KEYSWITCH PWR TO PLATFORM 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP D OR/RD C6-22 OR/BK C5-2 OR C6-40 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 A OR/RD C5-19 RD C6-23 RD C6-24 3 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 BR GND2 155 134A 134 133 132 118 59 46 45 D29 TB2C-DESC. ALARM 44 43 42 OR/BK ISM#2 41 40 39 37 36 35 BK/RD TS54-1(D13) BK/WH TS56-3 34 33 BK TS52-3 BK ISM#3 32 31 30 29 28 RD TS51-4 D6 27 RD ISM#4 24 WH KS1-1(D2) 23 WH ISM#7 BK C32-4 BK/12 KS1-3 22 WH HM(+) 21 RD/12 CB2-2 20 18 GR/BK TS57-1 17 GR TS57-3 OR/BK TS59-3 15 OR TS59-1 14 13 BK/RD R14(A) 9 BK/WH TS63-3 8 BK CR69-87A 7 6 WH/RD R14(A) 5 WH/BK TS62-1 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TB44C 2 RD/BK CR68-87A D30 1 RD TS61-4 BK GND1 C6-30 C211LO BL/BK C C D OR/RD TS62-5(D68) OR-BEACON (RIGHT) WH-BEACON (LEFT) RD C32-1 KS1-2 GR/BK C32-8 BL/WH C32-3 OR CR34#86 BL/BK L46(+) RD DL2 C6-38 C212LO GR/BK WH DL1 TB2D R2PBD RD/BK CR69 WH/BK C4B-9 TB7D R7PBE BK 5 CR68 B GND BR CR53 4 CR52 F19 RD/BK BK 10 AMP FUSE C32 BK-C7B-1 WH-TS51-5 RD-TS56-2 GN/BK-TB133C BR-GND 2 5 6 7 8 12 RD - TB134C BL/WH-TB132C BK-TB22C A TS61-6 C2PBD RD/BK TS63-1 C7PBE BK 6 1 3 4 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Perkins 804D-33 Models J K L C1B LABEL M FUNCTIONS ENGINE C6 C5 N GROUND STUD 2 CR23 CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY CR52 CR53 PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL CR68 PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY CR69 PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 R14 FUNCTION ENABLE TOGGLE SWITCH RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 TS51 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS56 GLOW PLUG TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U1 IGNITION START MODULE HARNESS TO SWITCH PANEL 3 Part No. 122985 1 D13 TS62 6 3 5 2 1 L46 4 1 4 5 6 2 CB2 TS61 2 1 1 3 1 2 3 4 4 5 6 NO D101 NO 3 P4 TS51 4 D64 3 2 1 2 3 1 S-80 • S-85 • S-80X GN/BK-TB18D BL/BK-TB59D BR-GND STUD TO GROUND CONTROL BOX CONNECTIONS C BR-HM(-) RD-TB20D RD-P1-2 D WH-C32-6 RD-TB27D RD-TS61-2 WH-KS1-1 D4 OR/RD-TB155D WH/BK-TB5D WH/RD-R14(A) WH-TB4D GN-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-CR52-30 BK-CR53-30 RD-R16 BK/WH-TB8D BK/RD-TB9D BK C6-12 OR-TB14D OR/BK-TB15D WH-ISM#10 BK-TB33D RD-C32-7 E D68 4 3 6 TS63 3 TS56 TS52 BL/WH-TB34D WH-TB23D RD-CB2-1 BK/RD-TB35D WH-TS51-2 BR-CR34#85 BR-L46(-) F 2 1 - G6 G TS57 1 2 B 3 H 2 3 TS54 D2 B1 + I 3 2B 2A 1 4 J TS59 NC NC 2 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 K L2 1B KS1 R16 OR-TB118D RD/WH-TB3D L 1A R14(A) R14 RD/WH-TS61-1 M P1 CR34 86 BR-HM(-) N 85 30 87 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models B A 1 2 3 4 5 6 7 8 ES0503D 6 - 99 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 99 6 - 100 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 101 6 - 102 BK P2 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS GR/WH C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C177LS BL/RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS6-C34SA BK/WH C1P-8 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK J22 C4P(BR) C3P(GR) C2P(BK) C1P(GY) LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) CR30 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) WH TS14 WH TS7 7 ES0503D FOOT SWITCH WH L1 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH 1 WH C9P-2 JC3-5 C159STC BL/WH CAN HI CAN LOW L51(-) C169LED1 GR L50(-) C169LED2 GR TS75-1 P109TS GR/WH C3P-12 P109LS BL/WH C1P-12 C177LS BL/WH TS75-2 C184PL WH TS75-3 SNSR BR 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH 1 BR BATGND (GROUND STUD) CR27 8 OPTION 12V BATTERY H1 Part No. 122985 S-80 • S-85 • S-80X 6 - 102 1 OPTION C9 + J22-1,2,9,10,11 AND 12 D40 C7P 6 RD C2P-6 4 CONTROL HARNESS TO PLATFORM SWITCH PANEL 6 11 J8 J7 J1 1 2 3 RD LS18 3 J2 2 9 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80X, Perkins 804D-33 Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX 1 D12 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 GR J8-5 BR J8-8 GR/WH J8-6 WH J8-2 GR J8-10 TS15 BL/RD J1-16 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) RD C9P-3 OR/RD C4P-4 BK/WH C1P-8 BK/RD C1P-9 BK C1P-7 RD C1P-1 RD/WH J1-8 BR GND STUD GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS4 1 2 JC3 JC7 TS6 3 + TS2 6 L47 + 1 6 1 L1 4 TS9 TS1 TS7 P3 + + TS14 + NO L48 L51 TS75 NC P2 L50 RD BK RD BK 5 BK RD ES0503D 6 COMPONENT INDEX H1 TILT ALARM TS6 GLOW PLUG TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH L1 LED - DRIVE ENABLE TS14 DRIVE SPEED TOGGLE SWITCH L47 LED - CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH L48 LED - TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH (OPTION) L50 LED - ZONE B, 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD L51 LED - ZONE A, 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 103 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 103 6 - 104 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS) Continental TME27 Models 6 - 105 6 - 106 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models A B C D E F G H I J K L M N C28TTA RD/BK C28TTA RD/BK P26ESTP BK 1 FS1 P2 C9P-1 BK C9P-3 P24FS WH GAS LP C2-1 GAS LP LOW L2 TS53 FUEL SELECT C39LP BL/RD TS54 ENGINE RPM TS64 ENGINE FAULT P134PWR RD C41RPM OR/BK D4 C27AUX+FE RD D11 C27AUX RD D13 TB33 TB155 TB23 GBOX GND TB21 TB35 TB39 C27AUX RD RD GN/WH 4 + G6 - TB27 D2 WH D67 C35RPM BK/RD RD TB28 D68 HIGH 8 TS52 ENGINE START C33STR BK 12 TB133 PUMP AUXILIARY C32 WH 7 P23PWR WH TB20 TS51 C27AUX RD 5 6 C28TTA RD/BK 1 C109LS GR/WH B C1-9 C4-4 C1-7 C1-1 C7-2 C1-2 P4 FUNCTION ENABLE 3 4 C46HRN GR 3 1 TB22 LOW D12 L48 C3-12 C2-5 KS1 TS3 FUEL SELECT D40 TB132 PLAT GND HIGH + B1 4 3 TS4 ENGINE RPM V155PCE OR/RD TS2 ENGINE START H1 - TB134 RD 2 RD D43 P22PWR BK P134PWR RD C177LS BL/RD P1 RD TS1 AUXILIARY PUMP C9P-2 C7-1 C1-12 C2-6 CB2 15 AMP P25FS RD P24FS WH P3 HORN P24FS WH D10 P25FS RD BK RD 2 P26ESTP BK P134PWR RD P23PWR WH TB46 TB41 RD C5-11 C5-19 C5-5 C5-1 C5-6 C6-28 C6-24 C5-7 C5-2 F17 20 A 5 V155PCE OR/RD C RD CR39B NC R27AUX RD C28TTA RD/BK R21IGN WH 7 C21RET WH 2 R33STR BK 5 R23PWR WH WH PR1 NO + 1 C38FP BL/WH 4 C38RET BL M4 3 SW4 NO M2 H2 FB FB REGULATOR IND Y74 BK WH - 14GA M3 CHECK ENGINE LIGHT FUEL PUMP ENGINE FAULT CODE TEST SWITCH HOUR METER STARTER PRESSURE COMP VALVE FUNCTION ENABLE IGNITION RELAY START RELAY APU CUT-OUT RELAY VOLTAGE DROP RELAY Part No. 122985 AUXILIARY PUMP RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR FLASHING BEACON (OPTION) HORN RELAY HORN HYD. OIL COOLER TEMP. SWITCH (OPTION) HYD. OIL COOLER FAN (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY S-80 • S-85 • S-80X B HARNESS - BK - 12GA M1 - P134PWR RD P134FB RD P134FB RD R46HRN GR A CR39A NO RD - 12GA STA 6 - 106 C116HYD WH R116HYD OR + 7 8 10 CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 B1BAT RD BAT - BAT + CR5 NO CR17 NO EXCT 12V DC B1 9 C127TSW GR CR2 NO CR1 NO R6 510W - 8 C108ESL BL/WH C5-8 6 B2 11 C35RPM BK/RD C5-13 P20BAT RD F7 20 A + 6 C39LP BL/RD C5-9 R21IGN WH BAT2 APU 12V DC C41RPM OR/BK C5-10 P24PWR RD ES0505D WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH 9 10 15 8 6 7 16 C144DER BL/WH RIGHT 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH C9PER BK/RD C8PBR BK/WH PRIMARY BOOM C7PBE BK EXTEND RETRACT C118LS OR P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP SNSR-GND BR C123PBS RD/BK C6-31 C6-9 C6-8 C6-7 C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 3 C6-11 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C29MS RD/WH C32BRK WH/RD C130TA WH/RD C31EDC WH/BK C30EDC WH C9PERF BK/RD C8PBR BK/WH C7PBE BK C129DA RD/BK C3PBF RD/WH C2PBD RD/BK C1PUB RD C6TRF WH/RD C5TRR WH/BK C4TRL WH C36STC BL C37STCC BL/BK 14 LED BL/RD LEFT C143DEL BL/BK 14 4 5 13 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C17PRL GR PLAT. ROTATE 4 3 2 1 RD BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND GROUND DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 107 S-80 • S-85 • S-80X Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 4 3 2 1 2 6 4 3 2 1 3 C4-5 CCW CW 7 22 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 P24FS WH P26ESTP BK J22-11 UP PLATFORM DOWN LEVEL UP DOWN J22-12 14 21 NC HO 22 LSB2S NC 21 14 21 NC 13 NO 14 22 13 NO 24 23 NO NO TB37 TB36 13 NO 24 23 NO 13 TB5 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W TB42 TB13 5 TB3 TB118 TB14 TB44 CR34 TB4 TB1 TB7 TB8 TB17 4 R14 10W CR34 TS62 TB30 TB31 TB29 J1 J1 J1 J1 TB40 TB32 TS61 TS63 TB59 TS59 TS58 TS57 TB15 TB43 TB18 CCW CW J22-7 J22-9 J22-10 Y20 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y19 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y72 Y73 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 5W C27AUX RD J2 J2 Y70 Y71 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS) Continental TME27 Models C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD J114 U4 September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 107 6 - 108 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 109 6 - 110 8 6 - 110 7 S-80 • S-85 • S-80X Part No. 122985 CABLE RESTRAINT WH-TB23B 3 1 2 G BK-C32-5 BR-GND STUD RD-TB20A F BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP RD-TB20B 3 2 1 E RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 WH C5-1 START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER GR-C5-8 BR-GND STUD D BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR JIB BOOM DOWN S-85 (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS GAS/LP FUEL SELECT STEER CCW STEER CW ENGINE SPEED BR GND2 BK GND1 RD DL2 WH DL1 WH/BK C4B-9 1 OR/RD C6-22 OR/BK C5-2 OR C6-40 BL/RD C5-10 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER CR23 C WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 A OR/RD C5-19 RD C6-23 RD C6-24 3 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK- TB133C BR-GND TB21C B BASE TERMINATION BLOCK 155 134A 134 GR/BK C32-8 133 BL/WH C32-3 132 OR CR34#86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 40 39 BL/RD TS53-1(D11) 37 36 BK/RD TS54-1(D13) 35 34 BK TS52-3 33 32 WH/RD-TRAVEL ALARM 31 30 29 28 RD TS51-4 27 24 WH KS1-1(D2) 23 BK/12 KS1-3 BK C32-4 22 WH HM(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TS61-6 2 D29 RD/BK TB44C RD TS61-4 1 6 C D OR/RD TS62-5(D68) WH-BEACON (RIGHT) WH-BEACON (LEFT) 5 10 AMP FUSE F19 DRIVE LIGHT OPTION RELAY A C32 4 RD BL/WH-TB132C BK-TB22C 2 5 6 7 8 12 1 3 4 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models H I 12V TO PLAT C7B J TS64 18/22 CABLE 16/22 CABLE C4B C2B C3B K C1B LABEL TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS53 FUEL SELECT TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH L FUNCTIONS ENGINE C6 C5 CB2 CONTROLS CIRCUIT BREAKER, 15A CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS64 ENGINE FAULT CODE TEST TOGGLE SWITCH M GROUND STUD DESCRIPTION ES0505D HARNESS TO SWITCH PANEL N Part No. 122985 1 2 TS62 6 3 5 2 4 1 L46 4 1 D11 2 CB2 4 5 TS61 6 1 1 2 3 P4 3 4 5 6 NO TS51 4 3 2 1 2 3 TS52 1 S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD C BR-HM(-) RD-TB20D D RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D BL/RD-TB39D RD-C32-7 OR/BK-TB15D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34#85 BR-L46(-) E D68 6 3 1 - F 3 1 2 TS63 2 G6 G TS57 1 3 3 3 + H 3 D13 TS53 B B1 4 WH-TB21D BK-TB22D RD-L45(+) BL/WH-C5-13 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 I 2 1 TS58 2 D2 1 2 KS1 R16 RD-TS61-2 J TS59 3 TS54 R14(A) OR-TB118D RD/WH-TB3D K L2 NC NC 2A 2B E-STOP 1B 1A CR34 R14 RD/WH-TS61-1 BR-HM(-) L P1 87 M + N + 87A 85 86 30 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models B A TO GROUND CONTROL BOX CONNECTIONS 1 2 3 4 5 6 7 8 ES0505D 6 - 111 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 111 6 - 112 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 113 6 - 114 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS BL/WH C3P-12 L47-C59CNK BL/BK C3P-11 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 TS3-C39LP BL/RD C2P-1 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 J22 ES0505D C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 OPTION 12V BATTERY BK P2 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C132PLI RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK 4 WH L1 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH 1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH RD C2P-6 Part No. 122985 S-80 • S-85 • S-80X 6 - 114 6 1 1 2 1 OPTION C9 H1 6 J1 C7P + J22-1,2,9,10,11 AND 12 D40 J2 2 9 3 RD LS18 3 CONTROL HARNESS TO PLATFORM SWITCH PANEL 11 J8 J7 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND BR BATGND (GROUND STUD) CR27 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 8 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 WH C9P-2 BL/RD J1-16 BL/BK J1-7 BL/WH J1-6 RD C1P-1 RD/BK H1 (D40) TS4 RD C9P-3 OR/RD C4P-4 BK/RD C1P-9 BK C1P-7 RD/WH J1-8 BL/RD C2P-1 GR/BK C4P-8/J22-6 GR C4P-7/J22-5 BR GND STUD BL/BK C3P-11 GR C4P-5/J22-4 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS3 1 2 TS15 1 D12 JC7 3 JC3 D10 6 TS2 + 1 L47 4 + L1 1 6 D43 TS7 TS14 L48 + NO 5 TS1 TS8 TS9 NC P3 P2 RD 6 BK RD RD ES0505D 7 COMPONENT INDEX CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) TS1 AUXILIARY TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) TS2 ENGINE START TOGGLE SWITCH 1 H1 TILT ALARM TS3 FUEL SELECT TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS4 RPM SELECT TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS7 PLATFORM ROTATE TOGGLE SWITCH L1 LED - DRIVE ENABLE TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) L47 LED - CABLE TENSION TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH L48 LED - TILT ALARM TS14 DRIVE SPEED TOGGLE SWITCH P2 EMERGENCY STOP BUTTON TS15 DRIVE ENABLE TOGGLE SWITCH P3 HORN BUTTON U13 ALC500 JOYSTICK CONTROLLER CARD ROCKER STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 115 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 115 6 - 116 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 117 6 - 118 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) A B C D E F G H I J K L M N C132PLI BK C28TTA RD/BK 1 P26ESTP BK LS18A LS18 FS1 P2 C9P-1 BK D88 3 C2-1 C1-9 GAS C39LP BL/RD LP LOW C35RPM BK/RD TB33 TB35 TB155 P134PWR RD C41RPM OR/BK D4 C27AUX+FE RD D11 C27AUX RD TB39 TB21 C27AUX RD RD GN/BK + H6 L2 TS53 FUEL SELECT D13 TB23 4 + G6 - TS54 ENGINE RPM TS64 ENGINE FAULT TB27 D2 WH GBOX GND D68 D67 HIGH RD TB28 C33STR BK 8 12 TS52 ENGINE START C27AUX RD TB133 WH 7 TS51 PUMP AUXILIARY U33 - C3-10 P4 FUNCTION ENABLE P23PWR WH 6 C28TTA RD/BK C133PLA GR/BK 5 TB20 C4-10 C4-4 C1-7 C1-1 C7-2 C1-2 C3-12 1 D12 3 4 C46HRN GR B 1 TB22 8 PBOX GND PBOX GND TB132 PLAT GND 3 8 D40 C2-5 KS1 3 NO 10A U34 D39 B1 4 3 GAS - 2 SEC. 2 TS3 FUEL SELECT LP NO 30A TS4 ENGINE RPM 9 LOW 2 + H1 L4 9 2 SEC. 5 HIGH P3 HORN P24FS WH TS2 ENGINE START V155PCE OR/RD U35 5 TB134 RD 2 RD D43 P22PWR BK RD C132PLI BL/WH P134PWR RD P1 TS1 AUXILIARY PUMP C9P-2 R20 4.7KW P24FS WH D10 P25FS RD P24FS WH C7-1 C1-12 C2-6 CB2 15 AMP C9P-3 P25FS RD RD PBOX GND 2 P26ESTP BK P134PWR RD P23PWR WH TB46 L45 TB41 RD C5-11 C5-15 C5-19 C5-17 C5-5 C5-1 C5-6 C6-28 C6-24 C5-7 5 C5-2 F17 20 A CR39B NC V155PCE OR/RD R27AUX RD C28TTA RD/BK C RD WH PR1 NO R21IGN WH 7 C21RET WH 2 R33STR BK 5 R23PWR WH 1 C38FP BL/WH + 4 C38RET BL M4 3 M2 H2 FB FB IND WH - 14GA M3 CHECK ENGINE LIGHT FUEL PUMP ENGINE FAULT CODE TEST SWITCH HOUR METER STARTER PRESSURE COMP VALVE FUNCTION ENABLE IGNITION RELAY START RELAY APU CUT-OUT RELAY VOLTAGE DROP RELAY Part No. 122985 AUXILIARY PUMP RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR FLASHING BEACON (OPTION) HORN RELAY HORN HYD. OIL COOLER TEMP. SWITCH (OPTION) HYD. OIL COOLER FAN (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY S-80 • S-85 • S-80X B Y74 BK HARNESS BK - 12GA SW4 NO REGULATOR - P134PWR RD P134FB RD P134FB RD R46HRN GR M1 6 - 118 A CR39A NO RD - 12GA STA 8 R21IGN WH R116HYD OR BAT - BAT + + B1 10 CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 B1BAT RD 12V DC CR5 NO CR17 NO EXCT - 9 C127TSW GR CR2 NO CR1 NO R6 510W B2 8 C108ESL BL/WH C5-8 F7 20 A + 11 C35RPM BK/RD C5-13 P20BAT RD 6 7 6 C39LP BL/RD C5-9 R21IGN WH BAT2 APU 12V DC C41RPM OR/BK C5-10 P24PWR RD ES0505A WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH 9 10 15 8 6 7 16 C144DER BL/WH RIGHT 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH C8PBR BK/WH C9PER BK/RD PRIMARY BOOM C7PBE BK EXTEND RETRACT C118LS OR P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP SNSR-GND BR C123PBS RD/BK C6-31 C6-9 C6-8 C6-7 C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 3 C6-11 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C29MS RD/WH C32BRK WH/RD C130TA WH/RD C31EDC WH/BK C30EDC WH C9PERF BK/RD C8PBR BK/WH C7PBE BK C129DA RD/BK C3PBF RD/WH C2PBD RD/BK C1PUB RD C6TRF WH/RD C5TRR WH/BK C4TRL WH C36STC BL C37STCC BL/BK 14 LED BL/RD LEFT C143DEL BL/BK 14 4 5 13 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C17PRL GR PLAT. ROTATE 4 3 2 1 RD BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND GROUND DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 119 S-80 • S-85 • S-80X Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 4 3 2 1 2 6 4 3 2 1 3 C4-5 CCW CW 7 22 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 P24FS WH P26ESTP BK J22-11 UP PLATFORM DOWN LEVEL UP DOWN J22-12 14 21 NC HO 22 LSB2S NC 21 14 21 NC 13 NO 14 22 13 NO 24 23 NO NO TB37 TB36 13 NO 24 23 NO 13 TB5 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W TB42 TB13 5 TB3 TB118 TB14 TB44 CR34 TB4 TB1 TB7 TB8 TB17 4 R14 10W CR34 TS62 TB30 TB31 TB29 J1 J1 J1 J1 TB40 TB32 TS61 TS63 TB59 TS59 TS58 TS57 TB15 TB43 TB18 CCW CW J22-7 J22-9 J22-10 Y20 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y19 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y72 Y73 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 5W C27AUX RD J2 J2 Y70 Y71 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD J114 U4 September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 119 6 - 120 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 121 6 - 122 8 6 - 122 RD DL2 ES0505A S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP 1 2 CABLE RESTRAINT WH-TB23B 3 G BK-C32-5 BR-GND STUD RD-TB20A F BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 WH C5-1 E WH/12 C7B-2 RD-TB20B 3 2 1 D START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER BR-GND STUD GR-C5-8 C BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR JIB BOOM DOWN S-85 (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS GAS/LP FUEL SELECT STEER CCW STEER CW ENGINE SPEED H6 OR/RD C6-22 OR/BK C5-2 OR C6-40 BL/RD C5-10 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER 3 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 A OR/RD C5-19 RD C6-23 RD C6-24 BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 5 6 7 8 12 B 155 WH-BEACON (LEFT) 134A 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34#86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 40 39 BL/RD TS53-1(D11) 37 36 BK/RD TS54-1(D13) 35 34 BK TS52-3 33 32 WH/RD-TRAVEL ALARM 31 30 29 28 RD TS51-4 27 24 WH KS1-1(D2) 23 BK/12 KS1-3 BK C32-4 22 WH HM(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34#30 3 RD/BK TS61-6 2 D29 RD/BK TB44C RD TS61-4 1 C 6 D OR/RD TS62-5(D68) WH-BEACON (RIGHT) RD L45(+) BR GND2 BK GND1 U33 RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) A RD-44C WH/BK-32C OR-134A(D) WH-134A (C) WH-134A (C) BK-GND BL-GND GR-GND 7 WH DL1 RD-H6(+) BL/WH-TB132C BK-TB22C 2 WH/BK C4B-9 1 3 4 C32 1 CR23 TB21C 4 10 AMP FUSE 5 F19 DRIVE LIGHT OPTION RELAY Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) H I 12V TO PLAT C7B J TS64 16/22 CABLE 18/22 CABLE C4B C2B C3B K C1B LABEL L CB2 CONTROLS CIRCUIT BREAKER, 15A CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 TS51 RESISTOR, 5W, PRIMARY BOOM UP / DOWN SPEED AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS53 FUEL SELECT TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH M FUNCTIONS ENGINE C6 C5 TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TS63 TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH U33 LOAD SENSE MODULE GROUND STUD DESCRIPTION HARNESS TO SWITCH PANEL N Part No. 122985 2 1 TS62 6 3 5 2 4 1 1 2 CB2 4 5 TS61 6 1 1 2 3 P4 3 4 5 6 NO L45 TS51 4 3 2 1 2 3 TS52 1 BR-L46(-) S-80 • S-85 • S-80X GR/BK-TB18D BL/BK-TB59D BR-GND STUD BR-HM(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 RD-P1-2 WH-C32-6 RD-TS61-2 WH-KS1-1 D4 WH/RD-R14(A) OR/RD-TB155D RD-TB27D WH-TB4D WH/BK-TB5D GR-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-TB2D BK-TB7D RD-R16 BK/WH-TB8D BK/RD-TB9D GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D BK-TB33D BL/RD-TB39D RD-C32-7 OR/BK-TB15D BK/RD-TB35D WH-TB23D RD-CB2-1 WH-TS51-2 BR-CR34#85 D L46 4 1 D11 - E D68 6 3 TS63 2 G6 F 3 1 2 3 3 + G TS57 1 3 D13 TS53 B B1 4 WH-TB21D BK-TB22D RD-L45(+) BL/WH-C5-13 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 H 2 1 TS58 2 D2 1 2 KS1 R16 OR-TB118D RD/WH-TB3D I 3 3 TS54 R14(A) R14 RD/WH-TS61-1 BR-HM(-) J TS59 L2 NC NC 2B 2A E-STOP 1B CR34 1A P1 87 K + L + M + N 87A 85 86 30 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) B A 1 2 3 4 5 6 7 8 ES0505A 6 - 123 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 123 6 - 124 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 125 6 - 126 CR27 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 8 RD LS18 CABLE WH TS14 WH TS7 R20 7 RD-E-STOP P134PWR RD BR BATGND (GROUND STUD) ES0505A P134PWR RD RD-H1+ LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) R26ESTP BK C9P-1 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 C1P(GY) C2P(BK) C3P(GN) C4P(BR) F.S. J1-SNSR GND BR C2P-10 J1-P109ANG GR/WH C2P-9 TS3-C39LP BL/RD C2P-1 P3-C46HRN GR C2P-5 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C132PLI RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 C3-10 C4-10 BATGND J3-1 U35 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK OPT. 12V BATT P26ESTP BK E-STOP BR GND BK P2 WH L1 WH C9P-2 JC3-5 C159STC BL/WH C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH Part No. 122985 CONTROL HARNESS TO PLATFORM SWITCH PANEL H1 D88 D39 LS18 C9 J22 C7P + 1 GR/BK C3P-12 D40 BATGND C7P-3 5 S-80 • S-85 • S-80X 6 - 126 RD C2P-6 4 BRN GND STUD 6 GR/BK L4 RD LS18 3 3 COM NO 2 3 5 1 5 J2 2 1 U34 11 J1 9 COM NO 2 3 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 1 C1P-2 C28TTA RD/BK J22-1, 2, 9, 10, 11 & 12 C132PLI BK C1P-12 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 WH C9P-2 BL/RD J1-16 BL/BK J1-7 BL/WH J1-6 RD C1P-1 RD/BK H1 (D40) TS4 RD C9P-3 OR/RD C4P-4 BK/RD C1P-9 BK C1P-7 BL/RD C2P-1 RD/WH J1-8 GR/BK C4P-8/J22-6 GR C4P-7/J22-5 BR GND STUD GR/BK H1 (D39) BL/BK C3P-11 GR C4P-5/J22-4 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS3 1 2 TS15 1 D12 L4 JC3 3 D10 JC7 + TS2 6 L47 L1 4 + 1 1 6 D43 TS9 TS1 TS8 5 TS14 L48 + NO NC TS7 P3 P2 RD BK RD 6 RD ES0505A COMPONENT INDEX C1P 18/22 CONTROL CABLE (GREY) P3 HORN BUTTON C2P 18/22 CONTROL CABLE (BLACK) R20 RESISTOR - 4700W C3P 16/22 CONTROL CABLE (GREEN) TS1 AUXILIARY TOGGLE SWITCH C4P 16/22 CONTROL CABLE (BROWN) TS2 ENGINE START TOGGLE SWITCH C7P 12VDC POWER TO PLATFORM TS3 FUEL SELECT TOGGLE SWITCH C9 FOOT SWITCH TS4 RPM SELECT TOGGLE SWITCH CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) H1 TILT ALARM TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH J22 PLATFORM MANIFOLD TS14 DRIVE SPEED TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS15 DRIVE ENABLE TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE U13 ALC500 JOYSTICK CONTROLLER CARD L1 LED - DRIVE ENABLE L4 LED - PLATFORM OVERLOAD U34 U35 TIME DELAY RELAY - 2 SECONDS, 10A TIME DELAY RELAY - 2 SECONDS, 30A L47 LED - CABLE TENSION L48 LED - TILT ALARM LS18 PLATFORM OVERLOAD LIMIT SWITCH P2 EMERGENCY STOP BUTTON 7 8 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER STEER OPTION Part No. 122985 S-80 • S-85 • S-80X 6 - 127 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 127 6 - 128 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 129 6 - 130 Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) A B C D E F G H I P26ESTP BK 1 P2 C2-1 TB155 TB23 TB35 TB21 GAS TB33 TB27 D2 FUEL SELECT C39LP BL/RD D13 TS53 LP TB28 P134PWR RD C27AUX + FE RD C27AUX RD D11 TB39 B1BAT RD P134PWR RD P23PWR WH TB46 TB41 C5-11 C5-19 C5-17 C5-15 C5-5 C5-1 C5-6 C6-28 C6-24 C5-7 C5-2 F17 20A C5-10 R21ING WH C5-9 C5-8 BAT 2 APU RD CR1 CR39A CR39B NC V155PCE OR/RD 8 C108ESL BL/WH 9 C127TSW GR 10 R21ING WH 7 R21RET WH 2 R33STR BK 5 R23PWR WH 1 C38FP BL/WH 4 C38RET BL M2 Y74 M4 3 BK 12GA FB RD 12GA FB BK B1 H2 + WH 14GA PR1 NO 11 C35RPM BK/RD CR2 R27AUX RD C WH - M3 VOLT REG. IND B CHECK ENGINE LIGHT FUEL PUMP ENGINE FAULT CODE TEST SWITCH HOUR METER STARTER MOTOR PRESSURE COMP VALVE (FUNCTION ENABLE) ENGINE IGNITION RELAY START RELAY AUXILIARY POWER CUT OUT RELAY VOLTAGE DROP RELAY Part No. 122985 AUXILIARY PUMP RELAY AUXILIARY PUMP TILT ALARM LEVEL SENSOR FLASHING BEACONS (OPTION) SERVICE HORN RELAY S-80 • S-85 • S-80X SERVICE HORN HYD. OIL COOLER TEMP. SWITCH (OPTION) HYD. OIL COOLER (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY 6 - 130 CONTROL BATTERY 8 RD SW4 NO M1 B2 NO NO + STA - A C28TTA RD/BK BAT - P134FB RD + 7 BAT + R46HRN GR 12V DC CR5 NO C116HYD WH 12V DC R116HYD OR EXCT CR17 NO P134FB RD AUX MAIN R6 510W P134PWR RD F7 20A NO 6 C39LP BL/RD VEHICLE INTERFACE 1 HARNESS C5-13 C41RPM OR/BK CONTINENTAL TME27 ENGINE B1BAT RD P24PWR RD B1BAT RD 6 C41RPM OR/BK D4 C27AUX RD GR/BK GROUND GROUND BOX ENGINE RPM L2 C32 5 GAS C1-9 ENGINE FAULT CODE LOW + G6 - TS54 C35RPM BK/RD D67 HIGH 8 TS64 D68 RUN 12 P4 FUNCTION ENABLE TEST TB133 TS51 AUX. PUMP C33STR BK 7 TS52 ENGINE START C27AUX RD TB20 4 LP HIGH C4-4 C1-7 C1-1 5 6 P23PWR WH 1 TS3 FUEL SELECT D12 C28TTA RD/BK B P24FS WH 3 4 PLAT GRND C46HRN GR 3 1 TB22 3 TS4 ENGINE RPM L48 C7-2 KS1 H1 C1-2 TB132 4 P24FS WH + C2-5 2 C28TTA RD/BK P26ESTP BK LOW P22PWR BK P134PWR RD B1 C28TTA RD/BK D40 TB134 P1 N P26ESTP BK V155PCE OR/RD C7-1 C2-6 CB2 15 AMP TS2 ENGINE START TS1 D43 - M P25FS RD C9P-2 P3 HORN L D10 P25FS RD P24FS WH 2 K C9P-3 FS1 C9P-1 J ES0505D WH 1 P26ESTP BK H1 RD/BK C29MS RD/WH LED BL/RD 9 6 7 2 4 1 3 18 17 9 11 10 6 7 8 14 13 12 5 15 16 19 20 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C1-11 C1-10 C3-6 C3-5 C3-4 C3-1 C3-2 C3-3 C3-9 C3-8 C3-7 C2-3 C1-4 C1-5 C1-6 C1-3 C123PBS RD/BK SNSR-GND BR P109ANG GN/WH C42LS OR/RD C40LS OR P134PWR RD C6-33 C6-34 C6-35 C6-22 C6-40 C6-25 C6-13 TURNTABLE ROTATE C4TRL WH C5TRR WH/BK C6TRF WH/RD C36STC BL C37STCC BL/BK C13DRE BL/RD CW CCW DOWN UP PRIMARY BOOM C1PBU RD C2PBD RD/BK C3PBF RD/WH P134PWR RD C8PBR BK/WH C9PER BK/RD PRIMARY BOOM C7PBE BK EXTEND RETRACT P134PWR RD C59CNK BL/BK C14PLU OR PLAT. LEVEL C15PLD OR/BK UP DOWN C44JD GR/BK C43JU GR DOWN JIB BOOM (S-85 OPTION) C18PRR GR/BK UP SNSR-GND BR C123PBS RD/BK C6-7 C6-8 C6-9 C6-11 J114 YL BR OR BL BK RD BR BK WH RD BR BK WH RD RD BR BK WH C6-31 C118LS OR C6-3 C6-2 C6-1 C6-6 C6-5 C6-4 C6-36 C6-37 P134PWR RD C13DRE BL/RD C40LS OR C42LS OR/RD P109ANG GN/WH BR C5-21 C5-20 C5-23 C5-24 5 6 4 C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C1PUB RD C2PBD RD/BK C3PBF RD/WH C129DA RD/BK C7PBE BK C8PBR BK/WH C9PERF BK/RD C30EDC WH C31EDC WH/BK C130TA WH/RD C32BRK WH/RD C29MS RD/WH 4 3 2 1 RD RD BR BK WH BR PLATFORM ROTATE CCW JIB BOOM UP JIB BOOM DOWN PLATFORM LEVEL DOWN PLATFORM LEVEL UP GROUND L46 / L47 LOOSE CABLE LED LSB2S LOOSE CABLE LIMIT SWITCH 2 SPEED MOTOR STROKE BRAKE RELEASE TRAVEL ALARM (OPTION) EDC - DRIVE REVERSE EDC - DRIVE FORWARD PRIMARY BOOM EXTEND / RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND LST3O - BOOM UP / DOWN SPEED REDUCTION LIMIT SWITCH CR34 - SPEED REDUCTION RELAY DESCENT ALARM PRIMARY BOOM UP / DOWN FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CW TURNTABLE ROTATE CCW STEER CW STEER CCW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO - BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O - STOWED ANGLE DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CW 6 - 131 S-80 • S-85 • S-80X 10 15 8 C144DER BL/WH RIGHT 16 LEFT C143DEL BL/BK 4 5 13 14 1 3 1 2 11 12 GND BR 4 2 P24FS WH 3 C4-2 C3-11 C4-3 C4-8 C4-7 C4-6 C17PRL GR PLAT. ROTATE 4 3 2 1 3 C4-5 CCW CW 24 Part No. 122985 Y3 Y4 Y24 Y23 Y13 Y21 Y22 Y12 H4 23 NO 14 13 NO U4 7 22 Y26 Y25 Y15 Y6 Y5 H3 Y27 Y2 P24FS WH P26ESTP BK J22-11 UP PLATFORM DOWN LEVEL UP DOWN J22-12 14 LSB2S NC 21 14 21 NC 13 NO 22 13 NO 24 23 NO NO 4 3 2 1 3 6 4 3 2 1 2 TB118 14 14 CR34 TB37 TB36 1 D29 D30 L46 TB6 TB2 TB9 R14(A) 5W TB42 TB13 5 TB3 TB14 TB44 CR34 13 NO 24 23 NO 13 TB5 4 R14 10W TB4 TB1 TB7 TB8 TB17 TS62 TB30 TB31 TB29 J1 J1 J1 J1 TB40 TB32 TS61 TS63 TB59 TS59 TS58 TS57 TB15 TB43 TB18 CCW CW J22-7 J22-9 J22-10 Y20 J22-2 S-85 (OPTION) J22-8 J22-6 J22-5 Y19 TS8 TS9 JIB BOOM (S-85 OPTION) J22-3 Y72 Y73 J22-1 TB134A P134PWR RD 2 TS7 PLATFORM ROTATE J22-4 R16 7.5W C27AUX RD J2 J2 Y70 Y71 JC3 DRIVE / STEER C163PES-WH/BK C165TRS-WH/RD C164PLS-RD/WH P162JPW2-OR JSGND2-BR JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 NC U13 ALC-500 JOYSTICK CONTROL CARD J2 CR30 NO LIFT / DRIVE (OPTION) ROCKER / STEER OPTION J25 6 5 4 3 2 1 J127 6 5 4 3 2 1 L47 J3 L1 C159STC-BL/WH C160JPL-WH/RD C159STC-BL/WH P162JPW1-OR JSGND1-BR TS14 DRIVE MODE TS15 DRIVE ENABLE P24FS WH A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) C28TTA RD/BK GND BR C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 131 6 - 132 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 133 6 - 134 6 - 134 7 C 6 U34 ES0505D S-80 • S-85 • S-80X CABLE RESTRAINT Part No. 122985 BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 WH C5-11 RD/12 BATT+ CABLE RESTRAINT WH-TB23B 3 1 2 G BK-C32-5 BR-GND STUD RD-TB20A F BASE TERMINATION BLOCK RD/12 BATT+ GR/BK C4B-6 GR C4B-5 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 POWER TO PLATFORM KEYSWITCH PWR TO PLAT 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE LS PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP TS64 RD-TB20B 3 2 1 E WH C5-1 BR-GND STUD GR-C5-8 D BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER PLATFORM LOAD ALARM PLATFORM LOAD INPUT LIFT SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR (OPTION) JIB BOOM DOWN S-85 (OPTION) JIB BOOM UP BOOM ANGLE STOWED LS RPM SIGNAL BOOM RETRACTED LS FUEL SELECT STEER CCW STEER CW ENGINE SPEED (UNUSED) START BRAKE REVERSE/EDCFORWARD/EDC+ DRIVE SPEED LEVEL SENSOR ALARM AUXILIARY POWER BK-C7B-1 WH-TS51-5 RD-TS53-2 GR/BK-H6(-) BR-GND H6 OR/RD C6-22 OR/BK C5-2 OR C6-40 BL/RD C5-10 BL/BK C6-37 BL C6-36 BK/RD C5-9 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 A OR/RD C5-19 RD C6-23 RD C6-24 5 6 7 8 12 RD-P134PWR TB134C GR/BK-TB133C GR/BK-L45(-) C WH/12 C7B-2 BL/BK C3B-11 GR C2B-5 GR/WH C2B-7 GR/BK C4B-8 GR C4B-7 OR/RD C2B-4 OR/BK C2B-3 OR C2B-2 BL/RD C2B-1 BL/BK C1B-11 BL C1B-10 BK/RD C1B-9 BK/WH C1B-8 BK C1B-7 WH/RD C1B-6 WH/BK C1B-5 WH C1B-4 RD/WH C1B-3 RD/BK C1B-2 RD C1B-1 B OR/RD C4B-4(D67) RD C6-25 RD C2B-6 GR/BK C3B-12 BL/WH C1B-12 U33 RD-H6(+) BL/WH-TB132C BK-TB22C B 155 RD U34-2 134A 134 RD H6(+) GR/BK H6(-) 133 BL/WH C32-3 132 OR CR34 #86 118 BL/BK L46(+) 59 46 45 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR TS58-1 43 42 41 40 BL/RD TS53-1(D11) 39 37 36 BK/RD TS54-1(D13) 35 34 BK TS52-3 33 32 WH/RD-TRAVEL ALARM 31 30 29 28 RD TS51-4 27 24 WH KS1-1(D2) 23 BK/12 KS1-3 BK C32-4 22 WH G6(+) 21 RD/12 CB2-2 20 GR/BK TS57-1 18 GR TS57-3 17 OR/BK TS59-3 15 OR TS59-1 14 13 9 BK/RD TS63-6 BK/WH TS63-3 8 BK TS63-1 7 WH/RD R14(A) 6 WH/BK TS62-1 5 4 WH TS62-3 RD/WH CR34 #30 3 RD/BK TS61-6 2 D29 TB44C RD TS61-4 1 D OR/RD TS62-5(D68) OR & WH-BEACONS RD L45(+) BR GND2 BK GND1 RD DL2 WH DL1 WH/BK C4B-9 1 3 4 C32 A RD-44C WH/BK-32C OR-134A(D) WH-134A (D) BK-GND BL-GND GR-GND 5 BR GND BK C3B-10 CR23 TB21C 4 3 RD TB134C (A) F19 10 AMP FUSE 3 WH C5-15 5 DRIVE LIGHT OPTION RELAY 1 2 8 WH C5-17 2 9 8 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) H I 12V TO PLAT C7B J 16/22 CABLE 18/22 CABLE C4B C2B C3B K C1B L LABEL TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS53 FUEL SELECT TOGGLE SWITCH M FUNCTIONS ENGINE C6 C5 TS54 RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS64 ENGINE FAULT CODE TEST TOGGLE SWITCH U33 LOAD SENSE MODULE U34 LOAD SENSE TIME DELAY GROUND STUD CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY G6 HOUR METER H6 PLATFORM OVERLOAD ALARM KS1 KEY SWITCH L2 LED - CHECK ENGINE L45 LED - PLATFORM OVERLOAD L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION) TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH HARNESS TO SWITCH PANEL N Part No. 122985 1 D13 TS62 6 3 3 5 2 1 1 L46 4 1 D11 2 4 5 6 NO P4 TS51 4 L45 1 1 2 3 4 D101 NO 3 2 1 2 3 1 S-80 • S-85 • S-80X GN/BK-TB18D BL/BK-TB59D BR-GND STUD BR-HM(-) TO GROUND CONTROL BOX CONNECTIONS C RD-TB20D RD-TB134D GR/BK-H6(-) RD-KS1-2 RD-P1-2 WH-C32-6 RD-TB27D RD-TS61-2 WH-KS1-1 D4 OR/RD-TB155D WH/BK-TB5D WH/RD-R14(A) WH-TB4D GN-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-CR52-30 BK-CR53-30 RD-R16 BK/WH-TB8D BK/RD-TB9D BK C6-12 GR-TB43D GR/BK-TB44D OR-TB14D OR/BK-TB15D RD-C32-7 BK-TB33D BL/RD-TB39D D 3 CB2 TS61 4 5 6 3 3 E D68 4 3 6 TS63 2 TS52 WH-TB23D RD-CB2-1 BK/RD-TB35D WH-TS51-2 BR-CR34#85 BR-L46(-) F 2 1 2 1 - G6 G TS57 1 2 3 TS58 2 TS53 B 3 H 3 3 TS54 D2 B1 + I 3 2B 2A 1 4 J TS59 NC NC 2 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-13 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 K L2 1B KS1 R16 OR-TB118D RD/WH-TB3D L 1A R14(A) R14 RD/WH-TS61-1 M P1 CR34 86 BR-HM(-) N 85 30 87 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) B A 1 2 4 5 6 7 8 ES0505D 6 - 135 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 135 6 - 136 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 137 6 - 138 RD LS18 CABLE 8 RD-E-STOP P134PWR RD CR30 R20 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) 4700W R26ESTP BK C9P-1 J22 CR27 CONTROL HARNESS TO PLATFORM SWITCH PANEL BR BATGND (GROUND STUD) P134PWR RD RD-H1+ P26ESTP BK E-STOP BR GND TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS8-C43JU GR J22-5 TS8-C44JD GR/BK J22-6 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS8-C43JU GR C4P-7 TS8-C44JD GR/BK C4P-8 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 H1-C133PLA GR/BK C3P-12 L47-C59CNK BL/BK C3P-11 C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH ES0505D 12V BATTERY J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 TS3-C39LP BL/RD C2P-1 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C132PLI2 BK C3P-10 D39 BK P2 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 C132PLI1 BL/WH C1P-12 D88 5 U35 J1 C28TTA RD/BK 4 WH L1 1 WH C9P-2 CAN HI CAN LOW JC3-5 C159STC BL/WH C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH GR/BK C3P-12 GR/BK L4 RD C2P-6 RD LS18 Part No. 122985 S-80 • S-85 • S-80X 6 - 138 1 C1P-2 C28TTA RD/BK BATGND J3-1 OPTION C9 H1 6 6 1 LS18 C7P + J22-1,2,9,10,11 AND 12 D40 J1 1 2 1 3 COM NO 2 3 5 3 J2 2 9 11 J8 J7 J3 U13 - JOYSTICK CONTROL CARD N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 1 BATGND C7P-3 GROUND D89 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX + 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 BL/RD J1-16 TS15 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) TS4 RD C9P-3 BK/RD C1P-9 OR/RD C4P-4 BL/RD C2P-1 BK C1P-7 RD C1P-1 RD/WH J1-8 GR/BK C4P-8/J22-6 GR C4P-7/J22-5 BR GND STUD GR/BK H1(D39) GR C4P-5/J22-4 BL/BK C3P-11 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS3 1 2 L4 D12 JC3 JC7 D10 3 + TS2 6 L47 + 1 6 1 L1 4 D43 TS9 TS1 TS14 + NO NC TS7 P3 L48 P2 TS8 RD 5 BK RD RD ES0505D 6 COMPONENT INDEX H1 TILT ALARM TS4 RPM SELECT TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS8 JIB BOOM UP / DOWN TOGGLE SWITCH L1 LED - DRIVE ENABLE TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH L4 LED - PLATFORM OVERLOAD TS14 DRIVE SPEED TOGGLE SWITCH L47 LED - CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH L48 LED - TILT ALARM U13 ALC500 JOYSTICK CONTROLLER CARD P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS3 FUEL SELECT TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 139 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 139 6 - 140 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Continental TME27 Models 6 - 141 6 - 142 Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Continental TME27 Models A B C D E F G H I J K L M N C28TTA RD/BK C28TTA RD/BK P26ESTP BK 1 P2 FS1 C9P-1 P25FS RD P25FS RD P24FS WH TB21 TB35 GR/BK P23PWR WH C5-11 C5-19 C5-17 C5-15 C5-5 C5-1 C5-6 C6-28 C6-24 C5-7 C5-2 C35RPM BK/RD 8 C108ESL BL/WH 9 C127TSW GR 10 R21IGN WH 7 C21RET WH 2 C5-8 86 30 CR1 30 30 85 87 C A RD CR39A 86 85 86 CR39B 85 30 NC 85 87 30 NO 87 CR2 86 85 87A WH V155PCE OR/RD M4 SW4 NO M1 - M2 H2 FB FB REGULATOR B Y74 BK 5 R23PWR WH 1 C38FP BL/WH 4 C38RET BL 3 HARNESS - STA 7 R33STR BK BK - 12GA RD - 12GA PR1 NO + WH - 14GA R46HRN GR BAT - NO NO R27AUX RD 87 C116HYD WH 85 CR5 P134FB RD NO 86 P134PWR RD 86 C28TTA RD/BK CR17 87 BAT + + NO R116HYD OR 12V DC 30 P134FB RD AUX MAIN R6 510W EXCT M3 IND CHECK ENGINE LIGHT FUEL PUMP ENGINE FAULT CODE TEST SWITCH STARTER HOUR METER PRESSURE COMP. VALVE FUNCTION ENABLE IGNITION RELAY START RELAY APU CUT-OUT RELAY Part No. 122985 VOLTAGE DROP RELAY AUXILIARY PUMP AUXILIARY PUMP RELAY TILT ALARM LEVEL SENSOR FLASHING BEACON (OPTION) HORN RELAY S-80 • S-85 • S-80X HORN HYD. OIL COOLER TEMP. SWITCH (OPTION) HYD. OIL COOLER FAN (OPTION) ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY 6 - 142 11 C5-13 B1BAT RD 6 8 6 C39LP BL/RD C5-9 R21IGN WH 20A B1 C41RPM OR/BK CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 B1BAT RD 20A BAT2 APU RD - C27AUX RD TB39 C5-10 F7 B2 C27AUX + FE RD TB41 P24PWR RD + C41RPM OR/BK D4 P134PWR RD F17 12V DC P210PWR BK P134PWR RD C27AUX RD TB46 5 D11 C39LP BL/RD TB27 TB23 B1BAT RD 4 TB155 LP D13 TS53 FUEL SELECT GAS D2 L2 C35RPM BK/RD + G6 - TB33 GROUND TS54 ENGINE RPM TS64 ENGINE FAULT D67 D68 HIGH RPM TB28 P4 FUNCTION ENABLE LOW RPM 8 C33STR/BK C32 C27AUX RD TB133 AUXILIARY PUMP 7 TS51 P23PWR WH 6 TB20 12 C2-1 500 LB (A & B) TS52 ENGINE START 5 C28TTA RD/BK 1 1000 LB (A) C46HRN GR 3 ZONE B 3 4 PLAT GRD C1-9 C4-4 TB22 3 B C1-7 KS1 1 C1-1 4 C7-2 TB132 2 B1 C1-2 C2-5 TB134 P1 LP ZONE A OFF CB2 15 AMP GAS D12 D101 L48 TS3 FUEL SELECT HIGH RPM (FS) P22PWR BK P134PWR RD D40 TS4 ENGINE RPM V155PCE OR/RD C7-1 C2-6 D43 + H1 - TS2 ENGINE START TS1 AUXILIARY PUMP C9P-2 P3 HORN P24FS WH D10 P24FS WH 2 P26ESTP BK P26ESTP BK C9P-3 ES0505D H1 RD/BK C29MS RD/WH 9 10 4 2 4 1 3 9 11 10 14 13 12 5 1 7 C7-3 C2-10 C2-9 C2-8 C2-4 C2-2 C4-1 C3-6 C3-5 C3-4 C3-9 C3-8 C3-7 C3-12 C2-3 GR/WH C1-12 D23 BL/RD C3-1 C3-2 C3-3 C1-4 C1-5 C1-11 CW GND BR C123PBS RD/BK SNSR-GND BR P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6TRF WH/RD C5TRR WH/BK C4TRL WH CCW C9PER BK/RD C8PBR BK/WH C7PBE BK EXTEND C177LS BL/RD P109LS GR/WH RETRACT UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C37STCC BL/BK C36STC BL C6-33 C6-34 C6-35 C6-22 C6-40 C6-23 C6-25 C6-13 C123PBS RD/BK SNSR-GND BR BL/RD C6-5 C6-6 C6-7 C6-8 C6-9 C6-31 C6-3 C6-2 C6-1 C6-12 C211PLO BL/BK S212PLO GR/BK GR/WH C6-4 P109ANG GR/WH C42LS OR/RD C40LS OR P134PWR RD C13DRE BL/RD C6-16 C6-38 C6-30 C6-21 P134PWR RD P210PWR BK C118LS OR C5-21 C5-20 C6-37 C6-36 6 OR BR YL RD OR WH BK WH BR RD BK WH BR RD BK WH BR RD RD BK BL 5 BK C29MS RD/WH C32BRK WH/RD C36STC BL C37STCC BL/BK C31EDC WH/BK C30EDC WH C3PBF RD/WH C2PBD RD/BK C1PBU RD BL BR C9PERF BK/RD C8PBR BK/WH C7PBE BK C6TRF WH/RD C5TRR WH/BK C4TRL WH 14 3 C1-10 C5-23 C5-24 14 13 NO NO 13 NO 5 13 14 15 8 7 16 6 LED BL/RD C144DER BL/WH RIGHT 5 10 8 6 2 6 7 8 15 16 18 17 C1-6 C1-3 C6-24 WH RD RD BL BR BK BK/WH BL BR BK BK/WH BK WH BR RD NC BR BK WH BR BK Y23 Y24 Y13 Y26 Y25 7 22 PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DESCENT ALARM LOOSE CABLE LED’S LSB2S LOOSE CABLE LIMIT SWITCH MOTOR STROKE BRAKE RELEASE STEER CW STEER CCW DRIVE EDC REVERSE DRIVE EDC FORWARD GROUND CR34 - PRIMARY BOOM SPEED REDUCTION RELAY PRIMARY BOOM FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP LST3O - BOOM UP/DOWN GROUND BOX - ZONE A OPERATION AND SPEED REDUCTION LIMIT SWITCH LSB1EO - BOOM EXTEND CAPACITY OPERATIONAL LIMIT SWITCH LSB1ES - BOOM EXTEND CAPACITY SAFETY LIMIT SWITCH LST3S - BOOM ANGLE STOWED GROUND BOX - ZONE A SAFETY LIMIT SWITCH PRIMARY BOOM EXTEND/RETRACT FLOW CONTROL PRIMARY BOOM RETRACT PRIMARY BOOM EXTEND TURNTABLE ROTATE FLOW CONTROL TURNTABLE ROTATE CCW TURNTABLE ROTATE CW LST1O DRIVE ENABLE LIMIT SWITCH LSB1RO BOOM RETRACT DRIVE / ROTATE SPEED LIMIT SWITCH LST2O ANGLE STOWED DRIVE SPEED REDUCTION LIMIT SWITCH S17 PRIMARY BOOM ANGLE SENSOR - OPERATIONAL S18 PRIMARY BOOM ANGLE SENSOR - SAFETY 8 PLATFORM ROTATE CCW 6 - 143 S-80 • S-85 • S-80X Part No. 122985 LEFT C143DEL BL/BK C209LED BL C208LED GR SNSR BR ZONE SELECT P109TS GR/WH C184PL WH 3 1 2 11 1 12 GND BR 2 4 19 20 J114 C6-11 13 NO 14 13 NO 14 14 13 NO NO U4 1 NC 13 NO 14 6 C129DA RD/BK 14 21 24 2 1 1 2 3 4 1 3 4 2 22 23 NO BK Y15 NC NC 21 22 21 22 21 22 23 24 NC Y22 1 2 3 4 J134 1 2 3 4 TB9 23 24 GR 6 J133 3 BL 2 1 2 TB7 2 1 J133 2 5 21 13 3 4 NO NO 14 13 H4 TB118 4 1 TB8 D29 Y21 Y12 Y6 Y5 Y3 Y4 Y2 Y27 P24FS WH P24FS WH 3 P134PWR RD C59CNK BL/BK C14PLU OR PLATFORM LEVEL C15PLD OR/BK UP C43JU GR DOWN C44JD GR/BK C17PRL GR C18PRR GR/BK CW CCW TB3 TB4 TB1 TB37 TB36 TB44 1 P24FS WH 4 CR53 R14 10W TB5 TB18 R14(A) 5W CR68 CR34 TB42 TB13 TB30 TB31 TB32 TB29 CR52 L46 P26ESTP BK C3-11 C4-2 TB134A P210PWR BK J1 J1 J1 D24 C59CNK BL/BK C4-3 C4-7 C4-8 C4-5 C4-6 TB59 TS59 TS62 TURNTABLE ROTATE C27AUX RD CR69 TB2 TB15 TB17 UP DOWN J22-11 J22-12 J22-9 J22-10 J22-2 J22-1 P134PWR RD P134PWR RD TS63 PRI. BOOM EXT. / RET. TS61 PRI. BOOM UP / DOWN R16 7.5W TS57 PLATFORM ROTATE P162JPW2-OR 5 TB14 TB43 D30 CW CCW J22-7 J22-8 J22-5 J22-6 J22-4 J22-3 Y20 Y19 Y70 P162JPW1-OR 2 CR30 J2 J2 Y71 2 2 J8 C159STC-BL/WH C164PES-RD/WH J8 JSGND1-BR 1 J25 JSGND2-BR 1 J127 NO J1 C160JPL-WH/RD 3 3 TS9 PLATFORM LEVEL JOYSTICK CONTROL CARD J3 4 C165TRS-WH/RD TS7 PLATFORM ROTATE LIFT / DRIVE (OPTION) C159STC-BL/WH 5 C163PLS-WH/BK 4 6 L50 L51 6 JC3 DRIVE / STEER 5 JC7 PRIMARY BOOM UP / DOWN EXTEND / RETRACT TURNTABLE ROTATE CR27 L47 TS14 DRIVE SELECT L1 TS15 DRIVE ENABLE TS75 ZONE SELECT NC ZONE B ZONE A P26ESTP BK A B C D E F G H I J K L M N Section 6 • Schematics September 2015 Electrical Schematic, S-80X, Continental TME27 Models GND BR C28TTA RD/BK C41RPM OR/BK C27AUX + FE RD September 2015 Section 6 • Schematics Electrical Schematic, S-80X, Continental TME27 Models 6 - 143 6 - 144 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Continental TME27 Models 6 - 145 6 - 146 6 - 146 8 RD-44C WH/BK-32C OR-134A(D) WH-134A(C) BK-GND BL-GND GR-GND TS63 C7PBE BK 7 ES0505D S-80 • S-85 • S-80X C B 6 Part No. 122985 D30 WH/RD C6-6 WH/BK C6-5 WH C6-4 RD/WH C6-3 RD/BK C6-2 RD C6-1 TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW PRI BOOM FLOW PRI BOOM DOWN PRI BOOM UP H 18/22 CABLE C4B C3B BASE TERMINATION BLOCK RD/BK TB44C WH/RD C3B-6 WH/BK C3B-5 WH C3B-4 RD/WH C3B-3 RD/BK C3B-2 RD C3B-1 C7B 6 5 4 3 2 1 12V TO PLATFORM WH/RD R14(A) WH/BK TS62-1 WH TS62-3 RD/WH CR34#30 RD/BK CR68-87A RD TS61-4 BL/RD C6-13 BK/RD C6-9 BK/WH C6-8 BK C6-7 G BK/RD R14(A) BK/WH TS63-3 BK CR69-87A WH-TB23B 1 OR/BK C4B-3 OR C4B-2 BL/RD C4B-1 BK/RD C3B-9 BK/WH C3B-8 BK C3B-7 3 15 14 13 9 8 7 BR-GND STUD BK-C32-5 CABLE RESTRAINT OR/BK TS59-3 OR TS59-1 WH C5-11 RD/12 BATT+ 3 2 1 F RD U16-2 RD-TB20A RD-TB20B GR-C5-8 E BK C5-5 WH/RD C5-23 WH/BK C5-20 WH C5-21 RD/WH C5-24 RD/BK C6-28 RD C5-6 LIMIT SWITCH - LST20 RPM / TACH SIGNAL LIMIT SWITCH - LSB1RO GAS/LP FUEL SELECT STEER CCW STEER CW ENGINE RPM (UNUSED) ENGINE START BRAKE RELEASE REVERSE / EDCFORWARD / EDC+ DRIVE SPEED PLATFORM LEVEL ALARM AUXILIARY POWER 12V POWER POWER TO PLATFORM KEYSWITCH PWR TO PLATFORM 12V IGNITION SUPPLY 12V BATT SUPPLY PLATFORM ROTATE CCW PLATFORM ROTATE CW PLATFORM LEVEL DOWN PLATFORM LEVEL UP DRIVE ENABLE PRI BOOM EXT/RET FLOW PRI BOOM RETRACT PRI BOOM EXT (UNUSED) BOOM SPEED REDUCTION LOOSE CABLE LED HORN AC GENERATOR (OPTION) (UNUSED) PRESSURE COMP ENABLE KEY SWITCH POWER (A) KEY SWITCH POWER (UNUSED) (UNUSED) BR-GND STUD D OR/RD C6-22 OR/BK C5-2 OR C6-40 BL/RD C5-10 BL/BK C6-37 BL C6-36 BK/RD C5-18 OR C6-31 BL/BK C6-11 GR C5-7 GR/WH C6-39 OR/RD C5-19 RD C6-23 RD C6-24 C6-30 C211LO BL/BK C6-38 C212LO GR/BK BR GND2 1 OR/RD TS62-5(D68) OR-BEACON (RIGHT) KS1-2 4 A CR69 C 155 OR/RD C4B-4(D67) WH-BEACON (LEFT) 134A RD C6-25 RD C32-1 134 RD C2B-6 GR/BK C32-8 133 BL/WH C32-3 132 118 OR CR34#86 59 BL/BK C3B-11 BL/BK L46(+) 46 GR C2B-5 45 GR/WH C2B-7 D29 TB2C-DESC. ALARM 44 GR/BK C4B-8 43 GR C4B-7 42 OR/RD C2B-4 41 OR/BK C2B-3 40 OR C2B-2 39 BL/RD C2B-1 BL/RD TS53-1(D11) 37 BL/BK C1B-11 36 BL C1B-10 35 BK/RD C1B-9 BK/RD TS54-1(D13) 34 33 BK C1B-7 BK TS52-3 32 WH/RD C1B-6 31 WH/BK C1B-5 30 WH C1B-4 29 RD/WH C1B-3 28 RD/BK C1B-2 RD TS51-4 27 RD C1B-1 24 WH KS1-1(D2) 23 WH/12 C7B-2 BK C32-4 BK/12 KS1-3 22 WH HM(+) 21 RD/12 CB2-2 20 RD/12 BATT+ 18 GR/BK C4B-6 GR/BK TS57-1 17 GR C4B-5 GR TS57-3 D TB2D R2PBD RD/BK TB7D R7PBE BK CR68 BK GND1 RD DL2 WH DL1 WH/BK C4B-9 B GND BR CR53 BK 5 CR52 RD/BK CR23 TB21C A TS61 C2PBD RD/BK C32 10 AMP FUSE F19 DRIVE LIGHT OPTION RELAY 3 BK-C7B-1 WH-TS51-5 RD-TS53-2 GN/BK-TB133C BR-GND RD - TB134C BL/WH-TB132C BK-TB22C 2 5 6 7 8 12 1 3 4 Section 6 • Schematics September 2015 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Continental TME27 Models I J 16/22 CABLE C2B C1B K LABEL L TS64 FUNCTION MANIFOLD ENGINE HARNESS C6 C5 TS51 AUXILIARY PUMP TS52 ENGINE START TOGGLE SWITCH TS53 FUEL SELECT TOGGLE SWITCH TS54 RPM SELECT TOGGLE SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH GROUND STUD 2 CB2 CONTROLS CIRCUIT BREAKER, 15A DESCRIPTION CR23 DRIVE LIGHT RELAY (OPTION) CR34 PRIMARY BOOM SPEED REDUCTION RELAY CR52 PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONAL CR53 PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONAL CR68 PRIMARY BOOM DOWN CUTOUT RELAY, SAFETY CR69 PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETY G6 HOUR METER KS1 KEY SWITCH L2 LED - CHECK ENGINE L46 LED - CABLE TENSION P1 EMERGENCY STOP BUTTON P4 FUNCTION ENABLE TOGGLE SWITCH R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS64 ENGINE FAULT CODE TEST TOGGLE SWITCH CABLE RESTRAINT HARNESS TO SWITCH PANEL M N 3 Part No. 122985 1 D13 TS62 6 3 2 5 2 1 L46 2 CB2 TS61 4 5 6 1 3 1 2 3 4 4 5 6 NO D101 NO 3 TS52 P4 TS51 4 3 2 1 2 3 1 WH-TS51-2 S-80 • S-85 • S-80X GN/BK-TB18D BL/BK-TB59D BR-GND STUD TO GROUND CONTROL BOX CONNECTIONS C BR-HM(-) RD-TB20D RD-P1-2 D WH-C32-6 RD-TB27D RD-TS61-2 WH-KS1-1 D4 OR/RD-TB155D WH/BK-TB5D WH/RD-R14(A) WH-TB4D GN-TB17D RD-TB1D RD/WH-R14 RD-R16 RD-TS51-1 RD/BK-CR52-30 BK-CR53-30 RD-R16 BK/WH-TB8D BK/RD-TB9D BK C6-12 OR-TB14D OR/BK-TB15D WH-ISM#10 BK-TB33D RD-C32-7 BL/RD-TB39D WH-TB23D RD-CB2-1 BK/RD-TB35D E D68 4 4 6 D11 1 1 3 TS63 3 BR-L46(-) BR-CR34#85 F 2 1 - G6 G TS57 1 2 TS53 B 3 H 2 3 TS54 D2 B1 + I 3 2B 2A 1 4 J TS59 NC NC 2 WH-TB21D BK-TB22D RD-L45(+) BL/RD-C5-15 WH/RD-TS62-4 WH/RD-TB6D RD-TS63-2 RD-TS61-2 K L2 1B KS1 R16 OR-TB118D RD/WH-TB3D L 1A R14(A) R14 M P1 86 BR-HM(-) RD/WH-TS61-1 N CR34 85 30 87 87A September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models B A 1 2 3 4 5 6 7 8 ES0505D 6 - 147 September 2015 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models 6 - 147 6 - 148 Section 6 • Schematics September 2015 Platform Control Box Wiring Diagram, S-80X, Continental TME27 Models 6 - 149 6 - 150 TS7-C18PRR GR/BK J22-3 TS7-C17PRL GR J22-4 TS9-C14PLU OR J22-7 TS9-C15PLD OR/BK J22-8 P2-P26ESTP BK C9P-1 TS2-P25FS RD C9P-3 J3-P24FS WH C9P-2 P2-P23PWR WH C7P-2 P2-P22PWR BK C7P-1 TS1-V155PCE OR/RD C4P-4 TS48-C49DLITE WH/BK C4P-9 TS7-C18PRR GR/BK C4P-6 TS7-C17PRL GR C4P-5 TS9-C14PLU OR C4P-2 TS9-C15PLD OR/BK C4P-3 J8-P109LS GR/WH C3P-12 L47-C59CNK BL/BK C3P-11 J22 LIFT / DRIVE SELECT (OPTION) OR/RD C40LS (SPLICE TO C40LS, C2P-2) WH TS14 WH TS7 7 J1-SNSR GND BR C1P-10 J1-P109ANG GR/WH C2P-9 TS3-C39LP BL/RD C2P-1 P3-C46HRN GR C2P-5 TS47-C45GEN GR/WH C2P-7 C1P(GY) C2P(BK) C3P(GR) C4P(BR) FOOT SWITCH ES0505D 12V BATTERY BK P2 C40LS OR C2P-2 C6TRF WH/RD C3P-6 C123PBS RD/BK C2P-8 C7PBE BK C3P-7 C13DRE BL/RD C4P-1 C8PBR BK/WH C3P-8 C42LS OR/RD C2P-4 C9PERF BK/RD C3P-9 C41RPM OR/BK C2P-3 C30EDC+ WH C1P-4 C1PBU RD C3P-1 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C36STC BL C1P-10 C3PBF RD/WH C3P-3 C37STCC BL/BK C1P-11 C4TRL WH C3P-4 C32BRK WH/RD C1P-6 C5TRR WH/BK C3P-5 C29MS RD/WH C1P-3 LS18-C177LS BL/RD C1P-12 TS1-C27AUX RD C1P-1 TS2-C33STR BK C1P-7 TS4-C35RPM BK/RD C1P-9 L48-C28TTA RD/BK H1 J1 C28TTA RD/BK 4 WH L1 C2P-9 P109ANG GR/WH JC7-4 C165TRS WH/RD C2P-10 SNSR GND BR JC7-3 C164PES RD/WH JC7-2 P162JPW2 OR JC7-5 C163PES WH/BK JC7-1 JSGND2 BR JC3-4 C160JPL WH/RD JC3-2 P162JPW1 OR JC3-3 C159STC BL/WH JC3-1 JSGND1 BR TS15-C144DER BL/WH 1 WH C9P-2 JC3-5 C159STC BL/WH CAN HI CAN LOW L51(-) C169LED1 GR L50(-) C169LED2 GR TS75-1 P109TS GR/WH C3P-12 P109LS BL/WH C1P-12 C177LS BL/WH TS75-2 C184PL WH TS75-3 SNSR BR 1 TS15-C143DEL BL/BK L1-C13DRE(A) BL/RD TS14-C29MS RD/WH RD C2P-6 Part No. 122985 S-80 • S-85 • S-80X 6 - 150 1 OPTION C9 H1 6 1 OPTION C7P + J22-1,2,9,10,11 AND 12 D40 6 11 J8 J7 J1 1 2 3 RD LS18 3 CONTROL HARNESS TO PLATFORM SWITCH PANEL J2 2 9 J3 U13 ALC-500 N M L K J I H G F E D C B A September 2015 Section 6 • Schematics Platform Control Box Wiring Diagram, S-80X, Continental TME27 Models 1 C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 5 GROUND BR BATGND (GROUND STUD) CR27 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 8 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models N M L K J I H G F E D C B A CONTROL HARNESS TO PLATFORM BOX 1 RD LS18 BK C7P-1 WH C7P-2 BK C9-1 BK J3-3 WH/RD J1-4 BL/WH J1-5 OR J1-13 BR J1-14 GR J8-5 BR J8-8 GR/WH J8-6 WH J8-2 GR J8-10 TS15 BL/RD J1-16 WH C9P-2 BL/BK J1-7 BL/WH J1-6 RD/BK H1 (D40) TS4 RD C9P-3 RD C1P-1 OR/RD C4P-4 BK/RD C1P-9 BL/RD C2P-1 BK C1P-7 RD/WH J1-8 BR GND STUD BL/BK C3P-11 GR C4P-5/J22-4 GR/BK C4P-6/J22-3 RD/WH J1-2 OR J1-11 BR J1-12 WH/BK J1-3 WH/RD J1-1 OR C4P-2/J22-7 OR/BK C4P-3/J22-8 GR C2P-5 TS3 1 2 D12 JC3 D10 JC7 TS2 3 + 6 1 + L47 6 1 4 TS1 TS9 + + TS7 P3 + TS14 NO L48 L51 BK RD TS75 BK NC P2 L50 RD BK 5 RD ES0505D 6 COMPONENT INDEX CR27 BRAKE CIRCUIT (LIFT / DRIVE OPTION) TS2 ENGINE START TOGGLE SWITCH CR30 LIMIT SWITCH (LIFT / DRIVE OPTION) TS3 FUEL SELECT TOGGLE SWITCH H1 TILT ALARM TS4 RPM SELECT TOGGLE SWITCH JC3 JOYSTICK - DRIVE / STEER TS7 PLATFORM ROTATE TOGGLE SWITCH JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH L1 LED - DRIVE ENABLE TS14 DRIVE SPEED TOGGLE SWITCH L47 LED - CABLE TENSION TS15 DRIVE ENABLE TOGGLE SWITCH L48 LED - TILT ALARM TS75 ZONE SELECT TOGGLE SWITCH L50 LED - ZONE B, 500 LB CAPACITY U13 ALC500 JOYSTICK CONTROLLER CARD L51 LED - ZONE A, 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH 7 NOTE: DASHED LINES INDICATE OPTIONS. 1 ROCKER / STEER OPTION 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 151 September 2015 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models 6 - 151 6 - 152 Section 6 • Schematics September 2015 Continental TME27 Engine Harness 6 - 153 6 - 154 Section 6 • Schematics September 2015 Continental TME27 Engine Harness A B C D E ORANGE 18 G H I J K BLACK/LT GREEN 18 A YELLOW/GRAY 18 B LT GREEN/BLACK 18 1 F TX B 5V C BLK/LT GREEN 18 RTN D M ECT OIL PRESSURE SWITCH BLACK/LT GREEN 18 1 TAN 18 2 LT GREEN/RED 18 3 LT GREEN 18 4 RX A DK GREEN 18 LT GREEN/RED 18 L TMAP SPLICE WITHIN 6" OF CONNECTOR COMM BLACK/LT GREEN 18 DK GREEN/ORANGE 18 PINK/DK GREEN 16 BLACK/WHITE 16 A B C D BLACK/LT GREEN 18 A TAN/DK GREEN 18 B PINK/DK GREEN 16 C BLACK/YELLOW 16 D PRE CAT HEGO POST CAT HEGO BLUE/WHITE 18 1 WHITE/ORANGE 18 2 WHITE/ORANGE 18 3 BLACK 16 6 2 PINK/YELLOW 16 7 WHITE/ORANGE 18 BLUE/WHITE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH 1 DK GREEN/ORANGE 18 2 TAN/DK GREEN 18 3 4 5 PURPLE/LT BLUE 18 6 LT BLUE/DK BLUE 18 7 LT GREEN 18 8 9 DK BLUE 18 10 PURPLE/YELLOW 18 11 WHITE/RED 18 12 13 WHITE/ORANGE 18 14 WHITE/ORANGE 18 15 BLUE/WHITE 18 CAN 2 CAN 2 + CAN 2 TERM + 5V EXT 5V RTN CRK POS CRK NEG CAM POS CAM NEG SPD POS SPD NEG KNK 1 + KNK 1 KNK 2 + KNK 2 - 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 4 5 6 SPK COIL 1A SPK COIL 1B SPK COIL 2A SPK COIL 2B SPK COIL 3A SPK COIL 3B SPK COIL 4A SPK COIL 4B IAT ECT EGT AUX DIG 1 AUX DIG 2 AUX DIG 3 V SWITCH 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 AUX ANA PU1 AUX ANA PU2 AUX ANA PU3 5V EXT 5V RTN GOV 1 GOV 2 OIL P AUX ANA PUD1 PC TX PC RX PULSE IN TACH V BAT PROT V BAT 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 INJ1 LS INJ2 LS INJ3 LS INJ4 LS INJ5 LS INJ6 LS INJ7 LS INJ8 LS GROUND STARTER RELAY EGOH 1 EGOH 2 EGOH 3 FUEL LOCKOFF BUZZ AUX PWM5 AUX PWM5 RECIRC V BAT MIL GROUND DBW+/STEP + DBW-/STEP FPUMP AUX PWM3 RECIRC AUX PWM3 AUX PWM1 AUX PWM2 AUX PWM4 AUX PWM4 RECIRC 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 COBRA EPR PURPLE/WHITE 18 PURPLE/WHITE 18 WHITE/PURPLE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH WHITE/PURPLE 18 C CRANK SENSOR WHITE/RED 18 A LT GREEN/RED 18 BLACK/LT GREEN 18 PURPLE/WHITE 18 WHITE/PURPLE 18 GRAY/BROWN 18 PURPLE/ORANGE 18 LT GREEN/RED 18 GRAY/BROWN 18 BLACK/LT GREEN 18 A GRAY/BROWN 18 B PURPLE/ORANGE 18 PURPLE/ORANGE 18 B LPG TEMP CAM SENSOR C TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH BLK/LT GREEN 18 JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR YELLOW 18 YELLOW/RED 18 YELLOW/BLACK 18 YELLOW/LT GREEN 18 BLACK/LT GREEN 18 LT GREEN/WHITE 18 LT GREEN/RED 18 WHITE/LT GREEN 18 TAN 18 YELLOW/GRAY 18 1 2 3 4 GASOLINE SENSOR INTERFACE TAN/BROWN 18 TAN/ORANGE 18 BLK/LT GREEN 18 LT GREEN/RED 18 PINK/WHITE 18 LT BLUE/DK BLUE 18 PURPLE/LT BLUE 18 PINK/TAN 18 DK BLUE/YELLOW 18 LT GREEN/WHITE 18 GRAY/DK BLUE 18 GRAY/WHITE 18 LT GREEN/BLACK 18 WHITE/LT GREEN 18 DK GREEN 18 ORANGE 18 1 2 3 4 5 6 VEHICLE INTERFACE 2 DEUTSCH DT06 PLUG DBW THROTTLE CONNECTOR YELLOW/LT GREEN 18 PINK/YELLOW 16 RED/TAN 16 BROWN/BLUE 16 BROWN/GREEN 16 BROWN/YELLOW 16 BROWN/WHITE 16 LT GREEN/RED 18 DK BLUE 18 BLACK/LT GREEN 18 DK BLUE/YELLOW 18 PURPLE/YELLOW 18 BLUE/GREEN 14 BLACK 16 1 2 3 4 5 6 7 8 9 WHITE/ORANGE 18 10 BLUE/WHITE 18 11 12 VREF FPP1 ANA RETURN AUX ANA PU1 FPP2 IVS START IN (AUTOCRANK) GROUND NOT USED (PLUGGED) NOT USED (PLUGGED) CAN HIGH CAN LOW NOT USED (PLUGGED) BLACK 16 WHITE/BLUE 18 BLACK/WHITE 16 BLACK/YELLOW 16 VEHICLE INTERFACE 1 DEUTSCH DT04 RECEPTACLE WHITE/BLACK 18 76 77 78 79 RED/TAN 16 80 LT BLUE/BLK 18 81 BLACK 16 82 PINK/WHITE 18 83 TAN/ORANGE 18 84 TAN/BLACK 18 85 PINK/YELL 16 86 BLACK/RED 16 87 RED/BLACK 18 88 GRAY/RED 18 89 PINK/BLACK 18 90 BLACK 16 BLACK 16 WHITE/BLACK 18 BLACK 12 PINK 18 RED/BLACK 18 BLACK/RED 16 PINK/YELLOW 16 LT BLUE/PINK 14 YELLOW/LT GREEN 18 GRAY/DK BLUE 18 GRAY/WHITE 18 LT BLUE/BLACK 18 ORANGE 18 TAN/BROWN 18 GRAY/RED 18 GROUND A PINK/TAN 18 B FUEL LOCKOFF WHITE/ORANGE 18 STARTER RELAY TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH 30 87 PINK/YELLOW 16 RED 14 RED/TAN 14 WHITE/BLUE 18 30 87 PINK/DK GREEN 16 PINK/DK GREEN 16 A B C COIL 4 D A B C A D COIL 3 B C D COIL 2 NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B PINK/DK GREEN 16 15A 86 85 F3 POWER RELAY BROWN/BLUE 16 PINK/TAN 18 F2 PINK 18 BROWN/WHITE 16 5A RED/TAN 14 F1 BROWN/GREEN 16 RED 14 RED 12 BROWN/YELLOW 16 BAT + 20A RED 14 S-80 • S-85 • S-80X INJECTOR 4 INJECTOR 3 INJECTOR 2 NOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER Part No. 122985 INJECTOR 1 A C COIL 1 PINK/DK GREEN 16 BLACK/LT GREEN 18 B YELLOW 18 BLACK 16 85 PINK/YELLOW 16 FUEL PUMP RELAY PINK/DK GREEN 16 TAN/BLACK 18 F4 15A 86 BLACK/LT GREEN 18 87 PINK/YELLOW 16 PINK/TAN 18 BLACK 16 30 BLUE/GREEN 14 STARTER RELAY YELLOW/LT GREEN 18 RED 14 87 PINK/DK GREEN 16 85 YELLOW/BLACK 18 PINK/BLACK 18 87A LT BLUE/PINK 14 BLACK/LT GREEN 18 86 BLACK 16 30 PINK/DK GREEN 16 WHITE 14 PINK/TAN 18 15A EPR RELAY BLACK/LT GREEN 18 85 BLACK 16 86 PINK/YELLOW 16 YELLOW/RED 18 RED/TAN 14 WHITE/BLUE 18 F5 PINK/DK GREEN 16 PINK/YELLOW 16 6 - 154 B BLK/LT GREEN 18 JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR BLUE/WHITE 18 8 GROUND LT GREEN/RED 18 A SPLICE WITHIN 6" FROM CONNECTOR WHITE 14 7 CAN + VBAT BLUE/WHITE 18 WHITE/ORANGE 18 BLACK 16 3 EGO 1 EGO 2 EGO 3 EGO 4 TPS1/STEP2 + TPS2/STEP2 MAP AUX ANA PD1 FPP1 FPP2-IVS AUX ANA PD2 AUX ANA PD3 CAN 1 TERM + CAN 1 + CAN 1 - CAN CAN + TERM D 1 2 3 4 5 6 7 8 9 10 11 12 VSW IGN OUT FUEL PUMP FUEL PUMP + START COMMAND TACH GOV SELECT 1 GOV SELECT 2 MIL ESL/TEST SWITCH FUEL SELECT TEMP SENDER N September 2015 Section 6 • Schematics Platform Level Cutout, CTE Option N M L K J I H G F E D C B A PLATFORM BOX 1 TS9-1 TS9-3 2 C14PLU OR C15PLD OR/BK C42LS OR/RD J2-4 3 C2P-4 CR20 NO CR21 NO 4 C15PLD OR/BK C14PLU OR J22-8 J22-7 6 Y20 C4-3 C4-2 Y19 5 7 TB15 TB14 PLATFORM LEVEL UP PLATFORM LEVEL DOWN GROUND 8 GROUND BOX MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED Part No. 122985 S-80 • S-85 • S-80X 6 - 155 September 2015 Section 6 • Schematics Platform Level Cutout, CTE Option 6 - 155 6 - 156 Section 6 • Schematics September 2015 Continental Options Schematic 6 - 157 6 - 158 Section 6 • Schematics September 2015 Continental Options Schematic A B C D E F G H I J P26ESTP BK 1 FS1 P2 C9P-1 P22BAT BK BK K L M N P26ESTP BK C9P-3 P25FS RD P25FS RD P24FS WH P25FS RD P24FS WH P24FS WH C9P-2 F18 10 A TS43 CONTROL BOX HEATER P134PWR RD WH L30 L30 BK R21 10W BK THS1 NC WH 2 TS48 DRIVE LIGHT TS49 WORK LIGHT R22 10W 3 C4-9 PLATFORM BOX GROUND 4 TB21 R21IGN WH C49LITE WH/BK 5 F19 10A G2 C25PSR BL/BK 6 G3 C26TSR GR/BK 12 CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 G1 CR23 L29 L29 HARNESS 7 ES0505C Part No. 122985 DRIVE LIGHTS S-80 • S-85 • S-80X WORK LIGHTS 6 - 158 PLATFORM CONTROL BOX HEATER COOLANT TEMP. GAUGE OIL PRESSURE GAUGE VOLT METER 8 September 2015 Section 6 • Schematics Deutz and Perkins Options Schematic N M L K J I H G F E D C B P26ESTP BK P2 P22BAT BK FS1 C9P-1 BK A P26ESTP BK C9P-3 P25FS RD P24FS WH P25FS RD P25FS RD P24FS WH P24FS WH C9P-2 1 F18 10 A TS43 CONTROL BOX HEATER P134PWR RD WH L30 L30 BK BK R21 10W WH THS1 NC TS47 GENERATOR TS48 DRIVE LIGHT TS49 WORK LIGHT 2 R22 10W 3 C2-7 C4-9 PLATFORM BOX GROUND TB21 TB45 4 C10-2 R21IGN WH C6-39 G1 C49LITE WH/BK F19 10A G3 5 G2 C10-1 C45GEN GR/WH C25PSR WH/BK C26TSR WH/RD C10-4 CR23 6 C10-3 L29 L29 7 Y29 CR46 ES0503D ES0504D HYDRAULIC GENERATOR OPTION BELT DRIVEN GENERATOR OPTION DRIVE LIGHTS WORK LIGHTS OIL PRESSURE GAUGE VOLT METER COOLANT TEMP. GAUGE PLATFORM CONTROL BOX HEATER 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 159 September 2015 Section 6 • Schematics Deutz and Perkins Options Schematic 6 - 159 6 - 160 Section 6 • Schematics September 2015 12 kW Hydraulic Generator Wiring Diagram 6 - 161 6 -162 Section 6 • Schematics September 2015 12 kW Hydraulic Generator Wiring Diagram A B C D E F G H I 12.5 KW HYDRAULIC GENERATOR 1 NEUTRAL BUSS BAR L2 L1 2 L3 Y X 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI 208 VAC OUTLET L2 RED 3 ORANGE N 3 6 5 4 1 2 L3 RED Z WHITE N BLACK L1 4 BLACK GREEN BLACK 12GA GREEN 20 AMP CIRCUIT BREAKER NEMA 4 CONTROL BOX GROUND STUD ON PANEL 5 BLACK 12GA SILVER 8 GA 4 CONDUCTOR 8 GA 5 CONDUCTOR BRASS 120 VAC GFI 6 GREEN 12GA 12 GA 3 CONDUCTOR 7 110 VAC GFI ENCLOSURE SILVER BRASS WHITE 8 GREEN GREEN BLACK ES0506B 6 - 162 12 GA 3 CONDUCTOR S-80 • S-85 • S-80X Part No. 122985 J K L M N September 2015 Section 6 • Schematics 12 kW Hydraulic Generator Electrical Schematic L K J I H G E D C B A 1 FOOTSWITCH P2 ALC-500 F P25FS-RD P26ESTP-BK P22PWR-BK P24FS-WH 19 RPM HI RPM LO 2 D12 OMRON RELAY CR66 5 SW INPUT 8 TIME DELAY MODULE 4S C2B-7 C5-21 C5-20 C5-4 WH 3 GND C45GEN GR/WH 4 2 COM TB24 3 C1B-9 C1B-3 C1B-4 C1B-5 1 N.O. C32BRK WH/RD C35RPM BK/RD C29MS RD/WH C30EDC WH C31EDC WH/BK 8 N.C. C2P-7 C1P-9 C1P-3 C1P-4 C1P-6 C32BRK WH/RD C1P-5 TS47 GENERATOR ON 7 20 15 16 TS4 5 124 ohms C5-21 C5-20 1 124 ohms 8 BK 16-2 NC Y75 RS232TxD RS232RxD C1TxD C2RxD C3/BOOT C6-39 F1DIG IN 0 F2DIG IN 1 GENERATOR ON F3DIG IN 2 SX Controller BRAKE RELEASE E1NOT USED E2NOT USED E3NOT USED C41RPM OR/BK D1ANALOG 0 JOYSTICK D2ANALOG 1 NC D3C41 RPM CR4 HIGH IDLE RELAY BR-2 (16-2) N.O. A B C MOTOR STROKE VALVE DRIVE EDC + DRIVE EDC - Y75 PS4 PRESSURE SWITCH 200 PSI BYPASS COIL C B A D U4 RD-1 7 6 BK-2 5 OMRON RELAY CR50 C57 6 C45GEN GR/WH C57 TB41 C5-12 OR/BK 4 TB45 C5-12 2 TB21 C5-23 3 D65 C5-18 1 B1VALVE 0 FWD COIL B2VALVE 1 NC B3DIGITAL OUTPUT BYPASS D98 C5-24 V151HG GR V150HG GR/BK A1BATTERY + A2SENSOR POWER +5 VDC A3BATTERY- 6 2 TB32 TB35 5 1k ohms TB29 2 4 C1B-4 C1B-5 D99 3 3 M 1 N 7 8 PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD DIVERTER MANIFOLD Part No. 122985 S-80 • S-85 • S-80X 6 - 163 September 2015 Section 6 • Schematics 12 kW Hydraulic Generator Electrical Schematic 6 - 163 6 - 164 Section 6 • Schematics September 2015 Belt Driven Generator Option 6 - 165 6 - 166 Section 6 • Schematics September 2015 Belt Driven Generator Option A B C D E F G H I J K L M N R20BAT RD VOLTAGE REGULATOR 1 NEUTRAL WH GND BR LINE BK FIELD BK/WH GENERATOR 2 BELT DRIVEN GENERATOR CB4 LINE BK TG2 NEUTRAL WH CB6 P20BAT LINE LINE BK 30A GND CR46 87A 30 + BATTERY 86 120VAC / 60HZ GFI OUTLET GND GR TG4 TG1 FIELD GR 3 15A NEUTRAL WH VOLTAGE REGULATOR NEU 87 C45GEN 85 TO GBOX CB4 12.5A- 220V 15A- 120V A B C45GEN TG3 - GND BR BATTERY+ A 120 VAC / 60 HZ with Regulator B TG CR46 4 BATTERY1 2 3 4 OUTLET 5 R20BAT RD VOLTAGE REGULATOR NEUTRAL WH GND BR LINE BK B A FIELD BK/WH 6 CB6 30A GENERATOR PIN# COLOR 1 WH 2 GR 3 BK 4 CIRCUIT # NEUTRAL FIELD LINE PLUG BELT DRIVEN GENERATOR CB2 LINE BK TG2 NEUTRAL WH 7 12.5A FIELD GR CB6 30A GND CR46 87A 30 + BATTERY 86 NEUTRAL WH C45GEN 85 - 8 220 VAC / 50 HZ with Regulator 6 - 166 S-80 • S-85 • S-80X NEU 87 TG3 GND BR 220VAC / 50HZ GFI OUTLET GND GR TG4 TG1 P20BAT LINE LINE BK Part No. 122985 TO GBOX 1 2 3 4 5 VOLTAGE REGULATOR PIN# COLOR 1 RD 12GA 2 WH 12GA 3 BR 12GA 4 BK 12GA 5 BK/WH 14GA CIRCUIT# R20BAT NEUTRAL GND LINE FIELD September 2015 Section 6 • Schematics Relay and Fuse Panel Legend N M L K J I H G F E D C B A Deutz TD2011L04i 5 6 8 7 NOT USED B1BAT F22 F17 CR17 CR2 F7 F20 1 2 4 3 P24PWR R21IGN CR1 CR5 CR15 CR39 CR3 02GND LABEL DESCRIPTION CR1 START RELAY CR2 IGNITION / FUEL RELAY CR3 HIGH IDLE RELAY CR5 HORN RELAY CR15 GLOW PLUG RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39 AUXILIARY PUMP RELAY CR39 AUXILIARY PUMP RELAY F7 FUSE, 30A, OIL COOLER FAN / HORN F17 FUSE, 30A, ENGINE / AUXILIARY PUMP F20 FUSE, 20A, ENGINE RPM SOLENOID F22 FUSE, 60A, GLOW PLUGS 1 5 6 8 7 B1PBAT F17 CR17 CR39B F7 1 2 B3PBAT 4 3 2 R21PIGN CR5 CR1 CR2 CR39A 02PGND 3 Continental TME27 5 6 8 7 B1BAT F22 F17 CR17 CR2 CR4 F7 CB20 1 2 4 3 P24PWR R21IGN CR1 CR5 02GND CR15 CR39 CR3 LABEL DESCRIPTION CR1 START RELAY CR2 IGNITION / FUEL RELAY CR5 HORN RELAY Perkins 804D-33 CR17 HYDRAULIC OIL COOLER RELAY CR39A AUXILIARY PUMP RELAY LABEL DESCRIPTION CR39B AUXILIARY PUMP ENGINE CUTOUT RELAY CB20 CIRCUIT BREAKER, 10A, ENGINE RPM SOLENOID F7 FUSE, 30A, OIL COOLER FAN / HORN CR1 START RELAY F17 FUSE, 30A, ENGINE / AUXILIARY PUMP CR2 IGNITION / FUEL RELAY CR3 HIGH IDLE RELAY CR4 ENGINE RPM SOLENOID RELAY CR5 HORN RELAY CR15 GLOW PLUG RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39 AUXILIARY PUMP RELAY F7 FUSE, 30A, OIL COOLER FAN / HORN F17 FUSE, 30A, ENGINE / AUXILIARY PUMP F22 FUSE, 60A, GLOW PLUGS 4 5 6 7 8 Part No. 122985 S-80 • S-85 • S-80X 6 - 167 September 2015 Section 6 • Schematics Relay and Fuse Panel Legend 6 - 167 6 - 168 Section 6 • Schematics September 2015 Hydraulic Schematic, 2WD Models 6 - 169 6 - 170 Section 6 • Schematics September 2015 Hydraulic Schematic, 2WD Models A B C D E F G H I TURNTABLE ROTATE 3 gpm / 11.4 L/min PRIMARY LIFT CYLINDER 15 gpm / 57 L/min (UP) 8 gpm / 30 L/min (DOWN) 1 BRAKE/2 SPEED MANIFOLD 0.025 inch 0.6 mm BB 2 BD MEDIUM PRESSURE FILTER 51 psi 3.5 bar T2 0.030 inch 0.8 mm S1 2SPEED TEST 1 2 B M2 X X 3750 psi 256 bar E T5 P1 SW1 SW2 L2 L1 S EXT F PB G G PR2 PR1 PLS1 PLS2 SI PTEST PR2 PR1 2400 psi 165 bar SN SP EA 2400 psi 165 bar SS ST T1 SC SD SM 950 psi 66 bar EF EB SH SE 25 psi 2 bar C SR SO L1 P4 P4 T4 T4 0.3 gpm 1.1 L/min 0.6 gpm 2.3 L/min 30 psi 2 bar 3.5 gpm 13 L/min EH EE EG 0.8 gpm 3 L/min S80 PLATFORM MANIFOLD SL 3.5 gpm 13 L/min FUNCTION MANIFOLD 30 psi 2 bar T2 OIL COOLER ST2 OSC RESERVOIR X T3 ST1 X P3 OSC TEST 5 6 8 X 6A X 8A 3 1 2 7 4 5 2B 7 4 5 HYDRAULIC ROTARY COUPLER X 8B X 6B 8C 6C 3 X 2A 1 COUNTERBALANCE VALVES 2C RATIO 6 TEST RIGHT REAR A DF DC M2 7 50% 0.070 inch 1.8 mm 3000 psi / 207 bar 1:1 3500 psi / 241 bar D 4.5:1 1000 psi / 69 bar E 4.5:1 3500 psi / 241 bar RIGHT F 3:1 3300 psi / 228 bar STEER CYLINDER G 3:1 3000 psi / 207 bar DE 280 psi 19 bar LEFT DB G G G T A LEFT REAR B A IN M3 OUT B OC TRACTION MANIFOLD OSCILLATE VALVE 6 - 170 G DD CDL 8 RIGHT DA 50% M1 1000 psi / 69 bar 1.5:1 A CDR 3:1 B M4 B PRESS A C B LEFT S-80 • S-85 • S-80X Part No. 122985 J2 ED C SF 3200 psi 221 bar S J1 SQ SG RETURN FILTER PLM2 RET SK 1.7 gpm 6.4 L/min FUNCTION PUMP 38cc 4 E R D EC SJ SB 9 PA MASTER CYLINDER SA AUXILIARY PUMP E F JIB BOOM CYLINDER (S-85 OPTION) B V1 P2 2900 psi 200 bar L N 102 psi 7 bar M 3 PLATFORM ROTATE SLAVE CYLINDER PLM1 250 psi 17 bar M RD RC V2 B 310 psi 21 bar L PLATFORM LEVEL CYLINDERS BOOM EXTEND / RETRACT 16 gpm / 61 L/min (EXTEND) 7 gpm / 26.5 L/min (RETRACT) A HIGH PRESSURE FILTER DRIVE PUMP K A B BC BRAKE RB FUNCTION ENABLE VALVE CP A BA A RA J HS0166C OSCILLATE CYLINDERS September 2015 Section 6 • Schematics Hydraulic Schematic, 4WD Models N M L K J I H G F E TURNTABLE ROTATE 3 gpm / 11.4 L/min 0.025 inch 0.6 mm BB A L PA E A JIB BOOM CYLINDER (S-85 OPTION) PLATFORM ROTATE F E B B PLATFORM LEVEL CYLINDERS SLAVE CYLINDER A R 1 F PB G G D B T2 A PR2 HIGH PRESSURE FILTER DRIVE PUMP 0.030 inch 0.8 mm S1 BC BRAKE RB FUNCTION ENABLE VALVE CP BD BA A RA MEDIUM PRESSURE FILTER 51 psi 3.5 bar C BOOM EXTEND / RETRACT 16 gpm / 61 L/min (EXTEND) 7 gpm / 26.5 L/min (RETRACT) PRIMARY LIFT CYLINDER 15 gpm / 57 L/min (UP) 8 gpm / 30 L/min (DOWN) BRAKE / 2 SPEED MANIFOLD D TEST 2SPEED B V2 1 2 M2 X 102 psi 7 bar T5 P1 SW1 SW2 PTEST SH SE 30 psi 2 bar T2 EF EB EH SP EA 2400 psi 165 bar SS SM 950 psi 66 bar P4 P4 T4 T4 EE 0.3 gpm 1.1 L/min 0.6 gpm 2.3 L/min 30 psi 2 bar 3.5 gpm 13 L/min EG 0.8 gpm 3 L/min 4 PLATFORM MANIFOLD SL 3.5 gpm 13 L/min FUNCTION MANIFOLD X T3 ST2 ST1 OSC RESERVOIR C SR ST SD OIL COOLER 2400 psi 165 bar SF SN SC J2 3 T1 25 psi 2 bar J1 ED C SO S PR1 RET SK 3200 psi 221 bar RETURN FILTER PR2 SQ SG L1 S PLM2 EC SJ SI SB FUNCTION PUMP 38cc 9 EXT 1.7 gpm 6.4 L/min AUXILIARY PUMP E L2 L1 SA P2 2900 psi 200 bar PLS1 PLS2 PLM1 M 3750 psi 256 bar 2 MASTER CYLINDER V1 B 250 psi 17 bar 310 psi 21 bar PR1 RD RC X P3 OSC TEST 5 6 8 3 1 2 7 4 5 2B 7 4 5 HYDRAULIC ROTARY COUPLER 8B 8C 6B 6C 6A 8A 3 1 2A 2C COUNTERBALANCE VALVES RATIO TEST RIGHT REAR DC M7 A B DF A A B RIGHT FRONT M8 LEFT STEER CYLINDERS DJ CDR RIGHT DI M6 B 6 PRESS A 3:1 1000 psi / 69 bar B 1.5:1 3000 psi / 207 bar C 1:1 3500 psi / 241 bar D 4.5:1 1000 psi / 69 bar E 4.5:1 3500 psi / 241 bar F 3:1 3300 psi / 228 bar G 3:1 3000 psi / 207 bar 7 M5 50% 0.040 inch 1 mm 50% 280 psi 19 bar DA DN DK 50% 50% 50% DB DG DD DL M3 G 50% G G G M4 B A RIGHT DM 0.040 inch 1 mm CDL LEFT REAR LEFT 0.040 inch 1 mm DE A DH M1 M2 T 8 B LEFT FRONT IN A OUT B OC TRACTION MANIFOLD HS0166C OSCILLATE CYLINDERS OSCILLATE VALVE Part No. 122985 S-80 • S-85 • S-80X 6 - 171 September 2015 Section 6 • Schematics Hydraulic Schematic, 4WD Models 6 - 171 6 - 172 September 2015 Section 6 • Schematics 12 kW Hydraulic Generator Hydraulic Schematic K J I H G F E D C B A 1 B DRIVE PUMP 3.5 GPM / 13.25L/min OIL COOLER A CASE 2 PMP B CLR PMP A WELDER MANIFOLD 3 CW 0.031 inch / 0.79 mm CV PRESSURE SWITCH 200 PSI / 13.8 BAR N.O. 4 CU CX CZ 270 PSI / 18.6 BAR @ 3.5 GPM / 13.25 L/min 5 CY G2 MTR B MTR A G1 6 HYDRAULIC ROTARY COUPLER L 3 M 1 N 7 TANK 8 21CC 21 GPM / 79.5 L/min G2 G1 HS0166C GENERATOR 12.5 KW Part No. 122985 S-80 • S-85 • S-80X 6 - 173 September 2015 Section 6 • Schematics 12 kW Hydraulic Generator Hydraulic Schematic 6 - 173 6 - 174 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. 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