Genia S-80 Boomlift - Service Manual - Rentalex

Service Manual

Part No. 122149

Rev B1

June 2015

Serial Number Range

from S8007-5381to S8008-7999S-80

S-85

TM

TM

June 2015

S-80 • S-85 Part No. 122149

Introduction

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Genie S-80 and S-85 Service Manual(from serial number 101 to 785) ..........34032

Genie S-80 and S-85 Service Manual(from serial number 786 to 965) ..........52270

Genie S-80 and S-85 Service Manual(from serial number 966 to 3081) ........72062

Genie S-80 and S-85 Service Manual(from serial number 3082 to 3737) ......77832

Genie S-80 and S-85 Service Manual(from serial number 3738 to 5380) ... 111165

Introduction

Copyright © 1994 by Genie Industries

122149 Rev B February 2012Sixth Edition, First Printing

"Genie" and "S" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

ii

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate operator'smanual on your machine before attempting anymaintenance or repair procedure.

This manual provides detailed scheduled maintenanceinformation for the machine owner and user. It alsoprovides troubleshooting fault codes and repairprocedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However, severalprocedures require specialized skills, tools, liftingequipment and a suitable workshop. In these instances,we strongly recommend that maintenance and repair beperformed at an authorized Genie dealer service center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degree ofaccuracy possible. However, continuous improvement ofour products is a Genie policy. Therefore, productspecifications are subject to change without notice.

Readers are encouraged to notify Genie of errors andsend in suggestions for improvement. Allcommunications will be carefully considered for futureprintings of this and all other manuals.

Contact Us:

http://www.genielift.come-mail: [email protected]

June 2015

Part No. 122149 S-80 • S-85

Revision Date Section Procedure / Schematic Page / Description

B 2/2012 2 - Spec. 2-1

3 - Maint. 3-1

4 - Repair 4-3 to 4-6

6 - Schem. 6-7, 6-11, 6-21, 6-25, 6-35, 6-39

B1 6/2015 4 - Repair 4-476 - Schem. 6-68, 6-69

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 numberhighlighted in blue to view the update.

Revision History

June 2015

S-80 • S-85 Part No. 122149

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 numberhighlighted in blue to view the update.

June 2015

Part No. 122149 S-80 • S-85 iii

Serial Number Legend

Introduction

S80 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5

CAN B.354.4

Model: S-80

Serial number: S8006-12345

Electrical schematic number: ES0274

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 80 ft/ 24.38 m

Maximum platform reach : 72 ft 5 in/ 22.07 m

Serial number(stamped on chassis)

Serial label(located under cover)

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S-80 • S-85 Part No. 122149

This page intentionally left blank.

iv

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Part No. 122149 S-80 • S-85

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-80 and Genie S-85Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

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S-80 • S-85 Part No. 122149

SAFETY RULES

Section 1 - Safety Rules

vi

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine usesignal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Note: Used to indicate operation or maintenanceinformation.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready for use.Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work area isproperly ventilated and well lit.

June 2015

Part No. 122149 S-80 • S-85

Table of Contents

Introduction

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

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

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Specifications

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

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

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

Hydraulic Component Specifications ...................................................................... 2 - 3

Valve Coil Resistance Specifications ..................................................................... 2 - 4

Continental TME27 Engine Specifications ............................................................. 2 - 5

Deutz BF4L-2011 Engine Specifications ................................................................ 2 - 6

Perkins 804C-33 Engine Specifications ................................................................. 2 - 8

Machine Torque Specifications .............................................................................. 2 - 9

Manifold Component Specifications ....................................................................... 2 - 9

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

SAE and Metric Torque Specifications ................................................................. 2 - 11

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TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

A-3 Grease the Extendable Axles ....................................................................... 3 - 8

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

A-5 Perform Function Tests .............................................................................. 3 - 10

A-6 Test the Oscillate Axle ............................................................................... 3 - 10

A-7 Test the Extendable Axles ......................................................................... 3 - 11

A-8 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 12

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

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

A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14

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

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

A-14 Replace the Drive Hub Oil .......................................................................... 3 - 16

A-15 Perform Engine Maintenance - Perkins Models .......................................... 3 - 18

Checklist B Procedures

B-1 Inspect the Battery(s) ................................................................................. 3 - 19

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 20

B-3 Test the Key Switch ................................................................................... 3 - 22

B-4 Check the Exhaust System ....................................................................... 3 - 22

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TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

` B-5 Inspect the Engine Air Filter ....................................................................... 3 - 23

B-6 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 24

B-7 Confirm the Proper Brake Configuration...................................................... 3 - 25

B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 26

B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 27

B-10 Check and Adjust the Engine RPM ............................................................ 3 - 28

B-11 Perform Engine Maintenance ..................................................................... 3 - 30

B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 31

B-13 Test the Ground Control Override ............................................................... 3 - 31

B-14 Test the Platform Self-leveling ................................................................... 3 - 32

B-15 Test the Engine Idle Select Operation ........................................................ 3 - 32

B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 33

B-17 Test the Drive Enable System ................................................................... 3 - 34

B-18 Test the Drive Brakes ................................................................................ 3 - 35

B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 36

B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 36

B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 37

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

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

Checklist C Procedures

C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 41

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 42

C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 42

C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 45

C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 45

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S-80 • S-85 Part No. 122149

Section 3 Scheduled Maintenance Procedures, continued

Checklist D Procedures

D-1 Check the Boom Wear Pads ...................................................................... 3 - 48

D-2 Check the Extendable Axle Wear Pads ...................................................... 3 - 49

D-3 Check the Free-wheel Configuration ........................................................... 3 - 50

D-4 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 51

D-5 Inspect the Turntable Bearing Wear ........................................................... 3 - 52

D-6 Perform Engine Maintenance ..................................................................... 3 - 54

D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 55

D-8 Replace the Drive Hub Oil .......................................................................... 3 - 56

D-9 Perform Engine Maintenance - Deutz Models ............................................. 3 - 58

Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 59

E-2 Perform Engine Maintenance - Perkins Models .......................................... 3 - 61

E-3 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 61

E-4 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 63

Section 4 Repair Procedures

Introduction ............................................................................................................ 4 - 1

Platform Controls

1-1 ALC-500 Circuit Board .................................................................................. 4 - 2

1-2 Joysticks ..................................................................................................... 4 - 3

Platform Components

2-1 Platform ....................................................................................................... 4 - 7

2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 8

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TABLE OF CONTENTS

Section 4 Repair Procedures, continued

2-3 Platform Rotator ........................................................................................... 4 - 9

2-4 Calibrate the Platform Overload System .................................................... 4 - 11

Jib Boom Components, S-85

3-1 Jib Boom.................................................................................................... 4 - 14

3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 15

Boom Components

4-1 Cable Track ................................................................................................ 4 - 16

4-2 Boom ......................................................................................................... 4 - 19

4-3 Boom Lift Cylinder ...................................................................................... 4 - 21

4-4 Boom Extension Cylinders ......................................................................... 4 - 24

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 26

Engines

5-1 RPM Adjustment ........................................................................................ 4 - 27

5-2 Flex Plate................................................................................................... 4 - 27

Ground Controls

6-1 Control Relays ............................................................................................ 4 - 32

Hydraulic Pumps

7-1 Function Pump ........................................................................................... 4 - 33

7-2 Drive Pump ................................................................................................ 4 - 34

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S-80 • S-85 Part No. 122149


Manifolds

8-1 Function Manifold Components - View 1 .................................................... 4 - 36

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

8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 42

8-4 Brake/Two-speed Manifold Components .................................................... 4 - 45

8-5 Turntable Rotation Manifold Components ................................................... 4 - 46

8-6 Jib Boom Select and Platform Manifold Components ................................. 4 - 47

8-7 Axle Select Manifold Components .............................................................. 4 - 48

8-8 2WD Traction Manifold Components .......................................................... 4 - 50

8-9 4WD Traction Manifold Components .......................................................... 4 - 52

8-10 Drive Oil Diverter Manifold Components ..................................................... 4 - 54

8-11 Valve Adjustments - Drive Manifold ........................................................... 4 - 55

8-12 Valve Coils ................................................................................................. 4 - 56

Fuel and Hydraulic Tanks

9-1 Fuel Tank ................................................................................................... 4 - 59

9-2 Hydraulic Tank ........................................................................................... 4 - 60

Turntable Rotation Components

10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 62

2WD Steer Axle Components

11-1 Yoke and Hub ............................................................................................ 4 - 65

11-2 Steer Cylinder ............................................................................................ 4 - 66

11-3 Tie Rod Cylinder ......................................................................................... 4 - 67

TABLE OF CONTENTS

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Part No. 122149 S-80 • S-85



12-1 Yoke and Drive Hub ................................................................................... 4 - 68

12-2 Drive Motor ................................................................................................ 4 - 69

12-3 Drive Hub ................................................................................................... 4 - 70

12-4 Steer Cylinders........................................................................................... 4 - 70

12-5 Tie Rod Cylinder ......................................................................................... 4 - 71

Non-steer Axle Components

13-1 Drive Motor ................................................................................................ 4 - 72

13-2 Drive Hub ................................................................................................... 4 - 72

Oscillating Axle Components

14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73

14-2 Valve Adjustments - Oscillate Directional Valve ......................................... 4 - 73

Extendable Axle Components

15-1 Extendable Axles ....................................................................................... 4 - 76

15-2 Axle Extension Cylinder ............................................................................. 4 - 76

Section 5 Fault Codes

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

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

Engine Fault Codes - Continental Models............................................................... 5 - 6

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Section 6 Schematics

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

Electrical Symbols Legend .................................................................................... 6 - 2

Hydraulic Symbols Legend .................................................................................... 6 - 3

Electrical Schematic, S-80/85 (before S/N 5520)Deutz BF4L2011 Models ........................................................................................ 6 - 6

Electrical Schematic, S-80/85 (after S/N 5519)Deutz BF4L2011 Models ...................................................................................... 6 - 10

Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models ..................................................................................... 6 - 14

Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Deutz BF4L 2011 Models ..................................................................................... 6 - 16

Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)Deutz BF4L 2011 Models ..................................................................................... 6 - 17

Electrical Schematic, S-80/85 (before S/N 5520)Perkins 804-33 Models ........................................................................................ 6 - 20

Electrical Schematic, S-80/85 (after S/N 5519)Perkins 804-33 Models ........................................................................................ 6 - 24

Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models ........................................................................................ 6 - 28

Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Perkins 804-33 Models ........................................................................................ 6 - 30

Platform Control Box Wiring Diagram, S-8/85 (after S/N 5519)Perkins 804-33 Models ........................................................................................ 6 - 31

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Part No. 122149 S-80 • S-85

Section 6 Schematics, continued

Electrical Schematic, S-80/85 (before S/N 5520)Continental TME27 Models .................................................................................. 6 - 34

Electrical Schematic, S-80/85 (after S/N 5519)Continental TME27 Models .................................................................................. 6 - 38

Ground Control Box Wiring Diagram, S-80/85Continental TME27 Models .................................................................................. 6 - 42

Platform Control Box Wiring Diagram, S-80/85 (before S/N 5520)Continental TME27 Models .................................................................................. 6 - 44

Platform Control Box Wiring Diagram, S-80/85 (after S/N 5519)Continental TME27 Models .................................................................................. 6 - 45

Continental TME27 Engine Harness..................................................................... 6 - 48

Joystick Wiring Diagram ...................................................................................... 6 - 49

Connector Pin Legend - View 1 ............................................................................ 6 - 52

Connector Pin Legend - View 2 ............................................................................ 6 - 53

Dual Battery Option ............................................................................................. 6 - 56

Belt Drive Generator Option ................................................................................. 6 - 57

CE Option ............................................................................................................ 6 - 60

Platform Level Cutout, CTE Option ...................................................................... 6 - 61

12kW Hydaulic Generator Option ......................................................................... 6 - 64

Hydaulic Schematiic, 12kW Generator ................................................................. 6 - 65

Hydraulic Schematic, 2WD Models ...................................................................... 6 - 68

Hydraulic Schematic, 4WD Models ...................................................................... 6 - 69

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S-80 • S-85 Part No. 122149


xvi

Part No. 122149 S-80 • S-85 2 - 1

Section 2 • SpecificationsFebruary 2012

Specifications

Machine Specifications

Tires and wheels

Tire size 15-22.5 SAT385/65-22.5

Tire ply rating 16

Overall tire diameter 43.5 in110.5 cm

Tire weight, new foam-filled (minimum), RT 622 lbs282 kg

Tire pressure, RT 100 psi6.9 bar

Tire pressure, Hi-floatation 60 psi4.1 bar

Wheel diameter 22.5 in57 cm

Wheel width 11.75 in29.8 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs569 Nm

Lug nut torque, lubricated 320 ft-lbs434 Nm

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

Fluid capacities

Fuel tank 33 gallons125 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 80 gallons(including tank) 303 liters

Turntable rotation drive hub 40 fl oz1.2 liters

Rexroth drive hubs 61 fl oz1.8 liters

Bonfiglioli drive hubs 51 fl oz1.5 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oilAPI service classification GL5

For operational specifications, refer to theOperator's Manual.

S-80 • S-85 Part No. 1221492 - 2

Section 2 • Specifications February 2012

SPECIFICATIONS


Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Performance Specifications

Drive speed, maximum

Stowed position 40 ft / 7.9-8.5 sec12.2 m / 7.9-8.5 sec

Raised or extended position 40 ft / 40-45 sec12.2 m / 40-45 sec

Braking distance, maximum

High range on paved surface 3 ft90 cm

Gradeability Refer to the Operator’s Manual

Boom function speeds, maximumfrom platform controls

Jib boom up (S-85) 60 to 70 seconds

Jib boom down (S-85) 40 to 50 seconds

Boom up 89 to 93 seconds

Boom down 90 to 94 seconds

Boom extend 73 to 79 seconds

Boom retract 79 to 84 seconds

Turntable rotate, 360° 95 to 103 secondsboom fully stowed

Turntable rotate, 360° 210 to 250 secondsboom raised or extended

Platform rotate, 160° 8 to 12 seconds

Platform level up 50 to 60 seconds

Platform level down 40 to 50 seconds

Part No. 122149 S-80 • S-85 2 - 3


SPECIFICATIONS

Hydraulic ComponentSpecifications

Drive pump

Type: bi-directional variable displacement piston pump

Flow rate @ 2300 rpm 30.3 gpm114.7 L/min

Drive pressure, maximum 4200 psi290 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in13.9 cc

Flow rate @ 2300 rpm 8 gpm30.3 L/min

Charge pressure @ 2300 rpm 320 psiNeutral position 22 bar

Function pump

Type: two-section tandem gear pump

Displacement - Pump 1 (inner) 1.4 cu in22.9 cc

Flow rate @ 2300 rpm 12.7 gpm48 L/min

Displacement - Pump 2 (outer) 0.24 cu in4 cc

Flow rate @ 2300 rpm 2.25 gpm8.5 L/min

Auxiliary pump

Type: fixed displacement gear pump

Displacement - static 0.151 cu in2.47 cc


Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.

Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

S-80 • S-85 Part No. 1221492 - 4


SPECIFICATIONS


Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve coil resistance specifications

Proportional solenoid valve 4.8 (schematic items K and W)

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

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

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

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

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

Function manifold

System relief pressure 2900 psi(measured at PTEST port) 200 bar

Boom down relief pressure 2100 psi(measured at PTEST port) 145 bar

Boom extend 2500 psi(measured at PTEST port) 172 bar

Steer/axle extend 3.5 gpmflow regulator 13.2 L/min

Oscillate relief pressure 850 psi58.6 bar

Drive manifold

Hot oil relief pressure 280 psi19.3 bar

Brake release pressure

Rexroth hubs 217.5 psi15 bar

Bonfiglioli hubs 189 psi13 bar

Drive motors

Displacement per revolution, variable 0.9 to 2.7 cu in(2 speed motor) 14.7 to 45 cc

Hydraulic filters

High pressure filter Beta 3 200

High pressure filter 102 psibypass pressure 7 bar

Medium pressure filter Beta 3 200

Medium pressure filter 51 psibypass pressure 3.5 bar

Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass

Part No. 122149 S-80 • S-85 2 - 5


SPECIFICATIONS

Continental TME27 Engine

Displacement 164 cu in2.68 liters

Number of cylinders 4

Bore and stroke 3.58 x 4.06 inches91 x 103.2 mm

Horsepower 59.03 @ 2500 rpm44 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Compression ratio 8.2:1

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

Low idle - computer controlled 1600 rpmFrequency 53.33 Hz

High idle - computer controlled 2500 rpmFrequency 83.33 Hz

Valve clearance, warm

Intake 0.014 in0.36 mm

Exhaust 0.018 in0.46 mm

Lubrication system

Oil pressure 40 to 60 psi2.75 to 4.14 bar

Oil capacity 7 quarts(including filter) 6.65 liters

Oil viscosity requirements

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

Fuel Requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Electronic fuel pump

Fuel pressure, static 55 psi3.8 bar

Fuel flow rate 0.42 gpm1.59 L/min

Batteries

Type 12V DC

Group 31

Quantity 2

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Alternator output 65A @ 13.8V DC

Fan belt deflection 1/2 inch12 mm


S-80 • S-85 Part No. 1221492 - 6


Lubrication system

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

Oil capacity 11 quarts(including filter) 10.4 liters


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

Oil temperature switch

Torque 8-18 ft-lbs11-24 Nm

Oil temperature switch point 275°F135°C

Oil pressure switch

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 7 psi0.48 bar

Deutz BF4L-2011 Engine

Displacement 189.6 cu in3.1 liters


Bore and stroke 3.7 x 4.409 inches94 x 112 mm

Horsepower

Continuous 69.1 @ 2500 rpmNet intermittent 72.8 @ 2500 rpmContinuous 51.5 KW @ 2500 rpmNet intermittent 54.3 KW @ 2500 rpm


Low idle 1500 rpmFrequency 382.5 Hz

High idle 2350 rpmFrequency 599.25 Hz

Compression ratio 17.5:1

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

Governor centrifugal mechanical

Valve clearance, cold



SPECIFICATIONS


Part No. 122149 S-80 • S-85 2 - 7


SPECIFICATIONS


Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum15,000 psi/1034 bar

Injector opening pressure 3046 psi210 bar

Fuel Requirement


Starter motor

Current draw, normal load 140-200A

Cranking speed 200-250 rpm

Batteries

Type 12V DC

Group 31

Quantity 1



Alternator output 80A @ 14V DC

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

S-80 • S-85 Part No. 1221492 - 8


SPECIFICATIONS

Injection system

Injection pump make Zexel

Injection pump pressure 1707 to 1849 psi117.7 to 127.5 bar

Injector opening pressure ~2000 psi~138 bar

Fuel Requirement


Engine coolant

Capacity 12.5 quarts11.8 liters

Batteries

Type 12V DC

Group 31

Quantity 1



Alternator output 90A, 12V DC

Fan belt deflection 3/8 to 1/2 in9 to 12 mm

Perkins 804C-33 Engine

Displacement 201 cu in3.3 liters


Bore and stroke 3.70 x 4.72 inches94 x 120 mm

Horsepower 63 @ 2600 rpm47 KW @ 2600 rpm


Compression ratio 22:1

Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi or bar) of lowest cylinder must bewithin 50 psi / 3.45 bar of highest cylinder

Low idle 1650 rpmFrequency 335.5 Hz

High idle 2300 rpmFrequency 467.67 Hz

Governor mechanical all speed

Valve clearance, cold



Lubrication system

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

Oil capacity 10.6 quarts(including filter) 10 liters


Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine. Continuous improvement of our products is a

Genie policy. Product specifications are subjectto change without notice.

Part No. 122149 S-80 • S-85 2 - 9


Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5, lubricated 480 ft-lbs651 Nm

3/8 -16 bolts, GR 8 35 ft-lbs**(use blue thread locking compound) 47 Nm*

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Rotate drive hub mounting bolts, lubricated 80 ft-lbs108 Nm

Backlash plate mounting bolts, lubricated 280 ft-lbs379 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 210 ft-lbs284 Nm

Drive hub mounting bolts, lubricated 185 ft-lbs**(use blue thread locking compound) 247 Nm

Drive motor mounting bolts, dry 110 ft-lbs149 Nm

Drive motor mounting bolts, lubricated 80 ft-lbs**(use blue thread locking compound) 108 Nm

Drive hub oil plug, O-ring seal 13 ft-lbs18 Nm


SPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 14 ft-lbs / 18.9 Nm




SAE No. 12 84 ft-lbs / 113.9 Nm

S-80 • S-85 Part No. 1221492 - 10


SPECIFICATIONS

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 14 ft-lbs / 18.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 48.8 Nm

-10 62 ft-lbs / 84.1 Nm

-12 84 ft-lbs / 113.9 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 250 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.

Note: The O-rings used in the Parker Seal Lok®fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Part No. 122149 S-80 • S-85 2 - 11


SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

Size

(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SPECIFICATIONS

10.9 12.98.84.6

S-80 • S-85 Part No. 1221492 - 12



Part No. 122149 S-80 • S-85 3 - 1

Section 3 • Scheduled Maintenance ProceduresFebruary 2012

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every two years as specified on theMaintenance Inspection Report. The frequencyand extent of periodic examinations and testsmay also depend on national regulations.

Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than three months must completethe quarterly inspection.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steer (yellow arrow) wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

3 - 2 S-80 • S-85 Part No. 122149

Section 3 • Scheduled Maintenance Procedures February 2012

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery PreparationReport to use for each inspection. Store completedforms as required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.To account for repeated procedures, theScheduled Maintenance Procedures Section andthe Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six month or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Part No. 122149 S-80 • S-85 3 - 3


Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000

Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex SouthDakota, Inc. 133192 Rev D

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before it isput into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirementslisted in the responsibilities manual.

3 - 4 S-80 • S-85 Part No. 122149



Part No. 122149 S-80 • S-85 3 - 5


Instructions• Make copies of this report to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Maintenance Inspection Report

Checklist B Y N R

B-1 Battery(s)

B-2 Electrical wiring

B-3 Key switch

B-4 Exhaust system

B-5 Engine air filter

B-6 Oil cooler and fins-Deutz models

B-7 Brake configuration

B-8 Tires, wheels andlug nut torque

B-9 Drive hub maintenance

B-10 Engine RPM

B-11 Engine maintenance

B-12 Oscillate directionalControl

B-13 Ground controloverride

B-14 Platform self-leveling

B-15 Engine idle select

B-16 Fuel select operation

B-17 Drive enable system

B-18 Drive brakes

B-19 Drive speed-stowed

B-20 Drive speed-raisedor extended

B-21 Alarm package anddescent alarm

B-22 Fuel and hydraulic tankventing systems

B-23 Hydraulic oil analysis

Checklist A Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Grease axles

A-4 Engine maintenance

A-5 Function tests

A-6 Oscillate axle

A-7 Extendable axles

A-8 Filter condition indicator

Perform after 40 hours:

A-9 30 day service


A-10 Engine maintenance -Deutz and Continentalmodels

Perform every 100 hours:

A-11 Inspect filter/separator -Diesel models

A-12 Grease rotationbearing

A-13 Engine maintenance


A-14 Replace Drive Hub oil


A-15 Engine maintenance -Perkins models

Comments

3 - 6 S-80 • S-85 Part No. 122149


Checklist C Y N R

C-1 Engine maintenance

C-2 Grease platformoverload (if equipped)

C-3 Test the platformoverload (if equipped)

C-4 Air filter element

C-5 Replace filter/separator -Deutz and Perkinsmodels

Checklist D Y N R

D-1 Boom wear pads

D-2 Axle wear pads

D-3 Free-wheelconfiguration

D-4 Turntable rotationbearing bolts

D-5 Turntable bearing wear

D-6 Engine maintenance

D-7 Replace hydraulic filters

D-8 Drive hub oil


D-9 Engine maintenance -Deutz models

MAINTENANCE INSPECTION REPORT

Checklist E Y N R

E-1 Hydraulic oil

E-2 Engine maintenance - Perkins models

E-3 Grease axle bearings,2WD models


E-4 Engine maintenance -Deutz and Perkinsmodels

Instructions• Make copies of this report to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Part No. 122149 S-80 • S-85 3 - 7


Checklist A Procedures

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

3 - 8 S-80 • S-85 Part No. 122149


CHECKLIST A PROCEDURES

A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed daily.

Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The pre-operation inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-3Grease the Extendable Axles

Genie specifications require that this procedure beperformed daily.

Proper lubrication of the extendable axle wearpads is essential to smooth operation andminimum wear of the wear pads.

Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldresult in the machine tipping over.

1 Locate the grease fitting on the platform side ofthe non-steer extendable axle and behind thedrive motor on the steer extendable axle.

2 Pump grease into each fitting until grease isvisible between the axle and wear pads.

3 Repeat for each axle.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

Part No. 122149 S-80 • S-85 3 - 9


A-4Perform Engine Maintenance

Engine specifications require that this procedurebe performed daily or every 8 hours, whichevercomes first.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.

Required maintenance procedures and additionalengine information are available in the:Deutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00) ORthe Continental TME27 Owner's Manual(Continental part number WM10303).

Deutz BF4L2011 Operation ManualGenie part number 84794

Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332

Continental TME27 Owner's ManualGenie part number 111901

To access the engine:

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

Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.


3 - 10 S-80 • S-85 Part No. 122149


A-6Test the Oscillate Axle

Genie specifications require that this procedure beperformed daily.

Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.


1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a 6 inch / 15 cmblock or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a6 inch / 15 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

If the chassis does not remainlevel during the test, refer toRepair Procedure 14-2, How toSet Up the Directional ValveLinkage.


A-5Perform Function TestsGenie specifications require that this procedure beperformed daily.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

Part No. 122149 S-80 • S-85 3 - 11



A-7Test the Extendable AxlesGenie specifications require that this procedure beperformed daily.

Tip-over hazard. Do not raise orextend the boom unless bothaxles are fully extended. If the axleextension system is not operatingcorrectly, the stability of themachine is compromised and itmay tip over.

Note: Be sure the axles are retracted beforeperforming this procedure.

1 Turn the key switch to ground control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.

2 Start the engine from the ground controls.

3 Move and hold the function enable switch toeither side and activate the boom up function.

Result: The boom should raise to 5° abovehorizontal and then stop. The boom should notraise above the limit switch unless both axlesare extended.

4 Move and hold the function enable switch toeither side and activate the boom downfunction.

Result: The boom should lower and return tothe stowed position.

5 Move and hold the function enable switch toeither side and activate the boom extendfunction.

Result: The boom will extend approximately1 foot / 30 cm and then stop. The boom shouldnot extend farther unless both axles areextended.

6 Move and hold the function enable switch toeither side and activate the boom retractfunction.

Result: The boom should retract.

7 Turn the key switch to platform controls.

8 Press down the foot switch and move the drivecontrol handle in the forward direction andactivate the axle extend function.

Result: The machine will drive forward and theaxles should extend.

Note: The axle extend function will only work whilethe machine is moving.

Note: The steer function will override the axleextend or the axle retract function.

9 Turn the key switch to ground controls.

10 At the ground controls, hold the function enableswitch to either side and activate the boom upand boom down function.

Result: The boom should raise and lowernormally.

11 At the ground controls, move and hold thefunction enable switch to either side andactivate the boom extend and boom retractfunction.

Result: The boom should extend and retractnormally.

3 - 12 S-80 • S-85 Part No. 122149



A-8Check the Hydraulic FilterCondition IndicatorsGenie specifications require that this procedure beperformed daily.

Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicatorswill show when the hydraulic flow is bypassing aclogged filter. If the filters are not frequentlychecked and replaced, impurities will remain in thehydraulic system and cause component damage.

Note: There are three hydraulic filters located onthe machine: one tank return filter, one mediumpressure filter and one high pressure filter. Thetank return and high pressure filter have acondition indicator on them. The medium pressurefilter does not have a filter condition indicator.


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

Tank return filter:

3 Open the ground control side turntable coverand inspect the filter condition indicator gauge.

Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6.

Result: The needle is operating in the red area.Proceed to step 4.

Note: The tank return filter indicator needle mayoperate in the red area when hydraulic oil is below50° F / 10° C.

REV B

a filter condition indicator gauge

4 Continue allowing the engine to run until thehydraulic oil temperature is above70° F / 21° C.

Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6.

Result: The needle is operating in the red area.Proceed to step 5.

5 Operate the machine until the hydraulic oiltemperature is above 104° F / 40° C.

Result: The needle on the gauge is operating inthe green area. The filter is good. Proceed tostep 6

Result: The needle is operating in the red area.The filter is clogged and is being bypassed.Replace the filter and repeat this procedurebeginning with step 1. See D-7, Replace theHydraulic Filter Elements.

High pressure filter:

Note: The high pressure filter is located to the leftof the medium pressure filter below the hydraulicpumps. A filter condition indicator is located on thetop of the high pressure filter.

6 Open the engine side turntable cover andInspect the filter condition indicator.

Result: The filter condition indicators should beoperating with the plungers in the green area.

Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-7, Replace the Hydraulic FilterElements.

a

Part No. 122149 S-80 • S-85 3 - 13


A-10Perform Engine Maintenance -Deutz and Continental Models

Engine specifications require that this one-timeprocedure be performed after the first 50 hours ofoperation.


Required maintenance procedures forcommissioning new and overhauled engines andadditional engine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theContinental TME27 Owner's Manual(Continental part number WM10303).






A-9Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-12 Grease the Turntable Rotation Bearingand Rotate Gear

• B-8 Inspect the Tires, Wheels andLug Nut Torque

• B-9 Check the Drive Hub Oil Level andFastener Torque

• D-4 Check the Turnable Rotation BearingBolts

• D-7 Replace the Hydraulic Filter Elements


3 - 14 S-80 • S-85 Part No. 122149



A-11Inspect the Fuel Filter/WaterSeparator - Deutz and PerkinsModels

Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Note: Perform this procedure with the engine off.

1 Open the turntable cover at the engine side ofthe machine. Locate the fuel filter/waterseparator.

2 Inspect the filter bowl for water.

Result: Water is not visible in the filter bowl.

Result: There is water present. Proceedto step 3.

3 Loosen the vent plug located on the head of thefuel filter/water separator.

a head boltb vent plugc drain plugd filter bowle separator head

4 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

5 Clean up any fuel that may have spilled.

Note: If the fuel filter/water separator is completelydrained, you must prime the fuel filter/waterseparator before starting the engine.See C-5, Replace The Fuel Filter/Water SeparatorElement, for instructions on how to prime the fuelfilter/water separator.

6 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

d

c

e

b

a

Part No. 122149 S-80 • S-85 3 - 15


A-13Perform Engine Maintenance

Engine specifications require that this procedurebe performed every 100 hours.






A-12Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Locate the grease fitting on the platform end ofthe tank side bulkhead.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in incrementsof 4 to 5 inches / 10 to 13 cm at a time andrepeat this step until the entire bearing hasbeen greased.

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




3 - 16 S-80 • S-85 Part No. 122149



A-14Replace the Drive Hub Oil

Manufacture specifications require that this one-time procedure be performed after the first 150hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the initial 150 hoursof use may cause the machine to perform poorlyand continued use may cause componentdamage.

Drive hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a. models with pipe plugs b. models with o-ring plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.

5 Models with pipe plugs: Apply pipe threadsealant to the plugs and install the plugs.

Models with O-ring plugs: Install the plugsinto the drive hub. Torque to Specification.Refer to Section 2, Specifications.

a

a

b




Part No. 122149 S-80 • S-85 3 - 17


6 Repeat steps 1 through 4 for the other drivehub.

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

Turntable rotate drive hub:

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Secure the turntable from rotating with theturntable rotation lock pin.

Note: The turntable rotation lock pin is located nextto the boom rest pad.

2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.


5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

a motorb drive hubc drive hub mounting bolts

6 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer to Section 2,Specifications.

7 Fill the drive hub with oil from the side plug holeuntil the oil level is even with the bottom of thehole. Apply pipe thread sealant to the plug.Install the plug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.

b

a

c

3 - 18 S-80 • S-85 Part No. 77832



A-15Perform Engine Maintenance -Perkins Models



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

Perkins 804C-33 Operation and Maintenance ManualGenie part number




Part No. 77832 S-80 • S-85 3 - 19


Checklist B Procedures

B-1Inspect the Battery(s)

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

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions. A singlebattery configuraton is standard. A dual batteryoption is available, where one battery is used tostart the engine and the other is used to power thecontrol system and auxiliary power unit. The twobatteries are charged by the alternator through abattery separator.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Be sure that the battery separator wireconnections are tight (if equipped).

5 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge, OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

3 - 20 S-80 • S-85 Part No. 122149


CHECKLIST B PROCEDURES

10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 11.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled.

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Open the turntable cover at the engine side ofthe machine.

2 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.

a engine tray anchor holeb engine tray retaining fastener

3 Locate the engine tray anchor hole on theturntable.

Part No. 122149 S-80 • S-85 3 - 21


13 Inspect for a liberal coating of dielectric greasein the following location:

• All wire harness connectors toplatform control box

14 Remove the engine tray retaining fastener fromthe engine tray anchor hole at the pivot end ofthe engine tray.

15 Swing the engine tray in towards the machine.

16 Install the engine tray retaining fasteners.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

4 Install the bolt that was just removed into theanchor hole to secure the engine tray frommoving.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

• Engine wiring harness

• Battery area wiring

6 Open the turntable cover at the ground controlsside of the machine.


• Inside the ground control box

• Hydraulic manifold wiring

• Hydraulic oil cooler wiring

8 Inspect for a liberal coating of dielectric greasein the following locations:

• All wire harness connectors toground control box

9 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.

10 Inspect the turntable area for burnt, chafed andpinched cables.

11 Lower the secondary boom to the stowedposition and turn the engine off.


• Cable track on the boom

• Cables on the boom and jib boom

• Jib boom/platform rotate manifold

• Inside of the platform control box


3 - 22 S-80 • S-85 Part No. 122149



B-3Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and nofunctions should operate.

B-4Check the Exhaust System


Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.




2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

Part No. 122149 S-80 • S-85 3 - 23


B-5Inspect the Engine Air Filter

Genie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst. Perform this procedure more often if dustyconditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

a clampb canister end capc dust discharge valve

a

b

c

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

5 Swing the engine pivot plate in towards themachine.

6 Install the bolts that were just removed into theoriginal holes to secure the engine pivot plate.

Crushing hazard. Failure to installthe bolts into the engine pivot plateto secure it from moving couldresult in death or serious injury.


3 - 24 S-80 • S-85 Part No. 122149



2 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

3 Remove the filter element.

4 Clean the inside of the canister and the end capwith a damp cloth.

5 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.Replace the filter if needed.

6 Install the filter element.

7 Install the air filter canister end cap and securethe end cap latches.

Note: Be sure the discharge slot is pointing down.

B-6Check the Oil Cooler and CoolingFins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.

Oil cooler:

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

2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.


Part No. 122149 S-80 • S-85 3 - 25


disengaged position

engaged position

3 Remove the fasteners from the engine sidecover, then remove the cover.

4 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

5 Clean the oil cooler of debris and foreignmaterial.

Cooling and fan blower fins:

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

9 Clean the cylinder head cooling passages ofdebris and foreign material.

10 Install the engine side cover.

11 Swing the engine back to its original positionand install the engine pivot plate retainingfastener.

cba

B-7Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.


3 - 26 S-80 • S-85 Part No. 122149


B-8Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque,is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldresult in death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

Note: The tires on some machines are foam filledand do not need air added to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

4 Check the pressure in each air-filled tire. Addair as necessary. Refer to Section 2,Specifications.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on thebottom of the drive pump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

Note: The free-wheel valve should always remainclosed.

a

d

c

b


Part No. 122149 S-80 • S-85 3 - 27




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

6 Repeat steps 1 through 5 for the other drivehubs.


1 Remove the plug located on the side of the huband check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

a plugb drive hub

2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole. Refer toSection 2, Specifications.

3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.

b

a

B-9Check Drive Hub Oil Level andFastener Torque

Genie specifications require that this procedure beperformed every 250 hours.

Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.

Drive hubs:

1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other one isat 90 degrees.


2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

a

a

b


3 - 28 S-80 • S-85 Part No. 122149


Deutz BF4L 2011 models:

1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.

Skip to step 4 if the low idle rpm is correct.

2 Loosen the locknut on the low idle adjustmentscrew.

3 Adjust the low idle adjustment screw until lowidle meets specification. Tighten the locknut.

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


B-10Check and Adjust theEngine RPM

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Continental models:

Note: The engine rpm is controlled by the ECMand can only be adjusted by re-programming theECM. If rpm adjustment or service is required,please contact the Genie Industries ServiceDepartment.

Part No. 122149 S-80 • S-85 3 - 29


Perkins modelsa solenoid bootb yoke lock nutc low idle adjustment screwd low idle lock nute yokef high idle adjustment nut

3 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) position.Refer to Section 2, Specifications.

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.


If the high idle is correct, disregard adjustmentstep 5.

5 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

Perkins models:

1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. 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 idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

3 - 30 S-80 • S-85 Part No. 122149



B-11Perform Engine Maintenance

Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.









Part No. 122149 S-80 • S-85 3 - 31


B-13Test the Ground Control OverrideGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the red EmergencyStop button at the platform controls is in the on oroff position. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the red Emergency Stop button at theplatform controls to the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.

B-12Check the Oscillate DirectionalValve Linkage

Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

Proper axle oscillation is essential to safe machineoperation. If the oscillate directional valve linkageis not operating correctly, the stability of themachine is compromised and it may tip over.

1 Remove the drive chassis cover from thenon-steer end of the machine.

2 Locate the oscillate directional valve inside ofthe non-steer axle and inspect the linkage forthe following:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve


3 - 32 S-80 • S-85 Part No. 122149



B-15Test the Engine Idle SelectOperationGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions only.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This setting activates high idleonly when the foot switch is pressed down.




4 Move and hold the function enable toggle switchin the high idle (rabbit symbol) position.

Result: The engine rpm should change to highidle.

B-14Test the Platform Self-levelingGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.


2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the boom through a full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

Note: The boom will not raise past horizontal andthe boom will not extend more than12 inches / 30.5 cm unless both axles are fullyextended.

Part No. 122149 S-80 • S-85 3 - 33


B-16Test the Fuel Select Operation -Gasoline/LPG Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Note: Perform this test after checking the gasolineand LPG fuel levels, and warming the engine tonormal operating temperature.

1 Move the fuel select toggle switch to gasolineand then move the engine idle select switch tofoot switch activated high idle (rabbit and footswitch symbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

5 Release the function enable toggle switch.

Result: The engine rpm should change to lowidle.


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


8 Move the engine idle select toggle switch to lowidle (turtle symbol).

Result: The engine rpm should change to lowidle.

9 Move the engine idle select toggle switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine rpm should not change tohigh idle.

10 Press down the foot switch.



3 - 34 S-80 • S-85 Part No. 122149



B-17Test the Drive Enable SystemGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper drive enable system operation isessential to safe machine operation. When theboom is past the non-steering wheels, drivemovement is stopped and theindicator light turns on. The driveenable switch must be held toeither side to reactivate the drivefunction and should alert theoperator that the machine maymove in the opposite direction that the drive andsteer controls are moved. An improperlyfunctioning drive enable system may allow themachine to be moved into an unsafe position.

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


2 Press down the foot switch.

3 Rotate the turntable until the boom moves pastone of the the non-steer wheels.

Result: The drive enable indicator light shouldturn on and remain on while theboom is anywhere in the rangeshown.

4 Slowly move the drive controlhandle off center.

Result: The drive function should not operate.

4 Release the foot switch and shut the engine offby pushing the red Emergency Stop button in tothe off position.

5 Move the fuel select toggle switch to LPG.

6 Start the engine and allow it to run at low idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

Note: The engine may hesitate momentarily andthen continue to run on the selected fuel if the fuelsource is switched while the engine is running.

Part No. 122149 S-80 • S-85 3 - 35


B-18Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-7, Confirm the ProperBrake Configuration.

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

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

1 Mark a test line on the ground for reference.


3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.

4 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.

5 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

5 Rotate the turntable until the boom moves pastthe other non-steer wheel.

Result: The drive enableindicator light should come onand remain on while the boomis anywhere in the rangeshown.

6 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.

Result: The drive function should operate.

Collision hazard. Always use thecolor-coded direction arrows onthe platform controls and the drivechassis to identify the direction oftravel.

Note: When the drive enable system is in use, themachine may drive in the opposite direction thatthe drive and steer control handle is moved.

Blue

Yellow


3 - 36 S-80 • S-85 Part No. 122149



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


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.

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

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


3 Extend the axles.

4 Move the engine idle select toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).

5 Press down the foot switch and raise the boom10° above horizontal.

6 Choose a point on the machine (i.e. contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.

7 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

B-19Test the Drive Speed -Stowed Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.

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


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


3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the start and finish lines.


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

Note: To adjust the speed, refer to Repairprocedure 1-2, How to Adjust the Joystick Max-outSetting.

Part No. 122149 S-80 • S-85 3 - 37


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


9 Press down the foot switch and lower the boomto the stowed position.

10 Extend the boom 3 feet / 90 cm.

11 Choose a point on the machine (i.e., contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.


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


B-21Test the Alarm Package(if equipped) and the DescentAlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The alarm package includes:

• Travel alarm

• Flashing beacons

Alarms and beacons are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable rear cover. Beacons are installed on bothturntable covers.

Note: The alarms and beacons will operate withthe engine running or not running.

Note: The descent alarm is standard beginningwith serial number 5612.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: Both flashing beacons should be on andflashing.

2 Move and hold the function enable toggle switchto either side and activate the boom toggleswitch in the down position, hold for a momentand then release it.

Result: The descent alarm should sound whenthe toggle switch is held down.


3 - 38 S-80 • S-85 Part No. 122149



B-22Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.



1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.Procced to step 4.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

When checking for positive tank cap venting, airshould pass freely through the cap.


Result: The flashing beacons should be onand flashing.

4 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe controller is held down.

5 Press down the foot switch. Move the drivecontroller off center, hold for a moment andthen release it. Move the drive controller offcenter in the opposite direction, hold for amoment and then release it.

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

Part No. 122149 S-80 • S-85 3 - 39


3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air passes through the hydraulic tankcap. Procced to step 8.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

B-23Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.


3 - 40 S-80 • S-85 Part No. 122149


C-1Perform Engine Maintenance










Checklist C Procedures

Part No. 122149 S-80 • S-85 3 - 41


CHECKLIST C PROCEDURES

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first. Perform this proceduremore often if dusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting.



C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

3 - 42 S-80 • S-85 Part No. 122149



4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.Illustration 1

Part No. 122149 S-80 • S-85 3 - 43


8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Activate the auxiliary power toggle switch.

Note: The engine will turn off when the auxiliarypower is activated.

12 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

13 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be an 2 second delay before theoverload indicator lights and alarm turn off.

14 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.

15 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).

17 Using a suitable lifting device, remove theremaining test weights from the platform.


3 - 44 S-80 • S-85 Part No. 122149



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

Engine specifications require that this procedurebe performed every 500 hours or six months,whichever comes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

2 Remove the filter element.

3 Use a damp cloth to wipe the filter sealingsurface and the inside of the outlet tube. Makesure that all contaminant is removed before thefilter is inserted.

4 Check new filter element gasket for damagebefore installing.

5 Install the new filter element.

6 Install the end cap on the canister and secure.

Note: Be sure the discharge slot is pointing down.

C-5Replace the Fuel Filter/WaterSeparator Element -Deutz and Perkins Models

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.

Regular replacement of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.


Perform this procedure with the engine off.

1 Open the engine side turntable cover and locatethe fuel filter/water separator.

Note: The fuel filter/water separator is located nearthe hydraulic pump.

2 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separatorhead.

Part No. 122149 S-80 • S-85 3 - 45


8 Apply a thin layer of oil onto the element gasket.Install the filter/bowl assembly onto the filterhead. Tighten the drain plug and vent plug.

Component damage hazard. Thedrain plug and vent plug can bedamaged if they areovertightened.

9 Install the fuel supply hose from the fuel tank tothe fuel filter/water separator. Tighten theclamp.

10 Clean up any diesel fuel that may have spilledduring the installation procedure.

11 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filter element.

Bleed the fuel system:

Note: Before bleeding the system, fill the fuel tank.

12 Loosen the vent plug located on thefuel filter/water separator head.

13 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the ventplug. Tighten the vent plug.

14 Loosen the air vent screw, located on top of thefuel injection pump.

15 Tighten the air vent screw when air stopscoming through the air vent.

16 Clean up any diesel fuel that may have spilledduring the bleeding procedure and dispose ofproperly.

17 Start the engine from ground controls andcheck for leaks.

3 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

4 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.

5 Rotate the filter bowl counterclockwise andremove it from the element.

6 Rotate the filter element counterclockwise andremove it from the filter head.

7 Install the filter bowl onto the new filter element.

c

b

d

a


3 - 46 S-80 • S-85 Part No. 122149


Checklist D Procedures

D-1Check the Boom Wear Pads

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

Note: If the wear pads are still within specification,refer to Repair Procedure 4-2, How to Shim theBoom.


2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot / 30 cm.

3 Measure each wear pad. Replace the wear padif it is less than specification. If the wear pad isstill within specification, shim as necessary toobtain zero clearance and zero drag.

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Note: Always maintain squareness between theouter and inner boom tubes.

Boom wear pad specifications Minimum

Boom number one

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

Side wear pads 5/8 inch(extension end of boom) 15.9 mm

Boom number two

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

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

Side wear pads 5/8 inch(pivot end of boom) 15.9 mm

Boom number three

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

a boom 1b boom 2c boom 3

b ca

Part No. 122149 S-80 • S-85 3 - 47


CHECKLIST D PROCEDURES

3 Extend and retract the axles through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the axletubes.

Note: Always maintain squareness between theouter and inner axle tubes.

Axle wear pad specifications Minimum

Outer axle

Top, bottom and side wear pads 1/2 inch(both ends of axle) 12.7 mm

Extendable inner axle

Top, bottom and side wear pads 1/2 inch(both ends of axle) 12.7 mm

D-2Check the Extendable AxleWear Pads


Maintaining the axle wear pads in good condition isessential to safe machine operation. Wear padsare placed on axle tube surfaces to provice a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn out wear pads may result incomponent damage and unsafe operatingconditions.

Note: If the wear pads are not worn belowspecification but are still within specification, referto Repair Procedure 15-1, How to Shim anExtendable Axle.

1 Start the engine from the platform controls andextend the axles.

2 Measure each wear pad.

If the wear pad is not less than specification,shim as necessary to obtain zero clearance andzero drag. Refer to Repair Procedure 15-1,How to Shim an Extendable Axle.

Replace the wear pad if it is less thanspecification. It is recommended to replace bothinner and outer wear pads. Refer to RepairProcedure 15-1, How to Remove an Inner Axle.

3 - 48 S-80 • S-85 Part No. 122149



D-3Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. The free-wheel configuration is used primarily for towing. Amachine configured to free-wheel without operatorknowledge could result in death or serious injuryand property damage.

Collision hazard. Select a worksite that is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer wheels.

3 Lift the wheels off the ground and place blocksunder the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

Steer wheels: 4WD models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer wheels.

9 Lift the wheels off the ground and then placeblocks under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each steer wheelhub.

disengaged position

engaged position

disengaged position

engaged position

Part No. 122149 S-80 • S-85 3 - 49


11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

All models:

13 Turn the valve in a clockwise direction to besure it is fully closed.

Note: The free-wheel valve is located on thebottom of the drive pump, and should alwaysremain closed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

a

d

c

b

D-4Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Start the engine from the platform controls andextend the axles.

2 Turn the key switch to ground controls.

3 Raise the boom and place a safety chock onthe lift cylinder rod. Carefully lower the boomonto the lift cylinder safety chock.

Crushing hazard. Keep handsaway from cylinder and all movingparts when lowering the boom.

Note: The lift cylinder safety chock is availablethrough Genie Service Parts.


3 - 50 S-80 • S-85 Part No. 122149



1

2

3

4

5

6

7

8

9

10

11

1213

14 15

1617

18

22

26

30

192327

2024 28

21

25

29

4 Remove the center turntable cover retainingfasteners. Remove the cover.

5 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.

Bolt torque sequence

6 Install the center turntable cover and tighten theretaining fasteners.

7 Raise the boom and remove the safety chock.

8 Lower the boom to the stowed position.

9 Confirm that each bearing mounting bolt underthe drive chassis is torqued in sequence tospecification. Refer to Section 2, Specifications.

Bolt torque sequence

1 15

7

12

4

17

5

14

9216

8

11

3

18

6

13

10

D-5Inspect for Turntable BearingWear


Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Note: Perform this procedure with the machine ona firm, level surface and the boom in the stowedposition.

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

2 Torque the turntable bearing bolts tospecification. See D-4, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

Part No. 122149 S-80 • S-85 3 - 51


7 Note the reading on the dial indicator.

Result: The measurement is less than0.063 inch / 1.6 mm. The bearing is good.

Result: The measurement is more than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero"position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch /2.5 cm from the turntable rotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Fully extend the boom and lower to a horizontalposition.

a

b

c

d


3 - 52 S-80 • S-85 Part No. 122149






D-6Perform Engine Maintenance







Part No. 122149 S-80 • S-85 3 - 53


D-7Replace the Hydraulic FilterElements

Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever come first. Perform this procedure moreoften if dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.


Hydraulic return filter:

1 Open the ground controls side turntable coverand locate the hydraulic return filter mounted onthe hydraulic tank.

2 Place a suitable container under the hydraulictank return filter.

3 Remove the filter with an oil filter wrench.

4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.

5 Install the new filter and tighten it securely byhand. Clean up any oil that may have spilledduring the installation procedure.

6 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

Medium and high pressure filters:

Note: The medium pressure filter is for the chargepump and the high pressure filter is for all machinefunctions except the drive circuit and oscillatingaxle circuit.

7 Open the engine side turntable cover and locatethe two filters mounted below the hydraulicpumps.

Note: The medium pressure filter is located on theright. The high pressure filter is located on the leftwith the condition indicator.

8 Place a suitable container under the filters.

9 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housings.

10 Remove the filter element from the housings.

11 Inspect the housing seals and replace them ifnecessary.


3 - 54 S-80 • S-85 Part No. 122149



D-8Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

Drive hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.


4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.



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

13 Clean up any oil that may have spilled duringthe installation procedure.

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


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

a

a

b

Part No. 122149 S-80 • S-85 3 - 55


6 Repeat steps 1 through 4 for the other drivehub.

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


Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.



2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.

5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

a motorb drive hubc drive hub mounting bolts

6 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer to Section 2,Specifications.

7 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.

b

a

c


3 - 56 S-80 • S-85 Part No. 122149


D-9Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedurebe performed every 1500 hours of operation.


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



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



Part No. 122149 S-80 • S-85 3 - 57


E-1Test or Replace theHydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or every two years,whichever comes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.


Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the fuel tank. Refer to RepairProcedure 9-1, How to Remove the Fuel Tank.

2 Models without hydraulic tank shutoffvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. Refer to Section 2,Specifications.

Models with hydraulic tank shutoff valves:Close the two hydraulic tank valves located atthe hydraulic tank.

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

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

4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.

5 Disconnect and plug the T-fitting located at thereturn filter with the two hoses connected to it.Cap the fitting on the return filter housing.

6 Disconnect and plug the supply hose for theauxiliary power unit. Cap the fitting on thehydraulic tank.

open closed

Checklist E Procedures

3 - 58 S-80 • S-85 Part No. 122149


CHECKLIST E PROCEDURES

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

8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an appropriatelifting device.

9 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank may become unbalanced andfall if it is not properly supportedand secured to the lifting device.

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

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

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

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

14 Install the hydraulic tank onto the machine.

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

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

17 Clean up any oil that may have spilled.

18 Open the hydraulic tank shutoff valves (ifequipped).

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank. Refer to Repair Procedure7-2, How to Prime the Pump.

Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.

19 Operate all machine functions through a fullcycle and check for leaks.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

Part No. 122149 S-80 • S-85 3 - 59


E-2Perform Engine Maintenance -Perkins Models



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






E-3Grease the Steer AxleWheel Bearings, 2WD Models

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steering wheels. Center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm Placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

3 - 60 S-80 • S-85 Part No. 122149



14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of thehub.

16 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen removing the hub.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.

21 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.


8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue to step 11 to greasethe wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

Part No. 122149 S-80 • S-85 3 - 61


E-4Perform Engine Maintenance -Deutz and Perkins Models



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







3 - 62 S-80 • S-85 Part No. 122149



Section 4 • Repair Procedures

Part No. 122149 S-80 • S-85 4 - 1

February 2012

Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie S-80and Genie S-85 Operator’s Manual on yourmachine.

Be sure that all necessary tools and parts areavailable and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

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

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steering wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine


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The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc boom extend/retract

joystick controllerd boom up/down and turntable rotate

left/right joystick controller

1-1ALC-500 Circuit Board

Note: When the ALC-500 circuit board is replaced,the joystick controllers will need to be calibrated.See 1-2, How to Calibrate a Joystick.

How to Remove the ALC-500Circuit Board1 Push in the Emergency Stop button to the off

position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted tothe inside of the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit boardfrom the platform control box.

Platform Controls

bcd

a

February 2012


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PLATFORM CONTROLS

February 2012

1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.


1 Open the platform control box.


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

4 Select a joystick to calibrate.

5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.

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

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

Result: The alarm should sound indicatingsuccessful joystick calibration.

Result: The alarm does not sound. Check theelectrical connections or replace the joystick.

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

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

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.


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7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

Result: The alarm does not sound. Repeat steps3 through 7.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time with thefunction times listed in Section 2,Specifications. Determine whether the functiontime needs to increase or decrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.

Note: Each time the drive enable toggle switch ismomentarily moved, the function speed will changein 2% increments.

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

13 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Result: The alarm does not sound. Theminimum or maximum adjustment has beenobtained. No changes can be saved.

Note: Do not operate any machine function duringthe 10 second waiting time.

14 Cycle the red Emergency Stop button off, thenback on.

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.




3 Push in the platform controls red EmergencyStop button to the off position.


Part No. 122149 S-80 • S-85 4 - 5

February 2012





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



9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 Release the foot switch.

12 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Note: Each time the drive enable toggle switch ismomentarily moved, the time will change in 5%increments.

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

14 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.




Ramp rate (factory settings)

Turntable rotateaccelerate 3 secondsdecelerate 2 second

Boom up/downaccelerate 3 secondsdecelerate 1 second

Boom extend/retractaccelerate 2.5 secondsdecelerate 1 second

Driveaccelerate 4 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.75 seconddecelerate, coasting 1 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 4 seconds


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PLATFORM CONTROLS

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.




3 Push in the red Emergency Stop button to theoff position at the platform controls.





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



9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntable rotate).

13 Return the joystick to the neutral position andwait for approximately 10 seconds.




Function speeds (factory settings)

Boom up 89 to 93 seconds

Boom down 90 to 94 seconds

Boom extend 73 to 79 seconds

Boom retract 79 to 84 seconds

Turntable rotate, 360°boom fully stowed 95 to 103 seconds

Drive speeds (factory settings)

Stowed- high speed 7.9 to 8.5 seconds

Non-stowed 40 to 45 seconds


Part No. 122149 S-80 • S-85 4 - 7

February 2012

Platform Components

2-1Platform

How to Remove the Platform1 Remove the cable clamp from the top of the

platform mounting weldment.

2 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side. Donot disconnect the wiring.

3 Remove the foot switch mounting fasteners.

4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.

5 Tag and disconnect the foot switch wiring fromthe foot switch. Remove the cable from theback of the platform.

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

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

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

Note: If your machine is equipped with an airline toplatform option, the airline must be disconnectedfrom the platform before removal.

7 Support and secure the platform to anappropriate lifting device.

8 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformcould become unstable and fallwhen it is removed from themachine if not properly supported.


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PLATFORM COMPONENTS

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave CylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is no air in theclosed loop.


1 Extend the primary boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

4 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to drive the rod-end pivot pin out.

Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.

5 Remove the external snap rings from the barrel-end pivot pin.

6 Use a soft metal drift to drive the barrel-endpivot pin out.

7 Carefully pull the cylinder out of the primaryboom to access the hydraulic hoses.

8 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder. Cap the fittings on thecylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

How to Bleed the Slave CylinderNote: Do not start the engine. Use auxiliary powerfor this procedure.

1 Raise the primary boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.


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February 2012

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.


1 Remove the platform. See 2-1,How to Remove the Platform.

PLATFORM COMPONENTS

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the rotator.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

3 S-85: Support the jib boom leveling arms andthe platform mounting weldment with anappropriate lifting device. Do not apply anylifting pressure.

4 Remove the mounting bolts from the platformmounting weldment. Remove the center boltand slide the platform mounting weldment off ofthe platform rotator.

Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if not properlysupported when removed from themachine.

5 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.

S-80:

6 Support the rod end of the platform levelingslave cylinder. Protect the cylinder rod fromdamage.

7 Remove the pivot pin retaining fasteners fromboth the slave cylinder rod-end pivot pin andthe rotator pivot pin.


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PLATFORM COMPONENTS

8 Use a soft metal drift to remove both pivot pins.Remove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.

Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.

S-85:

6 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

7 Support the jib boom leveling arms.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Bodily injury hazard. The jib boomleveling arms may fall if notproperly supported.

9 Lower the jib boom leveling arms.

Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.

Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.

How to Bleed the PlatformRotatorNote: This procedure will require two people. Donot start the engine. Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Place a suitable container underneath theplatform rotator.

3 Open the top bleed screw on the rotator, but donot remove it.



Part No. 122149 S-80 • S-85 4 - 11

February 2012

PLATFORM COMPONENTS

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

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


6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Clean up any hydraulic oil that may havespilled.

8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.

2-4Platform Overload System

How to Calibrate the PlatformOverload System (if equipped)

Calibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.


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February 2012

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.

PLATFORM COMPONENTS


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

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.


Part No. 122149 S-80 • S-85 4 - 13

February 2012

PLATFORM COMPONENTS



Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.


4 - 14 S-80 • S-85 Part No. 122149

February 2012

Jib Boom Components, S-85

3-1Jib Boom

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


1 Remove the platform. See 2-1, How to Removethe Platform.

Note: Models equipped with platform overoadsystem: If the platform overload components aredisassembled and/or removed from the platformsupport, the platform overload system will need tobe calibrated. See 2-4, How to Calibrate thePlatform Overload System.

2 Models equipped with platform overloadsystem: Tag and disconnect the electricalconnector from the platform load sense module.

3 Remove the hose and cable cover from the sideof the jib boom.

4 Remove the hose and cable clamp from the jibboom pivot pin. Lay all hoses and cables to theside.

Component damage hazard.Hoses and cables can becomedamaged if they are kinked orpinched.

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


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

7 Place blocks under the platform levelingcylinder for support. Protect the cylinder rodfrom damage.

8 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly attached to the overheadcrane.

9 Remove the pin retaining fastener from the jibboom bellcrank to primary boom pivot pin.

10 Use a soft metal drift to remove the pin andcarefully remove the jib boom assembly fromthe primary boom.

Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.


Part No. 122149 S-80 • S-85 4 - 15

February 2012

JIB BOOM COMPONENTS, S-85

3-2Jib Boom Lift Cylinder

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


1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

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


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Attach a lifting strap from an overhead crane tothe lug at the rod end of the jib boom liftcylinder.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.


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February 2012

4-1Cable Track

The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable track isnecessary when performing major repairs thatinvolve removing the boom.

How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Open the platform control box.

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

3 Loosen the squeeze connector and remove thefoot switch cable from the control box.

4 Disconnect the wire connectors from the bottomof the platform control box.

Note: When installing the wire connectors to thebottom of the platform control box, match the colorof the connectors to those on the control box to besure they are installed in the correct location.

5 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side.

Boom Components

6 S-80: Tag, disconnect and plug the hydraulichoses from the counterbalance valve manifoldlocated on the platform rotator. Cap the fittingson the manifold.


7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling slave cylinder at theunion and connect the hoses from the cylindertogether using a connector.


8 S-85:Remove the hose and cable cover fromthe side of the jib boom.

9 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate selectmanifold. Cap the fittings on the manifold.

10 Tag, disconnect and plug the wiring from the jibboom/platform rotate select manifold.


Part No. 122149 S-80 • S-85 4 - 17

February 2012

BOOM COMPONENTS

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


All models:

12 From the ground controls, raise the boom to ahorizontal position.

13 Remove the fasteners from the drive speed limitswitch bracket (LS1RS) mounted on the side ofthe boom at the platform end of the boom. Donot remove the limit switch from the bracket.

14 Remove the cotter pin from the upper cabletrack at the platform end of the boom.

Note: Always replace the cotter pin with a new one.

15 Remove the cable track guide fasteners fromthe cable track guides at the platform end of theboom. Remove the cable track guides from theboom.

16 Remove the cable clamp from the pivot end ofthe boom.

17 Place blocks between the upper and lowercable tracks and secure the upper and lowertracks together.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

18 Attach a lifting strap from an overhead crane tothe cable track.

19 Remove the mounting fasteners that attach thelower cable track to the boom.

20 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

Component damage hazard. Thecable track can be damaged if it istwisted.


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February 2012

BOOM COMPONENTS

How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.

Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 77896. The kit includes a 4-link section ofcable track.

1 Visually inspect the cable track and determinewhich 4 link section needs to be replaced.

2 Carefully remove the snap rings from each endof the damaged section of cable track.

3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.

4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

5 Remove the upper rollers from the replacementsection of cable track.

6 Lift up the hoses and cables and carefully insertthe new 4 link section of cable track.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.

8 Install the rollers onto the new section of cabletrack.

9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.


Part No. 122149 S-80 • S-85 4 - 19

February 2012

4-2Boom

How to Shim the Boom1 Measure each wear pad.

Note: Replace the pad if thickness is less thanminimum specification. If thickness is more thanminimum specification, perform the followingprocedure. Refer to Section 3, D-1, Check theBoom Wear Pads.

2 Extend the boom until the wear pads areaccessible.

3 Loosen the wear pad mounting fasteners.

4 Install the new shims under the wear pad toobtain zero clearance and zero drag.

5 Tighten the mounting fasteners.

6 Extend and retract the boom through an entirecycle. Check for tight spots that could causebinding or scraping.

Note: Always maintain squareness between theouter and inner boom tubes.

How to Remove the BoomBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



1 Remove the platform. See 2-1, How to Removethe Platform.

2 Remove the platform rotator and leveling slavecylinder. See 2-3, How to Remove the PlatformRotator.

3 Remove the cable track. See 4-1, How toRemove the Cable Track.

4 S-85: Remove the jib boom. See 3-1,How to Remove the Jib Boom.

BOOM COMPONENTS


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February 2012

BOOM COMPONENTS

5 Raise the boom to a horizontal position highenough that the boom lift cylinder rod end canclear the boom lift cylinder mounting boss.

6 Remove the turntable end cover.

7 Remove the pin retaining fasteners from themaster cylinder rod-end pivot pin.

8 Place a rod through the pin and twist to removethe pin. Lower the rod end of the mastercylinder.

9 Remove the fasteners from the boom angle limitswitches (LS2RO and LS2RS) mounted to theinside of both turntable riser side plates at thepivot end of the boom. Do not disconnect thewiring.

10 Remove the fasteners from the boom extendlimit switch (LS1RO) mounted next to the boomextension cylinder at the pivot end of the boom.Do not disconnect the wiring.

11 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


12 Attach an overhead 5 ton / 5000 kg crane to thecenter point of the boom.

13 Attach a similar lifting device to the boom liftcylinder for support.

14 Place support blocks under the boom liftcylinder, across the turntable.

15 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.

Crushing hazard. The boom liftcylinder could fall if not properlysupported.

16 Lower the rod end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.

17 Remove the pin retaining fastener from theboom pivot pin.

18 Use a soft metal drift to remove the boom pivotpin. Carefully remove the boom from themachine.

Crushing hazard. The boom couldbecome unbalanced and fall if notproperly supported by theoverhead crane.


Part No. 122149 S-80 • S-85 4 - 21

February 2012

How to Disassemble the BoomNote: Complete disassembly of the boom is onlynecessary if the outer or inner boom tubes must bereplaced. The extension cylinder can be removedwithout completely disassembling the boom. See4-4, How to Remove the Boom ExtensionCylinders.

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

2 Remove the external snap rings from theextension cylinder pivot pin at the pivot end ofthe number 1 boom tube. Use a soft metal driftto remove the pin.

3 Remove and label the wear pads from the top,side, and bottom of the number 1 boom tube atthe platform end of the boom.

Note: Note the location and quantity of shims usedwith each wear pad.

4 Remove the two wear pad stop bolts from eachside of the number 1 boom tube (located on theoutside).

5 Attach a lifting strap from an overhead crane tothe number 2 and number 3 boom tubes at theplatform end of the boom for support.

6 Support and slide the number 2 and 3 boomtubes out of the number 1 boom tube. Place thenumber 2 and 3 boom tubes on blocks forsupport.

Crushing hazard. The number 2and 3 boom tubes could becomeunbalanced and fall when they areremoved from the number 1 boomtube if they are not properlysupported.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

7 Tag and remove the wear pads from the top,side, and bottom of the number 2 boom tube atthe platform end of the boom.

8 Remove the trunnion pin retaining fasteners atthe base end of the number 2 boom tube. Use aslide hammer to remove the trunnion pins.

9 Attach a lifting strap from an overhead crane tothe number 3 boom tube at the platform end ofthe boom for support.

10 Support and slide the number 3 boom tube outof the number 2 boom tube. Place the number 3boom tube on blocks for support.

Crushing hazard. The number 3boom tube could becomeunbalanced and fall whenremoved from the number 2 boomtube if not properly supported.


BOOM COMPONENTS


4 - 22 S-80 • S-85 Part No. 122149

February 2012

BOOM COMPONENTS

11 Remove the external snap rings from theextension cylinder pivot pin at the platform endof the number 3 boom tube. Use a soft metaldrift to remove the pin.

12 Support and slide the extension cylinder out ofthe pivot end of the number 3 boom tube. Placethe extension cylinder on blocks for support.

Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe number 3 boom tube if notproperly supported.


4-3Boom Lift Cylinder

How to Remove the BoomLift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


1 Raise the boom to a horizontal position highenough that the boom lift cylinder rod end canclear the boom lift cylinder mounting boss.

2 Remove the center turntable cover fasteners.Remove the cover.

3 Place support blocks under the boom liftcylinder across the turntable side plates.

4 Attach an overhead 5 ton / 5000 kg crane tothe boom for support. Do not lift the boom.


Part No. 122149 S-80 • S-85 4 - 23

February 2012

5 Support the rod end of the boom lift cylinderwith an overhead crane or similar lifting device.

Crushing hazard. The boom liftcylinder could become unbalancedand fall when it is disconnectedfrom the machine if not properlysupported.

6 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin, and lower the liftcylinder onto the blocks. Protect the cylinderrod from damage.

Crushing hazard. The boom liftcylinder could become unbalancedand fall when it is disconnectedfrom the machine if not properlysupported.

8 Remove the mounting fasteners from thebarrel-end cylinder pivot pin retaining plates.

9 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform and remove it from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported.

Component damage hazard. Thecables and hydraulic hoses can bedamaged if the lift cylinder ispulled across them.

BOOM COMPONENTS


4 - 24 S-80 • S-85 Part No. 122149

February 2012

3 Place a 4 in x 4 in x 6 ft / 10 cm x 10 cm x 1.8 mblock on top of the number 3 boom tube andplace one end of the block against theweldment at the platform end of the boom.

4 Retract the boom until the number 2 boom tubeis fully retracted into the number 1 boom tube.

Note: The number 3 boom tube will remainextended approximately 6 feet / 1.8 m.

5 Remove the external snap rings from theextension cylinder pivot pin at the platform end.Use a soft metal drift to remove the pin.

6 Remove the turntable end cover.

7 Support the rod end of the master cylinder witha lifting device.

8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Place a rodthrough the pin and twist to remove the pin.

Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe machine if not properlysupported.

Note: Use the platform level toggle switch withauxiliary power to relieve pressure on the mastercylinder barrel-end pivot pin.

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

BOOM COMPONENTS

4-4Boom Extension Cylinders

The extension cylinder consists of two cylindersthat are fastened together. The first cylinderextends and retracts the number 2 boom tube. Thesecond cylinder extends and retracts the number 3boom tube. The extension cylinders are equippedwith counterbalance valves to prevent movementin the event of a hydraulic line failure.

How to Remove theBoom Extension Cylinders

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.


1 Raise the boom to a horizontal position, fullyextend the boom and fully lower the platform.

2 Remove the 2 bolts that are located on eachside of the number 3 boom tube near theplatform end of the number 2 boom tube.


Part No. 122149 S-80 • S-85 4 - 25

February 2012

10 Remove the external snap rings from theextension cylinder pivot pin at the pivot end ofthe boom. Use a soft metal drift to remove thepin through the access holes in the turntableriser.

11 Using auxiliary power, move the boomextend/retract toggle switch in the extenddirection and extend the extension cylinder outthe pivot end of the boom approximately1 foot / 30 cm.

12 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


13 Attach a lifting strap from an overhead crane tothe end of the extension cylinder and lift slightlyto relieve the pressure on the trunnion pins.

14 Remove the trunnion pin access covers fromboth sides of the number 1 boom tube at thepivot end of the boom.

15 Remove the trunnion pin retaining fastener anduse a slide hammer to remove the pins.

16 Slide the cylinder out to access the wear padson the bottom rod support bracket. Remove thewear pads.

17 Support and slide the extension cylinder out ofthe pivot end of the boom.

Crushing hazard. The extensioncylinder could become unbalancedand fall when it is removed fromthe machine if not properlysupported.

Note: Note the length of the cylinder after removal.The cylinder must be at the same length forinstallation.

Note: During re-assembly of the boom, fully retractthe boom after installing all pins. Install the two top¼-20 fasteners through the access holes locatedmid-section of the number 1 boom tube. Thenextend the boom and install the two lower ¼-20fasteners in the number 3 boom tube.

BOOM COMPONENTS


4 - 26 S-80 • S-85 Part No. 122149

February 2012

BOOM COMPONENTS

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed loop hydrauliccircuit that keeps the platform level through theentire range of boom motion. The master cylinderis located inside the pivot end of the boom.

How to Remove the PlatformLeveling Master CylinderNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Raise the boom until the master cylinderrod-end pivot pin is accessible.

2 Remove the turntable end cover to access themaster cylinder.

3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


4 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin.

5 Place a rod through the barel-end pivot pin andtwist to remove the pin.

6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

7 Remove the pin retaining fastener from therod-end pivot pin.

8 Place a rod through the rod-end pivot pin andtwist to remove the pin.

9 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properlysupported by the lifting devicewhen removed from the machine.


Part No. 122149 S-80 • S-85 4 - 27

February 2012

5-1RPM Adjustment

Refer to Maintenance Procedure B-10,Check and Adjust the Engine RPM.

Engines

a b c d e

f

5-2Flex Plate

The flex plate couples the engine to the pump. Theflex plate is bolted to the engine flywheel and has acut-out in the center for the pump coupler.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engine

0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.36 inch / 9.14 mm gap - Continental Engine


4 - 28 S-80 • S-85 Part No. 122149

February 2012

ENGINES

How to Remove the Flex PlateNote: Perform this procedure with the engine offand cool to the touch.

1 Open the engine side turntable cover.

2 Tag and disconnect the battery cables from thebattery(s).


3 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.

a engine tray anchor holeb engine tray retaining fastener

4 Tag and disconnect the wiring plug at theelectronic displacement controller (EDC),located on the drive pump.

Deutz model:

5 Tag and disconnect the wiring from the bellhousing.

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

Burn hazard. Hot engine parts cancause severe burns.

7 Remove the muffler bracket retaining fastenersfrom bell housing. Remove the muffler andbracket assembly from the engine.

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

9 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched

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


Part No. 122149 S-80 • S-85 4 - 29

February 2012

ENGINES

Perkins model:

5 Tag and disconnect the wiring from the bellhousing.

6 Remove the exhaust pipe clamp at the muffler.

Burn hazard. Hot engine parts cancause severe burns.

7 Remove the muffler mounting bracketfasteners. Remove the muffler and bracketassembly from the engine.

8 Remove the hose clamps from the air cleanerelbow and the engine intake manifold.

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

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

Continental model:

5 Tag and disconnect the wire harness from theoxygen sensor.

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

Burn Hazard. Hot engine parts cancause severe burns.

7 Remove the muffler retainer bracket fasteners.

8 Remove the muffler fasteners securing themuffler to the exhaust manifold. Remove themuffler from the bracket.

9 Remove the relay housing from the mufflermount. Do not disconnect the relays.

10 Disconnect and remove the ECM from themuffler mount.

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

12 Unbolt the EPR valve from the muffler mount.Leave the hoses attached to the EPR valve.

13 Remove the muffler mount.

14 Support the drive pump with an appropriatelifting device. Remove all of pump platemounting fasteners.

15 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

16 Remove the flex plate mounting fasteners.Remove the flex plate from the engine flywheel.


4 - 30 S-80 • S-85 Part No. 122149

February 2012

ENGINES

a b c d e

f

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump. ApplyLoctite® removable thread sealant to themounting screws.

Note: Torque the flex plate mounting bolts in twostages.

Continental model: Torque the flex platemounting bolts in sequence to20.8 ft-lbs / 28 Nm.Deutz model: Torque the flex plate mountingbolts in sequence to 28 ft-lbs / 38 Nm.Perkins model:(Before serial number 6091) Torque the flexplate mounting bolts in sequence to28 ft-lbs / 38 Nm.(After serial number 6090) Torque the flexplate mounting bolts in sequence to46.7 ft-lbs / 63.3 Nm.

2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

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

4 Install the pump onto the pump mounting plate.Apply Loctite® removable thread sealant to thepump retaining fasteners. Torque the pumpretaining fasteners to 57 ft-lbs / 77 Nm.

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

5 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

6 Install the pump and pump mounting plateassembly onto the engine. Apply Loctite®

removable thread sealant to the mountingscrews.Perkins model:Torque the pump mounting plate fasteners insequence to 28 ft-lbs / 38 Nm.Deutz model:Torque the pump mounting plate fasteners insequence to 46.7 ft-lbs / 63.3 Nm.Continental model:Torque the pump mounting plate fasteners insequence to 23 ft-lbs / 31.2 Nm.

Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.

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

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engine

0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.36 inch / 9.14 mm gap - Continental Engine


Part No. 122149 S-80 • S-85 4 - 31

February 2012

ENGINES

1

2

3

4 5

6

Perkins, Deutz and ContinentalFlex Plate

10

6 1

8

4

11

7 5

92

12

3

C

C C

C

C

C

C

CC

C

C

C

10

6 1

8

4

11

7 5

92

12

3

Deutz BF4L-2011Pump Mounting Plate

Perkins 804C-33Pump Mounting Plate

1

8

6

10

11 12

3

5

92

7

4

Continental Pump Mounting Plate


4 - 32 S-80 • S-85 Part No. 122149

February 2012

Ground Controls

6-1Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay


1 Tag and disconnect all the wiring from the relayto be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.

Test Desired result

terminal 85 to 86 with resistor 75 to 85

terminal 87 to 87a and 30 no continuity(infinite

terminal 87a to 30 continuity(zero )

3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87 to 87a and 30 no continuity(infinite

terminal 87 to 30 continuity(zero )

terminal no. 87a - N.C.terminal no. 85 - coil negative (-)terminal no. 30 - commonterminal no. 86 - coil positive (+)terminal no. 87 - N.O.

Control Relay Schematic


Part No. 122149 S-80 • S-85 4 - 33

February 2012

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


3 Remove the pump mounting fasteners.Carefully remove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves (if equipped) andprime the pump after installing thepump. See 7-2, How to Prime thePump.

Hydraulic Pumps

7-1Function Pump

How to Remove the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Close the two hydraulic tank valves located atthe hydraulic tank.

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

open closed


4 - 34 S-80 • S-85 Part No. 122149

February 2012

HYDRAULIC PUMPS

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


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

2 Close the two hydraulic tank valves located atthe hydraulic tank.

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

open closed


Part No. 122149 S-80 • S-85 4 - 35

February 2012

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


4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump assembly from themachine.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

Note: Before installing the pump, verify properpump coupler spacing. See 5-2, Flex Plate.

How to Prime the PumpComponent damage hazard. Besure that the hydraulic tank shutoffvalves (if equipped) are in theopen position before priming thepump. The engine must not bestarted with the hydraulic tankshutoff valves in the closedposition or component damage willoccur.

1 Connect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Continental models: If equipped, close thevalve on the LPG tank, then disconnect thehose from the tank. Move the fuel select toggleswitch to the LPG position.Deutz and Perkins models: Disconnect theengine wiring harness from the fuel solenoid atthe injector pump.

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 300 psi / 20.7 bar.

4 Continental models: If equipped, connect theLPG hose to the LPG tank and open the valveon the tank.Deutz and Perkins models: Connect theengine wiring harness to the fuel solenoid.

5 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS


4 - 36 S-80 • S-85 Part No. 122149

February 2012

Manifolds

8-1Function Manifold Components - View 1

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

Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ....... A ........... Platform rotate left/right .................... 25-30 ft-lbs / 34-41 Nm

2 Check valve, 30 psi / 2 bar ................ B ........... Platform rotate circuit(prevents hydraulic hosesfrom draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm

3 Check valve, 30 psi / 2 bar ................ C ........... Platform rotate circuit(prevents hydraulic hosesfrom draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm

4 Solenoid valve, 2 position 3 way ....... D ........... Boom retract ..................................... 33-37 ft-lbs / 45-50 Nm

5 Solenoid valve, 3 position 4 way ....... E ........... Turntable rotate left/right ................... 25-30 ft-lbs / 34-41 Nm

6 Relief valve, 2500 psi / 172 bar ......... F ........... Boom extend/retract circuit ............... 20-25 ft-lbs / 27-34 Nm

7 Solenoid valve, 2 position 3 way ....... G ........... Boom extend ..................................... 50-55 ft-lbs / 68-75 Nm

8 Check valve ....................................... H ........... Differential sensing circuit,turntable rotate left/right ...................... 8-10 ft-lbs / 10-15 Nm

9 Differential sensing valve .................. I ............ Boom extend/retract circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm

10 Differential sensing valve .................. J ............ Turntable rotate left/right circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm

11 Proportional solenoid valve ............... K ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm

12 Check valve ....................................... L ........... Differential sensing circuit,platform level down ............................. 8-10 ft-lbs / 10-15 Nm

13 Check valve ....................................... M .......... Differential sensing circuit,platform level up ................................. 8-10 ft-lbs / 10-15 Nm

14 Solenoid valve, 3 position 4 way ....... N ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm

15 Differential sensing valve .................. O ........... Boom up/down circuit(prevents overflowingthe proportional valve) ...................... 30-35 ft-lbs / 41-47 Nm

16 Counterbalance valve ........................ P ........... Platform level down circuit ................ 35-40 ft-lbs / 47-54 Nm

17 Counterbalance valve ........................ Q ........... Platform level up circuit ..................... 35-40 ft-lbs / 47-54 Nm

18 Solenoid valve, 2 position 3 way ....... R ........... Boom down ....................................... 33-37 ft-lbs / 45-50 Nm

19 Solenoid valve, 3 position 4 way ....... S ........... Steer left/right andaxle extend/retract ............................ 35-40 ft-lbs / 47-54 Nm

20 Relief valve, 2900 psi / 200 bar ......... T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm

This list continues. Please turn the page.


Part No. 122149 S-80 • S-85 4 - 37

February 2012

MANIFOLDS

A B C

D

E

G

K

L

M

P

R

S

Q

O

N

J

I

H

F

TUVWX

AA

CC

DD

EE

GG

FF

BB

Z

Y

1 2 3

202123 2224

25

26

27

28

29

30

31

32

33

4

5

6

7

10

8

9

11

12

13

14

16

15

17

18

19


4 - 38 S-80 • S-85 Part No. 122149

February 2012

MANIFOLDS

Function Manifold Components - View 1, continued


21 Check valve ....................................... U ........... Blocks flow from auxiliary pumpto function pump ............................... 30-35 ft-lbs / 41-47 Nm

22 Priority flow regulator valve,3.5 gpm / 13.2 L/min .......................... V ........... Steer circuit ....................................... 30-35 ft-lbs / 41-47 Nm

23 Proportional solenoid valve ............... W .......... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm

24 Solenoid valve, 2 position 3 way ....... X ........... Boom up ............................................ 33-37 ft-lbs / 45-50 Nm

25 Check valve ....................................... Y ........... Blocks flow from function pumpto auxiliary pump ............................... 30-35 ft-lbs / 41-47 Nm

26 Check valve ....................................... Z ........... Hydraulic oil cooler bypass ............... 30-35 ft-lbs / 41-47 Nm

27 Check valve ....................................... AA ......... Boom up/down circuit ......................... 8-10 ft-lbs / 10-15 Nm

28 Needle valve ...................................... AB ......... Platform level circuit .......................... 30-35 ft-lbs / 41-47 Nm

29 Proportional solenoid valve ............... AC ........ Turntable rotate circuit ...................... 20-30 ft-lbs / 27-47 Nm

30 Differential sensing valve .................. AD ........ Meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm

31 Check valve ....................................... AE ......... Differential sensing circuit,boom extend/retract ............................ 8-10 ft-lbs / 10-15 Nm

32 Flow regulator valve,0.1 gpm / 0.37 L/min .......................... AF ......... Bleeds off differential

sensing valves to tank ...................... 20-25 ft-lbs / 27-34 Nm

33 Flow regulator valve,0.6 gpm / 2.27 L/min .......................... AG ........ Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm


Part No. 122149 S-80 • S-85 4 - 39

February 2012

MANIFOLDS

A B C

D

E

G

K

L

M

P

R

S

Q

O

N

J

I

H

F

TUVWX

AA

CC

DD

EE

GG

FF

BB

Z

Y

1 2 3

202123 2224

25

26

27

28

29

30

31

32

33

4

5

6

7

10

8

9

11

12

13

14

16

15

17

18

19


4 - 40 S-80 • S-85 Part No. 122149

February 2012

8-2Function Manifold Components - View 2

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


1 Check valve, 30 psi / 2 bar ................ AH ........ Platform rotate circuit.......................................................................... (prevents hydraulic hoses.......................................................................... from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm

2 Flow regulator valve,0.3 gpm / 1.14 L/min .......................... AJ ......... Dump circuit source from.......................................................................... charge pump ..................................... 20-25 ft-lbs / 27-34 Nm

3 Solenoid valve, 2 position 2 way ....... AK ......... Allows boom functions tooperate with the boom inthe stowed position ........................... 26-30 ft-lbs / 34-41 Nm

4 Check valve, 30 psi / 2 bar ................ AI .......... Blocks flow from charge pumpto auxiliary pump ............................... 20-25 ft-lbs / 27-34 Nm

5 Check valve, 30 psi / 2 bar ................ AL ......... Blocks flow from auxiliary pumpto charge pump ................................. 20-25 ft-lbs / 27-34 Nm

6 Pressure Switch, 180 psi / 12.4 bar ... AY ......... Axle extend pressure switch ............. 26-30 ft-lbs / 34-41 Nm

7 Solenoid valve, 2 position 3 way ....... AM ........ Provides pilot signal to redirectsteer flow to axle extension system .. 26-30 ft-lbs / 34-41 Nm

8 Directional valve, 2 position 2 way,pilot operated ..................................... AN ........ Dump valve that allows boom

functions to operate whenaxles are fully extended .............. 90-100 ft-lbs / 122-136 Nm

9 Relief valve, 2100 psi / 145 bar ......... AO ........ Boom down ....................................... 20-25 ft-lbs / 27-34 Nm

MANIFOLDS

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1234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567123456789012345678901234567890121234567890123456789012345671234567890123456789012345678901212345678901234567890123456712345678901234567890123456789012123456789012345678901234567


Part No. 122149 S-80 • S-85 4 - 41

February 2012

MANIFOLDS

AH

AI

AL

AJ

AK

AMANAO

AY

79 8

1

2

4

3

5

6


4 - 42 S-80 • S-85 Part No. 122149

February 2012

MANIFOLDS

8-3Valve Adjustments -Function Manifold

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

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST port) onthe function manifold.


3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom retract toggle switch with theboom fully retracted. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item T) on thefunction manifold.

5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 to confirm relief valvepressure.

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



3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom down toggle switch with theboom fully lowered. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AO) onthe function manifold.

5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.


6 Repeat steps 2 through 5 and confirm reliefvalve pressure.


Part No. 122149 S-80 • S-85 4 - 43

February 2012

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



3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom extend toggle switch with theboom fully extended. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item F) on thefunction manifold.

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.


6 Repeat steps 2 through 5 to confirm relief valvepressure.

MANIFOLDS


4 - 44 S-80 • S-85 Part No. 122149

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MANIFOLDS



Part No. 122149 S-80 • S-85 4 - 45

February 2012

MANIFOLDS

8-4Brake / Two Speed Manifold Components

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


1 Solenoid valve, 2 position 3 way .... EA ........... Releases brakes .............................. 47-52 ft-lbs / 64-70 Nm

2 Solenoid valve, 2 position 3 way .... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm

3 Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm

4 Orifice, 0.042 inch / 1.07 mm ......... ED ........... Controls flow to tank

4

3

1 2

EA EB

EC

ED


4 - 46 S-80 • S-85 Part No. 122149

February 2012

MANIFOLDS

8-5Turntable Rotation Manifold Components

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


1 Shuttle valve, 2 position 3 way .......... PP ......... Turntable rotation brake release ......... 8-10 ft-lbs / 10-15 Nm

2 Counterbalance valve ........................ QQ ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm

3 Counterbalance valve ........................ RR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm

1 2 3

QQPP RR


Part No. 122149 S-80 • S-85 4 - 47

June 2015

MANIFOLDS

8-6Jib Boom Select and Platform Manifold Components, S-85

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


1 Solenoid valve, 2 position 3 way ...... CT ......... Platform rotate select ........................ 25-30 ft-lbs / 34-41 Nm

2 Counterbalance valve ....................... CR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm

3 Counterbalance valve ....................... CS ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm

Jib Manifold

Platform

Rotate Manifold

CR

CS

CT1

3

2


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February 2012

MANIFOLDS

8-7Axle Select Manifold Components

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


1 Directional valve, pilot operated2 position 3 way ................................. FA ......... Directs flow from steer cylinders

to axle extend circuit ......................... 30-35 ft-lbs / 41-47 Nm

2 Pressure reducing valve,1000 psi / 69 bar ................................ FB ......... Limits pressure to tie rod cylinder

during axle extension ........................ 30-35 ft-lbs / 41-47 Nm

3 Directional valve, pilot operated2 position 3 way ................................. FC ......... Directs flow from steer cylinders

to axle retract circuit .......................... 30-35 ft-lbs / 41-47 Nm

4 Directional valve, pilot operated2 position 2 way ................................. FD ......... Locks out steer cylinders during

axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm

5 Directional valve, pilot operated2 position 2 way ................................. FE ......... Locks out steer cylinders during

axle extend/retract ............................ 30-35 ft-lbs / 41-47 Nm


Part No. 122149 S-80 • S-85 4 - 49

February 2012

MANIFOLDS

FA FB FC

FD

FE

4

5

1 32


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8-82WD Traction Manifold Components

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


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

2 Flow Divider / Combiner Valve .......... BY ......... Controls flow to drive motors in.......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm

3 Check Valve, 5 psi / 0.34 bar ............ BZ ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

4 Check Valve, 5 psi / 0.34 bar ............ CA ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

5 Shuttle Valve, 3 position 3 way ......... CB ........ Controls flow to drive motors in.......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm

6 Orifice Plug, 0.070 inch / 1.78 mm .... CC ........ Equalizes flow across flow divider/.......................................................................... combiner valve BY

MANIFOLDS


Part No. 122149 S-80 • S-85 4 - 51

February 2012

MANIFOLDS

BX

BY

BZ

CA

CB

CC

1

6

2

5

3

4


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February 2012

8-94WD Traction Manifold Components

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


1 Relief valve, 280 psi / 19.3 bar .......... CD ........ Charge pressure circuit ..................... 35-40 ft-lbs / 48-54 Nm

2 Flow divider/combiner valve .............. CE ........ Controls flow to non-steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

3 Check valve ....................................... CF ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm

4 Check valve ....................................... CG ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm

5 Flow divider/combiner valve .............. CH ........ Controls flow to flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm

6 Check valve ....................................... CI .......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm

7 Orifice, 0.040 inch / 1 mm ................. CJ ......... Equalizes pressure on both sidesof flow divider/combiner valve 5

8 Orifice, 0.040 inch / 1 mm ................. CK ........ Equalizes pressure on both sidesof flow divider/combiner valve 2

9 Orifice, 0.040 inch / 1 mm ................. CL ......... Equalizes pressure on both sidesof flow divider/combiner valve 13

10 Check valve ....................................... CM ........ Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm

11 Check valve ....................................... CN ........ Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm

12 Shuttle valve, 3 position 3 way .......... CO ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ........................ 80-90 ft-lbs / 108-122 Nm

13 Flow divider/combiner valve .............. CP ........ Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

14 Check valve ....................................... CQ ........ Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm

MANIFOLDS


Part No. 122149 S-80 • S-85 4 - 53

February 2012

CE

CF

CG

CH

CD

CI

CJCK

CP

CO

CN

CM

CL

CQ

9 8 7

10

6

5

3

2

1

11

13

14

12

4

MANIFOLDS


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February 2012

CY

CX

CU

CV

CW

1

3

4

5

2

8-10Drive Oil Diverter Manifold Components (welder option)

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


1 Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm

2 Orifice disc, 0.030 inch / 0.080 cm . CV ........... Delays shift to drive

3 Solenoid valve ................................ CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm

4 Relief valve ..................................... CX ........... Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm

5 Check valve .................................... CY ........... Prevents oil to generator .................. 35-40 ft-lbs / 47-54 Nm

MANIFOLDS


Part No. 122149 S-80 • S-85 4 - 55

February 2012

MANIFOLDS

8-11Valve Adjustments -Traction Manifold

How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in thetraction manifold) is necessary to return hot oilfrom the closed loop drive circuit to the hydraulictank for cooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.

Note: The following procedure will require twopeople.

1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Start the engine from the platform controls andallow the engine to run at low idle. Note thepressure reading on the pressure gauge.

3 Turn the engine off and connect a0 to 600 psi / 0 to 40 bar pressure gauge to thediagnostic nipple located on the tractionmanifold.

4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item BJ). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.

6 Repeat steps 4 and 5 until a pressuredifferential (between the charge pump readingand the hot oil shuttle relief valve) of40 psi / 14.5 bar is obtained.


4 - 56 S-80 • S-85 Part No. 122149

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MANIFOLDS

Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Proportional solenoid valve 4.8 (schematic items K and W)

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

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

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

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

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

8-12Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infinite resistanceindicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification canproduce erratic operation. When coil resistancedecreases below specification, amperageincreases. As resistance rises above specification,voltage increases.

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


Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil tobe tested.

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

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

REV B


Part No. 122149 S-80 • S-85 4 - 57

February 2012

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.


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

2 Connect a 10 resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Note: The battery should read 9V DC or morewhen measured across the terminals.

a multimeterb 9V DC batteryc 10 resistord coil

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

3 Set a multimeter to read DC current.

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

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

9VBATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

d

a

b

b

c

c

MANIFOLDSREV B


4 - 58 S-80 • S-85 Part No. 122149

February 2012

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

MANIFOLDS


Part No. 122149 S-80 • S-85 4 - 59

February 2012

Fuel and Hydraulic Tanks

9-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

1 Turn the manual fuel shutoff valve to theclosed position (if equipped).

2 Remove the fuel filler cap from the tank.

3 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer tocapacity specifications.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Note: Be sure to only use a hand operated pumpsuitable for use with gasoline and diesel fuel.

4 Tag, disconnect, drain and plug the supply andreturn fuel hoses. Cap the fittings on the fueltank.

5 Remove the fuel tank retaining fasteners.

6 Remove the fuel tank from the machine.

Component damage hazard.The fuel tank is plastic and maybecome damaged if allowed to fall.

Component damage hazard.When installing the plastic fueltank, do not overtighten theretaining fasteners.

Note: Clean the fuel tank and inspect for damagebefore installing it onto the machine.


4 - 60 S-80 • S-85 Part No. 122149

February 2012

FUEL AND HYDRAULIC TANKS

9-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and de-aerate the hydraulic fluid duringoperation. The tank utilizes internal suctionstrainers for the pump supply hoses and has anexternal return filter equipped with a filter conditionindicator.

How to Remove theHydraulic Tank

Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.


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

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

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

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

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

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

6 Tag and disconnect and plug the supply hosefor the auxiliary power unit. Cap the fitting onthe hydraulic tank.

open closed


Part No. 122149 S-80 • S-85 4 - 61

February 2012

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

8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.

9 Remove the hydraulic tank from the machine.

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

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

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

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

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

14 Install the hydraulic tank onto the machine.

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

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

FUEL AND HYDRAULIC TANKS


18 Open the hydraulic tank shutoff valves(if equipped).

Component damage hazard.Be sure to open the two hydraulictank shutoff valves (if equipped)and prime the pump after installingthe hydraulic tank.

Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.


4 - 62 S-80 • S-85 Part No. 122149

February 2012

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

5 Remove the backlash pivot plate mountingbolts. Carefully remove the drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotation drive hub assembly couldbecome unbalanced and fall whenit is removed from the machine ifnot properly supported.

When installing the drive hub assembly:

6 Install the drive hub. Apply removable threadlocking compound to fastener threads.Torquethe backlash pivot plate mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.

7 Install the brake and then the motor onto thedrive hub. Apply removable thread lockingcompound to fastener threads.Torque themotor/brake mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.

8 Adjust turntable rotation gear backlash.See 10-1, How to Adjust the Turntable RotationGear Backlash.

10-1Turntable Rotation Drive HubAssembly

How to Remove the TurntableRotation Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.


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


3 Loosen the backlash pivot plate and adjustmentbolts.

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

Turntable Rotation Components

unlocked locked

a b c


Part No. 122149 S-80 • S-85 4 - 63

February 2012

TURNTABLE ROTATION COMPONENTS

How to Remove the TurntableRotation Hydraulic MotorNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.



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


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


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


a motorb drive hub with brakec drive hub mounting bolts

b

a

c


4 - 64 S-80 • S-85 Part No. 122149

February 2012

How to Adjust the TurntableRotation Gear BacklashThe turntable rotation drive hub is mounted on anadjustable plate that controls the gap between therotation motor pinion gear and the turntablebearing ring gear.

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



2 Loosen the backlash pivot plate mountingfasteners.

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

3 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation gear into the turntable bearing ringgear).

4 Loosen the lock nut on the adjustment bolt.

5 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.

6 Turn the adjustment bolt one half turncounterclockwise. Tighten the lock nut on theadjustment bolt.

7 Rotate the backlash pivot plate away from theturntable until it contacts the adjustment bolt.Then torque the mounting fasteners on thebacklash pivot plate. Refer to Section 2,Specifications.

8 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.

TURNTABLE ROTATION COMPONENTS

a b c


Part No. 122149 S-80 • S-85 4 - 65

February 2012


11-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from both

the steering cylinder and the tie rod cylinderpivot pins. Use a soft metal drift to remove thepins.


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

4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.


6 Remove the pin retaining fasteners from theyoke pivot pins.

7 Support and secure the yoke and hub assemblyto a lifting jack.

8 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.

9 Remove the yoke and hub assembly from themachine.

Crushing hazard. The yoke andhub assembly may becomeunbalanced and fall if not properlysupported and secured to thelifting jack when it is removed fromthe machine.

How to Remove the Huband Bearings1 Loosen the wheel lug nuts. Do not remove

them.

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



5 Remove the dust cap, cotter pin and castle nut.

Note: Always replace the cotter pin with a new onewhen installing the castle nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.


4 - 66 S-80 • S-85 Part No. 122149

February 2012

2WD STEER AXLE COMPONENTS

How to Install the Hub andBearings, 2WD ModelsNote: When replacing a wheel bearing, both theinner and outer bearings including the pressed-inraces must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearing.


8 Loosen the castle nut one turn, and then torqueto 35 ft-lbs / 47 Nm.

9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.

Note: Always use a new cotter pin when installinga castle nut.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

11-2Steer Cylinder

How to Remove aSteer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.


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


2 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.

3 Remove the steer cylinder from the machine.


Part No. 122149 S-80 • S-85 4 - 67

February 2012


11-3Tie Rod Cylinder

How to Remove theTie Rod CylinderNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

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


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

3 Remove the pin retaining fasteners from eachtie rod cylinder pivot pin.

4 Remove the pivot pin from each end of the tierod cylinder.

5 Remove the tie rod cylinder from the machine.

Crushing hazard. The tie rodcylinder may become unbalancedand fall if not properly supportedand secured to the lifting jackwhen it is removed from themachine.

How to Perform the Toe-inAdjustmentNote: Perform this procedure on a firm, levelsurface. Block the non-steer tires and be sure thatthe machine is in the stowed position.

1 Straighten the steer wheels.

2 Measure the steer tires, front to front and backto back, using a measuring fixture.

3 Center a lifting jack of ample capacity under thesteer axle and raise the machine until the steertires are off the ground.

4 Loosen the jam nut on the adjustable endof the tie rod cylinder.

5 Remove the pin retaining fasteners from theadjustable end of the tie rod cylinder. Removethe pivot pin.

6 Slide the tie rod cylinder off of the yoke andadjust it by turning the end.

Note: One half turn on the adjustable end equalsapproximately1/

8 inch / 3.2 mm change in the front and rear

measurements.

7 Slide the tie rod cylinder onto the yoke. Installthe pivot pin and the pin retaining fastener.

8 Tighten the jam nut against the tie rod cylinder.

9 Lower the machine and repeat step 2.If further adjustment is needed, repeatthis procedure beginning with step 3.

Toe-in specification 0 ± 1/8 inch / 6.35 mm


4 - 68 S-80 • S-85 Part No. 122149

February 2012


7 Remove the hydraulic hose clamp retainingfastener from the top of the yoke pivot pin.

8 Remove the drive motor mounting fasteners.

9 Slide the drive motor shaft out of the drive huband remove the drive motor from the machine.

10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

11 Support and secure the yoke and drive hubassembly to a lifting jack.

12 Use a slide hammer to remove the upper yokepivot pin. Use a soft metal drift to drive thelower yoke pivot pin down and out.

Crushing hazard. The yoke anddrive hub assembly could becomeunbalanced and fall when the yokepivot pins are removed if notproperly supported and secured tothe lifting jack.

13 Place the yoke and drive hub assembly on a flatsurface with the drive hub facing down.

14 Remove the drive hub mounting fasteners thatattach the drive hub to the yoke. Remove theyoke from the drive hub. Refer toSection 2, Specifications.

Note: Replace the thrust washer when installingthe yoke and drive hub assembly onto the axle.


12-1Yoke and Drive Hub

How to Remove the Yokeand Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the pin retaining fasteners from boththe steer cylinder and the tie rod cylinder pivotpins. Remove the pins.

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



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



Part No. 122149 S-80 • S-85 4 - 69

February 2012

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


4 Remove the drive motor mounting fasteners.

5 Slide the drive motor shaft out of the drive hub,and remove the drive motor from the machine.Refer to Section 2, Specifications.

12-2Drive Motor

How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSauer dealer.

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Extend the axles.

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



4 - 70 S-80 • S-85 Part No. 122149

February 2012


12-4Steer Cylinders

How to Remove a Steer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.


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


2 Remove the hose bracket mounting fastener onthe steer cylinder barrel-end pivot pin.

3 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.

4 Remove the steer cylinder from the machine.

12-3Drive Hub

How to Remove a Drive HubNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

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


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


5 Remove the wheel lug nuts, then the tire andwheel assembly.

6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.

7 Remove the drive hub mounting fasteners thatattach the drive hub to the axle. Remove thedrive hub.

Crushing hazard. The drivehub could become unbalancedand fall if not properly supportedand secured to the lifting jackwhen removed from the machine.

Note: Do not re-use the drive hub mountingfasteners. Genie specifications require the use ofnew fasteners.


Part No. 122149 S-80 • S-85 4 - 71

February 2012

12-5Tie Rod Cylinder

How to Remove theTie Rod CylinderThis procedure is the same as the 2WD procedure.See 11-3, How to Remove the Tie Rod Cylinder.

How to Perform the Toe-inAdjustmentThis procedure is the same as the 2WD procedure.See 11-3, How to Perform the Toe-in Adjustment.



4 - 72 S-80 • S-85 Part No. 122149

February 2012

Non-steer Axle Components

13-1Drive Motor

How to Remove a Drive MotorThis procedure is the same as the steer axleprocedure. See 12-2, How to Remove a DriveMotor.

13-2Drive Hub

How to Remove a Drive HubThis procedure is the same as the steer axleprocedure. See 12-3, How to Remove a Drive Hub.


Part No. 122149 S-80 • S-85 4 - 73

February 2012

Oscillating Axle Components

14-1Oscillate Axle Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the axle to maintaina level chassis while driving over uneven terrain.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic hose failure.

How to Remove an Oscillate AxleCylinderNote: Perform this procedure on firm, level surfacewith the boom in the stowed position.


1 Rotate the turntable until the boom is betweenthe steer tires.

2 Remove the fasteners from the drive chassiscover at the steer end. Remove the cover.

3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on thecylinder.


4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

7 Remove the cylinder from the machine.

Crushing hazard. The oscillatecylinder could become unbalancedand fall if not properly attached tothe overhead crane whenremoved from the machine.


4 - 74 S-80 • S-85 Part No. 122149

February 2012

OSCILLATING AXLE COMPONENTS

14-2Oscillate Directional Valve

How to Adjust the Oscillate ReliefValve Pressure1 Remove the drive chassis cover from the non-

steer end of the machine.

2 Connect a 0 to 2000 psi / 0 to 150 bar pressuregauge to the diagnostic nipple located near theoscillate directional valve.

3 Disconnect the directional valve linkage, byremoving the clevis yoke from the drivechassis.

4 Start the engine from the ground control.

5 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

6 Turn the engine off.

7 Locate the relief valve on the directional valve.

a relief valve

8 Loosen the jam nut on the relief valve.

9 Turn the valve clockwise to increase thepressure or counterclockwise to decrease thepressure.

Tip-over hazard. Do not adjust therelief valve higher than specified.

10 Tighten the jam nut.

11 Start the engine and manually activate the valveto confirm the valve pressure.

Result: Pressure is between 800 to 900 psi / 55to 65 bar.

Result: Pressure is less than 800 psi / 55 bar ormore than 900 psi / 65 bar. Repeat thisprocedure beginning with step 5.

12 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.

13 Install the cover on the non-steer end of thedrive chassis.

a


Part No. 122149 S-80 • S-85 4 - 75

February 2012

How to Set Up the DirectionalValve LinkageNote: Perform this procedure on a firm, levelsurface.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the surfacethe machine is on is completely level.


3 Check the tire pressure in all four tires and addair if needed to meet specification.

4 Remove the drive chassis cover from thenon-steer end of the machine.

5 Disconnect the linkage clevis yoke from theaxle.

6 Place a "bubble type" level on the turntablerotate bearing plate at the non-steer end.Confirm whether the drive chassis is completelylevel.

7 If the drive chassis is not level, start the engineand push up or pull down on the linkageadjustment rod until the machine is completelylevel.

8 Verify that the ground and drive chassis arecompletely level.

9 Adjust the length of the rod by turning the clevisyoke until the clevis yoke can be pinned to theaxle.

10 Install the shoulder bolt and nut.

11 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside of the drive chassis).

Result: The measurements should be equal.

Note: If the distance is not equal and theadjustment to the linkage was completed with theground and drive chassis level, consult GenieIndustries Service Department.

OSCILLATING AXLE COMPONENTS


4 - 76 S-80 • S-85 Part No. 122149

February 2012

15-1Extendable Axles

The extendable axles are used to widen the footprint of the drive chassis for stability.

How to Shim an Extendable AxleNote: Replace the pad if thickness is less thanminimum specification. If thickness is more thanminimum specification, perform the followingprocedure. Refer to Maintenance ProcedureD-2, Check the Extendable Axle Wear Pads.

1 Extend the axles.

Side wear pads:

2 Loosen the side wear pad mounting fastenerson the outer axle.

3 Install the new shims under the wear pads toobtain zero clearance and zero drag.

4 Use a round punch to align the shim to the wearpad. Tighten the mounting fasteners.

5 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping.

Note: Always maintain squareness between theinner and outer axle tubes.

Top and bottom wear pads:

1 Center a lifting jack of sufficient capacity underthe outer axle that needs to be shimmed. Donot raise the machine.

2 Block the wheels at the opposite end of themachine.

3 Raise the machine just until the weight of themachine is relieved off of the inner axle. Do notraise the wheels off of the ground.

4 Remove the drive chassis cover.

5 Loosen the wear pad mounting fasteners fromthe top and bottom wear pads on both the innerand outer axles.

6 Install the new shims under the wear pads ofthe inner and outer axle to obtain zeroclearance and zero drag.

7 Use a round punch through the wear padmounting holes to align the shims with the wearpad. Install the wear pad retaining fasteners.

8 Extend and retract the axle through an entirecycle. Check for tight spots that could causebinding or scraping of the axle tubes.

Note: Always maintain squareness between theinner and outer axle tubes.

Extendable Axle Components


Part No. 122149 S-80 • S-85 4 - 77

February 2012

EXTENDABLE AXLE COMPONENTS

How to Remove an Inner AxleNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

Note: Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.

Steer end:

1 Extend the axles.


3 2WD models: Remove the yoke and hubassembly. See 11-1, How to Remove the Yokeand Hub.

4WD models: Remove the yoke and drive hub.See 12-1, How to Remove the Yoke and DriveHub Assembly.

4 4WD models: Remove the hose bracket fromthe steer cylinder barrel-end pivot pin.

5 Remove the remaining steer cylinder pivot pin.Remove the steer cylinder and lay off to theside.


6 Remove the steer cylinder mounting lug fromthe inner axle.

7 Place blocks under the axle extension cylinderfor support.

8 Remove the external snap ring from the axleextension cylinder pivot pin. Use a soft metaldrift to remove the pin.

9 Attach a lifting strap from an overhead crane tothe inner axle for support.

10 Remove all wear pads from the outer axle.

Note: Pay careful attention to the quantity andlocation of shims used when removing the wearpads.

11 Carefully remove the inner axle from the outeraxle.

Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.

Non-steer end:


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



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


4 - 78 S-80 • S-85 Part No. 122149

February 2012


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



19 Remove the external snap rings from the axleextension cylinder pivot pin of the inner axle tobe removed. Use a soft metal drift to removethe pin.

20 Attach a strap from a lifting device through theinner axle close to the drive hub for support.

21 Remove all wear pads from the outer axle.

Note: Pay careful attention to the location andnumber of shims used when removing the wearpads.

22 Carefully remove the inner axle from the outeraxle.

Crushing hazard. The inner axlecould become unbalanced and fallif not properly supported when it isremoved from the outer axle.


15-2Axle Extension Cylinder

How to Remove the AxleExtension CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

Note: Perform this procedure with the boom in thestowed position and boom between the non-steerend tires.

1 Extend the axles.


Steer end:

3 Remove the engine side yoke and hub.

2WD models: Remove the yoke and hubassembly. See 11-1, How to Remove the Yokeand Hub.

4WD models: Remove the yoke and drive hub.See 12-1, How to Remove the Yoke and DriveHub Assembly.

4 Remove the access cover at the end of theinner axle.


Part No. 122149 S-80 • S-85 4 - 79

February 2012

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



7 Remove the external snap rings from the axleextension cylinder pivot pins. Use a soft metaldrift to remove the pins.

8 Carefully remove the axle extension cylinderfrom the machine by pulling it out the end of theinner axle.

Crushing hazard. The axleextension cylinder could becomeunbalanced and fall if not properlysupported when it is removed fromthe axle.

Non-steer end:

9 Remove the drive motor access covers fromboth sides of the axle.

10 Remove the drive motor. Refer to 12-2, How toRemove a Drive Motor.

11 Remove the drive hub. Refer to 12-3, How toRemove a Drive Hub.

12 Tag, disconnect and plug the axle extendcylinder hydraulic hoses from RAE and RAR portson the axle select manifold. Cap the fittings onthe manifold.








4 - 80 S-80 • S-85 Part No. 122149

February 2012



Part No. 122149 S-80 • S-85 4 - 81

February 2012

REV A

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






Non-steer end:

9 Remove the drive motor access covers fromboth sides of the axle.

10 Remove the drive motor. Refer to 12-2, How toRemove a Drive Motor.

11 Remove the drive hub. Refer to 12-3, How toRemove a Drive Hub.

12 Tag, disconnect and plug the axle extendcylinder hydraulic hoses from RAE and RAR portson the axle select manifold. Cap the fittings onthe manifold.








4 - 82 S-80 • S-85 Part No. 122149

February 2012

REV A


Part No. 122149 S-80 • S-85 5 - 1

February 2012 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie S-80 and Genie S-85 Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Perform all troubleshooting on a firm, levelsurface.

Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



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

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom between the non-steer wheels

· Turntable secured with the turntable rotation lock

· Key switch in the off position with the key removed

· Wheels chocked

· All external AC power disconnectedfrom the machine

5 - 2 S-80 • S-85 Part No. 122149

February 2012Section 5 • Fault Codes

FAULT CODES

Fault Codes - Control System

How to Retrieve Control SystemFault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.

Note: Perform this procedure with the engine off,the key switch turned to platform controls and bothred Emergency Stop button pulled out to the onposition at both the ground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platformcontrol box. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindidates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

Note: When the red LED is flashing the code, theyellow LED will be on solid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

Note: When the yellow LED is flashing the code,the red LED will be on solid.

5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.

Part No. 122149 S-80 • S-85 5 - 3


Continued on next page

FAULT CODES

Error Source Error Type ID Name ID Name

Condition Solution 11 12 15 16

Value at 5V Value too high Value too low Value at 0V

Limited speed and direction frozen at zero and neutral. Alarm sounds indicating fault.

Power up controller with problem corrected.

17 Not calibrated Joystick speed and direction frozen at zero and neutral.

Calibrate joystick.

21 Boom 1 Joystick (primary boom up/ down)

18 Just calibrated Initiate 1-second beep of alarm.

Self-clearing. (transient)

22 Boom 1 directional valves

21 Fault



12 15

Value too high Value too low



17 Not calibrated Calibrate valve thresholds.

23 Boom 1 flow control valve

18 Just calibrated

Normal function except threshold for one or both directions is zero.


11 12 15 16





Calibrate joystick.

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

18 Just calibrated Initiate 1 second beep of alarm.


32 Boom 2 directional valves

21 Fault



5 - 4 S-80 • S-85 Part No. 122149


FAULT CODES


Condition Solution

12 15





33 Boom 2 flow control valve

18 Just calibrated



11 12 15 16





Calibrate joystick.

41 Turntable rotate joystick



42 Turntable rotate directional valves

21 Fault



12 15





43 Turntable rotate flow control valve

18 Just calibrated



44 Drive enable override switches 21 Fault

Enable override direction is frozen at neutral.


Part No. 122149 S-80 • S-85 5 - 5


FAULT CODES


Condition Solution 11 12 15 16





Calibrate joystick.

51 Drive joystick



12 15





53 Drive flow valve (EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drive motor Valve

21 Fault

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


11 12 15 16





Calibrate joystick.

61 Steer joystick



62 Steer directional valves

21 Fault



5 - 6 S-80 • S-85 Part No. 122149


FAULT CODES

How to Retrieve ContinentalEngine Fault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highestefficiency while at the same time keepingexhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault codein memory that relates to the appropriate sensorand will turn on the Check Engine Light.

Note: Perform this procedure with the key switchin the off position.

1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.


Engine Fault Codes -Continental Models

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

4 Move and hold the run/test toggle switch tothe test position.

Result: The check engine light should turn on.The check engine light should begin to blink.

5 Continue to hold the run/test toggle switch inthe test position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 threetimes. After the fault codes, the check enginelight will blink a code 123 three times againindicating the end of the stored codes.

Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree digit code, pause, blink the second digit,pause, and then blink the third digit. Forexample: the check engine light blinks 5consecutive times, blinks 3 times and then 1time. That would indicate code 531.

Note: Once a fault code has been retrieved andthe repair has been completed, the ECMmemory must be reset to clear the fault codefrom the ECM. See How to Clear Engine FaultCodes from the ECM.

Part No. 122149 S-80 • S-85 5 - 7


FAULT CODES

Continued on next page

How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.

1 Open the engine side turntable cover andlocate the battery.

2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings,watches and other jewelry.

3 Connect the negative battery cable to thebattery.

5 - 8 S-80 • S-85 Part No. 122149


Continental Engine ECM Fault Code Chart

643 5V External 1 voltage high

685 Relay coil open

686 Relay control ground short

687 Relay coil short to power

1111 Fuel rev limit

1112 Spark rev limit

1151 CL (closed loop) high LPG

1152 CL (closed loop) low LPG

1155 CL (closed loop) high gasoline bank 1

1156 CL (closed loop) low gasoline bank 1

1161 Al (adaptive learning) high LPG

1162 AL (adaptive learning) low LPG

1165 LPG cat monitor

1171 EPR delivery pressure > than expected

1172 EPR delivery pressure < than expected

1173 EPR comm lost

1174 EPR voltage supply high

1175 EPR voltae supply low

1176 EPR intenal actuator fault detection

1177 EPR internal circuitry fault detection

1178 EPR internal comm fault detection

1612 RTI 1 loss

1613 RTI 2 loss

1614 RTI 3 loss

1615 A/D loss

1616 Invalid interrupt

1625 J1939 shutdown request

1626 J1939 CAN Tx failure

1627 J1939 CAN Rx failure

1628 J1939 CAN conflict failure

2111 Unable to reach < TPS

2112 Unable to reach > TPS

2122 FPP1 voltage high

2123 FPP1 voltage low

2135 TPS1/2 simultaneous voltages out of range

2229 BP (barometric pressure) high

2618 Tach output ground short

2619 Tach output short to power

Code DescriptionCode Description

16 Never crank synced at start

107 MAP (manifold absolute pressure) volt low

108 MAP (manifold absolute pressure) volt high

111 IAT (intake air temp) higher than expected 1

112 EAT (exhaust air temperature) voltage low

113 IAT (intake air temperature) voltage high

116 ECT higher than expected 1

117 ECT voltage low

118 ECT voltage high

121 TPS1 < TPS2 (throttle position sensor)

122 TPS1 (throttle position sensor) voltage low

123 TPS1 (throttle position sensor) voltage high

127 IAT (intake air temp) higher than expected 2

129 BP (barometric pressure) low

134 EGO open / lazy pre-cat 1

154 EGO open / lazy post-cat 1

171 AL (adaptive learning) high gasoline bank 1

172 AL (adaptive learning) low gasoline bank 1

217 ECT higher than expected 2

219 Max govern speed override

221 TPS1 > TPS2 (throttle position sensor)

222 TPS2 (throttle position sensor) voltage low

223 TPS2 (throttle position sensor) voltage high

261 Injector Loop Open or Low-Side short to gnd

262 Injector Coil shorted

336 Crank sync noise

337 Crank sensor loss

341 Cam sync noise

342 Cam sensor loss

420 Gasoline cat monitor

524 Oil pressure low

562 Battery voltage low

563 Battery voltage high

601 Flash checksum invalid

604 Ram failure

606 COP failure

642 5V External 1 voltage low

February 2012 Section 6 • Schematics

Part No. 122149 S-80 • S-85 6 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie S-80 and Genie S-85 Operator's Manualon your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes the drawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

February 2012Section 6 • Schematics

6 - 2 S-80 • S-85 Part No. 122149

Electrical Symbols Legend

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

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

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Battery separator

MA

INA

UX

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B


Part No. 122149 S-80 • S-85 6 - 3

Hydraulic Symbols Legend

Pumpfixed displacement

Motorbi-directional

Accumulator

Shut off valve

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve


6 - 4 S-80 • S-85 Part No. 122149


Section 6 • Schematics

6 - 5

February 2012

Electrical Schematic, S-80/85Deutz BF4L 2011 Models (before serial number 5520)

6 - 6


6 - 6 S-80 • S-85 Part No. 122149

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

1

2

3

4

5

6

7

8

Electrical Schematic, S80/85Deutz BF4L 2011 Models (before serial number 5520)

P1

34

TT

SR

D

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

20AMP.RD

P2

0B

AT

RD

RE

LA

Y

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

RD

TB41

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

NS

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

./STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER

IGN./FUEL ONENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

NOCR1

TB21

NO

CR28765

109

TS51

TB27

RD

TS1

TS52

12

TB33

3

RD

IGN./START

MODULE

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RDOR/BK

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

PS

WH

S2

NC

S1

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

BK

/WH

OP

TIO

N

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TILT

AL

AR

M

RD

WH

BK

BK

H2+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C2

-7

C1

-9C

35

ES

PD

BK

/ RD

CR3

TB23

TB24

TB46

D8

D7

-

DC

+

12 V

B1

D22

FAN

CR17NO

15AMP.

TB20

CB2

RD

FU

NC

.E

NA

BL

E

D6

70AFUSE

C6

-16

C6

-23

C6

-34

C6

-33

C5-3

C5

-2

C6

-28

C6

-27

C5

-15

C2

1IG

NW

H

C5

-22

C6

-24

P1

34

FB

RD

C5

-12

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

C5

-11

BL

/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

BA

TG

R/B

K

15AMP.

CB1

C2

8T

TA

RD

/BK

7

WH

GR

/BK

TB28

12 8

C32-8

C1

B-2

C2

B-5

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

C2

B-6

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C1

P-1

2

C7

P-1

C2

P-6

P3HORN

RD

P2

3B

AT

WH

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1P2

NOCR39

D42

EN

GIN

ES

PE

ED

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

T.)

SE

ND

ER

(OP

T.)

WA

TE

RT

EM

PC

26

TS

RW

H/R

D

C2

5P

SR

WH

/BK

VO

LTM

ET

ER

(OP

T.)

TB24A

C5

-5

D51

C21IGN WH C21IGN WH

C27AUX RD

C41RPM OR/BK

P46 RD

P23 RD

P25FS RD

P24FS WH

P26ESTP BK P26ESTP BK

C28TTA RD/BK

HY

D.

OIL

TE

MP.

HY

D.

CO

OL

ING

ALT

ER

NA

TO

R

BA

TT

ER

Y

SE

PA

RA

TO

R(O

PT.)

STA

RT

BA

TT

ER

Y

FA

N(O

PT.)

SW

ITC

H(O

PT.)

D40

+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:

ADD D40 ONLY IF UNIT HAS L4 AND L48.

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION . C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.

SEE ES0180 SHEET7 FOR SECOND BATTERY OPTION.

PR2NO

GL

OW

PL

UG

1

GL

OW

PL

UG

1R

EL

AY

RD

B2

BA

TR

DB2BAT RD

C5

-16

C5

-14

TB33A

TB26 TB25

F18

BK

BK

WH

WH

TS49

FU

SE

10

AR

D

RD

TS48

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

CR23CR23

NO

PBOX GND

DL

ITE

OP

TIO

NW

IRE

FUSE 10A

L29 L29

L30L30

P134BAT RD

C4

-11/1

2

HO

LD

PU

LL

INW

H

BK

21

RD

3MODULE

TIME DELAY-COM

+AUX

S-613

+BAT

MOM N.O.

BRN

WH

RD

RP

MS

OL

EN

OID

C5

-18

RP

MM

OD

UL

E

CH

EC

KE

NG

INE

LE

D

J1

44

-8J1

44

-7

J1

44

-3

J1

44

-5

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

D44

U16NO

TIMER30

70AFUSE

PR3NO

GL

OW

PL

UG

2

GL

OW

PL

UG

2R

EL

AY

C34SA

P3

4S

A

L48

ANSI/CSA (DOMESTIC MACHINE) ADD L48.

C32CONN.PLUG

STARTER

G1

G3 G2E

NG

INE

STA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

ON

AU

XIL

IAR

YP

UM

P

WO

RK

LIG

HT

DR

IVE

LIG

HT

GE

NE

RA

TO

RO

FF

ON

1

2

3

2

3

CE Option, See 6 - 60


Part No. 122149 S-80 • S-85 6 - 7

N M L K J I H G F E D C B A 1

2

3

4

5

6

7

8


DR

IVE

/RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

BRN

DE

SC

EN

TA

LA

RM

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

TB14

TB15

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

TB9

C9

PE

RF

BK

/RD

TS63

TB8

BK

/WH

C8

PB

RB

K/W

H

C1

4P

LU

OR

BK

/RD

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C7

PB

BE

BK

C8

PB

RB

K/W

H

BK

TB7

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

TS61

C2

PB

DR

D/B

K

C1

PB

UR

D

TB3

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

TS62

C5

TR

RW

H/B

K

TB1

TB6

C6

TT

RF

WH

/RD

TB4

C1

PB

UR

D

PR

I.B

OO

ME

XT

EN

D

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TB5

BR

AK

ER

EL

EA

SE

VA

LV

E

C2

9M

SR

D/W

HM

OT

OR

ST

RO

KE

LS

1R

O-B

OO

MR

ET

RA

CT

OP.

DR

IVE

/ RO

TA

TE

SP

EE

D

LS

2A

S-B

OO

MA

NG

LE

SA

FE

TY

DR

I VE

LI M

I TS

WIT

CH

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

C4

0L

SO

R/R

D

TB42

C2

9M

SR

D/W

H

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C3

6S

TC

CB

L

C3

7S

TC

BL

/BK

TB37

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

LIM

ITS

WIT

CH

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

GR

OU

ND

TS15

C1

2D

RE

BL

/WH

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C3

2B

RK

WH

/RD

C5

-20

C3

2B

RK

WH

/RD

TB32

L1

BR

N

H4

H3

EXTEND/RETRACT

JOYSTICK CONTROL CARD

3

BR

N

OR

YE

L

1 542 3 76

12

C5

- 21

14

LS3

13

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

10 9 3

1 742 3 5 6

PRI UP/DN & TT ROTATE

1 742 3 5 6

DRIVE & STEERING

RD

1

BK

2

BR

N

OR

BR

N

OR

WH

BL

5 4

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

P23 RD

13

1411

122

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P-4

C1

P-5

C1

P-6

C1

P-3

C1

P-1

1

C1

P- 1

0

C3

P-6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P- 4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/R

D

CD

E2

BL

/BK

J2

J3 J1 J1 J1 J1

OU

T

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

C4

P-6

C4

P-5

DR

IVE

ED

CF

OR

WA

RD

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK

NOHC NCNOHCNCNOHC2AO2AS1RO1RS

TS16

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NCCR26

D37

D38

D35 D36

D41

AX

LE

EX

T/R

ET

SE

LE

CT

C6

0A

XO

R/R

D

C2

P-4

AX

LE

DU

MP

VA

LV

E

NC

CR8

D34

D15

TB16

S3NC

NCCR29

OP

EN

WH

EN

AX

LE

FU

LLY

EX

T.

AX

LE

NO

TE

XT

PR

ES

SU

RE

SW

AX

LE

EX

TE

ND

RLY

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

/JIB

UP

/JIB

DO

WN

C3

1E

DC

WH

/BK

C3

0E

DC

WH

CR8

C6

-36

C6

-37

C6

-11

C6

-39

C6

-13

C5

-23

C5

-24

C6

-4

C6

-5

C6

-6

C6

-1

C6

-2

C6

-3

C6

-7

C6

-8

C6

-9

C6

-12

C6

-30

C6

-14

C6

-15

C6

-18

C6

-17

C6

-19

C6

-21

C6

-22

C6

-10

C6

-31

C6

-20

LS

2A

O-B

OO

MA

NG

LE

OP.

DR

IVE

LIM

ITS

WIT

CH

LI M

I TS

WIT

CH

LI M

I TS

WIT

CH

WH

RD

C4

0L

S2

BK

U4

ADC B

C3

5-1

C3

5-2

C3

4- 1

C3

4-2

1

2

C2

9-2

C2

9-1

C1

6-1

C1

6-2

C1

7-2

C1

7-1

C2

7-2

C2

7-1

C1

3-1

C1

3-2

C1

2-1

C1

2-2

C3

1-1

C3

1-2

C1

4-1

C1

4-2

C1

5-1

C1

5-2

C2

8-2

C2

8-1

C2

6-2

C2

6-1

C2

4-2

C2

4- 1

C2

5- 2

C2

5-1

C1

2D

RE

BL

/WH

C2

3B

AT

RD

21

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

2A

XD

PW

H

C6

0A

XO

R/R

D

S3

LE

DB

L/ R

D

J4

BK

J3

WH

J1

WH

J5

BK

J2

WH

D57

C6

-32

C4

P-1

2 13 4

2

2

2

3

3

4

4

4

1

1

1

BL

C27AUX + FE RD

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

C2

1-1

C2

1-2

C2

4-2

C2

3-1

C2

2-1

C2

2-2

C2

0-1

C2

0-2

3

D41 CR38

NC

CR38

C6

-40

C4

0L

S1

OR

P24FS WH

C28TTA RD/BK

P26ESTP BK

C8

PB

RB

K/W

HC

6-3

8

C6

-29

R1

6P

BR

BK

/WH

3 4

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

XO

UT

P134BAT RD

CR20 A

CR20 B

NO

NO

UP

DO

WN

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TA

XL

E

D2

7

JIB

BO

OM

D2

7D

27

LE

FT

RIG

HTP

LA

TR

OTA

TE

LE

FT

RIG

HT

TS57

C4

P-7

TS7 TS8

JIB

VA

LV

E

C19JSV GR/WH

CR13

BRN

JIB

BO

OM

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C1

9JS

VG

R/W

H

JIB

VA

LV

E

TS58

CE Option, See 6-60

7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7

Joystick Adaptor Harness

1

2

34

5

6

Deutsch

RE

TR

AC

TE

XT

EN

DA

XLE


6 - 8

February 2012


6 - 7

July 2007


6 - 9

February 2012

Electrical Schematic, S80/85Deutz BF4L 2011 Models (after serial number 5519)


6 - 10 S-80 • S-85 Part No. 122149



1

2

3

4

5

6

7

8

P1

34

TT

SR

D

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

20AMP.RD

P2

0B

AT

RD

RE

LA

Y

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

RD

TB41

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

NS

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

./STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

NOCR1

TB21

NO

CR28765

109

TS51

TB27

RD

TS1

TS52

12

TB33

3

RD

IGN./START

MODULE

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RDOR/BK

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

PS

WH

S2

NC

S1

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

BK

/WH

OP

TIO

N

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TILT

AL

AR

M

RD

WH

BK

BK

H2+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C2

-7

C1

-9C

35

ES

PD

BK

/ RD

CR3

TB23

TB24

TB46

D8

D7

-

DC

+

12 V

B1

D22

FAN

CR17NO

15AMP.

TB20

CB2

RD

FU

NC

.E

NA

BL

E

D6

70AFUSE

C6

-16

C6

-23

C6

-34

C6

-33

C5-3

C5

-2

C6

-28

C6

-27

C5

-15

C2

1IG

NW

H

C5

-22

C6

-24

P1

34

FB

RD

C5

-12

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

C5

-11

BL

/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

BA

TG

R/B

K

15AMP.

CB1

C2

8T

TA

RD

/BK

7

WH

GR

/BK

TB28

12 8

C32-8

C1

B-2

C2

B-5

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

C2

B-6

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C1

P-1

2

C7

P-1

C2

P-6

P3HORN

RD

P2

3B

AT

WH

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1P2

NOCR39

D42

EN

GIN

ES

PE

ED

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

T.)

SE

ND

ER

(OP

T.)

WA

TE

RT

EM

PC

26

TS

RW

H/R

D

C2

5P

SR

WH

/BK

VO

LTM

ET

ER

(OP

T.)

TB24A

C5

-5

D51

C21IGN WH C21IGN WH

C27AUX RD

C41RPM OR/BK

P46 RD

P23 RD

P25FS RD

P24FS WH


C28TTA RD/BK

HY

D.

OIL

TE

MP.

HY

D.

CO

OL

ING

ALT

ER

NA

TO

R

BA

TT

ER

Y

SE

PA

RA

TO

R(O

PT.)

STA

RT

BA

TT

ER

Y

FA

N(O

PT.)

SW

ITC

H(O

PT.)

D40

+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:




PR2NO

GL

OW

PL

UG

1

GL

OW

PL

UG

1R

EL

AY

RD

B2

BA

TR

DB2BAT RD

C5

-16

C5

-14

TB33A

TB26 TB25

F18

BK

BK

WH

WH

TS49

FU

SE

10

AR

D

RD

TS48

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

CR23CR23

NO

PBOX GND

DL

ITE

OP

TIO

NW

IRE

FUSE 10A

L29 L29

L30L30

P134BAT RD

C4

-11/1

2

HO

LD

PU

LL

INW

H

BK

21

RD

3MODULE

TIME DELAY-COM

+AUX

S-613

+BAT

MOM N.O.

BRN

WH

RD

RP

MS

OL

EN

OID

C5

-18

RP

MM

OD

UL

E

CH

EC

KE

NG

INE

LE

D

J1

44

-8J1

44

-7

J1

44

-3

J1

44

-5

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

D44

U16NO

TIMER30

70AFUSE

PR3NO

GL

OW

PL

UG

2

GL

OW

PL

UG

2R

EL

AY

C34SA

P3

4S

A

L48


C32CONN.PLUG

STARTER

G1

G3 G2E

NG

INE

STA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

ON

AU

XIL

IAR

YP

UM

P

WO

RK

LIG

HT

DR

IVE

LIG

HT

GE

NE

RA

TO

RO

FF

ON

1

2

3

2

3



Part No. 122149 S-80 • S-85 6 - 11


N M L K J I H G F E D C B A 1

2

3

4

5

6

7

8DR

I VE

/RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

BRN

DE

SC

EN

TA

LA

RM

P46 RDC41RPM OR/BK

C1

5P

LD

OR

/BK

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

TB14

TB15

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

TB9

C9

PE

RF

BK

/RD

TS63

TB8

BK

/WH

C8

PB

RB

K/W

H

C1

4P

LU

OR

BK

/RD

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C7

PB

BE

BK

C8

PB

RB

K/W

H

BK

TB7

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

TS61

C2

PB

DR

D/B

K

C1

PB

UR

D

TB3

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

TS62

C5

TR

RW

H/B

K

TB1

TB6

C6

TT

RF

WH

/RD

TB4

C1

PB

UR

D

PR

I.B

OO

ME

XT

EN

D

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TB5B

RA

KE

RE

LE

AS

EV

ALV

E

C2

9M

SR

D/W

HM

OT

OR

ST

RO

KE

LS

1R

O-B

OO

MR

ET

RA

CT

OP.

DR

I VE

/RO

TA

TE

SP

EE

D

LS

2A

S-B

OO

MA

NG

LE

SA

FE

TY

DR

IVE

LIM

ITS

WIT

CH

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

C4

0L

SO

R/R

D

TB42

C2

9M

SR

D/W

H

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C3

6S

TC

CB

L

C3

7S

TC

BL

/BK

TB37

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

LIM

ITS

WIT

CH

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

GR

OU

ND

TS15

C1

2D

RE

BL

/WH

C3

0E

DC

+W

H

C3

1E

DC

-W

H/ B

K

C3

2B

RK

WH

/RD

C5

-20

C3

2B

RK

WH

/RD

TB32

L1

BR

N

H4

H3


3

12

C5

-21

14

LS3

13

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

P23 RD

2

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P-4

C1

P-5

C1

P-6

C1

P-3

C1

P-11

C1

P-1

0

C3

P-6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P-4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/ R

D

CD

E2

BL

/BK

J2

J3 J1

DR

IVE

ED

CF

OR

WA

RD

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK


TS16

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-11

C6

1A

XB

L/B

K

TB46

NCCR26

D37

D38

D35 D36

D41

AX

LE

EX

T/R

ET

SE

LE

CT

C6

0A

XO

R/R

D

C2

P-4

AX

LE

DU

MP

VA

LVE

NC

CR8

D34

D15

TB16

S3NC

NCCR29

OP

EN

WH

EN

AX

LE

FU

LLY

EX

T.

AX

LE

NO

TE

XT

PR

ES

SU

RE

SW

AX

LE

EX

TE

ND

RLY

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

/JIB

UP

/JIB

DO

WN

C3

1E

DC

WH

/BK

C3

0E

DC

WH

CR8

C6

-36

C6

-37

C6

-1 1

C6

-39

C6

-13

C5

-23

C5

-24

C6

-4

C6

-5

C6

-6

C6

-1

C6

-2

C6

-3

C6

-7

C6

-8

C6

-9

C6

-12

C6

-30

C6

-14

C6

-15

C6

-18

C6

-17

C6

-19

C6

-21

C6

-22

C6

-10

C6

-31

C6

-20

LS

2A

O- B

OO

MA

NG

LE

OP.

DR

I VE

LI M

I TS

WIT

CH

LIM

ITS

WI T

CH

LIM

ITS

WIT

CH

WH

RD

C4

0L

S2

BK

U4

ADC B

C3

5-1

C3

5-2

C3

4-1

C3

4-2

1

2

C2

9-2

C2

9-1

C1

6-1

C1

6-2

C1

7-2

C1

7-1

C2

7-2

C2

7-1

C1

3-1

C1

3-2

C1

2-1

C1

2-2

C3

1-1

C3

1-2

C1

4-1

C1

4-2

C1

5-1

C1

5-2

C2

8- 2

C2

8-1

C2

6-2

C2

6-1

C2

4-2

C2

4- 1

C2

5-2

C2

5-1

C1

2D

RE

BL

/WH

C2

3B

AT

RD

21

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

2A

XD

PW

H

C6

0A

XO

R/R

D

S3

LE

DB

L/R

D

J4

BK

J3

WH

J1

WH

J5

BK

J2

WH

D57

C6

-32

C4

P-1

2 13 4

2

2

2

3

3

4

4

4

1

1

1

C27AUX + FE RD

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

C2

1-1

C2

1-2

C2

4-2

C2

3-1

C2

2-1

C2

2-2

C2

0-1

C2

0-2

3

D41 CR38

NC

CR38

C6

-40

C4

0L

S1

OR

P24FS WH

C28TTA RD/BK

P26ESTP BK

C8

PB

RB

K/W

HC

6-3

8

C6

-29

R1

6P

BR

BK

/WH

3 4

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

P134BAT RD

CR20 A

CR20 B

NO

NO

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

PL

AT

LE

VE

L

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TA

XL

EEXTEND/RETRACT

BR

N

OR

WH

/BK

1 542 3 6

10 9 3

1 42 3 5 6


1 42 3 5 6

DRIVE & STEERING

WH

/RD

1

RD

/WH

2

BR

N

OR

BR

N

OR

BL/W

H5 4

13

1411

12

J1 J1 J1

OU

T

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL/W

H

XO

UT

WH

/RD

TB17

TB18

WH

C4

P-6

C4

P-5

D2

7

D2

8

UP

DO

WN

PL

AT

RO

TA

TE

UP

DO

WN

D2

7

JIB

BO

OM

D2

7D

27

LE

FT

RIG

HTP

LAT

RO

TAT

E

LE

FT

RIG

HT

TS57

C4

P-7

TS7 TS8

JIB

VA

LVE

C19JSV GR/WH

CR13

JIB

BO

OM

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C1

9JS

VG

R/W

H

TS58


RE

TR

AC

TE

XT

EN

DA

XLE


6 - 12

February 2012


6 - 11


6 - 13

February 2012

Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models

6 - 14


6 - 14 S-80 • S-85 Part No. 122149

February 2012


1

2

3

4

5

6

7

8

Ground Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models

CHECK ENGINE LED

TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH

CR3

CR5

CR1

CR2

TS61

CB1

TS62

L2

G6

CB2

HIGH IDLE CUTOUT RELAY

CIRCUIT BREAKER, ENGINE, 15A

PRIMARY BOOM UP/DOWN SWITCH

CIRCUIT BREAKER, CONTROLS, 15A

SERVICE HORN RELAY

IGNITION POWER RELAY

IGNITION / START RELAY

HOUR METER

TURNTABLE ROTATE SWITCH

LABEL

TS51

KS1

TS54

TS59

TS57

TS52

P1

PLATFORM ROTATE SWITCH

PLATFORM LEVEL SWITCH

START ENGINE SWITCH

FUNCTION ENABLE SWITCH

AUXILIARY SWITCH

EMERGENCY STOP BUTTON

KEY SWITCH

DESCRIPTION

G1

G2

G3

VOLT METER GAUGE (OPT.)

OIL PRESSURE GAUGE (OPT.)

WATER TEMP. GAUGE (OPT.)

BK C1B-7 33 BK-S.P.

HOUR METER

HARNESS:TO BASE

WIRING

CONNECTIONSCONTROL BOX

WH/BK-5AWH-4A

WH-23D

START ENG

GLOW PLUG

STEER RT/AXLE EXTENGINE RPM

LIMIT SW #1

L.P.

ENG RPM

BRN-GND STUD

GR C2B-5

CR5

CR1 CR2

BK C6-16

OR-14A

WH/RD-6A

GR-17A

GR/BK-18A

GR/WH C4B-7

RD-B1-20A

RD-24A

BK-22B

ALL BRN WIRES

BK/RD-35A

TS54

D14

D13

OR/BK-15A

OR/BK C2B-3

OR C6-10

BL/BK C6-37

OR C6-40

OR/BK C5-2

RD C6-31

41

46B

40

BL/BK C1B-11

BK/RD C1B-9BK/WH C1B-8

39

37

35

34

BK/RD-9A

GROUND STUD

BK-33

RD-1A

WH-21A

OR C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

LEVELPLAT. PLATFORM

ROTATE

CB1 CB2

START

TS52

TURNTABLE

TS59

ROTATE

TS62

TS63

BOOM EXTEND/RETRACT UP/DOWN

BOOM

TS61

PRI. BOOM UP

TURN. ROT. L

TURN. ROT. R

PRI. BOOM F.C.

BOOM EXTEND

BOOM RETRACTEXT./RET. F.C.

TURN. ROT. F.C.

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. R.

PLAT. ROT. L.

KEYSWITCH PWR/PWR TO PLAT

OIL COOLER FAN

FUSED 12V

IGNITION PWR.

PRI. BOOM DOWN

12V BATT. SUPPLY

AUX PUMP

BRAKE WH/RD C5-23RD

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3OR C4B-2

21

WH/RD C1B-6

RD CR39#86&C1B-1

WH C7B-2

24 RD CR2#30

WH/RD C6-3227

32

BK CR5#30

23

22

GR C6-17

GR/BK C6-18

OR C6-14OR/BK C6-15

20

18

17

16

15

14

WH/RD C3B-6

BK/RD C3B-9

BK/WH C3B-8

BK C3B-7

RD/WH C3B-3

WH/BK C3B-5

WH C3B-4

RD C3B-1

RD/BK C3B-2&C6-2

6WH/RD C6-6

BK/RD C6-9

BK C6-7

BK/WH C6-8

11

10

7

8

9

RD/WH C6-3WH C6-4

WH/BK C6-5

RD C6-1

3

5

4

2

1

WH/BK C5-14

WH S.P.

RD-S.P.-CB3RD-S.P.

BK-S.P.

GR-S.P.

GR/BK-S.P.

OR-S.P.

OR/BK-S.P.

WH/RD-S.P.

BK/RD-S.P.

BK-S.P.

BK/WH-S.P.

RD/WH-S.P.WH-S.P.

WH/BK-S.P.

RD-S.P.RD/BK-S.P.

WH/RD C5-16

E-STOP

D2

NC

P1

NC

AUXILIARY PUMPTS51

CB3

RD-B2-S.P.

RD-B1-20C

RD-24AA

RD-B2-H1

RD CR1#30

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

24A

WH-S.P.-D2

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

CIRCUIT DESCRIPTION FROM TO

61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21

19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.

25 OIL PRESSEURE SENDER WH/RD C5-16 WH/RD-S.P

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

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

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

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

36 STEER LEFT/AXLE RETRACT BL C1B-10 BL C6-36

43 HORN GR C2B-5 GR CR5#86

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

RD CR17#30

RD C6-30

33A

R2

OR/RD CR20A#86

38

BL/BK C6-20

OR/RD CR29#86

CR17

CR25

CR29

HYDRAULIC COOLER FAN RELAY

AXLE RET L/O RELAY

AXLE EXTEND LED RELAY

AXLE DUMP VALVE

HORN

START RELAY

LIMIT SW #2

LIMIT SW PWR

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

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

HIGH/LOWRPM

RD-S.P.-CB1

U1 IGNITION/START MODULE

WH CR17 #86

CONTROLSENGINE

OIL COOLER/OPTION

CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A

RD-B1-20D

RD-B1-H1

BRN(GND)

R2 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS

OR/RD CR8#87A

CR29CR8

RD/BK 2B

BL/RD C4B-1

OR/RD 42B

OR/RD 16B

BL/RD C6-13

BK 7B

CR8 BOOM FUNCTION CUTOUT

RD C6-23 RD C2B-6 134 RD-H6 RD-KSI-SPKS POWER

CHECK ENGLED L2

WH-23A

BK-22A

KSI

RD-134A

PLATFORM OVERLOAD MODULEU33

RD C6-24 134A

28 TILT ALARM RD/BK C1B-2 RD/BK C6-28

KS POWER

D42

OR/RD CR38#87A

RD CR38#86

BK/WH C6-38

AUXILARY PUMP RELAY

EXTEND FUNCTION CUTOUT

CR39

CR38

KEYSWITCH

B

B11

24

3

CR38

CR39

BK/WH C6-29

OR/RD 16C

RD-1B

RD-27D

RD-24C

RD C6-27

CR17

WH-21B

RD-24AB

WH-C6-34

OR C6-33

BL/RD C2B-1

CR20B LOW VOLTAGE DROP RELAY

CR20A LOW VOLTAGE DROP RELAY

OR/RD C6-11

TB16D OR/RD

TB134A-A

CR20A

CR20B

GR

OU

ND

ST

UD

-

+

-

+

TS58 JIB UP/DOWN (JIB OPTION ONLY)

TS58

JIB

OIL PRESSURE

G2G1

VOLT METER

G3

WATER TEMP.

CR23 DRIVE LIGHT RELAY OPTION

BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

OPTION WIRE TO PBOX

TB24AD

DRIVE LIGHT OPTION RELAY

(SPARE WIRE)

(SPARE WIRE)

GAS ENGINE: C1-8 BK/WH

DIESEL ENGINE: C2-1 BL/RD

TS56 GLOW PLUG SWITCH (DIESEL ONLY)

BK ISM#3

BK-C23-5

KEY PWR.WH-23B7

TB33AB

10

WH-CR2#86

ENG. FAULT

KEY BYPASS

IGN./FUEL ON9

8

BK/WH-34A

RD-27B

BRN GND

OR/BK-41BBK-33B

4 AUX. ON

BATTERY6

5 GROUND

START RELAY

TACHOMETER

START INPUT3

1

2

BK/RD CR3#30

BK/WH C5-22

OR/BK ISM#2

BK/WH-S.P.

BK C23-4

ISM#4

WH L2

U1

BK-CR1#87BK C5-5 D51

IGN./STARTMODULE

BK CR1#86

GLOW PLUG SW

TS56

RD C23-6

RD-C23-7

-

PLATFORMOVERLOADLED L45

+

GR/BK-H6

PLATFORM OVERLOAD LEDL45

WH ISM#7

WH ISM #10

WH C5-3

RD-24D

C3

2

BK-22DBL/WH C1-12

BK C7B-1

GR/BK-C3B-10

GR/BK H6

P134PWR RD-134BRD H6

BRN

RD-TS51

+

GR/BK-L45

RD-TS52

43

5

8

1

12

67

H6CE ONLY

BK/RD-35B

BK/RD C5-18

CR3

WH-21C

WH C5-11

WH CR3#86

WH C5-15

RD ISM#6

D6

1

3

5

2 RD TB23

BR GND STUD

BK/WH TB34D

BK TB33C

U16

BK/WH U16-5

BK U16-5

+RD U16-2

EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B 1

BASE TERMINATION BLOCK

D7

CD AB

G6

H1

868686

D34

RD/BK C6-19

D8

CR8#86+

D15

GND STUDD57

RD/BK CR8#30

8686 86

D42

86

86

8686 86

PL

UG

AN

SI/C

SA

ON

LYC

32

CO

NN

EC

TO

R

NOTE: CE OPTION- LOADSENSEMODULE CONNECTS TO C32.


6 - 15

February 2012

Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (before serial number 5520)

6 - 16


6 - 16 S-80 • S-85 Part No. 122149

1

2

3

4

5

6

7

8


Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (before serial number 5520)

BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2

U13

JC1

JIB BOOM CUTOUT RELAY

AXLE CUTOUT RELAY

TILT ALARM

ALC500

BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE

COMPONENT INDEX

TS2

TS9

TS15

P3

TS1

TS14

L1

P2

DRIVE ENABLE LED

PLATFORM LEVEL TOGGLE SWITCH

HORN SWITCH


AUXILIARY TOGGLE SWITCH

ENGINE START SWITCH

TS47 GENERATOR TOGGLE SWITCH (OPTION)

TS4

TS7

TS8

HIGH RPM SWITCH

PLATFORM ROTATE TOGGLE SWITCH

JIB BOOM UP/DOWN TOGGLE SWITCH

LOW/HIGH SWITCHDRIVE SPEED TOGGLE

DRIVE ENABLE TOGGLE SWITCH

JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT

CR13

CR26

H1

TS48

TS49

WORK LIGHT TOGGLE SWITCH (OPTION)

DRIVE LIGHT TOGGLE SWITCH (OPTION)

GLOW PLUG OPTIONTS6

TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH

L40 AXLE EXTENDED LED

CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM

CR27WH-TS7

WH-TS1

BRN BATGND

GND STUD

WH/RD C32BRK

OR/RD R40LS2

(SPLICE TO C32BRK)

(SPLICE TO R40LS2)

CR30

OR

C4

P-2

OR

/BK

C4

P-3

GR

C2

P-5

NO

BL

/BK

J1

-7

RD

C1

P-1

GR

/BK

C4

P-6

GR

C4

P-5

YE

LJ1

-3

RD

J1

-1

BK

/RD

C1

P-9

BL

/RD

J1

-16

RD

C9

-3

BK

C1

P-7

OR

J1

-9

RD

/WH

J1

-8

BK

C9

-1

NC

HORN

GR

/WH

JIB

CA

BL

E

WH

C7

P-2

BK

C7

P-1

CR26AXLE CUTOUT

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

ENGINESTART

L1

TS1AUXILIARY

PUMP

TS14DRIVESPEED

TS7PLATFORM

ROTATE

TS9PLATFORM

LEVEL

P3

JC2PRIMARY BOOMUP/DOWN AND

TURNTABLEROTATE

JC1BOOM

EXTEND/RETRACT

BK

/WH

C1

P-8

JC3DRIVE

GND STUD

H1TILT

ALARM

RD

LS

18

BRN

C1

2D

RE

BL

/WH

C3

P-1

2

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

C3

PB

FR

D/W

HC

3P

-3

C8

PB

RB

K/W

HC

3P

-8

C6

TR

FW

H/R

DC

3P

-6

C9

PE

RF

BK

/RD

C3

P-9

C7

PB

EB

KC

3P

-7

C2

PB

DR

D/B

KC

3P

-2

C1

PB

UR

DC

3P

-1

HI-C

13

3P

LA

GN

/BL

C3

P-1

0

TS

9-C

15

PL

DO

R/B

KC

4P

-3

FOOT SWITCH

C3

P(G

R)

C1

P(G

Y)

C2

P(B

K)

12V DCBATTERY

C4

P(B

R) C7P

BATGND C7P-3

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

14

PL

UO

RC

4P

-2

C9 JIB

P2

-P2

3S

WB

AT

WH

C7

P-2

R4

0L

S2

OR

/RD

C4

P-4

TS

7-C

18

JD

GR

/BK

C4

P-6

TS

7-C

17

JU

GR

C4

P-5

J3

-P2

4C

ON

TW

HC

9-2

P2

-P2

2B

AT

BK

C7

P-1

TS

2-P

25

ST

RR

DC

9-3

TS

6-C

34

SA

BK

/WH

C1

P-8

C3

2B

RK

WH

/RD

C1

P-6

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

1P

-3

C3

1E

DC

-W

H/B

KC

1P

-5

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C3

0E

DC

+W

HC

1P

-4

TS

1-C

27

AU

XR

DC

1P

-1

P2

-P2

6F

SB

KC

9-1

TS

2-C

33

ST

RB

KC

1P

-7

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

C4

1R

PM

OR

/BK

C2

P-3

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C3

7S

TC

BL

/BK

C1

P-11

DL

ITE

GR

/BK

C2

P-6

C4

0L

S1

OR

C2

P-2

C3

6S

TC

CB

LC

1P

-10

P3

-C4

3H

RN

GR

C2

P-5

BK

J1

-2

+

TS15DRIVE

ENABLE

19/18 CONTROL CABLE

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

TS6GLOW PLUG

OPTION

LS18(OPTION)

7

6

5

4

3

2

1

4

2

1

3

5

6

7

4

2

1

3

5

6

7

BR

NJ1

-10

+-

+-

+-

OR

J1

-13

BR

NJ1

-14

OR

J1

-11

BR

NJ1

-12

1

11

1

9

3

1

JC

3-5

WH

JC

2-2

BR

N

JC

3-6

BL

JC

2-3

OR

JC

1-5

YE

L

JC

1-2

BR

N

JC

2-5

BK

JC

2-4

RD

JC

1-3

OR

TS

14

-C2

9M

SR

D/W

H

L1

-C1

3L

ED

BL

/RD

TS

15

-DR

EB

BL

/BK

JC

3-2

BR

N

TS

15

-DR

EA

BL

/WH

JC

3-3

OR

GND STUD

J1 J2

J3

WH

J1

-5

BL

J1

-4

BR

N

+

L40

EX/RET

TS16

AXLE

WH

J3

-2

BL

/RD

C4

P-1

OR

/RD

C2

P-4

J2

-DIO

DE

WH

D12D12

WH

TS

4

WH

CR

26

#8

5

BL

C1

P-1

0

BL

/BK

C3

P-11

BK

P2

BL

/WH

J1

-6

WH

C9

-2

BK

J3

-3

BL

TS

16

TS

16

-C6

1A

XB

L/B

KC

3P

11

CR13 BRN

RD

LS

18

U13ALC-500

D2

CE MODELS (SEE DETAIL A)

RD

/BK

H1

RD LS CABLERD-H1

RD-P2

+

L4

BK LS CABLE CIP-12

RD

C2

P-6

GN

/BK

L4

L4 PLATFORM OVERLOAD LED

LS18 PLATFORM OVERLOAD LIMIT SWITCH

GN

/BK

C3

P-1

0

RD

/BK

L4

8

OPT.

GN

/BK

H1

(D3

9)

L48

BK

+

TS48/TS49

RD WL1

RD WL2

TS15

DETAIL C: WORKLIGHT/DRIVELIGHT OPTION

L48 TILT ALARM LED

D40

D39

TS2

GR

/WH

C2

P-7

DETAIL B: GENERATOR OPTION

TS8JIB BOOM

JIB

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7

RD/BK JIB CABLE

GND

CR13

CUTOUT

JIB

GR/WH C4P-7

GR/WH TS7


Part No. 122149 S-80 • S-85 6 - 17

1

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7

8

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

Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (after serial number 5519)

GR

C2

P-5

OR

/BK

C4

P-3

OR

C4

P-2

BL

/BK

C3

P-11

BL

C1

P-1

0

OR

/RD

C2

P-4

BL

/RD

C4

P-1

BRN

J2

-DIO

DE

WH

GR

/WH

JIB

CA

BL

E

RD

/WH

J1

-8

GR

C4

P-5

GR

/BK

C4

P-6

RD

C1

P-1

RD

BK

BK

RD RD

RD

/BK

H1

BL

/WH

J1

-6

WH

J3

-2

BK

C1

P-7

RD

C9

-3

BK

/WH

C1

P-8

BK

/RD

C1

P-9

BL

/BK

J1

-7

GN

/ BK

H1

(D3

9)

BK

J3

-3

BK

C7

P-1

WH

C7

P-2

BK

C9

-1

GN

/BK

C3

P-1

0

GN

/BK

L4

RD

C2

P-6

RD

LS

18

RD

/BK

H1

TS

15

-DR

EB

BL

/BK

L1

-C1

3L

ED

BL

/RD

TS

14

-C2

9M

SR

D/W

H

C1

34

PW

RG

R/B

KC

2P

-6

U13

BL

TS

16

WH

C9

-2

BK

P2

WH

CR

26

#8

5

WH

TS

4

ALC-500

RD

/BK

L4

8

TS

2-C

33

ST

RB

KC

1P

-7

TS

1-C

27

AU

XR

DC

1P

-1

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C2

9M

SR

D/W

HC

1P

-3

TS

6-C

34

SA

BK

/WH

C1

P-8

BATGND C7P-3

C28TTA RD/BK C1P-2

JC

3-3

OR

TS

15

-DR

EA

BL

/WH

JC

3-2

BR

NJC

3-6

BL

(1)

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

2-5

BK

JC

1-2

BR

N

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

(2)

P3

-C4

3H

RN

GR

C2

P-5

C3

6S

TC

CB

LC

1P

-10

C4

0L

S1

OR

C2

P-2

C3

7S

TC

BL

/BK

C1

P-11

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

2B

RK

WH

/RD

C1

P-6

R4

0L

S2

OR

/RD

C4

P-4

C1

PB

UR

DC

3P

-1

C2

PB

DR

D/B

KC

3P

-2

C7

PB

EB

KC

3P

-7

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C3

PB

FR

D/W

HC

3P

-3

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C1

2D

RE

BL

/WH

C3

P-1

2

GND STUD

CC

13

2P

LI

BL

/WH

C3

P-1

2

TS

16

-C6

1A

XB

L/B

KC

3P

11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P2

-P2

6F

SB

KC

9-1

TS

2-P

25

ST

RR

DC

9-3

P2

-P2

2B

AT

BK

C7

P-1

J3

-P2

4C

ON

TW

HC

9-2

TS

7-C

17

JU

GR

C4

P-5

TS

7-C

18

JD

GR

/BK

C4

P-6

P2

-P2

3S

WB

AT

WH

C7

P-2

TS

9-C

14

PL

UO

RC

4P

-2

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

15

PL

DO

R/B

KC

4P

-3

C1

33

PL

AB

LC

3P

-10

RD

LS

18

P3

HORN

NO

TILT ALARM

D39

H1

CE SEE DETAIL A

PLATFORM

LEVEL

TS9TS7

ROTATE

PLATFORM

TS1

AUX. PUMPTS14

SPEEDDRIVE

19/18 CONTROL CABLE

C2

P(B

K)

D2 TS16

L40

+

AXLE

EX/RET

GND STUD

C1

P(G

Y)

12V BATT

C4

P(B

R)

C3

P(G

R) C7P C9

F.S.

RPM

TS2

START

+

L1

HIGH/LOW

+

L4

TS4

E- STOP

P2

NC

TS15

DRV.ENA

+

D12

L48

OPT.

D40

J2J1

1

9

D12 D12

1

J31

3

11

PLATFORM CONTROL BOX

PLATFORM OVERLOAD LIMIT SWITCHLS18

L48 TILT ALARM LED

PLATFORM OVERLOAD LED (OPTION)

DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT

DRIVE SPEED LOW/HIGH SWITCH


GENERATOR SWITCH ( OPTION )

BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE

AXLE EXTENDED LED

DRIVE ENABLE LED

ALC500

JC1

H1

JC2

U13

L4

L40

JC3

L1

TILT ALARM

AXLE EXT/RET SWITCH

DRIVE ENABLE SWITCH

HIGH RPM SWITCH


TS16

TS47

TS14

TS15

TS7

TS4

TS9


COMPONENT INDEX

START ENGINE SWITCH

AUXILIARY SWITCH

HORN SWITCH

P2

TS1

P3

TS2

TT ROTATE

UP/DOWN

PRI. BOOM BOOM

EXT/RET

DRIVE/STEERAXLE CUTOUT

C2P-9 & 10CR13 BRN

CR

26

BK LS CABLE CIP-12

RD LS CABLE RD-P2

RD-H1

YY

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

RD WL1

DETAIL C: WORKLIGHT OPTION

TS48

E-STOP BK

F18 10A

RD WL2

(SPARE WIRE)

OPTION WIRE TO GBOX

DRIVELIGHT OPTION

TS49

TS48 PIN2

DETAIL A: LIFT/DRIVE OPTION

REPLACE WIRE WITH THIS WIRING DIAGRAM

C32BRK)

R40LS2)

(SPLICE TO

OR/RD R40LS2

CR30

(SPLICE TO

WH/RD C32BRK

WH TS7CR27

GENERATOR OPTION

DETAIL B:

TS47

WH TS1

(GND STUD)

BRN BATGND GR

/WH

C2

P-7

TS2 RD

DRIVE LIGHT RELAY (OPTION)

WORK LIGHT RELAY (OPTION)

GLOW PLUG

TS48

TS48

TS6

2

GN

DB

RN

JIB UP/DOWN (JIB OPTION ONLY)

JIB CUTOUT RELAY ( JIB ONLY )CR13

TS8

D27

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

J1

-11O

RJC

2-2

J1

-12

BR

NJC

2-1

JC2

J1

-3W

H/B

KJC

1-4

J1

-9O

RJC

1-2

J1

-10

BR

NJC

1-1

JC1

JC3

J1

-5B

L/W

HJC

3-5

J1

-4W

H/R

DJC

3-4

J1

- 13

OR

JC

3-2

J1

-14

BR

NJC

3- 1

J1

-5B

L/W

HJC

3-3

TS6

GLOW PLUG

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7

GR/WH TS7BK JIB CABLE YY

GR/WH C4P-7

JIB

CUTOUT

JIB

CR13

TS8

JIB

GND

OPT.LS18


6 - 18

February 2012

Platform Control Box Wiring Diagram, S-80/85Deutz BF4L 2011 Models (after serial number 5519)

6 - 17


6 - 19

February 2012

Electrical Schematic, S-80/85Perkins 804-33 Models (before serial number 5520)

6 - 20


6 - 20 S-80 • S-85 Part No. 122149

1

2

3

4

5

6

7

8



P1

34

TT

SR

D

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

20AMP.RD

P2

0B

AT

RD

RE

LA

Y

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

RD

TB41

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

NS

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

./STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

NOCR1

TB21

NO

CR28765

109

TS51

TB27

RD

TS1

TS52

12

TB33

3

RD

IGN./START

MODULE

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RDOR/BK

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

PS

WH

S2

NC

S1

NO

OIL

PR

ES

SU

RE

WA

TE

RT

EM

PE

RA

TU

RE

SW

ITC

H

SW

ITC

H

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

BK

/WH

OP

TIO

N

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TILT

AL

AR

M

RD

WH

BK

BK

H2+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C2

-7

C1

-9C

35

ES

PD

BK

/ RD

CR3

TB23

TB24

TB46

D8

D7

-

DC

+

12 V

B1

D22

FAN

CR17NO

15AMP.

TB20

CB2

RD

FU

NC

.E

NA

BL

E

D6

70AFUSE

C6

-16

C6

-23

C6

-34

C6

-33

C5-3

C5

-2

C6

-28

C6

-27

C5

-15

C2

1IG

NW

H

C5

-22

C6

-24

P1

34

FB

RD

C5

-12

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

C5

-11

BL

/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

BA

TG

R/B

K

15AMP.

CB1

C2

8T

TA

RD

/BK

7

WH

GR

/BK

TB28

12 8

C32-8

C1

B-2

C2

B-5

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

C2

B-6

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C1

P-1

2

C7

P-1

C2

P-6

P3HORN

RD

P2

3B

AT

WH

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1P2

NOCR39

D42

EN

GIN

ES

PE

ED

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

T.)

SE

ND

ER

(OP

T.)

WA

TE

RT

EM

PC

26

TS

RW

H/R

D

C2

5P

SR

WH

/BK

VO

LTM

ET

ER

(OP

T.)

TB24A

C5

-5

D51

C21IGN WH C21IGN WH

C27AUX RD

C41RPM OR/BK

P46 RD

P23 RD

P25FS RD

P24FS WH


C28TTA RD/BK

HY

D.

OIL

TE

MP.

HY

D.

CO

OL

ING

ALT

ER

NA

TO

R

BA

TT

ER

Y

SE

PA

RA

TO

R(O

PT.)

STA

RT

BA

TT

ER

Y

FA

N(O

PT.)

SW

ITC

H(O

PT.)

D40

+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:




PR2NO

GL

OW

PL

UG

1

GL

OW

PL

UG

1R

EL

AY

RD

B2

BA

TR

DB2BAT RD

C5

-16

C5

-14

TB33A

TB26 TB25

F18

BK

BK

WH

WH

TS49

FU

SE

10

AR

D

RD

TS48

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

CR23CR23

NO

PBOX GND

DL

ITE

OP

TIO

NW

IRE

FUSE 10A

L29 L29

L30L30

P134BAT RD

C4

-11/1

2

C5

-18

RP

MS

OL

EN

OID

J1

44

-8J1

44

-7

J1

44

-3

J1

44

-5

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

L48


C32CONN.PLUG

STARTER

G1

G3 G2E

NG

INE

STA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

ON

AU

XIL

IAR

YP

UM

P

WO

RK

LIG

HT

DR

IVE

LIG

HT

GE

NE

RA

TO

RO

FF

ON

C3

4S

A

CR4

RP

MR

EL

AY

CR4NO

FUELPUMP

FU

EL

PU

MP

FU

EL

SO

LE

NO

ID

M4

HM

1

2

3

2

3CE Option, See 6 - 60


Part No. 122149 S-80 • S-85 6 - 21

1

2

3

4

5

6

7

8



DR

IVE

/RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

BRN

DE

SC

EN

TA

LA

RM

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

TB14

TB15

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

TB9

C9

PE

RF

BK

/RD

TS63

TB8

BK

/WH

C8

PB

RB

K/W

H

C1

4P

LU

OR

BK

/RD

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C7

PB

BE

BK

C8

PB

RB

K/W

H

BK

TB7

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

TS61

C2

PB

DR

D/B

K

C1

PB

UR

D

TB3

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

TS62

C5

TR

RW

H/B

K

TB1

TB6

C6

TT

RF

WH

/RD

TB4

C1

PB

UR

D

PR

I.B

OO

ME

XT

EN

D

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TB5

BR

AK

ER

EL

EA

SE

VA

LV

E

C2

9M

SR

D/ W

HM

OT

OR

ST

RO

KE

LS

1R

O- B

OO

MR

ET

RA

CT

OP.

DR

IVE

/ RO

TA

TE

SP

EE

D

LS

2A

S-B

OO

MA

NG

LE

SA

FE

TY

DR

IVE

LIM

ITS

WIT

CH

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

C4

0L

SO

R/R

D

TB42

C2

9M

SR

D/W

H

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C3

6S

TC

CB

L

C3

7S

TC

BL

/ BK

TB37

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

LIM

ITS

WIT

CH

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

GR

OU

ND

TS15

C1

2D

RE

BL

/WH

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C3

2B

RK

WH

/ RD

C5

-20

C3

2B

RK

WH

/RD

TB32

L1

BR

N

H4

H3

EXTEND/RETRACT


3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

14

LS3

13

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

10 9 3

1 742 3 5 6


1 742 3 5 6

DRIVE & STEERING

RD

1

BK

2

BR

N

OR

BR

N

OR

WH

BL

5 4

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

P23 RD

13

1411

122

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P- 4

C1

P-5

C1

P-6

C1

P-3

C1

P- 1

1

C1

P-1

0

C3

P- 6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P- 4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/R

D

CD

E2

BL

/BK

J2

J3 J1 J1 J1 J1

OU

T

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

C4

P-6

C4

P-5

DR

IVE

ED

CF

OR

WA

RD

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK


TS16

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NCCR26

D37

D38

D35 D36

D41

AX

LE

EX

T/R

ET

SE

LE

CT

C6

0A

XO

R/ R

D

C2

P-4

AX

LE

DU

MP

VA

LV

E

NC

CR8

D34

D15

TB16

S3NC

NCCR29

OP

EN

WH

EN

AX

LE

FU

LLY

EX

T.

AX

LE

NO

TE

XT

PR

ES

SU

RE

SW

AX

LE

EX

TE

ND

RLY

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

/JIB

UP

/JIB

DO

WN

C3

1E

DC

WH

/ BK

C3

0E

DC

WH

CR8

C6

-36

C6

-37

C6

-11

C6

-39

C6

-13

C5

- 23

C5

-24

C6

-4

C6

-5

C6

-6

C6

-1

C6

-2

C6

-3

C6

-7

C6

-8

C6

-9

C6

-12

C6

-30

C6

-14

C6

-15

C6

-18

C6

-17

C6

-19

C6

- 21

C6

-22

C6

-10

C6

-31

C6

-20

LS

2A

O-B

OO

MA

NG

LE

OP.

DR

IVE

LIM

ITS

WI T

CH

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

WH

RD

C4

0L

S2

BK

U4

ADC B

C3

5-1

C3

5-2

C3

4-1

C3

4-2

1

2

C2

9-2

C2

9-1

C1

6-1

C1

6-2

C1

7-2

C1

7-1

C2

7-2

C2

7-1

C1

3-1

C1

3-2

C1

2-1

C1

2-2

C3

1-1

C3

1-2

C1

4-1

C1

4-2

C1

5-1

C1

5-2

C2

8-2

C2

8- 1

C2

6- 2

C2

6-1

C2

4-2

C2

4-1

C2

5-2

C2

5- 1

C1

2D

RE

BL

/WH

C2

3B

AT

RD

21

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

2A

XD

PW

H

C6

0A

XO

R/ R

D

S3

LE

DB

L/R

D

J4

BK

J3

WH

J1

WH

J5

BK

J2

WH

D57

C6

-32

C4

P-1

2 13 4

2

2

2

3

3

4

4

4

1

1

1

BL

C27AUX + FE RD

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

C2

1-1

C2

1-2

C2

4-2

C2

3-1

C2

2-1

C2

2-2

C2

0-1

C2

0-2

3

D41 CR38

NC

CR38

C6

-40

C4

0L

S1

OR

P24FS WH

C28TTA RD/BK

P26ESTP BK

C8

PB

RB

K/W

HC

6-3

8

C6

-29

R1

6P

BR

BK

/WH

3 4

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

XO

UT

P134BAT RD

CR20 A

CR20 B

NO

NO

UP

DO

WN

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TA

XL

E

D2

7

JIB

BO

OM

D2

7D

27

LE

FT

RIG

HTP

LA

TR

OTA

TE

LE

FT

RIG

HT

TS57

C4

P-7

TS7 TS8

JIB

VA

LV

E

C19JSV GR/WH

CR13

BRN

JIB

BO

OM

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C1

9JS

VG

R/W

H

JIB

VA

LV

E

TS58


7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch

RE

TR

AC

TE

XT

EN

DA

XLE


6 - 22

February 2012


6 - 21


6 - 23

February 2012

Electrical Schematic, S-80/85Perkins 804-33 Models (after serial number 5519)

6 - 24


6 - 24 S-80 • S-85 Part No. 122149


1

2

3

4

5

6

7

8


P1

34

TT

SR

D

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

20AMP.RD

P2

0B

AT

RD

RE

LA

Y

C4

3H

RN

BK

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

GR

NO

CB3

RD

TB41

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

NS

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

./STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

NOCR1

TB21

NO

CR28765

109

TS51

TB27

RD

TS1

TS52

12

TB33

3

RD

IGN./START

MODULE

GR

/WH

FB

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

BK

/RD

TS54

HIG

HR

PM

TS4

BRN

RDOR/BK

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

L5

C2

4T

PS

WH

S2

NC

S1

NO

OIL

PR

ES

SU

RE

WA

TE

RT

EM

PE

RA

TU

RE

SW

ITC

H

SW

ITC

H

TB34

TS56

C3

4S

AB

K/W

H

TS6

CR3

NO

BK

/WH

OP

TIO

N

RP

MR

EL

AY

HIG

H(F

S)

LO

WR

PM

TILT

AL

AR

M

RD

WH

BK

BK

H2+

_

RD

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C2

-7

C1

-9C

35

ES

PD

BK

/ RD

CR3

TB23

TB24

TB46

D8

D7

-

DC

+

12 V

B1

D22

FAN

CR17NO

15AMP.

TB20

CB2

RD

FU

NC

.E

NA

BL

E

D6

70AFUSE

C6

-16

C6

-23

C6

-34

C6

-33

C5-3

C5

-2

C6

-28

C6

-27

C5

-15

C2

1IG

NW

H

C5

-22

C6

-24

P1

34

FB

RD

C5

-12

D14

D13

D52

D12

R2

1IG

NW

H

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

C5

-11

BL

/RD

RD

P2

2B

AT

BK

C1

32

PL

IB

L/W

H

P1

34

BA

TG

R/B

K

15AMP.

CB1

C2

8T

TA

RD

/BK

7

WH

GR

/BK

TB28

12 8

C32-8

C1

B-2

C2

B-5

TB134

RDRD

PLAT

GRD

BK

KS1 TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

C2

B-6

C1

B-1

2 C7

B-1

C2

P-5

C1

P-2

H1

C1

P-1

2

C7

P-1

C2

P-6

P3HORN

RD

P2

3B

AT

WH

WH

TB23

C7

B-2

D2

C7

P-2

FS1

BKC9P-1P2

NOCR39

D42

EN

GIN

ES

PE

ED

OIL

PR

ES

SU

RE

SE

ND

ER

(OP

T.)

SE

ND

ER

(OP

T.)

WA

TE

RT

EM

PC

26

TS

RW

H/R

D

C2

5P

SR

WH

/BK

VO

LTM

ET

ER

(OP

T.)

TB24A

C5

-5

D51

C21IGN WH C21IGN WH

C27AUX RD

C41RPM OR/BK

P46 RD

P23 RD

P25FS RD

P24FS WH


C28TTA RD/BK

HY

D.

OIL

TE

MP.

HY

D.

CO

OL

ING

ALT

ER

NA

TO

R

BA

TT

ER

Y

SE

PA

RA

TO

R(O

PT.)

STA

RT

BA

TT

ER

Y

FA

N(O

PT.)

SW

ITC

H(O

PT.)

D40

+

C3

P-1

0C

13

3P

LA

BL

C3

B-1

0

NOTES:




PR2NO

GL

OW

PL

UG

1

GL

OW

PL

UG

1R

EL

AY

RD

B2

BA

TR

DB2BAT RD

C5

-16

C5

-14

TB33A

TB26 TB25

F18

BK

BK

WH

WH

TS49

FU

SE

10

AR

D

RD

TS48

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

CR23CR23

NO

PBOX GND

DL

ITE

OP

TIO

NW

IRE

FUSE 10A

L29 L29

L30L30

P134BAT RD

C4

-11/1

2

C5

-18

RP

MS

OL

EN

OID

J1

44

-8J1

44

-7

J1

44

-3

J1

44

-5

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

L48


C32CONN.PLUG

STARTER

G1

G3 G2E

NG

INE

STA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

ON

AU

XIL

IAR

YP

UM

P

WO

RK

LIG

HT

DR

IVE

LIG

HT

GE

NE

RA

TO

RO

FF

ON

C3

4S

A

CR4

RP

MR

EL

AY

CR4NO

FUELPUMP

FU

EL

PU

MP

FU

EL

SO

LE

NO

ID

M4

HM

1

2

3

2

3CE Option, See 6 - 60


Part No. 122149 S-80 • S-85 6 - 25


1

2

3

4

5

6

7

8


DR

IVE

/ RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

BRN

DE

SC

EN

TA

LA

RM

P46 RDC41RPM OR/BK

C1

5P

LD

OR

/BK

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

TB14

TB15

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

TB9

C9

PE

RF

BK

/RD

TS63

TB8

BK

/WH

C8

PB

RB

K/W

H

C1

4P

LU

OR

BK

/RD

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C7

PB

BE

BK

C8

PB

RB

K/W

H

BK

TB7

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

TS61

C2

PB

DR

D/B

K

C1

PB

UR

D

TB3

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

TS62

C5

TR

RW

H/B

K

TB1

TB6

C6

TT

RF

WH

/RD

TB4

C1

PB

UR

D

PR

I.B

OO

ME

XT

EN

D

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TB5B

RA

KE

RE

LE

AS

EV

ALV

E

C2

9M

SR

D/W

HM

OT

OR

ST

RO

KE

LS

1R

O-B

OO

MR

ET

RA

CT

OP.

DR

I VE

/RO

TA

TE

SP

EE

D

LS

2A

S-B

OO

MA

NG

LE

SA

FE

TY

DR

IVE

LIM

ITS

WIT

CH

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

C4

0L

SO

R/R

D

TB42

C2

9M

SR

D/W

H

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C3

6S

TC

CB

L

C3

7S

TC

BL

/BK

TB37

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

LIM

ITS

WIT

CH

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

GR

OU

ND

TS15

C1

2D

RE

BL

/WH

C3

0E

DC

+W

H

C3

1E

DC

-W

H/ B

K

C3

2B

RK

WH

/RD

C5

-20

C3

2B

RK

WH

/RD

TB32

L1

BR

N

H4

H3


3

12

C5

-21

14

LS3

13

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

P23 RD

2

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P-4

C1

P-5

C1

P-6

C1

P-3

C1

P-11

C1

P-1

0

C3

P-6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P-4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/ R

D

CD

E2

BL

/BK

J2

J3 J1

DR

IVE

ED

CF

OR

WA

RD

CD

E1

BL

/ WH

C2

9M

SR

D/W

H

H1

RD

/ BK


TS16

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-11

C6

1A

XB

L/B

K

TB46

NCCR26

D37

D38

D35 D36

D41

AX

LE

EX

T/R

ET

SE

LE

CT

C6

0A

XO

R/ R

D

C2

P- 4

AX

LE

DU

MP

VA

LVE

NC

CR8

D34

D15

TB16

S3NC

NCCR29

OP

EN

WH

EN

AX

LE

FU

LL Y

EX

T.

AX

LE

NO

TE

XT

PR

ES

SU

RE

SW

AX

LE

EX

TE

ND

RLY

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

/JIB

UP

/JIB

DO

WN

C3

1E

DC

WH

/BK

C3

0E

DC

WH

CR8

C6

-36

C6

-37

C6

-1 1

C6

-39

C6

-13

C5

- 23

C5

-24

C6

-4

C6

-5

C6

-6

C6

-1

C6

-2

C6

-3

C6

-7

C6

-8

C6

-9

C6

-12

C6

-30

C6

-14

C6

-15

C6

-18

C6

-17

C6

-19

C6

-21

C6

- 22

C6

- 10

C6

- 31

C6

- 20

LS

2A

O- B

OO

MA

NG

LE

OP.

DR

I VE

LI M

ITS

WI T

CH

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

WH

RD

C4

0L

S2

BK

U4

ADC B

C3

5-1

C3

5-2

C3

4-1

C3

4-2

1

2

C2

9-2

C2

9-1

C1

6-1

C1

6-2

C1

7-2

C1

7-1

C2

7-2

C2

7-1

C1

3-1

C1

3-2

C1

2-1

C1

2-2

C3

1-1

C3

1-2

C1

4-1

C1

4-2

C1

5-1

C1

5-2

C2

8- 2

C2

8-1

C2

6-2

C2

6-1

C2

4-2

C2

4- 1

C2

5-2

C2

5-1

C1

2D

RE

BL

/WH

C2

3B

AT

RD

21

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

2A

XD

PW

H

C6

0A

XO

R/R

D

S3

LE

DB

L/R

D

J4

BK

J3

WH

J1

WH

J5

BK

J2

WH

D57

C6

-32

C4

P-1

2 13 4

2

2

2

3

3

4

4

4

1

1

1

C27AUX + FE RD

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

C2

1-1

C2

1-2

C2

4-2

C2

3-1

C2

2-1

C2

2-2

C2

0-1

C2

0-2

3

D41 CR38

NC

CR38

C6

-40

C4

0L

S1

OR

P24FS WH

C28TTA RD/BK

P26ESTP BK

C8

PB

RB

K/W

HC

6-3

8

C6

-29

R1

6P

BR

BK

/WH

3 4

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

P134BAT RD

CR20 A

CR20 B

NO

NO

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

PL

AT

LE

VE

L

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TA

XL

EEXTEND/RETRACT

BR

N

OR

WH

/BK

1 542 3 6

10 9 3

1 42 3 5 6


1 42 3 5 6

DRIVE & STEERING

WH

/RD

1

RD

/WH

2

BR

N

OR

BR

N

OR

BL/W

H5 4

13

1411

12

J1 J1 J1

OU

T

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL/W

H

XO

UT

WH

/RD

TB17

TB18

WH

C4

P-6

C4

P-5

D2

7

D2

8

UP

DO

WN

PL

AT

RO

TA

TE

UP

DO

WN

D2

7

JIB

BO

OM

D2

7D

27

LE

FT

RIG

HTP

LAT

RO

TAT

E

LE

FT

RIG

HT

TS57

C4

P-7

TS7 TS8

JIB

VA

LVE

C19JSV GR/WH

CR13

JIB

BO

OM

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C1

9JS

VG

R/W

H

TS58


RE

TR

AC

TE

XT

EN

DA

XLE


6 - 26

February 2012


6 - 25


6 - 27

February 2012

Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models

6 - 28


6 - 28 S-80 • S-85 Part No. 122149

February 2012


1

2

3

4

5

6

7

8

Ground Control Box Wiring Diagram, S-80/85Perkins 804-33 Models

CHECK ENGINE LED

TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH

CR3

CR5

CR1

CR2

TS61

CB1

TS62

L2

G6

CB2

HIGH IDLE CUTOUT RELAY




SERVICE HORN RELAY



HOUR METER


LABEL

TS51

KS1

TS54

TS59

TS57

TS52

P1



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION

G1

G2

G3




BK C1B-7 33 BK-S.P.

HOUR METER

HARNESS:TO BASE

WIRING


WH/BK-5AWH-4A

WH-23D

START ENG

GLOW PLUG

STEER RT/AXLE EXTENGINE RPM

LIMIT SW #1

L.P.

ENG RPM

BRN-GND STUD

GR C2B-5CR5CR1 CR2

BK C6-16

OR-14A

WH/RD-6A

GR-17A

GR/BK-18A

GR/WH C4B-7

RD-B1-20A

RD-24A

BK-22B

ALL BRN WIRES

BK/RD-35A

TS54

D14

D13

OR/BK-15A

OR/BK C2B-3

OR C6-10

BL/BK C6-37

OR C6-40

OR/BK C5-2

RD C6-31

41

46B

40

BL/BK C1B-11


39

37

35

34

BK/RD-9A

GROUND STUD

BK-33

RD-1A

WH-21A

OR C2B-2

BK/RD-S.P.

BK/WH-8A

RD/WH-3A

RD/BK-2A

BK-7A

RD-27A

TS57

LEVELPLAT. PLATFORM

ROTATE

CB1 CB2

START

TS52

TURNTABLE

TS59

ROTATE

TS62

TS63

BOOM EXTEND/RETRACT UP/DOWN

BOOM

TS61

PRI. BOOM UP

TURN. ROT. L

TURN. ROT. R

PRI. BOOM F.C.

BOOM EXTEND


TURN. ROT. F.C.

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. R.

PLAT. ROT. L.


OIL COOLER FAN

FUSED 12V

IGNITION PWR.

PRI. BOOM DOWN

12V BATT. SUPPLY

AUX PUMP

BRAKE WH/RD C5-23RD

GR C4B-5

GR/BK C4B-6

OR/BK C4B-3OR C4B-2

21

WH/RD C1B-6

RD CR39#86&C1B-1

WH C7B-2

24 RD CR2#30

WH/RD C6-3227

32

BK CR5#30

23

22

GR C6-17

GR/BK C6-18

OR C6-14OR/BK C6-15

20

18

17

16

15

14

WH/RD C3B-6

BK/RD C3B-9

BK/WH C3B-8

BK C3B-7

RD/WH C3B-3

WH/BK C3B-5

WH C3B-4

RD C3B-1

RD/BK C3B-2&C6-2

6WH/RD C6-6

BK/RD C6-9

BK C6-7

BK/WH C6-8

11

10

7

8

9

RD/WH C6-3WH C6-4

WH/BK C6-5

RD C6-1

3

5

4

2

1

WH/BK C5-14

WH S.P.

RD-S.P.-CB3RD-S.P.

BK-S.P.

GR-S.P.

GR/BK-S.P.

OR-S.P.

OR/BK-S.P.

WH/RD-S.P.

BK/RD-S.P.

BK-S.P.

BK/WH-S.P.

RD/WH-S.P.WH-S.P.

WH/BK-S.P.

RD-S.P.RD/BK-S.P.

WH/RD C5-16

E-STOP

D2

NC

P1

NC

AUXILIARY PUMPTS51

CB3

RD-B2-S.P.

RD-B1-20C

RD-24AA

RD-B2-H1

RD CR1#30

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

24A

WH-S.P.-D2

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

CIRCUIT DESCRIPTION FROM TO

61 AXLE RETRACT BL/BK C3B-11 BL/BK C6-21

19 JIB VALVE GR/WH C4B-7 GR/WH-S.P.

25 OIL PRESSEURE SENDER WH/RD C5-16 WH/RD-S.P

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

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

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

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

36 STEER LEFT/AXLE RETRACT BL C1B-10 BL C6-36

43 HORN GR C2B-5 GR CR5#86

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

RD CR17#30

RD C6-30

33A

R2

OR/RD CR20A#86

38

BL/BK C6-20

OR/RD CR29#86

CR17

CR25

CR29


AXLE RET L/O RELAY


AXLE DUMP VALVE

HORN

START RELAY

LIMIT SW #2

LIMIT SW PWR

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

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

HIGH/LOWRPM

RD-S.P.-CB1

U1 IGNITION/START MODULE

WH CR17 #86

CONTROLSENGINE

OIL COOLER/OPTION

CB3 CIRCUIT BREAKER, OIL COOLER/OPTION, 20A

RD-B1-20D

RD-B1-H1

BRN(GND)

R2 TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS

OR/RD CR8#87A

CR29CR8

RD/BK 2B

BL/RD C4B-1

OR/RD 42B

OR/RD 16B

BL/RD C6-13

BK 7B

CR8 BOOM FUNCTION CUTOUT

RD C6-23 RD C2B-6 134 RD-H6 RD-KSI-SPKS POWER

CHECK ENGLED L2

WH-23A

BK-22A

KSI

RD-134A

PLATFORM OVERLOAD MODULEU33

RD C6-24 134A

28 TILT ALARM RD/BK C1B-2 RD/BK C6-28

KS POWER

D42

OR/RD CR38#87A

RD CR38#86

BK/WH C6-38

AUXILARY PUMP RELAY


CR39

CR38

KEYSWITCH

B

B11

24

3

CR38

CR39

BK/WH C6-29

OR/RD 16C

RD-1B

RD-27D

RD-24C

RD C6-27

CR17

WH-21B

RD-24AB

WH-C6-34

OR C6-33

BL/RD C2B-1

CR20B LOW VOLTAGE DROP RELAY

CR20A LOW VOLTAGE DROP RELAY

OR/RD C6-11

TB16D OR/RD

TB134A-A

CR20A CR20B

GR

OU

ND

ST

UD

-

+

-

+

TS58 JIB UP/DOWN (JIB OPTION ONLY)

TS58

JIB

OIL PRESSURE

G2G1

VOLT METER

G3

WATER TEMP.


BRN GND

CR23

10 AMP FUSE

RD C4B-11

RD C4B-12

OPTION WIRE TO PBOX

TB24AD


(SPARE WIRE)

(SPARE WIRE)



EN

GIN

E

C5

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B 1


D7

CD AB

G6

H1

868686

D34

RD/BK C6-19

D8

CR8#86+

D15

GND STUDD57

RD/BK CR8#30

8686 86

D42

86

86

8686 86

BK-C23-5IGN./STARTMODULE

WH-CR2#86

TB33AB

WH C5-11

WH L2

WH-23B

RD-24D

CR3

BK/RD C5-18

WH-21C

BK/RD-35B

IGN./FUEL ON

KEY BYPASS

ENG. FAULT

KEY PWR.

BATTERY

10

8

9

7

6

U1

GLOW PLUG SWBK/WH-34A

RD-C23-7

TS56

BK CR1#86

OR/BK-41B

BRN GND

RD-27B

BK-33B

WH CR3#86

D51

RD ISM#6

BK C23-4

BK C5-5

WH C5-3

3 BL/WH C1-12

76

128

5

4C

23

RD-TS52GR/BK H6BRN

RD-TS51BK C7B-1

BK-22D2

1 RD H6

START INPUT

TACHOMETER

START RELAY

GROUND

AUX. ON

3

5

4

2

1

OR/BK ISM#2

BK/RD CR3#30

BK ISM#3

WH ISM#7

BK-CR1#87

ISM#4D6

BK/WH-S.P.

WH C5-15

WH ISM #10

GR/BK-H6

P134PWR RD-134B

GR/BK-L45GR/BK-C3B-10 CE ONLY

H6

+

RD C23-6

PLATFORMOVERLOADLED L45

-

+

L45

TS56

PLATFORM OVERLOAD LED

GLOW PLUG SWITCH (DIESEL ONLY)

NOTE: CE OPTION- LOADSENSEMODULE CONNECTS TO C32.


6 - 29

February 2012

Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (before serial number 5520)

6 - 30


6 - 30 S-80 • S-85 Part No. 122149


1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (before serial number 5520)

BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWNJC2

U13

JC1

JIB BOOM CUTOUT RELAY

AXLE CUTOUT RELAY

TILT ALARM

ALC500

BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE

COMPONENT INDEX

TS2

TS9

TS15

P3

TS1

TS14

L1

P2

DRIVE ENABLE LED

PLATFORM LEVEL TOGGLE SWITCH

HORN SWITCH


AUXILIARY TOGGLE SWITCH

ENGINE START SWITCH

TS47 GENERATOR TOGGLE SWITCH (OPTION)

TS4

TS7

TS8

HIGH RPM SWITCH

PLATFORM ROTATE TOGGLE SWITCH

JIB BOOM UP/DOWN TOGGLE SWITCH

LOW/HIGH SWITCHDRIVE SPEED TOGGLE

DRIVE ENABLE TOGGLE SWITCH

JC3 DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT

CR13

CR26

H1

TS48

TS49

WORK LIGHT TOGGLE SWITCH (OPTION)

DRIVE LIGHT TOGGLE SWITCH (OPTION)

GLOW PLUG OPTIONTS6

TS16 AXLE EXTEND/RETRACT TOGGLE SWITCH

L40 AXLE EXTENDED LED

CE LIFT/DRIVE OPTIONREPLACE WIRE WITH THIS WIRING DIAGRAM

CR27WH-TS7

WH-TS1

BRN BATGND

GND STUD

WH/RD C32BRK

OR/RD R40LS2

(SPLICE TO C32BRK)

(SPLICE TO R40LS2)

CR30

OR

C4

P-2

OR

/BK

C4

P-3

GR

C2

P-5

NO

BL

/BK

J1

-7

RD

C1

P-1

GR

/BK

C4

P-6

GR

C4

P-5

YE

LJ1

-3

RD

J1

-1

BK

/RD

C1

P-9

BL

/RD

J1

-16

RD

C9

-3

BK

C1

P-7

OR

J1

-9

RD

/WH

J1

-8

BK

C9

-1

NC

HORN

GR

/WH

JIB

CA

BL

E

WH

C7

P-2

BK

C7

P-1

CR26AXLE CUTOUT

P2EMERGENCY

STOP

TS4HIGH/LOW

RPMTS2

ENGINESTART

L1

TS1AUXILIARY

PUMP

TS14DRIVESPEED

TS7PLATFORM

ROTATE

TS9PLATFORM

LEVEL

P3


TURNTABLEROTATE

JC1BOOM

EXTEND/RETRACT

BK

/WH

C1

P-8

JC3DRIVE

GND STUD

H1TILT

ALARM

RD

LS

18

BRN

C1

2D

RE

BL

/WH

C3

P-1

2

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

C3

PB

FR

D/W

HC

3P

-3

C8

PB

RB

K/W

HC

3P

-8

C6

TR

FW

H/R

DC

3P

-6

C9

PE

RF

BK

/RD

C3

P-9

C7

PB

EB

KC

3P

-7

C2

PB

DR

D/B

KC

3P

-2

C1

PB

UR

DC

3P

-1

HI-C

13

3P

LA

GN

/BL

C3

P-1

0

TS

9-C

15

PL

DO

R/B

KC

4P

-3

FOOT SWITCH

C3

P(G

R)

C1

P(G

Y)

C2

P(B

K)

12V DCBATTERY

C4

P(B

R) C7P

BATGND C7P-3

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

14

PL

UO

RC

4P

-2

C9 JIB

P2

-P2

3S

WB

AT

WH

C7

P-2

R4

0L

S2

OR

/RD

C4

P-4

TS

7-C

18

JD

GR

/BK

C4

P-6

TS

7-C

17

JU

GR

C4

P-5

J3

-P2

4C

ON

TW

HC

9-2

P2

-P2

2B

AT

BK

C7

P-1

TS

2-P

25

ST

RR

DC

9-3

TS

6-C

34

SA

BK

/WH

C1

P-8

C3

2B

RK

WH

/RD

C1

P-6

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

HC

1P

-3

C3

1E

DC

-W

H/B

KC

1P

-5

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C3

0E

DC

+W

HC

1P

-4

TS

1-C

27

AU

XR

DC

1P

-1

P2

-P2

6F

SB

KC

9-1

TS

2-C

33

ST

RB

KC

1P

-7

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

C4

1R

PM

OR

/BK

C2

P-3

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C3

7S

TC

BL

/BK

C1

P-11

DL

ITE

GR

/BK

C2

P-6

C4

0L

S1

OR

C2

P-2

C3

6S

TC

CB

LC

1P

-10

P3

-C4

3H

RN

GR

C2

P-5

BK

J1

-2

+

TS15DRIVE

ENABLE

19/18 CONTROL CABLE

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C2P-9 & 10

D12

TS6GLOW PLUG

OPTION

LS18(OPTION)

7

6

5

4

3

2

1

4

2

1

3

5

6

7

4

2

1

3

5

6

7

BR

NJ1

-10

+-

+-

+-

OR

J1

-13

BR

NJ1

-14

OR

J1

-11

BR

NJ1

-12

1

11

1

9

3

1

JC

3-5

WH

JC

2-2

BR

N

JC

3-6

BL

JC

2-3

OR

JC

1-5

YE

L

JC

1-2

BR

N

JC

2-5

BK

JC

2-4

RD

JC

1-3

OR

TS

14

-C2

9M

SR

D/W

H

L1

-C1

3L

ED

BL

/RD

TS

15

-DR

EB

BL

/BK

JC

3-2

BR

N

TS

15

-DR

EA

BL

/WH

JC

3-3

OR

GND STUD

J1 J2

J3

WH

J1

-5

BL

J1

-4

BR

N

+

L40

EX/RET

TS16

AXLE

WH

J3

-2

BL

/RD

C4

P-1

OR

/RD

C2

P-4

J2

-DIO

DE

WH

D12D12

WH

TS

4

WH

CR

26

#8

5

BL

C1

P-1

0

BL

/BK

C3

P-11

BK

P2

BL

/WH

J1

-6

WH

C9

-2

BK

J3

-3

BL

TS

16

TS

16

-C6

1A

XB

L/B

KC

3P

11

CR13 BRN

RD

LS

18

U13ALC-500

D2

CE MODELS (SEE DETAIL A)

RD

/BK

H1

RD LS CABLERD-H1

RD-P2

+

L4

BK LS CABLE CIP-12

RD

C2

P-6

GN

/BK

L4

L4 PLATFORM OVERLOAD LED

LS18 PLATFORM OVERLOAD LIMIT SWITCH

GN

/BK

C3

P-1

0

RD

/BK

L4

8

OPT.

GN

/BK

H1

(D3

9)

L48

BK

+

TS48/TS49

RD WL1

RD WL2

TS15

DETAIL C: WORKLIGHT/DRIVELIGHT OPTION

L48 TILT ALARM LED

D40

D39

TS2

GR

/WH

C2

P-7

DETAIL B: GENERATOR OPTION

TS8JIB BOOM

JIB

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7

RD/BK JIB CABLE

GND

CR13

CUTOUT

JIB

GR/WH C4P-7

GR/WH TS7


Part No. 122149 S-80 • S-85 6 - 31


1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (after serial number 5519)

GR

C2

P-5

OR

/BK

C4

P-3

OR

C4

P-2

BL

/BK

C3

P-11

BL

C1

P-1

0

OR

/RD

C2

P-4

BL

/RD

C4

P-1

BRN

J2

-DIO

DE

WH

GR

/WH

JIB

CA

BL

E

RD

/WH

J1

-8

GR

C4

P-5

GR

/BK

C4

P-6

RD

C1

P-1

RD

BK

BK

RD RD

RD

/BK

H1

BL

/WH

J1

-6

WH

J3

-2

BK

C1

P-7

RD

C9

-3

BK

/WH

C1

P-8

BK

/RD

C1

P-9

BL

/BK

J1

-7

GN

/ BK

H1

(D3

9)

BK

J3

-3

BK

C7

P-1

WH

C7

P-2

BK

C9

-1

GN

/BK

C3

P-1

0

GN

/BK

L4

RD

C2

P-6

RD

LS

18

RD

/BK

H1

TS

15

-DR

EB

BL

/BK

L1

-C1

3L

ED

BL

/RD

TS

14

-C2

9M

SR

D/W

H

C1

34

PW

RG

R/B

KC

2P

-6

U13

BL

TS

16

WH

C9

-2

BK

P2

WH

CR

26

#8

5

WH

TS

4

ALC-500

RD

/BK

L4

8

TS

2-C

33

ST

RB

KC

1P

-7

TS

1-C

27

AU

XR

DC

1P

-1

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C2

9M

SR

D/W

HC

1P

-3

TS

6-C

34

SA

BK

/WH

C1

P-8

BATGND C7P-3

C28TTA RD/BK C1P-2

JC

3-3

OR

TS

15

-DR

EA

BL

/WH

JC

3-2

BR

NJC

3-6

BL

(1)

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

2-5

BK

JC

1-2

BR

N

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

(2)

P3

-C4

3H

RN

GR

C2

P-5

C3

6S

TC

CB

LC

1P

-10

C4

0L

S1

OR

C2

P-2

C3

7S

TC

BL

/BK

C1

P-1 1

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

2B

RK

WH

/RD

C1

P-6

R4

0L

S2

OR

/RD

C4

P-4

C1

PB

UR

DC

3P

-1

C2

PB

DR

D/B

KC

3P

-2

C7

PB

EB

KC

3P

-7

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C3

PB

FR

D/W

HC

3P

-3

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C1

2D

RE

BL

/WH

C3

P-1

2

GND STUD

CC

13

2P

LI

BL

/WH

C3

P-1

2

TS

16

-C6

1A

XB

L/B

KC

3P

11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P2

-P2

6F

SB

KC

9-1

TS

2-P

25

ST

RR

DC

9-3

P2

-P2

2B

AT

BK

C7

P-1

J3

-P2

4C

ON

TW

HC

9-2

TS

7-C

17

JU

GR

C4

P-5

TS

7-C

18

JD

GR

/BK

C4

P-6

P2

-P2

3S

WB

AT

WH

C7

P-2

TS

9-C

14

PL

UO

RC

4P

-2

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

15

PL

DO

R/B

KC

4P

-3

C1

33

PL

AB

LC

3P

-10

RD

LS

18

P3

HORN

NO

TILT ALARM

D39

H1

CE SEE DETAIL A

PLATFORM

LEVEL

TS9TS7

ROTATE

PLATFORM

TS1

AUX. PUMPTS14

SPEEDDRIVE

19/18 CONTROL CABLE

C2

P(B

K)

D2 TS16

L40

+

AXLE

EX/RET

GND STUD

C1

P(G

Y)

12V BATT

C4

P(B

R)

C3

P(G

R) C7P C9

F.S.

RPM

TS2

START

+

L1

HIGH/LOW

+

L4

TS4

E- STOP

P2

NC

TS15

DRV.ENA

+

D12

L48

OPT.

D40

J2J1

1

9

D12 D12

1

J31

3

11



L48 TILT ALARM LED








AXLE EXTENDED LED

DRIVE ENABLE LED

ALC500

JC1

H1

JC2

U13

L4

L40

JC3

L1

TILT ALARM

AXLE EXT/RET SWITCH

DRIVE ENABLE SWITCH

HIGH RPM SWITCH


TS16

TS47

TS14

TS15

TS7

TS4

TS9


COMPONENT INDEX

START ENGINE SWITCH

AUXILIARY SWITCH

HORN SWITCH

P2

TS1

P3

TS2

TT ROTATE

UP/DOWN

PRI. BOOM BOOM

EXT/RET


C2P-9 & 10CR13 BRN

CR

26

BK LS CABLE CIP-12

RD LS CABLE RD-P2

RD-H1

YY

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

RD WL1


TS48

E-STOP BK

F18 10A

RD WL2

(SPARE WIRE)

OPTION WIRE TO GBOX

DRIVELIGHT OPTION

TS49

TS48 PIN2



C32BRK)

R40LS2)

(SPLICE TO

OR/RD R40LS2

CR30

(SPLICE TO

WH/RD C32BRK

WH TS7CR27

GENERATOR OPTION

DETAIL B:

TS47

WH TS1

(GND STUD)

BRN BATGND GR

/WH

C2

P-7

TS2 RD



GLOW PLUG

TS48

TS48

TS6

2

GN

DB

RN



TS8

D27

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

J1

-11O

RJC

2-2

J1

-12

BR

NJC

2-1

JC2

J1

-3W

H/B

KJC

1-4

J1

-9O

RJC

1-2

J1

-10

BR

NJC

1-1

JC1

JC3

J1

-5B

L/W

HJC

3-5

J1

-4W

H/R

DJC

3-4

J1

- 13

OR

JC

3-2

J1

-14

BR

NJC

3- 1

J1

-5B

L/W

HJC

3-3

TS6

GLOW PLUG

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7


GR/WH C4P-7

JIB

CUTOUT

JIB

CR13

TS8

JIB

GND

OPT.LS18


6 - 32

February 2012

Platform Control Box Wiring Diagram, S-80/85Perkins 804-33 Models (after serial number 5519)

6 - 31


6 - 33

February 2012

Electrical Schematic, S-80/85Continental TME27 Models (before serial number 5520)

6 - 34


6 - 34 S-80 • S-85 Part No. 122149




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

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

NOTES:

STA

RT

BA

TT

ER

Y

P2

0B

AT

RD

FA

N(O

PT.)

HY

D.C

OO

LIN

G

ALT

ER

NA

TO

R

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

FANFB

HY

D.O

ILT

EM

P.

SW

ITC

H(O

PT.)

TILT

AL

AR

M

RE

LA

Y

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

H2

B

BK

NOCR17

P1

34

FB

RD

R11

6H

YD

OR

R16

51

0C

21

IGN

WH

C5

-3

C6

-24 C

6-3

3

R2

1IG

NW

H

C4

3H

RN

BK

CA

RD

WH

C6

-34

C6

-16

NOCR5

C2

8T

TA

RD

/BK

P1

34

TT

SR

D

TS64

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

STA

RT

ER

MO

TO

R

M3

PUMPSTARTER

PUMP

C2

7A

UX

RD

PR1

NO

C6

-27

C5

-10

C5

-18

C5

-2

C5

-19

C5

-11

C5

-9

C2

5P

SR

BL

/BK

TE

ST

SW

ITC

H

CH

EC

KE

NG

INE

LE

D

HO

UR

ME

TE

R

GE

NE

RA

TO

R

OP

TIO

N

_

+

OIL

PR

ES

SU

RE

SE

ND

ER

&

GA

UG

E(O

PT.)

WA

TE

RT

EM

P

VO

LTM

ET

ER

(OP

T.)

BRN

GR

/WH

L2

C5

-12

C5

-16

C5

-14

G1G3G2

C2

P-5

P1

34

BA

TG

R/B

K

P2

2B

AT

BK

RD

TB20

RD

15AMP.

CB1

C2

B-5

C1

B-2

TB24ARD

CB3

20AMP.

15AMP.

CB2

RD

WH

RD

C6

-28

C6

-23

TB

28

TB23D2

C2

B-6

BK

GRD

PLAT

P1

RD

RD

TB22

TB134

C4

6H

RN

GR

C2

8T

TA

RD

/BK

WH

C7

B-1

C1

B-1

2

C1

P-2

C2

P-6 C

7P

-1

C1

P-1

2

HORN

C1

32

PL

IB

L/W

H

P3

H1

RD

P2

C7

B-2 TB33R

D

CR1NO

CR39A

TB27

TB24CR39B

TB21

NO

TB41

P23BAT

NO

CR2

P2

3B

AT

WH

TS51

C2

7A

UX

RD

C7

P-2

C1

-1

C3

3S

TR

BK

TS52

C1

-7

C21IGN WH

D7

D8

TB46 D13

TB35

D14 D42

C3

9L

PB

L/R

D

TB39

D11

TS53 C4

5G

EN

GR

/WH

C2

-1

C2

-7

FU

NC

.E

NA

BL

EL

OW

RP

M

HIG

HR

PM

TS54

C3

5R

PM

BK

/RD

OR/BK

RDRDRD

C1

-9

P25FS RD

P24FS WH

D43

FS1

C9P-1

P26ESTP BK

TS1

TS2

D10

TS3 TS47

EN

GIN

ES

PE

ED

HIG

H(F

S)

D12

TS4

WH

BK

P134BAT RD

RD/BK

P46 RD

C2

7A

UX

RD

P23 RD

C41RPM OR/BK

C9P-3

C9P-2

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

B1

B3

1

4

2

KS1

L48

C3

P-1

0

D40

C3

B-1

0

C3

8F

P-B

L/W

H

C1

28

RP

M-O

R/R

D

BK

-12

GA

RD

-12

GA

WH

-14

GA

HARNESS

1 2 365 41011 12 987

CONTINENTAL TME27 ENGINE

VEHICLE INTERFACE 1

C1

08

ES

L-B

L/W

H

C1

27

TS

W-G

N

C3

5R

PM

-BK

/RD

VS

W-R

D

R3

3S

TR

-BK

C3

9L

P-B

L/R

D

C3

8R

ET

-BL

C1

33

PL

AB

L

RD

WH

GN

DB

R

RD

1K

R1

RD

TB21

C4

1R

PM

-OR

/BK

C2

6T

SR

-GN

/BK

NC

FU

EL

PU

MP

GA

UG

E(O

PT.)

FU

SE

10

AR

D

RD

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

&

CR23CR23

NO

L29

BK

BK

WH

WH

TS49 TS48

PBOX GND

OP

TIO

NW

IRE

FUSE 10A

L30

C4

-11/1

2

2

5

6

AUX AUX

WO

RK

LIG

HT

DR

IVE

LIG

HT

HM

C5

-13

C5

-8

C5

-5

BK

7 FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13

E2

1IG

N-W

H

C21IGN WH

B1

-

+

12 VDC

7

12 8

6

1

4

3

5

C32

GR

/BK

GR

/BK

BL

/WH

CONN.PLUG

6

5

A B C D E F G H I J K L M N1

2

3

4

5

6

7

8



Part No. 122149 S-80 • S-85 6 - 35


1

2

3

4

5

6

7

8


DR

IVE

/RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

BRN

DE

SC

EN

TA

LA

RM

P46 RD

C41RPM OR/BK

C1

5P

LD

OR

/BK

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

TB17

TB18

GR

-17

-M.H

.

GR

/BK

-18

-M.H

.

TS9

TS59

TB14

TB15

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

TB9

C9

PE

RF

BK

/RD

TS63

TB8

BK

/WH

C8

PB

RB

K/W

H

C1

4P

LU

OR

BK

/RD

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C7

PB

BE

BK

C8

PB

RB

K/W

H

BK

TB7

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

TS61

C2

PB

DR

D/B

K

C1

PB

UR

D

TB3

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

TS62

C5

TR

RW

H/B

K

TB1

TB6

C6

TT

RF

WH

/RD

TB4

C1

PB

UR

D

PR

I.B

OO

ME

XT

EN

D

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TB5

BR

AK

ER

EL

EA

SE

VA

LV

E

C2

9M

SR

D/ W

HM

OT

OR

ST

RO

KE

LS

1R

O- B

OO

MR

ET

RA

CT

OP.

DR

IVE

/ RO

TA

TE

SP

EE

D

LS

2A

S-B

OO

MA

NG

LE

SA

FE

TY

DR

IVE

LIM

ITS

WIT

CH

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

C4

0L

SO

R/R

D

TB42

C2

9M

SR

D/W

H

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C3

6S

TC

CB

L

C3

7S

TC

BL

/ BK

TB37

C3

7S

TC

BL

/BK

C3

6S

TC

CB

L

LIM

ITS

WIT

CH

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

EN

AB

LE

GR

OU

ND

TS15

C1

2D

RE

BL

/WH

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C3

2B

RK

WH

/ RD

C5

-20

C3

2B

RK

WH

/RD

TB32

L1

BR

N

H4

H3

EXTEND/RETRACT


3

BR

N

OR

YE

L

1 542 3 76

12

C5

-21

14

LS3

13

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

10 9 3

1 742 3 5 6


1 742 3 5 6

DRIVE & STEERING

RD

1

BK

2

BR

N

OR

BR

N

OR

WH

BL

5 4

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

P23 RD

13

1411

122

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P- 4

C1

P-5

C1

P-6

C1

P-3

C1

P- 1

1

C1

P-1

0

C3

P- 6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P- 4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/R

D

CD

E2

BL

/BK

J2

J3 J1 J1 J1 J1

OU

T

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

C4

P-6

C4

P-5

DR

IVE

ED

CF

OR

WA

RD

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK


TS16

C4

0L

S1

OR

TB40

C2

P-2

1

C3

P-1

1C

61

AX

BL

/BK

TB46

NCCR26

D37

D38

D35 D36

D41

AX

LE

EX

T/R

ET

SE

LE

CT

C6

0A

XO

R/ R

D

C2

P-4

AX

LE

DU

MP

VA

LV

E

NC

CR8

D34

D15

TB16

S3NC

NCCR29

OP

EN

WH

EN

AX

LE

FU

LLY

EX

T.

AX

LE

NO

TE

XT

PR

ES

SU

RE

SW

AX

LE

EX

TE

ND

RLY

L5

C7

-3

S3

LE

DB

L/R

D

+

5R2

D29

D2

7

D2

8

/JIB

UP

/JIB

DO

WN

C3

1E

DC

WH

/ BK

C3

0E

DC

WH

CR8

C6

-36

C6

-37

C6

-11

C6

-39

C6

-13

C5

- 23

C5

-24

C6

-4

C6

-5

C6

-6

C6

-1

C6

-2

C6

-3

C6

-7

C6

-8

C6

-9

C6

-12

C6

-30

C6

-14

C6

-15

C6

-18

C6

-17

C6

-19

C6

- 21

C6

-22

C6

-10

C6

-31

C6

-20

LS

2A

O-B

OO

MA

NG

LE

OP.

DR

IVE

LIM

ITS

WI T

CH

LIM

ITS

WIT

CH

LIM

ITS

WIT

CH

WH

RD

C4

0L

S2

BK

U4

ADC B

C3

5-1

C3

5-2

C3

4-1

C3

4-2

1

2

C2

9-2

C2

9-1

C1

6-1

C1

6-2

C1

7-2

C1

7-1

C2

7-2

C2

7-1

C1

3-1

C1

3-2

C1

2-1

C1

2-2

C3

1-1

C3

1-2

C1

4-1

C1

4-2

C1

5-1

C1

5-2

C2

8-2

C2

8- 1

C2

6- 2

C2

6-1

C2

4-2

C2

4-1

C2

5-2

C2

5- 1

C1

2D

RE

BL

/WH

C2

3B

AT

RD

21

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

2A

XD

PW

H

C6

0A

XO

R/ R

D

S3

LE

DB

L/R

D

J4

BK

J3

WH

J1

WH

J5

BK

J2

WH

D57

C6

-32

C4

P-1

2 13 4

2

2

2

3

3

4

4

4

1

1

1

BL

C27AUX + FE RD

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

C2

1-1

C2

1-2

C2

4-2

C2

3-1

C2

2-1

C2

2-2

C2

0-1

C2

0-2

3

D41 CR38

NC

CR38

C6

-40

C4

0L

S1

OR

P24FS WH

C28TTA RD/BK

P26ESTP BK

C8

PB

RB

K/W

HC

6-3

8

C6

-29

R1

6P

BR

BK

/WH

3 4

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

XO

UT

P134BAT RD

CR20 A

CR20 B

NO

NO

UP

DO

WN

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

PL

AT

LE

VE

L

UP

DO

WN

RE

TR

AC

T

EX

TE

ND

BO

OM

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TA

XL

E

D2

7

JIB

BO

OM

D2

7D

27

LE

FT

RIG

HTP

LA

TR

OTA

TE

LE

FT

RIG

HT

TS57

C4

P-7

TS7 TS8

JIB

VA

LV

E

C19JSV GR/WH

CR13

BRN

JIB

BO

OM

C1

7JU

/PR

LG

R

C1

8JD

/PR

RG

R/B

K

C1

9JS

VG

R/W

H

JIB

VA

LV

E

TS58


7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch

RE

TR

AC

TE

XT

EN

DA

XLE


6 - 36

February 2012


6 - 35


6 - 37

February 2012

Electrical Schematic, S-80/85Continental TME27 Models (after serial number 5519)

6 - 38


6 - 38 S-80 • S-85 Part No. 122149


2

3

4

5

6

7

8



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

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

NOTES:

STA

RT

BA

TT

ER

Y

P2

0B

AT

RD

FA

N(O

PT.)

HY

D.C

OO

LIN

G

ALT

ER

NA

TO

R

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

FANFB

HY

D.O

ILT

EM

P.

SW

ITC

H(O

PT.)

TILT

AL

AR

M

RE

LA

Y

SE

RV

ICE

HO

RN

LE

VE

LS

EN

SO

R

SE

RV

ICE

HO

RN

H2

B

BK

NOCR17

P1

34

FB

RD

R11

6H

YD

OR

R16

51

0C

21

IGN

WH

C5

-3

C6

-24 C

6-3

3

R2

1IG

NW

H

C4

3H

RN

BK

CA

RD

WH

C6

-34

C6

-16

NOCR5

C2

8T

TA

RD

/BK

P1

34

TT

SR

D

TS64

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

STA

RT

ER

MO

TO

R

M3

PUMPSTARTER

PUMP

C2

7A

UX

RD

PR1

NO

C6

-27

C5

-10

C5

-18

C5

-2

C5

-19

C5

-11

C5

-9

C2

5P

SR

BL

/BK

TE

ST

SW

ITC

H

CH

EC

KE

NG

INE

LE

D

HO

UR

ME

TE

R

GE

NE

RA

TO

R

OP

TIO

N

_

+

OIL

PR

ES

SU

RE

SE

ND

ER

&

GA

UG

E(O

PT. )

WA

TE

RT

EM

P

VO

LTM

ET

ER

(OP

T.)

BRN

GR

/WH

L2

C5

-12

C5

-16

C5

-14

G1G3G2

C2

P-5

P1

34

BA

TG

R/B

K

P2

2B

AT

BK

RD

TB20

RD

15AMP.

CB1

C2

B-5

C1

B-2

TB24ARD

CB3

20AMP.

15AMP.

CB2

RD

WH

RD

C6

-28

C6

-23

TB

28

TB23D2

C2

B-6

BK

GRD

PLAT

P1

RD

RD

TB22

TB134

C4

6H

RN

GR

C2

8T

TA

RD

/BK

WH

C7

B-1

C1

B-1

2

C1

P-2

C2

P-6 C

7P

-1

C1

P-1

2

HORN

C1

32

PL

IB

L/W

H

P3

H1

RD

P2

C7

B-2 TB33R

D

CR1NO

CR39A

TB27

TB24CR39B

TB21

NO

TB41

P23BAT

NO

CR2

P2

3B

AT

WH

TS51

C2

7A

UX

RD

C7

P-2

C1

-1

C3

3S

TR

BK

TS52

C1

-7

C21IGN WH

D7

D8

TB46 D13

TB35

D14 D42

C3

9L

PB

L/R

D

TB39

D11

TS53 C4

5G

EN

GR

/WH

C2

-1

C2

-7

FU

NC

.E

NA

BL

EL

OW

RP

M

HIG

HR

PM

TS54

C3

5R

PM

BK

/RD

OR/BK

RDRDRD

C1

-9

P25FS RD

P24FS WH

D43

FS1

C9P-1

P26ESTP BK

TS1

TS2

D10

TS3 TS47

EN

GIN

ES

PE

ED

HIG

H(F

S)

D12

TS4

WH

BK

P134BAT RD

RD/BK

P46 RD

C2

7A

UX

RD

P23 RD

C41RPM OR/BK

C9P-3

C9P-2

REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

B1

B3

1

4

2

KS1

L48

C3

P-1

0

D40

C3

B-1

0

C3

8F

P-B

L/W

H

C1

28

RP

M-O

R/R

D

BK

-12

GA

RD

-12

GA

WH

-14

GA

HARNESS

1 2 365 41011 12 987

CONTINENTAL TME27 ENGINE

VEHICLE INTERFACE 1

C1

08

ES

L-B

L/W

H

C1

27

TS

W-G

N

C3

5R

PM

-BK

/RD

VS

W-R

D

R3

3S

TR

-BK

C3

9L

P-B

L/R

D

C3

8R

ET

-BL

C1

33

PL

AB

L

RD

WH

GN

DB

R

RD

1K

R1

RD

TB21

C4

1R

PM

-OR

/BK

C2

6T

SR

-GN

/BK

NC

FU

EL

PU

MP

GA

UG

E(O

PT.)

FU

SE

10

AR

D

RD

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

&

CR23CR23

NO

L29

BK

BK

WH

WH

TS49 TS48

PBOX GND

OP

TIO

NW

IRE

FUSE 10A

L30

C4

-11/1

2

2

5

6

AUX AUX

WO

RK

LIG

HT

DR

IVE

LIG

HT

HM

C5

-13

C5

-8

C5

-5

BK

7 FOR S85, INSTALL JIB-VALVE, TS8, TS58, D27, D28, AND CR13

E2

1IG

N-W

H

C21IGN WH

B1

-

+

12 VDC

7

12 8

6

1

4

3

5

C32

GR

/BK

GR

/BK

BL

/WH

CONN.PLUG

6

5




Part No. 122149 S-80 • S-85 6 - 39


1

2

3

4

5

6

7

8


P134BAT RD

C28TTA RD/BK

P24FS WH

P26ESTP BK

C41RPM OR/BK

P23 RDC27AUX RD

P46 RD

C4

2L

S2

GR

C6

1A

XR

TB

L

C4

0L

S1

OR

C4

0L

S2

BK

C4

0L

S1

OR

DR

IVE

/RO

TA

TE

SP

EE

D

PR

I.B

OO

MR

ET

RA

CT

LIM

ITS

WIT

CH

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

21

C2

1-1

C2

3-1

C2

2-1

C2

0-1

DE

SC

EN

TA

LA

RM

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

/JIB

DO

WN

H4

C2

4-2

C2

2-2

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

C2

0-2

C2

1-2

LS3

NOHC

13 14

GR

/BK

-18

-M.H

.

GR

-17

-M.H

.

C6

-19

C6

-18

C6

-17

D29

OR

/BK

-15

-M.H

.

OR

-14

-M.H

.

C1

2D

RE

BL

/WH

R1

6P

BR

BK

/WH

C2

3B

AT

RD

C8

PB

RB

K/W

H

3 4

C6

-15

C6

-14

C6

-30

C6

-38

C6

-12

C6

-29

C2

8-1

C2

9-1

C1

6-1

C1

7-1

C2

7-1

C1

3-1

C1

2-1

C3

1-1

C1

4-1

C1

5-1

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

BO

OM

EX

T/R

ET

FL

OW

CO

NT

RO

L

PR

I.B

OO

ME

XT

EN

D

PR

I.B

OO

ME

XT

EN

D

CU

TO

UT

RE

LA

Y

C1

7-2

C2

7-2

C1

6-2

CR8

C2

9-2

D57

MO

TO

RS

TR

OK

E

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

CU

TO

UT

RE

LA

Y

PR

I.B

OO

MU

P

C3

1-2

C1

4-2

C1

3-2

C1

2-2

CR38

C2

8-2

C1

5-2

C9

PE

RF

BK

/RD

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C6

-8

C6

-9

C6

-7

C6

-3

C5

TR

RW

H/B

K

C6

TT

RF

WH

/RD

C2

PB

DR

D/B

K

C1

PB

UR

D

C2

9M

SR

D/W

H

C4

TR

LW

H

C6

-1

C6

-2

C6

-5

C6

-6

C6

-4

C5

-24

CR38

NCCR8

AN

GL

ES

AF

ET

Y

PR

ES

SU

RE

SW

AX

LE

FU

LLY

EX

T.

RE

TR

AC

TO

P.

LS

1R

S-B

OO

MR

ET

RA

CT

SA

FE

TY

CR20 B

C3

5-1

C2

6-1

C2

4-1

C2

5-1

NC

1RO

DR

IVE

/RO

TA

TE

SP

D.

LIM

ITS

WIT

CH

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

C2

4-2

C2

6-2

C B

D

U4

A

C2

5-2

NOHC1RS

DR

IVE

LIM

ITS

WIT

CH

DR

IVE

LIM

ITS

WIT

CH

AN

GL

EO

P.

AX

LE

DU

MP

VA

LVE

2AO

NCNOHC

2AS

C3

5-2

C3

6S

TC

CB

L

C3

0E

DC

WH

C3

2B

RK

WH

/RD

C3

1E

DC

WH

/BKH3

J5

BK

J2

WH

C3

7S

TC

BL

/BK

32 14

WH

RD 2

C6

-36

C5

-20

C5

-23

C6

-32

C5

-21

C6

-37

C6

-20

C6

-31

3

J1

WH

J3

WH

J4

BK

2 3 14

1 3 2 C4

2A

XD

PW

H

4

C6

-11

4 1NO

C3

4-1

AX

LE

EX

TE

ND

RLY

AX

LE

EX

T/R

ET

GR

OU

ND

C3

4-2

2

S3

NC

S3

LE

DB

L/R

D

C6

0A

XO

R/R

D

1

C6

-39

C6

-13

20

1110

TB9

C1

7JU

/PR

LG

R

TB17

TB18

TS57

C1

8JD

/PR

RG

R/B

K

TB15

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

TS59

C1

2D

RE

BL

/WH

C4

P-5 C

2P

-3

C3

P-1

2

C4

P-6

C4

P-2

C4

P-3

5 3

BK

BK

/WH

BK

/RD

TB7

TB8 TB2

TB3

C7

PB

BE

BK

C8

PB

RB

K/W

H

C1

PB

UR

D

C9

PE

RF

BK

/RD

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB1

TB6

TB5

NC

TB4

D41D15

5R2

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

TS61

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C3

P-8

C3

P-7

TS63

14

12

13 8 7 6

C1

P-3

C3

P-6

C3

P-5

C3

P-4

TS62

9

TS7 TS9

J2

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K


J3

3 4 12

BR

N

18

17

15

16

19

C6

1A

XB

L/B

K

C4

0L

SO

R/R

D

C6

0A

XO

R/R

D

C4

0L

S1

OR

TB32

TB37

TB46

C3

6S

TC

CB

L

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C3

2B

RK

WH

/RD

C3

7S

TC

BL

/BK

C6

-40

C6

-10

C6

-40

TB40TB16

C6

-22

C6

-21

CR20 A

NO

D34

TB42

C1

P-6 C

1P

-5

C1

P-4

C1

P-1

0

C1

P-11

D35 D36 D37

D38

C2

P-2

C4

P-4

C2

P-4

C3

P-11

1 4

S3

LE

DB

L/R

D

NCCR29

BR

N

C4

P-1

C7

-3

DR

IVE

MO

DE

H1

RD

/BK

LE

DB

L/R

D

CD

E2

BL

/BK

CD

E1

BL

/WH

C2

9M

SR

D/W

H

DR

IVE

EN

AB

LE

6

167

J1

8

15

LE

FT

RIG

HT

TS15L1

TS14

TS16

CR26

D41

NC

L5

+

AX

LE

NO

TE

XT

OP

EN

WH

EN

AX

LE

DU

MP

RE

LA

Y

SE

LE

CT

LS

2A

OB

OO

M

LS

2A

SB

OO

M

LS

1R

O-B

OO

M

EX

TE

ND

RE

TR

AC

TA

XL

E

LE

FT

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

DO

WN

UP

EX

TE

ND

RE

TR

AC

TB

OO

M

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

RO

TA

TE

LE

FT

RIG

HT

RIG

HT

LE

FT

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

J1 J1 J1

EXT/RET

BR

OR

WH

/BK

431 2 65

10 9 3

1 42 3 5 6


631 2 4 5

DRIVE & STEERING

WH

/RD

1

RD

/WH

2

BR

OR

BR

OR

WH

/RD

BL

/WH

5 4

13

1411

12

YO

UT

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL

/WH

XO

UT

C1

9JS

VG

R/W

HC

4P

-7

BRN

WH

JIB

VA

LVE

S

D2

7

D2

8

TS58

CR13

JIB

VA

LVE

CR13

TS8

NC

DO

WN

UP

JIB

JIB

UP

DO

WN



6 - 40

February 2012


6 - 39


6 - 41

February 2012

Ground Control Box Wiring Diagram, S-80/85Continental TME27 Models

6 - 42


6 - 42 S-80 • S-85 Part No. 122149

February 2012

1

2

3

4

5

6

7

8


Ground Control Box Wiring Diagram, S-80/85Continental Models

41OR/BK C2B-3 OR/BK C5-2ENG RPM

CR8 CR29

CR20A CR20B

GROUND

ALL BRN WIRES

OR/RD -16D

RD-134AA

WH-C5-19

WH-23B

RD-27D

OR/RD-42B

CR39B

OR/RD-16B

OR-C6-33

WH-21B

WH-C6-34

RD-24AB

CR17

RD/BK-2B

BL/RD-C4B-1

CR39

OR/RD-C6-11

OR/RD CR29#86

RD C2B-6

RD C6-31

OR/RD C4B-4

RD C6-23

RD C6-24

LIMIT SW #2

LIMIT SW PWR

KS POWER

KS POWER

BRN-GND STUD

CR1 CR2

WH-23D

RD-B1-20C

RD-B1-20D

RD-B2-S.P.

BK C5-5

BK-33C

WH C5-3

WH-21C

BK-22D

46B

42 OR/RD C6-22

RD-KSI-SP134

134A

RD-H6

WH-C5-11

RD-1B

RD-24C

GR C2B-5

BK-C6-16

BK-7B

RD-C6-27

CR5 BK-22BCR38

BL/RD-C6-13

BK/WH-C6-29

OR/RD-16C

RD/BK C3B-2&C6-2

WH C6-4

BK C6-7

WH/RD C6-6

WH/BK C6-5

OR C6-14

OR/BK C6-15

BK/RD C6-9

BK/WH C6-8

GR C6-17

RD-B1-H1WH CR2#87

GR/BK C6-18

RD CR1#30

RD C6-30

WH/RD C1B-6

OR/RD CR38#87A

BK CR1#86


OR C6-40

BL/RD C2B-1

BL/BK C1B-11

RD/WH C6-3

RD C6-1RD C3B-1PRI. BOOM UP

PRI. BOOM DOWN

WH/RD C3B-6

BK C3B-7

WH/BK C3B-5

WH C3B-4

OR/BK C4B-3

OR C4B-2

BK/RD C3B-9

BK/WH C3B-8

GR C4B-5

GR/BK C4B-6

RD-B1-H1OR/RD C5-9

WH/RD C5-23

RD CR39#86&C1B-1

WH C7B-2

BK C7B-1

OR/RD CR20A/B #86

TURN. ROT. L

TURN. ROT. R

BOOM EXTEND


TURN. ROT. F.C.

PLAT. LEVEL. UP

PLAT. LEVEL DN.

FUSED 12V

AUX PUMP

BRAKE

HORN

PLAT. ROT. R.

PLAT. ROT. L.


OIL COOLER FAN

IGNITION PWR.

12V BATT. SUPPLY

AXLE DUMP VALVE

BK C1B-7

BL/BK C6-37BK/RD C5-18

OR C2B-2BL/RD C5-10

START ENG

GLOW PLUG

ENGINE RPM

L.P.

LIMIT SW #1

STEER RT/AXLE EXT

START RELAY

PRI. BOOM F.C. RD/WH C3B-3

RD-S.P.

RD/BK-S.P.2

1 RD CR38#86

WH/RD-S.P.

BK-S.P.

WH-S.P.

WH/BK-S.P.

OR-S.P.

OR/BK-S.P.

BK/RD-S.P.

BK/WH-S.P.

3

5

4

6

7

10

9

15

14

11

8 BK/WH C6-38

WH S.P.

GR-S.P.

GR/BK-S.P.

RD-B1-S.P.

RD-S.P.-CB3

RD-S.P.

WH-S.P.-D2

RD-S.P.-CB1

BK-S.P.

18

17

16

21

20WH CR17 #86

24

23

RD27

32

24A

RD CR2#30

WH/RD C6-32

RD CR39#30

RD CR17#30

BK CR5#3022

OR/RD CR8#87A

BK-S.P.

BK/RD-S.P.

BL/RD TS53

33

34

33A

37

35

BL/BK C6-20

40

39OR C6-10

38

RD/WH-S.P.

BL/WH C5-13

UP/DOWN

TS57

PLATFORM

TURNTABLE

ROTATE

BOOM

PLAT.CONTROLSENGINE

HARNESS:TO BASE


WIRING

WH/BK-5AWH-4A

OR-14A

WH/RD-6A

GR-17A

GR/BK-18A

GR/WH C4B-7

RD-B1-20A

RD-24AROTATELEVEL

TS52

HOUR METER

WH-21A

BK/WH-8A

BK-7A

BRN(GND)

BL/RD-39A

D14

D42

TS54

HIGH/LOWRPM

D13BK/RD-35A

OR/BK-15A

BK-33

RD-1A

RD-24AA

RD-B2-H1

BK/RD-9A

TS61

TS62

TS63

TS53LP/GASSEL SW

D11

CB3

OIL COOLER/OPTION

CB2CB1

START

BOOM EXTEND/RETRACT

P1

NC

NC

E-STOP

RD/WH-3A

RD/BK-2A

RD-27A

WH/BK C5-14

WH/RD C5-16

WH-23A

BK-22A

RD-134A

TS51KSI

KEYSWITCH

1

2

B

B13

D2

4

CHECK ENGLED L2

AUXILIARY PUMP




PRIMARY BOOM EXTEND/RETRACT SWITCH

CIRCUIT BREAKER, OIL COOLER/OPTION, 20A

GR/WH-S.P.

WH/RD-S.P

WH/BK-S.P.

BL/WH C3B-12

RD/BK C6-28

WH C5-21

WH/BK C1B-5

BL C6-36

GR CR5#86

GR/WH C5-12

OR/RD C2B-4

BL/BK C6-21

RD/WH C1B-3

TURNTABLE ROTATE LIMITING RESISTOR 5 OHMS

RD/WH C5-2429 2WD/4WD

36 STEER LEFT/AXLE RETRACT

60 AXLE EXT/RET SELECT

30 E.D.C. FWD

31 E.D.C. REV

43 HORN

45 GEN. OPTION

61 AXLE RETRACT BL/BK C3B-11

WH C1B-4

WH/BK C5-20

BL C1B-10

GR C2B-5

GR/WH C2B-7

OR/RD C6-39

25 OIL PRESSEURE SENDER

26 WATER TEMP SENDER

19 JIB VALVE

12 DRIVE ENABLE

28 TILT ALARM

CIRCUIT DESCRIPTION

CR8

CR17

CR25

CR29

CR38

CR20B

CR20A


AXLE RET L/O RELAY


BOOM FUNCTION CUTOUT


LOW VOLTAGE DROP RELAY

LOW VOLTAGE DROP RELAY

TO

U1

R2

U33

FROM

GR/WH C4B-7

WH/RD C5-16

WH/BK C5-14

BL/WH C6-12

IGNITION/START MODULE

PLATFORM OVERLOAD MODULE

RD/BK C1B-2

AUXILARY PUMP RELAYCR39

TS54

TS57 PLATFORM ROTATE SWITCH


CB1

CB2

TS63

TS61

TS62

TS59

G6

G1

G2

G3

L2

CB3

CHECK ENGINE LED YELLOW (#110395)

HOUR METER






CR1

CR2

CR5

CR3 HIGH IDLE CUTOUT RELAY

SERVICE HORN RELAY



DESCRIPTION

P1

LABEL

KS1

TS51

TS52 START ENGINE SWITCH

AUXILIARY SWITCH


KEY SWITCH

STUD

R1 RESISTOR, 1K OHM/2W, CHECK ENGINE (#104333)

RD CR20A #30

TS64

SWITCHRUN/TEST

GN C5-8

GND

1

2

3

RUN

TEST

R1

R2

-

+

AUXILARY PUMP/ENGINE SHUT DOWN RELAY


CR39A

OPTION WIRE TO PBOX

RD C4B-11

RD C4B-12

(SPARE WIRE)



BRN GND

TB24AD

(SPARE WIRE)CR23

10 AMP FUSE


TS53 GAS/LP (DUAL FUEL OPTION)

TS58

TS59

JIB

JIB UP/DOWN (JIB OPTION ONLY)TS58

D28

G1 G3G2

VOLT METER OIL PRESSURE WATER TEMP.

FU

NC

TIO

NS

EN

GIN

E1

9/1

8C

AB

LE

S1

2V

TO

PL

AT

8686

8686

C6

C5

8686

86


3

8686

2

1

H1

C3

BC

1B

C2

BC

4B

C7

B

D8D7

8686

D

RD/BK C6-19

AB

D15 RD/BK CR8#30

D57CR8#86+ GND STUD

D34

C

D42

G6


6 - 43

February 2012

Platform Control Box Wiring Diagram, S-80/85Continental models (before serial number 5520)

6 - 44


6 - 44 S-80 • S-85 Part No. 122149

Platform Control Box Wiring Diagram, S-80/85Continental models (before serial number 5520)


2

3

4

5

6

7

8

GR

C2

P-5

OR

/BK

C4

P-3

OR

C4

P-2

BL

/BK

C3

P-11

BL

C1

P-1

0

OR

/RD

C2

P-4

BL

/RD

C4

P-1

J2

-DIO

DE

WH

GR

/WH

JIB

CA

BL

E

RD

/WH

J1

-8

GR

C4

P-5

GR

/BK

C4

P-6

RD

C1

P-1

RD

BK

BK

RD RD

RD

/BK

H1

BL

/WH

J1

-6

WH

J3

-2

BK

C1

P-7

RD

C9

-3

BL

/RD

J1

-16

BK

/RD

C1

P-9

BL

/BK

J1

-7

GN

/BK

H1

(D3

9)

BK

J3

- 3

BK

C7

P- 1

WH

C7

P- 2

BK

C9

-1

RD

LS

18

P3

HORN

NO

CE SEE DETAIL A

PLATFORM

LEVEL

TS9TS7

ROTATE

PLATFORM

TS1

AUX. PUMPTS14

SPEEDDRIVE

D2 TS16

L40

+

AXLE

EX/RET

RPM

TS2

START

+

L1

HIGH/LOW

+L4

TS4

E- STOP

P2

NC

TS15

DRV.ENA

+

D12

L48


L48 TILT ALARM LED








AXLE EXTENDED LED

DRIVE ENABLE LED

ALC500

JC1

H1

JC2

U13

L4

L40

JC3

L1

TILT ALARM

AXLE EXT/RET SWITCH

DRIVE ENABLE SWITCH

HIGH RPM SWITCH


TS16

TS47

TS14

TS15

TS7

TS4

TS9


COMPONENT INDEX

START ENGINE SWITCH

AUXILIARY SWITCH

HORN SWITCH

P2

TS1

P3

TS2

TT ROTATE

UP/DOWN

PRI. BOOM BOOM

EXT/RET

DRIVE/STEER

AXLE CUTOUT

CR

26

FUEL SELECT

TS3

D10

D12

BL

/RD

C2

P-1

RD WL1


TS48

E-STOP BK

F18 10A

RD WL2

(SPARE WIRE)

OPTION WIRE TO GBOX

DRIVELIGHT OPTION

TS49

TS48 PIN2



C32BRK)

R40LS2)

(SPLICE TO

OR/RD R40LS2

CR30

(SPLICE TO

WH/RD C32BRK

WH TS7CR27

GENERATOR OPTION

DETAIL B:

TS47

WH TS1

(GND STUD)

BRN BATGND GR

/WH

C2

P-7

TS2 RD



FUEL SELECT SWITCH (FORD)

TS48

TS48

TS3

2

GN

DB

RN



TS8

D27

CUTOUT

JIB

CR13

TS8

JIB

YE

LJ1

-3

OR

J1

-9

4

2

1

3

5

6

7

BR

NJ1

-10

+-

4

2

1

3

5

6

7

+-

OR

J1

-13

BR

NJ1

-14

WH

J1

-5

BL

J1

-4

RD

J1

-1

BK

J1

-2

7

6

5

4

3

2

1

+-

OR

J1

-11

BR

NJ1

-12

BRN

GN

/BK

C3

P-1

0

GN

/BK

L4

RD

C2

P-6

RD

LS

18

RD

/BK

H1

TS

15

-DR

EB

BL

/BK

L1

-C1

3L

ED

BL

/RD

TS

14

-C2

9M

SR

D/W

H

C1

34

PW

RG

R/B

KC

2P

-6

U13

BL

TS

16

WH

C9

-2

BK

P2

WH

CR

26

#8

5

WH

TS

4

ALC-500

RD

/BK

L4

8

TS

2-C

33

ST

RB

KC

1P

-7

TS

1-C

27

AU

XR

DC

1P

-1

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C2

9M

SR

D/W

HC

1P

-3

TS

6-C

34

SA

BK

/WH

C1

P-8

BATGND C7P-3

C28TTA RD/BK C1P-2

JC

3-3

OR

TS

15

-DR

EA

BL

/WH

JC

3-2

BR

NJC

3-6

BL

(1)

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

2-5

BK

JC

1-2

BR

N

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

(2)

P3

-C4

3H

RN

GR

C2

P-5

C3

6S

TC

CB

LC

1P

-10

C4

0L

S1

OR

C2

P-2

C3

7S

TC

BL

/BK

C1

P-11

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

2B

RK

WH

/RD

C1

P-6

R4

0L

S2

OR

/RD

C4

P-4

C1

PB

UR

DC

3P

-1

C2

PB

DR

D/B

KC

3P

-2

C7

PB

EB

KC

3P

-7

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C3

PB

FR

D/W

HC

3P

-3

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C1

2D

RE

BL

/WH

C3

P-1

2

GND STUD

CC

13

2P

LI

BL

/WH

C3

P-1

2

TS

16

-C6

1A

XB

L/B

KC

3P

11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P2

-P2

6F

SB

KC

9-1

TS

2-P

25

ST

RR

DC

9-3

P2

-P2

2B

AT

BK

C7

P-1

J3

-P2

4C

ON

TW

HC

9-2

TS

7-C

17

JU

GR

C4

P-5

TS

7-C

18

JD

GR

/BK

C4

P-6

P2

-P2

3S

WB

AT

WH

C7

P-2

TS

9-C

14

PL

UO

RC

4P

-2

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

15

PL

DO

R/B

KC

4P

-3

C1

33

PL

AB

LC

3P

-10

TILT ALARM

D39

H1

19/18 CONTROL CABLE

C2

P(B

K)

GND STUD

C1

P(G

Y)

12V BATT

C4

P(B

R)

C3

P(G

R) C7P C9

F.S.

OPT.

D40

J2J1

1

9

D12 D12

1

J31

3

11


C2P-9 & 10CR13 BRNBK LS CABLE CIP-12

RD LS CABLE RD-P2

RD-H1

YY

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7


GR/WH C4P-7

JIB

GND

OPT.LS18


Part No. 122149 S-80 • S-85 6 - 45

Platform Control Box Wiring Diagram, S-80/85Continental models (after serial number 5519)


1

2

3

4

5

6

7

8

GR

C2

P-5

OR

/BK

C4

P-3

OR

C4

P-2

BL

/BK

C3

P-11

BL

C1

P-1

0

OR

/RD

C2

P-4

BL

/RD

C4

P-1

J2

-DIO

DE

WH

GR

/WH

JIB

CA

BL

E

RD

/WH

J1

-8

GR

C4

P-5

GR

/BK

C4

P-6

RD

C1

P-1

RD

BK

BK

RD RD

RD

/BK

H1

BL

/WH

J1

-6

WH

J3

-2

BK

C1

P-7

RD

C9

-3

BL

/RD

J1

-16

BK

/RD

C1

P-9

BL

/BK

J1

-7

GN

/BK

H1

(D3

9)

BK

J3

- 3

BK

C7

P- 1

WH

C7

P- 2

BK

C9

-1

RD

LS

18

P3

HORN

NO

CE SEE DETAIL A

PLATFORM

LEVEL

TS9TS7

ROTATE

PLATFORM

TS1

AUX. PUMPTS14

SPEEDDRIVE

D2 TS16

L40

+

AXLE

EX/RET

RPM

TS2

START

+

L1

HIGH/LOW

+

L4

TS4

E- STOP

P2

NC

TS15

DRV.ENA

+

D12

L48


L48 TILT ALARM LED








AXLE EXTENDED LED

DRIVE ENABLE LED

ALC500

JC1

H1

JC2

U13

L4

L40

JC3

L1

TILT ALARM

AXLE EXT/RET SWITCH

DRIVE ENABLE SWITCH

HIGH RPM SWITCH


TS16

TS47

TS14

TS15

TS7

TS4

TS9


COMPONENT INDEX

START ENGINE SWITCH

AUXILIARY SWITCH

HORN SWITCH

P2

TS1

P3

TS2

TT ROTATE

UP/DOWN

PRI. BOOM BOOM

EXT/RET


CR

26

FUEL SELECT

TS3

D10

D12

BL

/RD

C2

P-1

RD WL1


TS48

E-STOP BK

F18 10A

RD WL2

(SPARE WIRE)

OPTION WIRE TO GBOX

DRIVELIGHT OPTION

TS49

TS48 PIN2



C32BRK)

R40LS2)

(SPLICE TO

OR/RD R40LS2

CR30

(SPLICE TO

WH/RD C32BRK

WH TS7CR27

GENERATOR OPTION

DETAIL B:

TS47

WH TS1

(GND STUD)

BRN BATGND GR

/WH

C2

P-7

TS2 RD



FUEL SELECT SWITCH (FORD)

TS48

TS48

TS3

2

GN

DB

RN



TS8

D27

J1

-5

BL

/WH

JC

3-

5

J1

-4

WH

/RD

JC

3-

4

J1

-5

BL

/WH

JC

3-

3

J1

-1

3O

RJC

3-

2

J1

-1

4B

RN

JC

3-

1

JC3

J1

-5

BL

/WH

JC

3-

3

J1

-1

3O

RJC

3-

2

J1

-1

4B

RN

JC

3-

1

JC3

J1

-3

WH

/BK

JC

1-

4

J1

-9

OR

JC

1-

2

J1

-1

0B

RN

JC

1-

1

JC1

J1

-2

RD

/WH

JC

2-

4

J1

-1

WH

/RD

JC

2-

3

J1

-11

OR

JC

2-

2

JC1

J1

-1

2B

RN

JC

2-

1

BRN

GN

/BK

C3

P-1

0

GN

/BK

L4

RD

C2

P-6

RD

LS

18

RD

/BK

H1

TS

15

-DR

EB

BL

/BK

L1

-C1

3L

ED

BL

/RD

TS

14

-C2

9M

SR

D/W

H

C1

34

PW

RG

R/B

KC

2P

-6

U13

BL

TS

16

WH

C9

-2

BK

P2

WH

CR

26

#8

5

WH

TS

4

ALC-500

RD

/BK

L4

8

TS

2-C

33

ST

RB

KC

1P

-7

TS

1-C

27

AU

XR

DC

1P

-1

TS

4-C

35

ES

PD

BK

/RD

C1

P-9

C2

9M

SR

D/W

HC

1P

-3

TS

6-C

34

SA

BK

/WH

C1

P-8

BATGND C7P-3

C28TTA RD/BK C1P-2

JC

3-3

OR

TS

15

-DR

EA

BL

/WH

JC

3-2

BR

NJC

3-6

BL

(1)

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

2-5

BK

JC

1-2

BR

N

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

(2)

P3

-C4

3H

RN

GR

C2

P-5

C3

6S

TC

CB

LC

1P

-10

C4

0L

S1

OR

C2

P-2

C3

7S

TC

BL

/BK

C1

P-11

TS

16

-C6

0A

XO

R/R

DC

2P

-4

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

2B

RK

WH

/RD

C1

P-6

R4

0L

S2

OR

/RD

C4

P-4

C1

PB

UR

DC

3P

-1

C2

PB

DR

D/B

KC

3P

-2

C7

PB

EB

KC

3P

-7

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C3

PB

FR

D/W

HC

3P

-3

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C1

2D

RE

BL

/WH

C3

P-1

2

GND STUD

CC

13

2P

LI

BL

/WH

C3

P-1

2

TS

16

-C6

1A

XB

L/B

KC

3P

11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P2

-P2

6F

SB

KC

9-1

TS

2-P

25

ST

RR

DC

9-3

P2

-P2

2B

AT

BK

C7

P-1

J3

-P2

4C

ON

TW

HC

9-2

TS

7-C

17

JU

GR

C4

P-5

TS

7-C

18

JD

GR

/BK

C4

P-6

P2

-P2

3S

WB

AT

WH

C7

P-2

TS

9-C

14

PL

UO

RC

4P

-2

L4

0-S

3L

ED

BL

/RD

C4

P-1

TS

9-C

15

PL

DO

R/B

KC

4P

-3

C1

33

PL

AB

LC

3P

-10

TILT ALARM

D39

H1

19/18 CONTROL CABLE

C2

P(B

K)

GND STUD

C1

P(G

Y)

12V BATT

C4

P(B

R)

C3

P(G

R) C7P C9

F.S.

OPT.

D40

J2J1

1

9

D12 D12

1

J31

3

11


C2P-9 & 10CR13 BRNBK LS CABLE CIP-12

RD LS CABLE RD-P2

RD-H1

YY

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

JIB

CA

BL

E-C

19

JS

VG

R/W

HC

4P

-7


GR/WH C4P-7

JIB

GND

OPT.LS18


6 - 46

February 2012

Platform Control Box Wiring Diagram, S-80/85Continental models (after serial number 5519)

6 - 45


6 - 47

February 2012

Continental TME27 Engine Harness

6 - 48


6 - 48 S-80 • S-85 Part No. 122149

1

2

3

4

5

6

7

8


Continental TME27 Engine Harness

WHITE/LT GREEN 1854

TAN/BLACK 18

PINK/TAN 18

RED/TAN 14

WHITE/BLUE 18

RED 14

85

30

86

86

85

AUX PWM4 RECIRC

AUX PWM3 RECIRC

AUX PWM5 RECIRC

BLACK/RED 1686

PINK/BLACK 18AUX PWM4AUX PWM2AUX PWM1AUX PWM3

87888990

RED/BLACK 18GRAY/RED 18

RED/TAN 14

PINK/TAN 18

PINK/BLACK 18

WHITE/BLUE 18

RED 14 30

86

85

WHITE 14 30

85

PINK/YELLOW 16

86

30

70

TAN/ORANGE 18

77AUX PWM5

FPUMP

V BAT

GROUNDDBW+/STEP +

DBW-/STEP -8485

78

80

8281

79

83

MIL

EGOH 2EGOH 3

FUEL LOCKOFF

BUZZ

RELAYEGOH 1

STARTER

76

71

73

7574

72

TAN/BLACK 18

LT BLUE/BLK 18

PINK/WHITE 18

PINK/YELL 16

BLACK 16

RED/TAN 16

BLACK/YELLOW 16BLACK/WHITE 16

WHITE/BLACK 18

WHITE/BLUE 18

YELLOW/LT GREEN 18

ORANGE 18

61INJ1 LS

INJ8 LSINJ7 LSINJ6 LSINJ5 LSINJ4 LSINJ3 LSINJ2 LS

GROUND

68

62

6463

6667

65

69

TACHPULSE IN

V BATV BAT PROT

PC RXPC TX

AUX ANA PUD1

57

5958

60

5655

BROWN/BLUE 16

BROWN/WHITE 16

BROWN/GREEN 16BROWN/YELLOW 16

BLACK 16

PINK/YELLOW 16

DK GREEN 18

RED/TAN 16

F4

BAT +

PINK/TAN 18

RED/TAN 14

5A

F2

F1

20A

FUEL PUMP RELAY

PINK/DK GREEN 16

POWER RELAY

87

PINK/YELLOW 1687

F3

15A

15A

RED 12

RED 14

PINK 18

RED 14

PINK/DK GREEN 16

PINK/YELLOW 16

PINK/DK GREEN 16

PIN

K/D

KG

RE

EN

16

BL

AC

K1

6

PINK/TAN 18

WHITE/BLACK 18

STARTER RELAY

LT BLUE/PINK 14

BLUE/GREEN 14

EPR RELAY

87A

87

PINK/YELLOW 1687

15A

F5

FUEL LOCKOFF

PINK/YELLOW 16

WHITE 14

A

B

STARTER RELAY

BLACK 16BLACK 16 BLACK 12

GROUND

SPLICE WITHIN 6" FROM CONNECTOR

WHITE/PURPLE 18

TAN/BROWN 18

GRAY/WHITE 18GRAY/DK BLUE 18

TAN/BROWN 18

LT GREEN/BLACK 18

GRAY/DK BLUE 18GRAY/WHITE 18

YELLOW/GRAY 18

5V EXTAUX ANA PU3AUX ANA PU2AUX ANA PU1

OIL PGOV 2GOV 1

5V RTN

4748

46

49

5253

5150

SPK COIL 4B

ECT

V SWITCHAUX DIG 3AUX DIG 2AUX DIG 1

EGT

38

4039

41

IAT

45

4344

42

DK BLUE/YELLOW 18

LT GREEN/WHITE 18

DK BLUE/YELLOW 18

TAN 18

PINK/TAN 18

YELLOW/BLACK 18

30KNK 2 -

SPK COIL 4ASPK COIL 3BSPK COIL 3ASPK COIL 2BSPK COIL 2ASPK COIL 1BSPK COIL 1A 31

32

3637

353433

CAM POSCRK NEG

SPD NEGSPD POSCAM NEG

KNK 1 -KNK 2 +

KNK 1 +

2223

2928

2627

2524

YELLOW/RED 18

YELLOW/LT GREEN 18

YELLOW 18

PURPLE/ORANGE 18GRAY/BROWN 18

LT BLUE/DK BLUE 186TPS1/STEP2 +

PURPLE/YELLOW 18DK BLUE 18

WHITE/RED 18

DK BLUE 18

LT GREEN 18

14CAN 1 +

5V RTN5V EXT

CAN 2 TERM +CAN 2 +

CRK POS

CAN 2 -

CAN 1 - 15

21

17

1920

18

16

TPS2/STEP2 -MAP

AUX ANA PD2FPP2-IVS

AUX ANA PD1FPP1

AUX ANA PD3CAN 1 TERM + 13

10

1211

987

PURPLE/WHITE 18

LT GREEN/RED 18BLACK/LT GREEN 18

TAN/DK GREEN 18

PURPLE/LT BLUE 18

DK GREEN/ORANGE 18

EGO 2

EGO 4EGO 3

EGO 1

3

54

12

LT GREEN/BLACK 18

TXDK GREEN 18

BLK/LT GREEN 18

LT GREEN/RED 18

B

C5V

DRTN

COMM

ORANGE 18 ARX

OIL PRESSURE SWITCH

DK BLUE/YELLOW 18

PIN

K/D

KG

RE

EN

16

PIN

K/D

KG

RE

EN

16

YE

LL

OW

/BL

AC

K1

8

BL

AC

K/L

TG

RE

EN

18

PIN

K/D

KG

RE

EN

16

YE

LL

OW

/RE

D1

8

BL

AC

K/L

TG

RE

EN

18

PIN

K/D

KG

RE

EN

16

BL

AC

K/L

TG

RE

EN

18

BL

AC

K/L

TG

RE

EN

18

YE

LL

OW

/LT

GR

EE

N1

8

NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B

NOTE: INECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER

INJECTOR 2

BROWN/GREEN 16

BROWN/YELLOW 16

INJECTOR 4 INJECTOR 3

BROWN/WHITE 16

COIL 4

BA

BL

AC

K1

6

C D

COIL 3

A B

BL

AC

K1

6

C D

BROWN/BLUE 16

INJECTOR 1

COIL 2

A

BL

AC

K1

6

DCB

COIL 1

A

BL

AC

K1

6

DB C

YE

LL

OW

18

TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH

BLUE/WHITE 18

WHITE/ORANGE 18

LT BLUE/BLACK 18

TAN/BROWN 18

ORANGE 18

GRAY/RED 18

ESL/TEST SWITCH

FUEL SELECTTEMP SENDER12

11

109 MIL

BLACK 16BLUE/GREEN 14

PURPLE/YELLOW 18

WHITE/ORANGE 18

BLUE/WHITE 18

RED/BLACK 18

LT BLUE/PINK 14

BLACK/RED 16

GRAY/WHITE 18GRAY/DK BLUE 18

YELLOW/LT GREEN 18

PINK/YELLOW 16

PINK 18

VEHICLE INTERFACE 1

DEUTSCH DT04 RECEPTACLE

FUEL PUMP -FUEL PUMP +

GOV SELECT 2GOV SELECT 1

START COMMAND

2

4

678

3

5TACH

IGN OUT1 VSW

NOT USED (PLUGGED)NOT USED (PLUGGED)

START IN (AUTOCRANK)

NOT USED (PLUGGED)CAN LOW11

12

FPP2 IVS

GROUND

CAN HIGH

AUX ANA PU14

765

8910

POST CAT HEGO

DBW THROTTLE CONNECTOR

A

C

A

C

PRE CAT HEGO

TAN/ORANGE 18BLK/LT GREEN 18LT GREEN/RED 18

PURPLE/LT BLUE 18LT BLUE/DK BLUE 18

PINK/WHITE 18


PURPLE/ORANGE 18

GRAY/BROWN 18

2

6

345

1

BLK/LT GREEN 18

PURPLE/ORANGE 18

GRAY/BROWN 18 B


WHITE/PURPLE 18

PURPLE/WHITE 18


LT GREEN/RED 18

BLK/LT GREEN 18

PURPLE/WHITE 18

WHITE/PURPLE 18

B

LT GREEN/RED 18

LT GREEN 18

BLACK/LT GREEN 18TAN/DK GREEN 18PINK/DK GREEN 16BLACK/YELLOW 16

BLACK/LT GREEN 18DK GREEN/ORANGE 18

PINK/DK GREEN 16BLACK/WHITE 16

AB

DC

4

AB

DC

LT GREEN/RED 18TAN 18

BLACK/LT GREEN 18

BLACK/LT GREEN 18

YELLOW/GRAY 18 ECT

321

B

TMAP

A

SPLICE WITHIN 6" OF CONNECTOR

BLACK/LT GREEN 18

LT GREEN/RED 18

DK BLUE 18

GASOLINE SENSOR INTERFACE

WHITE/LT GREEN 18 4

LT GREEN/WHITE 18LT GREEN/RED 18

BLACK/LT GREEN 18

CAM SENSOR

3

12

VEHICLE INTERFACE 2

DEUTSCH DT06 PLUG

VREF

ANA RETURNFPP1

1

32

PINK/YELLOW 16

CRANK SENSOR

BLACK/LT GREEN 18

WHITE/RED 18 A

BLPG TEMP

WHITE/ORANGE 18WHITE/ORANGE 18

BLUE/WHITE 18

JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR

JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR

BLUE/WHITE 18

WHITE/ORANGE 18

WHITE/ORANGE 18

BLUE/WHITE 18

WHITE/ORANGE 18

COBRA EPR

3

6

7

BLACK 16 GROUND

CAN +

VBAT

WHITE/ORANGE 18

BLUE/WHITE 18

CAN + TERM2

1 CAN -


Part No. 122149 S-80 • S-85 6 - 49

1

2

3

4

5

6

7

8


Joystick Wiring Diagram

TS15L1


3

12

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

2

BR

N

C2

P-3

C3

P- 1

C3

P-2

C3

P-9

C3

P-3

C1

P-4

C1

P-5

C1

P-6

C1

P- 3

C1

P- 11

C1

P-1

0

C3

P-6

C3

P- 5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P- 4

C3

P-1

2

LE

DB

L/R

D

CD

E2

BL

/BK

J2

J3 J1

CD

E1

BL

/WH

C2

9M

SR

D/W

H

H1

RD

/BK

C2

P-2

1

D35 D36

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

P24FS WH

C28TTA RD/BK

P26ESTP BK

EXTEND/RETRACTB

RN

OR

YE

L

1 542 3 6

10 9 3

1 42 3 5 6


1 42 3 5 6

DRIVE & STEERING

RD

1

BK

2

BR

N

OR

BR

N

OR

BL

5 4

13

1411

12

J1 J1 J1

YO

UT

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL

XO

UT

WH

TS15L1


3

12

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

2

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P- 4

C1

P-5

C1

P-6

C1

P-3

C1

P-11

C1

P-1

0

C3

P-6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P-4

C3

P-1

2

LE

DB

L/R

D

CD

E2

BL

/BK

J2

J3 J1C

DE

1B

L/W

H

C2

9M

SR

D/W

H

H1

RD

/BK

C2

P-2

1

D35 D36

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

P24FS WH

C28TTA RD/BK

P26ESTP BK

EXTEND/RETRACT

BR

N

OR

WH

/BK

1 542 3 6

10 9 3

1 42 3 5 6


1 42 3 5 6

DRIVE & STEERING

WH

/RD

1

RD

/WH

2

BR

N

OR

BR

N

OR

BL/W

H5 4

13

1411

12

J1 J1 J1

YO

UT

PW

R

GN

D

PW

R

GN

D

YO

UT

XO

UT

RK

OU

T

YO

UT

PW

R

GN

D

JC1 JC2 JC3

BL/W

H

XO

UT

WH

/RD

7 7 7

TT ROTATE

UP/DOWN

PRI. BOOM

BOOM

EXT/RETDRIVE/STEER

JC2 JC1

JC3

J1

-14

BR

NJ

C3

-PIN

1

J1

-13

OR

JC

3-P

IN2

J1

-5B

L/W

HJ

C3

-PIN

3

J1

-4W

H/R

DJ

C3

-PIN

4

J1

-5B

L/W

HJ

C3

-PIN

5

J1

-10

BR

NJ

C1

-PIN

1

J1

-9O

RJ

C1

-PIN

2

J1

-3W

H/B

KJ

C1

-PIN

4

J1

-12

BR

NJ

C2

-PIN

1

J1

-11O

RJ

C2

-PIN

2

J1

-1W

H/R

DJ

C2

-PIN

3

J1

-2R

D/W

HJ

C2

-PIN

4

Deutsch - 6 Pin Connector

AMP - 7 Pin Connector

Note: Production changed to Deutsch 6 pin connectors at serial number 5520.

YE

LJ1

-3

RD

J1

-1

OR

J1

-9


TURNTABLEROTATE

JC1BOOM

EXTEND/RETRACT

JC3DRIVE

BK

J1

-2

7

6

5

4

3

2

1

4

2

1

3

5

6

7

4

2

1

3

5

6

7

BR

NJ1

-10

+-

+-

+-

OR

J1

-13

BR

NJ1

-14

OR

J1

-11

BR

NJ1

-12

WH

J1

-5

BL

J1

-4

7

6

5

4

3

2

1

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

Deutsch


6 - 50

Joystick Wiring Diagram

6 - 49

Section 6 • SchematicsFebruary 2012

6 - 51

Connector Pin Legend - Sheet 1

6 - 52


6 - 52 S-80 • S-85 Part No. 122149

WH/RD

10

12

11

C34SA

C35RPM

C36STCC

C33STR

C32BRK

BK/WH

BL

BK/RD

BK

C4

8

9

7

6

COLOR

WH

CKT # PIN #

C27AUX

C30EDC+

C31EDC-

C29MS

C28TTA

RD/WH

WH/BK

RD/BK

RD

3

4

5

2

1

BL/BK C37STC

BL/WH

6C134BATGR/BK

12

10

C45GEN

NC

GR/WH

9

11

8

7

OR/RD

COLOR CKT # PIN #

C40LS1

C41RPM

C43HRN

C60AX

C39LP

GR

OR/BK

OR

BL/RD

5

4

2

3

1

C2

C1 DT06-12SC

C2 DT06-12SD

NC

NC

NC

NC

BROWN

BLACK

GRAY

GREEN

C3

C1

C7

BK

WH

BRN

COLOR CKT # PIN #

P23SWBAT

BATGND

N/C

P22BAT

C7: DTP06-4S

4

2

3

1

A

WH/RD-3

OR-1C40LS1

WH/BK-3

BK/RD-3

WH-3

BK-3

BK/WH-3C8PBR

C7PBE

C45GEN

C6TRF

C4TRL

C9PERF

C5TRR

GR/BK-3

GR-3

OR/BK-3

OR-3

RD/BK-3

RD-3

RD/WH-3

COLOR

C15PLD

C14PLU

C2PBD

C1PBU

C3PBF

C18JD

C17JU

RD-1

BL-1

BL/BK-1C37STC

C36STCC

C27AUX

OR

BL/WH-3

WH

RD/BK

RD

BKR43HRN

P23BAT

C28TTA

C42LD

C12DRE

C40LS2

C6

C1

C2

11R1DRVLITE

R2DRVLITE 12

6C6TRFWH/RD

GR/BK

GR/WH

OR/RD

COLOR

OR/BK

BL/RD

BL/WH

BL/BK

BK

BK/RD

BL

BK/WH

GR

OR

C18JD

NC

C19JSV

NC

NC

S3LED (AX)

C14PLU

C15PLD

C17JU

C40LS2

8

10

9

7

6

3

4

5

2

1

CKT # PIN #

C4 DT06-12SB

11

12

10

C12DRE

C61AX

C7PBE

C133PLA

C9PERF

C8PBR

9

8

7

RD

RD/BK

WH/BK

RD/WH

WH

COLOR

C3 DT06-12SA

CKT # PIN #

C2PBD

C3PBF

C5TRR

C4TRL

C1PBU

5

4

2

3

1

C4

C3

C3

RD

RD

RD

RD

BRN

BRN

P24BAT

C21IGN

C30EDC+

C31EDC-

C32BRK

C29MS

C34SA

P23BAT

22

24

23

20

21

19

C24SW

C35RPM

16

18

17

15

14

P134BAT

C39LP10

C108ESL13

12

11

C127TSW8

9

7

C107AF

C41RPM

R33STR5

6

4

2

3

1

CKT #PIN

#

BL/WH

BL/RD

BK/RD

WH

BK/WH

RD/WH

WH/RD

WH/BK

WH

WH/BK

WH

WH/RD

RD/WH

BK/WH

WH/RD

RD/WH

WH

WH/BK

BK/RD(14)

WH

WH(14)WH

GR

WH(14)

DEUTZ

ENGINE

OR/BKOR/BK

BK(14)

WH

BK(14)

WH

C5-GBOX

FORD

ENGINE

OR/BK

BK(14)

WH

ENGINE

PERKINS

C108ESL

C39LP

C127TSW

C29MS

C32BRK

C34SA

C30EDC

C31EDC

P23BAT

C35RPM

P24BAT

C24SW

C21IGN

R33STR

C107AF

C41RPM

P24BAT

CKT #

6

15

20

24

23

22

21

18

19

17

16

14

13

12

11

10

9

8

7

3

5

4

2

1

#

PIN

WH

WH(14)

BK/RD(14)

WH/BK

WH

BK/WH

WH/RD

RD/WH

WH

RD/WH

WH/RD

WH

WH/BK

RD

WH/BK

WH

BK/WH

WH/RD

RD/WH

BK/RD(14)

WH

BL/WH

GR

WH(14)

ENGINE

PERKINS

OR/BK

BL/RD

OR/BK

ENGINE

FORD

WH

BK(14)

OR/BK

BK(14)

WH

BK(14)

DEUTZ

ENGINE

C5-ENGINE HARNESS

MARK NUMBER ON CABLE 3

WH

WHWH

CIRCUIT #

C9 FS DT04-4P

RD

WH

BK

COLOR

3P25BAT

N/C 4

P24BAT

CKT # PIN #

P22BAT 1

2

WH/RD

RD/WH

WH/BK

WH

WH

BK(14)

OR/BK

WH

3.0L GM

ENGINE

WH/RD

RD/WH

WH/BK

WH

WH

BK(14)

OR/BK

WH

3.0L GM

ENGINE

BL/RD BL/RD

BK/RD BK/RD

17

28

27

24

18

15

14

11

10

9

8

7

6

5

4

3

2

1

12

13 S3LED BL/RD-3

16

19

20

C2DA

C37STC

RD/BK

BL/BK

C42LS2

C61AXRT21

22 OR/RD-1

BL/BK

23 P23BATSR RD

25

26

29

30

31 C46PWR

C46PWR RD

RD

32 C32TA WH/RD-1

33

34

35

36

37

38

39

40

C60AX OR/RD

R116HYD OR

R21IGN WH

C9

C45GENGR/WH GR/WH GR/WH GR/WH GR/WH GR/WH

WH

RD

BL/RD

C132PLI

C46BBR

C46BBR RD

GR

GR GR

GR/WH GR/WH

BK/RD(14) BK/RD

WH

XX

2

3

1

4

COLOR

GRN

BK

WH

C9 FS DT04-4P

CHASSIC

LINE

NEUTRAL

CKT # PIN #

N/C

AC

DC

RD

WHWH WH

BL/WH BL/WH

WH(14) WH(14)

R16PBR BK/WH

C8PBR BK/WH

C26TSR OPT.

C25PSR OPT.

C128RPM(OPT)

WH/RD

WH/BK WH/BK

WH/RD

C128RPM(OPT)

C25PSR OPT.

C26TSR OPT. WH/RD

WH/BKWH/BK

WH/RD

OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD OR/RD

WH/RD

WH/BK


1

2

3

4

5

6

7

8



Part No. 122149 S-80 • S-85 6 - 53


1

2

3

4

5

6

7

8


GRAY

C1

C41RPM

GND1

PUMP+

-----

P23BATSA

C27AUX

C21IGN

C38ESL

C35RPM

C33STR

C39LP

RD/WH

WH/RD

BLC36STCC

C32BRK

C29MS20

19

18

OR/RD

WIRE

RD

RD/WH

RD/BK

OR/BK

OR

BL/WH

BK/RD

BK/WH

BK

WH/RD

WH/BK

BL/BK

WH/BK

WH

WH

CKT#PIN#

1

2

C3PBF

6

8

7

5

4

3

C8PBR

C9PERF14

13

12

11

10

C37STC

C31EDC-

17

16

15

C4TRL9

C30EDC+

C7PBE

C6TRF

C5TRR

C12DRE

C1PBU

C2PBD

C41RPM

C40LS1

R40LS2

NC

JC2-5

JC2-4

JC3-5

JC3-6

DRE B

DRE A

JC1-5

JC1-2

JC2-3

JC2-2

H1

9 JC1-3

15

16 C13LED

10

11

12

13

14 JC3-2

JC3-3

3

4

5

7

8

6

C29MS

2

1

PIN# CKT#

OR

RD/BK

BL/RD

BRN

OR

BRN

OR

BRN

YL

WH

BL

BL/BK

RD/WH

BL/WH

WIRE

RD

BK BK/RD

BL/RD

HARN

WH

OR/BK

BL/RD

RD

RD

BK

BRN

BL/WH

-----

BRN

CKT#PIN#

1

2

6

8

7

5

4

3

12

11

10

9

ALC500 JOYSTICKS/INPUT

ALC500 OUTPUT

GM PLUG

----- YL/BK

-----

RD/BL

PU

GR/BK

WH/BL

DK BL

RD

YL

LT BL

PU/BK

BK

GM ENGINE

J1

J2

11

0

20

119

16

81


6 - 54


6 - 53


6 - 55

Dual Battery Option

6 - 56


6 - 56 S-80 • S-85 Part No. 122149

20ARD

P2

0B

AT

RD

C1

07

AF

WH

C4

1R

PM

OR

/BK

CB3

RD

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

W

-

+

12V DC

B1

D22

15A

TB20

CB1

RD

C5

-3 C5

-2

15A

CB2

WH

RDRD

PLAT

GRD

KS1

P1 RD

ALT

ER

NA

TO

R

STA

RT

BA

TT

ER

YSINGLE BATTERY (STANDARD)

CB215A

WH

RDRD

PLAT

GRD

KS1 TB22

P1 RD

+

-

RD

P2

0B

AT

RD

C1

07

AF

WH

C4

1R

PM

OR

/BK

CB320A

RD

12 VDC

12 VDC

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

-

+

BATTERYSEPARATOR

B1B2

D22

TB20

CB115A

RD

C5

-3 C5

-2

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

AR

AT

OR

(OP

TIO

N)

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

(OP

TIO

N)

DUAL BATTERY (OPTION)

1

2

3

4

5

6

7

8


Dual Battery Option


Part No. 122149 S-80 • S-85 6 - 57

N M L K J I H G F E D C B A1

2

3

4

5

6

7

8

Belt Drive Generator Option

120VAC / 60HZ

LINE BK

NEUTRAL WH

GND GR

GND BR

P20BAT

TG3

TG1TG4

TG2

CR1

CB2

15A

LINE BK

FIELD BK/WH

GND BR

NEUTRAL WH

R20BAT RD

C45GEN

TO GBOX

GENERATOR

FIELD GR

NEUTRAL WH

OUTLET

NEU

LINE

GND

LINE BK

BA

T

30A

CB1

BELT DRIVEN

VO

LTA

GE

RE

GU

LA

TO

R

220VAC / 50HZ

LINE BK

NEUTRAL WH

GND GR

GND BR

P20BAT

TG3

TG1TG4

TG2

CR1

CB2

12.5A

LINE BK

FIELD BK/WH

GND BR

NEUTRAL WH

R20BAT RD

C45GEN

TO GBOX

GENERATOR

FIELD GR

NEUTRAL WH

OUTLET

NEU

LINE

GND

LINE BK

BA

T

30A

CB1

BELT DRIVEN

VO

LTA

GE

RE

GU

LA

TO

R

87A

87

8586

30

87A

87

8586

30

B

YY

YY

YF

-

+

LINE

FIELD

CB1

CB2

VOLTAGE

BK/WH 14GA

BK 12GA

5

54321

VOLTAGE REGULATOR

3

4

1

PIN#

2 WH 12GA

COLOR

NEUTRAL

CKT#

RD 12GA

BR 12GA

R20BAT

GND

LINE

NEUTRAL

BK

WH

CKT#COLORPIN#

1

4

3

GENERATOR

REGULATOR

C45GEN

GENERATOR

BATTERY-

OUTLET4

3

2

1

12.5A- 220V15A- 120V

30A

A B

BATTERY+

PLUG

CR1

BA

BAFIELDGR2

TG

120 VAC / 60 HZ with Regulator

220 VAC / 50 HZ with Regulator

-

+


6 - 58

Belt Drive Generator Option

6 - 57


6 - 59

CE Option

6 - 60


6 - 60 S-80 • S-85 Part No. 122149

CE Option

1

2

3

4

5

6

7

8


P2

0B

AT

RD

C2

P-5

P1

34

BA

TG

R/B

K

P2

2B

AT

BK

RD

TB20

RD

15AMP.

CB2

C2

B-5

C1

B-2

TB24

RD

CB3

20AMP.

15AMP.

CB1

RD

WH

C6

-28

C6

-23

TB

28

TB23D2

C2

B-6

BK

GRD

PLAT

P1

RD

RD

TB22

TB134

C4

6H

RN

GR

C2

8T

TA

RD

/BK

WH

C7

B-1

C1

B-1

2

C1

P-2

C2

P-6 C

7P

-1

C1

P-1

2

HORN

C1

32

PL

IB

L/W

H

P3

H1

RD

P2

C7

B-2

P2

3B

AT

WH

C7

P-2

D43

C9P-1

B1

B3

1

4

2

KS1

C3

P-1

0C

3B

-10

C1

33

PL

AB

L

RD

WH

BK

7

12 8

6

1

4

3

5

U33

H6

L45

LS18

L4

D39

GR

/BK

GR

/BK

BL

/WH

LOADSENSEMODULE

TB24A

P134BAT RD

P26ESTP BK

P28TTA RD/BK

TO TS52, TS54

TO TS51

TO

SE

RV

ICE

HO

RN

BK

TO AUX PUMP

TO

GR

OU

ND

TO

FB

OP

T

TS9

TS15L1

WH


3

12

13

14 8 7 6 10 9 11 43 20

17

18

19

16

15

4 1 10 9 3 1 2 5 4

TS14

6

16 8

15

DR

IVE

MO

DE

7

5

NC

CR27 CE

13

1411

12

2

BR

N

C2

P-3

C3

P-1

C3

P-2

C3

P-9

C3

P-3

C1

P-4

C1

P-5

C1

P-6

C1

P-3

C1

P- 11

C1

P- 1

0

C3

P-6

C3

P-5

C3

P-4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

C3

P-8

C3

P-7

C4

P-4

C3

P-1

2

C4

P-2

C4

P-3

LE

DB

L/R

D

CD

E2

BL

/ BK

J2

J3 J1 J1 J1 J1

C4

P-6

C4

P-5

CD

E1

BL

/ WH

C2

9M

SR

D/W

H

H1

RD

/ BK

TS16

C2

P-2

1

C3

P-11

NCCR26

D37

D38

D35 D36

D41

C2

P-4

L5

C7

-3

+

D2

7

C4

P-1

CR30

NO

LE

FT

RIG

HT

DR

IVE

EN

AB

LE

P24FS WH

C28TTA RD/BK

UP

DO

WN

PL

AT

LE

VE

L

LE

FT

RIG

HT

PL

AT

RO

TA

TE

EX

TE

ND

RE

TR

AC

TA

XL

E

TS7

C3

2B

RK

WH

/RD

C4

0L

SO

R/ R

D

P26ESTP BK

RE

TR

AC

TE

XT

EN

D


Part No. 122149 S-80 • S-85 6 - 61


1

2

3

4

5

6

7

8

Platform Level Cutout, CTE Option


6 - 62

Platform Level Cutout, CTE Option

6 - 61


6 - 63

12kW Hydraulic Generator Option

6 - 64

February 2012


6 - 64 S-80 • S-85 Part No. 122149

12 kW Hydraulic Generator Option

1

2

3

4

5

6

7

8


TB24

TIME DELAY

MODULE 4S

5 SW INPUT3 GND

1 N.O.

2 COM

8 N.C.

C1P-4C1P-5

C3

0E

DC

WH

C3

1E

DC

WH

/BK

C1

B-4

C1

B-5

C5

-20

C5

-21

C32BRK WH/RD C2

P-7

P25FS-RD

P24FS-WH

TS4

C1

P-9

RP

MH

I

GENERATOR

D12

RP

MLO

FOOTSWITCH

P26ESTP-BK

TS47

P22PWR-BK

ON

C1

P-3

CR66

753

18

642

C2

B-7

C4

5G

EN

GR

/WH

TB45TB35

C3

5R

PM

BK

/RD

C1

B-9

CR

4

HIG

HID

LE

RE

LA

Y

TB29

C1

B-3

C2

9M

SR

D/W

HM

OT

OR

ST

RO

KE

VA

LVE

C5

-18

C5

-24

D98

D99

C57

BK

-2Y75

Y75

C57

RD

-1

PR

ES

SU

RE

SW

ITC

H

20

0P

SI

OMRON

RELAY

SX Controller

BY

PA

SS

CO

IL

3

1

2

A

B

C

124 ohms

124 ohms1k ohms

V150HG GR/BK

V151HG GR

RS232TxD

A1BATTERY +

A2SENSOR POWER +5 VDC

A3BATTERY-

B1VALVE 0 FWD COIL

B2VALVE 1 NC

B3DIGITAL OUTPUT BYPASS

C1TxD

C2RxD

C3/BOOT

D1ANALOG 0 JOYSTICK

D2ANALOG 1 NC

D3C41 RPM

E1NOT USED

E2NOT USED

E3NOT USED

F1DIG IN 0

F2DIG IN 1 GENERATOR ON

F3DIG IN 2

RS232RxD

75

31 8

6

42

C1

B-4

C1

B-5

C5

-20

C5

-21

D A

U4

CB

DR

IVE

ED

C+

DR

IVE

ED

C-

PILOT PRESSURE SIGNAL

FROM GENERATOR MANIFOLD

DIVERTER MANIFOLD

N.O.

NC

CR50

PS4

C4

5G

EN

GR

/WH

C6

-39

C5

-12

BK 16-2

C5

-23

BR

AK

E

RE

LE

AS

E

TB32

C1

P-6

C3

2B

RK

WH

/RD

D65

BR-2

(16-2)

TB21

TB41

C5

-4W

H

C5

-12

OR

/BK

C4

1R

PM

OR

/BK

P2

OMRON

RELAY

20

ALC-500

15

16

19


Part No. 122149 S-80 • S-85 6 - 65

Hydraulic Schematic, 12kW Generator


1

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

OIL COOLER

0.031 inch /0.79 mm

WELDERMANIFOLD

DRIVE PUMP

B

A

3.5 GPM / 13.25L/min

PMP B CLR PMP A

270 PSI / 18.6 BAR@ 3.5 GPM / 13.25 L/min

MTR B MTR A G1

G2

21 GPM / 79.5 L/min G2 G1

21CC

TANK

13

GENERATOR12.5 KW

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

PRESSURE SWITCH200 PSI / 13.8 BARN.O.

CASE

CY

CX

CU

CV

CW

CZ

HS0166C


6 - 66

Hydraulic Schematic, 12kW Generator

6 - 65


6 - 67

Hydraulic Schematic, 2WD Models

6 - 68

JUne 2015Section 6 • Schematics

6 - 68 S-80 • S-85 Part No. 122149


1

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8



RESERVOIR

OIL COOLER

OPTION

BRAKE/2 SPEED

MANIFOLD

DRIVE PUMP

E

3625 psi

250 bar

3 psi

0.2 bar

3 psi

0.2 bar

FUNCTION

PUMP

2139

TEST

A

B

TEST310 psi

21.4 bar

51 psi

3.5 bar

T2

CP

2 SPEED

RETURN

FILTER25 psi

1.7 bar

102 psi

7 bar

BRAKE

OC1 LS TESTOC2

T1

PRESS

PR2

0.030 in

0.076 mm

0.070 in

1.77 mm

30 psi

2 bar

T2

PR1

30 psi

2 bar

30 psi

2 bar

TANK

SW2

V1

SW1

2500 psi

172 bar

V2

T3

S1

RET

TURNTABLE

ROTATE

1200 psi

82.7 bar

ST2ST1

PTEST

AUX

EXTACCUM

2900 psi

200 bar

SECONDARY

RETRACT

4 GPM

PRIMARY

BOOM EXTENSION CYLINDER

3300 PSI3:1D

E 3:1 3500 PSI

COUNTERBALANCE VALVE

3:1

C

B

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESSURE

AXLE CP LIM SW

1.7M

PS

3.5 gpm

13.2 L/min

HIGH

PRESSURE

FILTER

EXTEND

7 GPM (REGEN)

FUNCTION

MANIFOLD

ACCUMULATOR450 psi

22 bar

AXLE EXTEND

PRESSURE SWITCH0.1 gpm

0.38 L/min0.3 gpm

1.1 L/min

AUXILIARY

PUMP

MEDIUM

PRESSURE

FILTER

DUMP

MANIFOLD

150 psi

10.3 bar

A

F 5:1 3500 PSI

B

B

B A A

C

C

DD

6 8 3 1

HYDRAULIC ROTARY COUPLER

2 954 10

AXLE SELECT

MANIFOLD

FLB

FLR

V2 PILOT

FAR

RAR

FAE

RAEAXLE EXTEND

CYLINDERS

FRONT REAR

2A 2D 2B136A8A8B6B 9A 9B2C

TE

54 10

STEER

CYLINDERS

TIE ROD

CYLINDER

RIGHT

LEFT

C C

C C CC

FRB

FRR

1000 psi

68.9 barTEST

V1

7

7

M1REAR

LEFT

M4

50%

280 psi

19.3 bar

REAR

RIGHT

M2

50%

M3

T

CP

X

A B

T1

2WD DRIVE MANIFOLD

30 psi

2 bar

0.6 gpm

2.27 L/min

PL2PL1

SLAVE

MASTER

0.6 gpm

2.27 L/min

PLATFORM LEVEL

CYLINDERS

F F

EE

P2

2100 psi

145 bar

P1

PRIMARY LIFT

CYLINDER

C C

A

B

DE

F

H

EE

FF

FA

FB

FD

FE

FC

BYCC

CB

BX

GG

HH

NN

CT

LL

MM

II

JJ

KK

J

K

L

PQ

NO

OO

W

M

S

Z

VU

Y

T

R

X

AA

PP

RRQQ

CC

DD

BB

I

G

C

GENERATOR

MANIFOLD

OPTIONAL

2400 PSI

OPTIONAL

GENERATOR

T4

PTEST

150 psi

10.3 bar

150 psi

10.3 bar

LIM SW

BZ

CA

V2 V1

PR2 PR1

J1

J2

PR2 PR1

L R

S85 JIB BOOM

PLATFORM

ROTATE

MANIFOLD

SELECT

JIB

.030

.042

C

C

C

C

OSCILLATE VALVE

850 psi

58.6 bar

OSCILLATE CYLINDERS

LEFT

RIGHT

A

B

OUT

IN

TEST

HS0076L

EA

EB

EC

ED

Ø.030

31

B

A

T4

21CC

MTR B MTR A

21 GPMG2

CLRPMP B

HY

DR

AU

LIC

RO

TA

RY

21

GP

M

G1

3.5 GPM

PMP A

12.5 KW GENERATOR

270 PSI @

3.5 GPM

G2 G1

CO

UP

LE

R

NO PRESS SW

200 PSI

DRIVE

PUMP

HYDRAULIC WELDER OPTION

FUNCTION

MANIFOLD

WELDER

MANIFOLD

1

2

1

2

0.030 orifice added at

SN 4139


SN 5381

June 2015 Section 6 • Schematics

Part No. 122149 S-80 • S-85 6 - 69

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REAR

RIGHT

REAR

LEFTM1

CDL

T

M2

FRONT

LEFT

M3

50%

0.040 in/

1 mm

1000 psi

69 bar

50%

M7

M5

CDR

50%

280 psi

19.3 bar

50%

TEST

TEST

BA

6 8 3 1

M4

50%

50%

FRONT

RIGHT

M8

M6

HYDRAULIC ROTARY COUPLER

2 954 10

OC1 LS TESTOC2

DRIVE MANIFOLD

PL2PL1

SLAVE

MASTER

0.030 in

0.076 mm

30 psi

2 bar

T2

P2

2100 psi

145 bar

P1

TANK

SW2

V1

SW1

2500 psi

172 bar

V2

T3

S1

RET

TURNTABLE

ROTATE

1200 psi

82.7 bar

ST2ST1

PTEST

AUX

EXTACCUM

2900 psi

200 bar

SECONDARY

RETRACT

4 GPM

PRIMARY

BOOM EXTENSION CYLINDER

3300 PSI3:1D

E 3:1 3500 PSI

COUNTERBALANCE VALVE

3:1

C

B

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESSURE

AXLE CP LIM SW

PS

3.5 gpm

13.2 L/min

AXLE SELECT

MANIFOLD

EXTEND

7 GPM (REGEN)

FUNCTION

MANIFOLD

FLB

FLR

V1 V2 PILOT

FAE

FAR

RAR

RAE

ACCUMULATOR

FRONT REAR

450 psi

22 bar

AXLE EXTEND

PRESSURE SWITCH

2A 2D2B138A6A6B8B 9A 9B2C

0.6 gpm

2.27 L/min

0.1 gpm

0.38 L/min

0.3 gpm

1.1 L/min

TE

54 10

PLATFORM LEVEL

CYLINDERS

PRIMARY LIFT

CYLINDER

DUMP

MANIFOLD

STEERING

CYLINDERS

150 psi

10.3 bar

TIEROD

CYLINDER

LEFT

RIGHT

A

F 5:1 3500 PSI

B

B

B A A

C C

F F

EE

C C

C C CC

FRB

FRR

DE

F

H

EE

FF

FA

FB

FD

FE

FC

CD

CMCI

CL

CK

CE

CF

CQ

CP

CO

CG

CH

NN

LL

MM

II

JJ

KK

J

K

L

PQ

NO

OO

W

M

S

Z

V

T

R

X

AA

PP

RRQQ

CC

DD

BB

I

G

OIL COOLER

OPTION

RESERVOIR

BRAKE/2 SPEED

MANIFOLD

DRIVE PUMP

E

3625 psi

250 bar

3 psi

0.2 bar

3 psi

0.2 bar

FUNCTION

PUMP

2139

TEST

A

B

TEST310 psi

21.4 bar

51 psi

3.5 bar

T2

CP

2 SPEED

RETURN

FILTER25 psi

1.7 bar

102 psi

7 bar

BRAKE

T1

PRESS

AUX

1.7M

HIGH

PRESSURE

FILTER

AUXILIARY

PUMP

MEDIUM

PRESSURE

FILTER

U

Y

GENERATOR

MANIFOLD

OPTIONAL

2400 PSI

OPTIONAL

GENERATOR

T4

PTEST

150 psi

10.3 bar

150 psi

10.3 bar

LIM SW

CN

0.040 in/

1 mm

0.040 in/

1 mm

CJ

PR2 PR1

30 psi

2 bar

30 psi

2 bar

C

C

DD

30 psi

2 bar

0.6 gpm

2.27 L/min

A

B

GG

HH

CT

C

V2 V1

PR2 PR1

J1

J2

PR2 PR1

L R

S85 JIB BOOM

PLATFORM

ROTATE

MANIFOLD

SELECT

JIB

.030

.042

7

7

C

C

C

C

OSCILLATE VALVE

850 psi

58.6 bar

OSCILLATE CYLINDERS

LEFT

RIGHT

A

B

OUT

IN

TEST

HS0076L

EA

EB

EC

ED

Ø.030

31

B

A

T4

21CC

MTR B MTR A

21 GPMG2

CLRPMP B

HY

DR

AU

LIC

RO

TA

RY

21

GP

M

G1

3.5 GPM

PMP A

12.5 KW GENERATOR

270 PSI @

3.5 GPM

G2 G1

CO

UP

LE

R

NO PRESS SW

200 PSI

DRIVE

PUMP

HYDRAULIC WELDER OPTION

FUNCTION

MANIFOLD

WELDER

MANIFOLD

1

2

1

2


SN 4139


SN 5381


6 - 70


6 - 69

Dis

trib

ute

d B

y:

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

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Genie IbericaPhone +34 93 572 5090

Fax +34 93 572 5091

Genie GermanyPhone 0800 180 9017

Phone +49 4221 491 810

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Genie U.K.Phone +44 1476 584333

Fax +44 1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

Documents

Genia S-80 Boomlift - Service Manual - Rentalex