Genie S-80 Service Manual
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Genie S-80 Service Manual

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  • Page 2: Introduction

    Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.
  • Page 3 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Part No. 122985 S-80 • S-85 • S-80X...
  • Page 4 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. S-80 • S-85 • S-80X Part No. 122985...

  • Page 5: Serial Number Legend

    Country of manufacture: USA This machine complies with: Terex South Dakota 500 Oak Wood road PO Box 1150 Watertown, SD 57201 Serial label Sequence number (located under cover) (stamped on chassis) PN - 77055 Part No. 122985 S-80 • S-85 • S-80X...
  • Page 6 February 2012 This page intentionally left blank. S-80 • S-85 • S-80X Part No. 122985...

  • Page 7: Safety Rules

    Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-80 and Genie S-85 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 8 Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. S-80 • S-85 • S-80X Part No. 122985...

  • Page 9: Table Of Contents

    Machine Torque Specifications ................2 - 8 Manifold Component Specifications ............... 2 - 8 Hydraulic Hose and Fitting Torque Specifications ..........2 - 9 SAE and Metric Torque Specifications ..............2 - 10 Part No. 122985 S-80 • S-85 • S-80X...
  • Page 10 Inspect the Battery(s) ................. 3 - 18 Inspect the Electrical Wiring ............... 3 - 19 Test the Key Switch ................... 3 - 21 Check the Exhaust System ............... 3 - 21 viii S-80 • S-85 • S-80X Part No. 122985...
  • Page 11 Replace the Engine Air Filter Element - Deutz and Perkins Models .... 3 - 43 Replace the Fuel Filter/ Water Separator Element - Diesel Models ..... 3 - 43 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X ..3 - 45 Part No. 122985 S-80 • S-85 • S-80X...
  • Page 12 Introduction ......................4 - 1 Platform Controls ALC-500 Circuit Board .................. 4 - 2 Joysticks ..................... 4 - 3 Platform Components Platform ....................... 4 - 9 Platform Leveling Slave Cylinder ..............4 - 10 S-80 • S-85 • S-80X Part No. 122985...
  • Page 13 RPM Adjustment ..................4 - 33 Flex Plate ....................4 - 33 Ground Controls Control Relays .................... 4 - 38 Hydraulic Pumps Function Pump ................... 4 - 39 Drive Pump ....................4 - 40 Part No. 122985 S-80 • S-85 • S-80X...
  • Page 14 Turntable Rotation Manifold Components ........... 4 - 47 Platform Rotate Manifold Components ............4 - 48 Platform Manifold Components, S-80 ............4 - 49 Platform Manifold Components, S-85 ............4 - 50 2WD Traction Manifold Components ............4 - 51 4WD Traction Manifold Components (before serial number 8581) ....
  • Page 15 Electrical Symbols Legend ..................6 - 2 Hydraulic Symbols Legend ..................6 - 3 Connector Pin Legend - View 1 ................6 - 6 Connector Pin Legend - View 2 ................6 - 7 Part No. 122985 S-80 • S-85 • S-80X xiii...
  • Page 16 Deutz TD2011L04i Models ................. 6 - 10 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ....6 - 14 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ....6 - 15 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models .................
  • Page 17 Perkins 804D-33 Models ................6 - 58 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...... 6 - 62 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...... 6 - 63 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ................
  • Page 18 TABLE OF CONTENTS Section 6 Schematics, continued Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ......... 6 - 74 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) .........
  • Page 19 Continental TME27 Models ............... 6 - 106 Ground Control Box Terminal Strip Wiring Diagram S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ....6 - 110 Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ....6 - 111 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ...............
  • Page 20 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ....... 6 - 138 Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ....... 6 - 139 Electrical Schematic, S-80X, Continental TME27 Models ...............

  • Page 21: Machine Specifications

    320 ft-lbs 434 Nm For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 122985 S-80 • S-85 • S-80X 2 - 1...

  • Page 22: Performance Specifications

    Chevron Rando HD MV oil is fully compatible and Braking distance, maximum mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are High range on paved surface 3 ft designed to give maximum protection to hydraulic...

  • Page 23: Hydraulic Component Specifications

    0 to 114.7 L/min Note: Genie specifications require additional Drive pressure, maximum 3750 psi equipment and special installation instructions for 259 bar the approved optional fluids. Consult the Genie Charge pump Industries Service Department before use. Type: gerotor Displacement 0.85 cu in 13.9 cc...

  • Page 24: Valve Coil Resistance Specifications

    Hydraulic tank 10 micron with return filter 25 psi / 1.7 bar bypass Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 S-80 • S-85 • S-80X Part No. 122985...

  • Page 25: Continental Tme27 Engine Specifications

    For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 122985 S-80 • S-85 • S-80X...

  • Page 26: Deutz Td2011L04I Engine Specifications

    9 to 12 mm Oil capacity 12.8 quarts (including filter) 12.1 liters Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 S-80 • S-85 • S-80X Part No. 122985...

  • Page 27: Perkins 804D-33 Engine Specifications

    For oil requirements, refer to the Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 122985 S-80 • S-85 • S-80X...

  • Page 28: Machine Torque Specifications

    108 Nm Drive hub oil plug, O-ring seal 13 ft-lbs 18 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 8 S-80 • S-85 • S-80X Part No. 122985...

  • Page 29: Hydraulic Hose And Fitting Torque Specifications

    O-rings. or when new hoses or fittings are installed. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part SAE O-ring Boss Port number 49612). (tube fitting - installed into Aluminum) 2 Lubricate the O-ring before installation.
  • Page 30 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 77.4 30.1 40.8 54.3 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 2 - 10 S-80 • S-85 • S-80X Part No. 122985...
  • Page 31 Repair any machine damage or malfunction indicate the presence of a before operating machine. potentially hazardous situation Use only Genie approved replacement parts. which, if not avoided, may result in minor or moderate injury. Machines that have been out of service for a...
  • Page 32 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of four years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 S-80 • S-85 • S80X Part No. 122985...

  • Page 33: Pre-Delivery Preparation

    500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...
  • Page 34 Section 3 • Scheduled Maintenance Procedures February 2012 This page intentionally left blank. 3 - 4 S-80 • S-85 • S80X Part No. 122985...

  • Page 35: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 122985 S-80 • S-85 • S80X 3 - 5...
  • Page 36 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 S-80 • S-85 • S80X Part No. 122985...

  • Page 37: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed daily. Result: The machine is equipped with all required decals, and all decals are legible and Maintaining the operator’s and safety manuals in...

  • Page 38: Perform Pre-Operation Inspection

    February 2012 CHECKLIST A PROCEDURES Perform Pre-operation Perform Engine Maintenance Inspection Genie specifications require that this procedure be performed daily. Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes Completing a pre-operation inspection is essential first.

  • Page 39: Perform Function Tests

    Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES Perform Function Tests Test the Oscillate Axle Genie specifications require that this procedure be performed daily. Completing the function tests is essential to safe Genie specifications require that this procedure be machine operation.

  • Page 40: Check The High Pressure Hydraulic Filter Condition Indicator

    Check the High Pressure Perform 30 Day Service Hydraulic Filter Condition Indicator Note: Genie specifications require that this The 30 day maintenance procedure is a one time procedure be performed daily or every 8 hours, sequence of procedures to be performed after the whichever comes first.

  • Page 41: Perform Engine Maintenance - Deutz And Continental Models

    Inspect the Fuel Filter/Water Deutz and Continental Models Separator - Diesel Models Engine specifications require that this one-time Note: Genie specifications require that this procedure be performed after the first 50 hours of procedure be performed every 100 hours or operation.
  • Page 42 See C-6, Replace The Fuel Filter/Water Separator Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 Clean up any fuel that may have spilled. 3 - 12 S-80 • S-85 • S-80X Part No. 122985...

  • Page 43: Grease The Turntable Rotation Bearing And Rotate Gear

    Bearing and Rotate Gear Immediately tighten the drain plug. Note: Do not completely drain the filter. Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life.

  • Page 44: Perform Engine Maintenance

    (Continental part number WM10303). Deutz TD2011 Operation Manual Genie part number 139320 Perkins 804D-33 Operation and Maintenance Manual Genie part number 111332 Continental TME27 Owner's Manual Genie part number 111901 3 - 14 S-80 • S-85 • S-80X Part No. 122985...

  • Page 45: Replace The Drive Hub Oil

    Cap the fittings on the drive motor. 3 Attach a suitable lifting device to the lifting eyes located near the drive motor. models with o-ring plugs Part No. 122985 S-80 • S-85 • S-80X 3 - 15...
  • Page 46 Single fill port rotator 8 Adjust turntable rotation gear backlash. Refer to motor Repair Procedure 10-1, How to Adjust the fill port drive hub mounting bolts Turntable Rotation Gear Backlash. drive hub 3 - 16 S-80 • S-85 • S-80X Part No. 122985...

  • Page 47: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 S-80 • S-85 • S-80X 3 - 17...

  • Page 48: Checklist B Procedures

    4 Be sure that the battery separator wire connections are tight (if equipped). 5 Fully charge the battery(s) and allow the Genie specifications require that this procedure be battery(s) to rest at least 6 hours. performed every 250 hours or quarterly, whichever 6 Remove the battery vent caps and check the comes first.

  • Page 49: Inspect The Electrical Wiring

    10° / 5.5° C above 80° F / 26.7° C. • Subtract 0.004 from the reading of each cell for Genie specifications require that this procedure be every 10° / 5.5° C below 80° F / 26.7° C. performed every 250 hours or quarterly, whichever comes first.
  • Page 50 Cable track on the boom • Cables on the boom and jib boom • Jib, rotate, level manifold • Inside of the platform control box • 3 - 20 S-80 • S-85 • S-80X Part No. 122985...

  • Page 51: Test The Key Switch

    Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Test the Key Switch Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be...

  • Page 52: Inspect The Engine Air Filter

    5 Swing the engine pivot plate in towards the machine. 6 Install the bolts that were just removed into the Note: Genie specifications require that this original holes to secure the engine pivot plate. procedure be performed every 250 hours or Crushing hazard.

  • Page 53: Check The Oil Cooler And Cooling Fins - Deutz Models

    Check the Oil Cooler and 4 Inspect the oil cooler for leaks and physical Cooling Fins - Deutz Models damage. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the oil cooler in good condition is essential for good engine performance.

  • Page 54: Confirm The Proper Brake Configuration

    Confirm the Proper Inspect the Tires, Wheels Brake Configuration and Lug Nut Torque Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 55: Check The Drive Hub Oil Level And Fastener Torque

    Refer to Section 2, Specifications . 6 Repeat steps 1 through 5 for the other drive hubs. Genie specifications require that this procedure be performed every 250 hours. Turntable rotate drive hub: Failure to maintain proper drive hub oil levels may...

  • Page 56: Check And Adjust The Engine Rpm

    Note: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact the Genie Industries Service Department. Deutz TD2011L04i models: 1 Connect a tachometer to the engine. Start the engine from the ground controls and check the rpm.
  • Page 57 Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. Part No. 122985 S-80 • S-85 • S-80X 3 - 27...

  • Page 58: Perform Engine Maintenance

    Check the Oscillate Directional Valve Linkage Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever Note: Genie specifications require that this comes first. procedure be performed every 250 hours or quarterly, whichever comes first. Proper engine maintenance, following the engine...

  • Page 59: Test The Ground Control Override

    B-14 Test the Ground Control Test the Platform Self-leveling Override Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 60: Test The Engine Idle Select Operation

    Result: The engine rpm should change to low idle. Operation 6 Turn the key switch to platform controls. Genie specifications require that this procedure be 7 Move the engine idle select toggle switch to low performed every 250 hours or quarterly, whichever idle (turtle symbol).

  • Page 61: Test The Fuel Select Operation - Gasoline/Lpg Models

    6 Start the engine and allow it to run at low idle. 7 Press down the foot switch to allow the engine Genie specifications require that this procedure be to run at high idle. performed every 250 hours or quarterly, whichever Result: The engine should start promptly and comes first.

  • Page 62: Test The Drive Enable System

    5 Rotate the turntable until the boom moves past the other non-steer wheel. Test the Drive Enable System Result: The drive enable Genie specifications require that this procedure be indicator light should come on performed every 250 hours or quarterly, whichever and remain on while the boom comes first.

  • Page 63: Test The Drive Brakes

    B-19 Test the Drive Brakes Test the Drive Speed - Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 64: Test The Drive Speed - Raised Or Extended Position

    Note: To adjust the speed, refer to Repair procedure 1-2, How to Adjust the Joystick Max-out Setting. Genie specifications require that this procedure be 8 Press down the foot switch and lower the boom performed every 250 hours or quarterly, whichever to the stowed position.

  • Page 65: Test The Alarm Package (If Equipped) And The Descent Alarm

    4 Press down the foot switch. Move the boom Alarm controller to the down position, hold for a moment and then release it. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Result: The descent alarm should sound when comes first.

  • Page 66: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever 6 Check for proper venting. comes first. Perform this procedure more often if Result: Air passes through the hydraulic tank dusty conditions exist.

  • Page 67: Perform Hydraulic Oil Analysis

    B-24 Perform Hydraulic Oil Analysis Inspect the Boom Extend/Retract Cables Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Replacement or testing of the hydraulic oil is comes first.
  • Page 68 How to Adjust the Boom Extend/Retract Cables. Note: A pulley groove gauge should be used to check the condition of the pulleys. 3 - 38 S-80 • S-85 • S-80X Part No. 122985...

  • Page 69: Checklist C Procedures

    Mechanism (if equipped) Engine specifications require that this procedure be performed every 500 hours. Genie specifications require that this procedure be performed every 500 hours or six months, Proper engine maintenance, following the engine whichever comes first. Perform this procedure more manufacturer's maintenance schedule, is essential often if dusty conditions exist.

  • Page 70: Test The Platform Overload System (If Equipped)

    Section 3 • Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES Test the Platform Overload System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Illustration 1 Testing the platform overload system regularly is essential to safe machine operation.
  • Page 71 Wire Result: The platform overload indicator lights should turn off at both the ground and platform Terminal 5 controls and the alarm should not sound. Illustration 2 Part No. 122985 S-80 • S-85 • S-80X 3 - 41...
  • Page 72 Remove the machine from service and contact resistance. Remove the machine from service the Genie Service Department . and contact the Genie Service Department . 23 Securely install the red wire, disconnected in 29 Using a suitable lifting device, remove all weight step 20, onto terminal 5 of the relay timer.

  • Page 73: Replace The Fuel Filter/Water Separator Element - Diesel Models

    Separator Element - Diesel Models Engine specifications require that this procedure be performed every 500 hours or six months, Note: Genie specifications require that this whichever comes first. procedure be performed every 500 hours or six months, whichever comes first.
  • Page 74 See C-6, Replace The Fuel Filter/Water Separator Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 Clean up any fuel that may have spilled. 3 - 44 S-80 • S-85 • S-80X Part No. 122985...

  • Page 75: Check The Safety Envelope Limit Switches And Angle Sensor, S-80X

    Switches and Angle Sensor, Immediately tighten the drain plug. S-80X Note: Do not completely drain the filter. Note: Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Testing the safety envelope system regularly is essential to safe machine operation.
  • Page 76 6 Turn the key switch to the off position and push in the red Emergency Stop button. Note: The follwing step can be done using a measuring tape or a digital protractor (Genie part number 58377). 3 - 46 S-80 • S-85 • S-80X...
  • Page 77 Result: The primary boom does not stop after 10 degrees. Calibrate the boom angle sensor. Refer to Repair Procedure 1-2, How to Calibrate the Boom angle Sensor. Part No. 122985 S-80 • S-85 • S-80X 3 - 47...

  • Page 78: Checklist D Procedures

    Check the Boom Wear Pads may cause binding or scraping of the boom. Note: Always maintain squareness between the outer and inner boom tubes. Genie specifications require that this procedure be Boom wear pad specifications Minimum performed every 1000 hours or annually, whichever comes first.

  • Page 79: Check The Free-Wheel Configuration

    6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever Collision hazard. Failure to comes first.

  • Page 80: Check The Turntable Rotation Bearing Bolts

    12 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Genie specifications require that this procedure be performed every 1000 hours or annually, whichever Collision hazard. Failure to comes first.

  • Page 81: Inspect The Turntable Bearing Wear

    Refer to Inspect for Turntable Bearing Section 2, Specifications. Wear Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life.
  • Page 82 5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 3 - 52 S-80 • S-85 • S-80X Part No. 122985...

  • Page 83: Perform Engine Maintenance

    Perform Engine Maintenance Replace the Hydraulic Filters Engine specifications require that this procedure be Note: Genie requires that this procedure be performed every 1000 hours. performed every 1000 hours or annually, whichever comes first. Perform this procedure more often if Proper engine maintenance, following the engine dusty conditions exist.

  • Page 84: Replace The Drive Hub Oil

    Medium and high pressure filters: Genie specifications require that this procedure be Note: The medium pressure filter is for the charge performed every 1000 hours or annually, whichever pump and the high pressure filter is for all machine comes first.
  • Page 85 Crushing hazard. The turntable drive hub rotate drive hub assembly could become unbalanced and fall if not properly supported by the lifting device. Part No. 122985 S-80 • S-85 • S-80X 3 - 55...

  • Page 86: Perform Engine Maintenance - Deutz Models

    8 Adjust turntable rotation gear backlash. Refer to death or serious injury. Repair Procedure 10-1, How to Adjust the Turntable Rotation Gear Backlash. 3 - 56 S-80 • S-85 • S-80X Part No. 122985...

  • Page 87: Checklist E Procedures

    Models with hydraulic tank shutoff valves: Close the two hydraulic tank valves located at the hydraulic tank. Genie specifications require that this procedure be Component damage hazard. The performed every 2000 hours or every two years, engine must not be started with the whichever comes first.
  • Page 88 Note: Genie specifications require additional clean them using a mild solvent. equipment and special installation instructions for the approved optional fluids. Consult the Genie 11 Rinse out the inside of the tank using a mild Industries Service Department before use.

  • Page 89: Perform Engine Maintenance - Perkins Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 122985 S-80 • S-85 • S-80X 3 - 59...

  • Page 90: Remove And Replace The Boom Extend/Retract Cables

    February 2012 CHECKLIST E PROCEDURES Replace the Boom Extend/ Retract Cables Genie specifications require that this procedure be performed every 7 years. The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Replacement of the boom extend/retract cables is essential to good machine performance and safe machine operation.
  • Page 91 Used to indicate the presence of a available and ready for use. potentially hazardous situation which, if not avoided, could result Use only Genie approved replacement parts. in death or serious injury. Read each procedure completely and adhere With safety alert symbol—used to to the instructions.

  • Page 92: Platform Controls

    6 Remove the ALC-500 circuit board mounting turntable rotate right/left fasteners. joystick controller 7 Carefully remove the ALC-500 circuit board from the platform control box. 4 - 2 S-80 • S-85 • S-80X Part No. 122985...

  • Page 93: Joysticks

    Emergency Stop button to the on position. successful joystick calibration. 6 When the alarm sounds, release the drive Result: The alarm does not sound. Check the enable toggle switch. electrical connections or replace the joystick. Part No. 122985 S-80 • S-85 • S-80X 4 - 3...
  • Page 94 2 Turn the key switch to platform control. Do not start the engine. 3 Push in the platform controls red Emergency Stop button to the off position. 4 - 4 S-80 • S-85 • S-80X Part No. 122985...
  • Page 95 4 seconds Note: Each time the drive enable toggle switch is momentarily moved, the time will change in 5% increments. Part No. 122985 S-80 • S-85 • S-80X 4 - 5...
  • Page 96 8 Start the engine from the platform controls and press down the foot switch. Stowed- high speed 7.9 to 8.5 seconds 9 Select a boom function joystick to set the Non-stowed 40 to 45 seconds threshold. 4 - 6 S-80 • S-85 • S-80X Part No. 122985...
  • Page 97 1 time to set the stowed position. Note: The alarm will not sound indicating the setting. 8 Raise the primary boom to the fully elevated position. Part No. 122985 S-80 • S-85 • S-80X 4 - 7...
  • Page 98 Section 4 • Repair Procedures October 2011 This page intentionally left blank. 4 - 8 S-80 • S-85 • S-80X Part No. 122985...

  • Page 99: Platform Components

    Cables can be damaged if they are kinked or pinched. Note: If your machine is equipped with an airline to platform option, the airline must be disconnected from the platform before removal. Part No. 122985 S-80 • S-85 • S-80X 4 - 9...

  • Page 100: Platform Leveling Slave Cylinder

    Note: Do not rest the entire weight of the boom on remove any air that might be in the system. the blocks. 4 - 10 S-80 • S-85 • S-80X Part No. 122985...

  • Page 101: Platform Rotator

    1 Remove the platform. See 2-1, 7 Remove the pivot pin retaining fasteners from How to Remove the Platform . both the slave cylinder rod-end pivot pin and the rotator pivot pin. Part No. 122985 S-80 • S-85 • S-80X 4 - 11...
  • Page 102 Note: When installing the platform rotator fasteners, torque the fasteners to specifications. Refer to Section 2, Specifications . 4 - 12 S-80 • S-85 • S-80X Part No. 122985...

  • Page 103: Calibrate The Platform Overload System

    4 Using a suitable lifting device, place a test inspect the bleed screws for leaks. weight equal to the maximum platform capacity at the center of the platform floor. Part No. 122985 S-80 • S-85 • S-80X 4 - 13...
  • Page 104 Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator lights and alarm responds. 4 - 14 S-80 • S-85 • S-80X Part No. 122985...
  • Page 105 Result: All ground control functions should operate normally. 14 Turn the key switch to platform control. 15 Test all machine functions from the platform controls. Result: All platform control functions should operate normally. Part No. 122985 S-80 • S-85 • S-80X 4 - 15...

  • Page 106: Jib Boom Components

    Component damage hazard. when removed from the machine if Hoses and cables can become not properly attached to the damaged if they are kinked or overhead crane. pinched. 4 - 16 S-80 • S-85 • S-80X Part No. 122985...

  • Page 107: Jib Boom Lift Cylinder

    Remove the cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall if not properly supported when removed from the machine. Part No. 122985 S-80 • S-85 • S-80X 4 - 17...

  • Page 108: Boom Components

    Section 4 • Repair Procedures February 2012 Boom Components 6 S-80: Tag, disconnect and plug the hydraulic hoses from the counterbalance valve manifold Cable Track located on the platform rotator. Cap the fittings on the manifold. The boom cable track guides cables and hoses Bodily injury hazard.
  • Page 109 Remove the cable track guides from the boom. 17 Remove the cable clamp from the pivot end of the boom. Part No. 122985 S-80 • S-85 • S-80X 4 - 19...
  • Page 110 Component damage hazard. Note: A cable track repair kit is available through Hoses and cables can be the Genie Industries Service Parts Department, damaged if they are kinked or part no. 77896. The kit includes a 4-link section of pinched.

  • Page 111: Boom

    1 Remove the jib boom. See 3-1, How to Remove the Jib Boom. 2 Remove the cable track. See 4-1, How to Remove the Cable Track. Part No. 122985 S-80 • S-85 • S-80X 4 - 21...
  • Page 112 Note: A spreader bar and other hardware may be needed to safely remove the counterweight. Crushing hazard. The boom could fall if not properly supported when the lift cylinder rod-end pivot pin is removed. 4 - 22 S-80 • S-85 • S-80X Part No. 122985...
  • Page 113 Do not allow oil to squirt or spray. 22 Remove the external snap rings from both boom pivot pins at the short and long link arms. Do not remove the pins. Part No. 122985 S-80 • S-85 • S-80X 4 - 23...

  • Page 114: Boom Lift Cylinder

    Use a soft metal drift to remove the pin. Crushing hazard. The boom will fall if not properly supported when the primary boom rod-end pivot pin is removed. 4 - 24 S-80 • S-85 • S-80X Part No. 122985...

  • Page 115: Boom Extension Cylinders

    1 Raise the boom to a horizontal position. Crushing hazard. The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 122985 S-80 • S-85 • S-80X 4 - 25...
  • Page 116 11 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube. cable guard retaining block 4 - 26 S-80 • S-85 • S-80X Part No. 122985...
  • Page 117 1 boom tube. hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 122985 S-80 • S-85 • S-80X 4 - 27...

  • Page 118: Boom Extend/Retract Cables

    6 Inspect the threaded ends of the boom extend cables. The threads must be clean and in good condition with no damaged threads. 4 - 28 S-80 • S-85 • S-80X Part No. 122985...
  • Page 119 12 Using a dial type torque wrench, torque the retract cable adjustment nut to 32-36 ft lbs / 43-49 Nm using gentle and steady torque. Illustration 1 Part No. 122985 S-80 • S-85 • S-80X 4 - 29...
  • Page 120 Note: Be sure the boom extend cables are routed through the grooves of the pulley and the upper 19 Fully retract and lower the boom to the stowed wear pad on the extension cylinder. position. 4 - 30 S-80 • S-85 • S-80X Part No. 122985...
  • Page 121 Note: A cable pulling tool is available through 22 Adjust the boom extend/retract cables. Genie Service Parts Department (Genie part no. See Section 4-5, How to Adjust the Boom 94510) Extend/Retract Cables. 12 At the platform end of the boom, pull on the boom retract cable that has the rope attached to it.

  • Page 122: Platform Leveling Master Cylinder

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 32 S-80 • S-85 • S-80X Part No. 122985...

  • Page 123: Rpm Adjustment

    Type "B" flex plates combines the pump coupler, as part of the flex plate, which is installed onto the engine flywheel. Type "B" (flexplate with coupler combined) Part No. 122985 S-80 • S-85 • S-80X 4 - 33...
  • Page 124 4 Tag and disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 4 - 34 S-80 • S-85 • S-80X Part No. 122985...
  • Page 125 Burn Hazard. Hot engine parts can cause severe burns. 19 Remove the muffler retainer bracket fasteners. 20 Remove the muffler fasteners securing the muffler to the exhaust manifold. Remove the muffler from the bracket. Part No. 122985 S-80 • S-85 • S-80X 4 - 35...
  • Page 126 Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 4 - 36 S-80 • S-85 • S-80X Part No. 122985...
  • Page 127 February 2012 Section 4 • Repair Procedures ENGINES Perkins 804C-33 Pump Mounting Plate Perkins, Deutz and Continental Flex Plate Continental Pump Mounting Plate Deutz BF4L-2011 Pump Mounting Plate Part No. 122985 S-80 • S-85 • S-80X 4 - 37...

  • Page 128: Ground Controls

    86, then test the following terminal combinations. Test Desired result terminal 87 to 87a and 30 no continuity (infinite  terminal 87 to 30 continuity (zero ) 4 - 38 S-80 • S-85 • S-80X Part No. 122985...

  • Page 129: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. open closed Part No. 122985 S-80 • S-85 • S-80X 4 - 39...

  • Page 130: Drive Pump

    Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications . 1 Disconnect the wire harness at the electronic displacement controller (EDC), located on the drive pump. 4 - 40 S-80 • S-85 • S-80X Part No. 122985...
  • Page 131 Deutz and Perkins models: Connect the engine wiring harness to the fuel solenoid. 5 Start the engine from the ground controls and check for hydraulic leaks. Part No. 122985 S-80 • S-85 • S-80X 4 - 41...

  • Page 132: Function Manifold Components

    Differential sensing valve ....SG ..Differential sensing/turntable rotate . 30-35 ft-lbs / 41-47 Nm Flow regulator valve ......SM ..Steering flow control ......20-25 ft-lbs / 27-34 Nm 4 - 42 S-80 • S-85 • S-80X Part No. 122985...
  • Page 133 February 2012 Section 4 • Repair Procedures MANIFOLDS Part No. 122985 S-80 • S-85 • S-80X 4 - 43...

  • Page 134: Valve Adjustments - Function Manifold

    Install the relief valve cap. Component damage hazard. Do not adjust the relief valve higher than specified. 5 Repeat step 2 to confirm relief valve pressure. 6 Remove the pressure gauge. 4 - 44 S-80 • S-85 • S-80X Part No. 122985...
  • Page 135 Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 through 5 to confirm relief valve pressure. Part No. 122985 S-80 • S-85 • S-80X 4 - 45...

  • Page 136: Brake/Two-Speed Manifold Components

    Solenoid valve, 2 position 3 way ..BC ... Two-speed motor shift ..... 20-25 ft-lbs / 27-34 Nm Check valve ........BB ... Brake release circuit ......20-25 ft-lbs / 27-34 Nm Orifice, 0.025 inch / 0.63 mm ..BD ... Turntable rotation brake release 4 - 46 S-80 • S-85 • S-80X Part No. 122985...

  • Page 137: Turntable Rotation Manifold Components

    Shuttle valve, 2 position 3 way ..RD ..Turntable rotation brake release ..8-10 ft-lbs / 10-15 Nm Orifice, 0.030 inch / 0.8 mm ....RC ..Brake release circuit Part No. 122985 S-80 • S-85 • S-80X 4 - 47...

  • Page 138: Platform Rotate Manifold Components

    Counterbalance valve, 3300 psi ..PA ..Platform rotate right ......37-44 ft-lbs / 50-60 Nm Counterbalance valve, 3300 psi ..PB ..Platform rotate left ......37-44 ft-lbs / 50-60 Nm 4 - 48 S-80 • S-85 • S-80X Part No. 122985...

  • Page 139: Platform Manifold Components, S-80

    Needle valve ........EA ..Platform level ........20-25 ft-lbs / 27-34 Nm Pressure comp., flow control valve ... EE ..Platform rotate flow control ....33-37 ft-lbs / 45-50 Nm Part No. 122985 S-80 • S-85 • S-80X 4 - 49...

  • Page 140: Platform Manifold Components, S-85

    Pressure comp., flow control valve ..EE ..Platform rotate flow control ....33-37 ft-lbs / 45-50 Nm Pressure comp., flow control valve ..EG ..Platform rotate flow control ....33-37 ft-lbs / 45-50 Nm 4 - 50 S-80 • S-85 • S-80X Part No. 122985...

  • Page 141: 2Wd Traction Manifold Components

    ................forward and reverse ......50-55 ft-lbs / 67-73 Nm Orifice Plug, 0.070 inch / 1.8 mm ..DA ..Equalizes flow across flow divider/ ................combiner valve BY Part No. 122985 S-80 • S-85 • S-80X 4 - 51...
  • Page 142 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 52 S-80 • S-85 • S-80X Part No. 122985...

  • Page 143: 4Wd Traction Manifold Components (Before Serial Number 8581)

    Flow divider/combiner valve ..... DM ..Controls flow to steer end drive motors in forward and reverse ........80-90 ft-lbs / 108-122 Nm Check valve ........DP ..Non-steer end drive motor circuit ..35-40 ft-lbs / 48-54 Nm Part No. 122985 S-80 • S-85 • S-80X 4 - 53...
  • Page 144 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 54 S-80 • S-85 • S-80X Part No. 122985...

  • Page 145: 4Wd Traction Manifold Components (After Serial Number 8580)

    Flow divider/combiner valve ..... DM ..Controls flow to steer end drive motors in forward and reverse ........80-90 ft-lbs / 108-122 Nm Check valve ........DP ..Non-steer end drive motor circuit ..35-40 ft-lbs / 48-54 Nm Part No. 122985 S-80 • S-85 • S-80X 4 - 55...
  • Page 146 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 56 S-80 • S-85 • S-80X Part No. 122985...

  • Page 147: Drive Oil Diverter Manifold Components (Welder Option)

    Pressure switch ......CZ ... Power to relay ..........16 ft-lbs / 22 Nm Connector ........--- .... For pressure switch ........11 ft-lbs / 15 Nm Check valve ........CY ... Prevents oil to generator ....35-40 ft-lbs / 47-54 Nm Part No. 122985 S-80 • S-85 • S-80X 4 - 57...

  • Page 148: Valve Adjustments - Traction Manifold

    3 Turn the engine off and connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the diagnostic nipple located on the traction manifold. 4 - 58 S-80 • S-85 • S-80X Part No. 122985...

  • Page 149: Valve Coils

    2 Test the coil resistance using a multimeter set to resistance (. Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. Part No. 122985 S-80 • S-85 • S-80X 4 - 59...
  • Page 150 February 2012 MANIFOLDS How to Test a Coil Diode AMMETER Genie incorporates spike suppressing diodes in all COIL of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes.

  • Page 151: Fuel And Hydraulic Tanks

    Note: Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel. Part No. 122985 S-80 • S-85 • S-80X 4 - 61...

  • Page 152: Hydraulic Tank

    Cap the fitting on the return filter housing. 6 Tag and disconnect and plug the supply hose for the auxiliary power unit. Cap the fitting on the hydraulic tank. 4 - 62 S-80 • S-85 • S-80X Part No. 122985...
  • Page 153 16 Fill the tank with hydraulic oil until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. Part No. 122985 S-80 • S-85 • S-80X 4 - 63...

  • Page 154: Turntable Rotation Components

    4 Attach a suitable lifting device to the lifting eyes 8 Adjust turntable rotation gear backlash. on the drive hub assembly. See 10-1, How to Adjust the Turntable Rotation Gear Backlash. 4 - 64 S-80 • S-85 • S-80X Part No. 122985...
  • Page 155 Do not allow oil to squirt or spray. 4 Remove the motor/brake mounting fasteners. Carefully remove the motor from the brake. 5 Clean up any oil that may have spilled. Part No. 122985 S-80 • S-85 • S-80X 4 - 65...
  • Page 156 8 Rotate the turntable through an entire rotation. fasteners. Check for tight spots that could cause binding. Readjust if necessary. backlash pivot plate adjustment bolt with lock nut backlash pivot plate mounting bolts 4 - 66 S-80 • S-85 • S-80X Part No. 122985...

  • Page 157: 2Wd Steer Axle Components

    Crushing hazard. The yoke and hub assembly may become unbalanced and fall if not properly supported and secured to the lifting jack when it is removed from the machine. Part No. 122985 S-80 • S-85 • S-80X 4 - 67...

  • Page 158: Steer Cylinder

    Note: Always use a new cotter pin when installing a castle nut. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to specification. Refer to Section 2, Specifications. 4 - 68 S-80 • S-85 • S-80X Part No. 122985...

  • Page 159: 4Wd Steer Axle Components

    5 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. Part No. 122985 S-80 • S-85 • S-80X 4 - 69...

  • Page 160: Drive Motor

    Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications . 1 Extend the axles. 2 Remove the drive motor access covers from both sides of the inner axle. 4 - 70 S-80 • S-85 • S-80X Part No. 122985...

  • Page 161: Drive Hub

    4 Remove the steer cylinder from the machine. and secured to the lifting jack when removed from the machine. Note: Do not re-use the drive hub mounting fasteners. Genie specifications require the use of new fasteners. Part No. 122985 S-80 • S-85 • S-80X...

  • Page 162: Non-Steer Axle Components

    This procedure is the same as the steer axle This procedure is the same as the steer axle procedure. See 12-2, How to Remove a Drive procedure. See 12-3, How to Remove a Drive Hub. Motor. 4 - 72 S-80 • S-85 • S-80X Part No. 122985...

  • Page 163: Oscillating Axle Components

    2 Remove the fasteners from the drive chassis removed from the machine. cover at the steer end. Remove the cover. Part No. 122985 S-80 • S-85 • S-80X 4 - 73...

  • Page 164: Oscillate Directional Valve

    12 Turn the engine off, remove the pressure gauge and assemble the directional valve linkage. 13 Install the cover on the non-steer end of the drive chassis. oscillate valve clevis yoke drive chassis 4 - 74 S-80 • S-85 • S-80X Part No. 122985...
  • Page 165 7 If the drive chassis is not level, start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level. Part No. 122985 S-80 • S-85 • S-80X 4 - 75...
  • Page 166 Section 4 • Repair Procedures February 2012 This page intentionally left blank. 4 - 76 S-80 • S-85 • S-80X Part No. 122985...
  • Page 167 • All external AC power disconnected gradually. Do not allow oil to from the machine squirt or spray. Note: Two persons will be required to safely perform some troubleshooting procedures. Part No. 122985 S-80 • S-85 • S-80X 5 - 1...

  • Page 168: Fault Codes - Control System

    OR use a grounded wrist strap. 5 - 2 S-80 • S-85 • S-80X Part No. 122985...
  • Page 169 Value at 0V indicating a fault. corrected. Not calibrated Calibrate angle sensor. Invalid setup Angle sensor Out of range cross check (S-80X) Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5 - 3...
  • Page 170 Joystick Value too low frozen at zero problem has been Value at 0V and neutral. corrected. Alarm sounds indicating a fault. Not calibrated Calibrate joystick. 5 - 4 S-80 • S-85 • S-80X Part No. 122985...
  • Page 171 Value too low Frozen at zero problem has been Value at 0V and neutral. corrected. Alarm sounds indicating a fault. Not calibrated Calibrate joystick. Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5 - 5...
  • Page 172 Calibrate joystick. Steer Fault Limited speed Cycle power off, Directional and direction. then on after Valve Frozen at zero problem has been and neutral. corrected. Alarm sounds indicating a fault. 5 - 6 S-80 • S-85 • S-80X Part No. 122985...
  • Page 173 The check engine light should begin to blink. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. Part No. 122985 S-80 • S-85 • S-80X 5 - 7...
  • Page 174 (target TPS - actual TPS) < -20% 2135 TPS1/2 simultaneous Uses same parameters as individual voltages out of range TPS1/2 voltage fault detection above * Adaptive Learn Key Cycle 5 - 8 S-80 • S-85 • S-80X Part No. 122985...
  • Page 175 EGO2 RMS > 0.005 phi and EGO2 RMS > EGO1 RMS* 50% and EGO2 RMS > CL waveform RMS* 50% * Adaptive Learn Key Cycle Continued on next page Part No. 122985 S-80 • S-85 • S-80X 5 - 9...
  • Page 176 1174 EPR Voltage Supply High 1175 EPR Voltage Supply Low 1176 EPR Internal Actuator fault detection 1177 EPR Internal Circuitry fault detection 1178 EPR Internal Comm fault detection * Adaptive Learn Key Cycle 5 - 10 S-80 • S-85 • S-80X Part No. 122985...
  • Page 177 TX error counter > 100 1627 CAN Rx Failure Rx error counter > 100 1628 CAN Address Conflict Failure Address conflict counter > 5 * Adaptive Learn Key Cycle Part No. 122985 S-80 • S-85 • S-80X 5 - 11...
  • Page 178 Section 5 • Fault Codes February 2012 This page intentionally left blank. 5 - 12 S-80 • S-85 • S-80X Part No. 122985...
  • Page 179 Be sure that all necessary tools and test discovered symptoms equipment are available and ready for use. problem still exists Return to Inspect Perform service and test repair problem solved Part No. 122985 S-80 • S-85 • S-80X 6 - 1...

  • Page 180: Electrical Symbols Legend

    Toggle switch DPDT Fuse with amperage N.O. Fuel or RPM Battery separator Control relay contact solenoid normally open Starting aid: glow plug or Circuit breaker flame ignitor with amperage Coil 6 - 2 S-80 • S-85 • S-80X Part No. 122985...

  • Page 181: Hydraulic Symbols Legend

    Flow divider/combiner valve Pump prime mover with pressure balancing orifice (engine or motor) and flow percentages Directional valve pilot operated 2 position, 2 way Double acting cylinder Differential sensing valve Part No. 122985 S-80 • S-85 • S-80X 6 - 3...
  • Page 182 Section 6 • Schematics February 2012 This page intentionally left blank. 6 - 4 S-80 • S-85 • S-80X Part No. 122985...
  • Page 183 Section 6 • Schematics February 2012 Connector Pin Legend - View 1 6 - 5 6 - 6...

  • Page 184: Connector Pin Legend - View 1

    12V POWER TO PLAT FOOTSWITCH C40LS C7 DTP06-4S C9 FS DT04-4P CIRCUIT # PIN # CKT # PIN # COLOR COLOR P22PWR P26ESTP P23PWR P24FS BATGND P25FS PLUG PLUG ES0507C 6 - 6 S-80 • S-85 • S-80X Part No. 122985...

  • Page 185: Connector Pin Legend - View 2

    C41RPM OR/BK C1PBU C169LED1 C2PBD RD/BK C3PBF RD/WH C4TRL C5TRR WH/BK C6TRF WH/RD C7PBE C8PBR BK/WH C9PERF BK/RD C30EDC+ C31EDC- WH/BK C36STC C37STCC BL/BK C32BRK WH/RD RD/WH C29MS ES0507C Part No. 122985 S-80 • S-85 • S-80X 6 - 7...
  • Page 186 February 2012 Section 6 • Schematics Connector Pin Legend - View 2 6 - 7 6 - 8...
  • Page 187 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models 6 - 9 6 - 10...

  • Page 188: Deutz Td2011L04I Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK P26ESTP BK P24FS WH C9P-3 P25FS RD P25FS RD P24FS WH P24FS WH...
  • Page 189 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE MODE DRIVE ENABLE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 190 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models 6 - 11 6 - 12...
  • Page 191 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 13 6 - 14...
  • Page 192 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 16/22 CABLE 18/22 CABLE ENGINE 12V TO PLAT FUNCTIONS GROUND STUD CABLE RESTRAINT DRIVE LIGHT OPTION RELAY...
  • Page 193 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models ES0504D Part No. 122985 S-80 • S-85 • S-80X 6 - 15...
  • Page 194 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 15 6 - 16...
  • Page 195 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 17 6 - 18...

  • Page 196: Platform Control Box Wiring Diagram, S-80 And S-85 (Ansi / Csa / As Deutz Td2011L04I Models

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models ALC-500 CONTROL HARNESS TO PLATFORM SWITCH PANEL C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 J22-1,2,9,10,11 AND 12 GROUND...
  • Page 197 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models CONTROL HARNESS TO PLATFORM BOX TS15 TS14 ES0504D COMPONENT INDEX TILT ALARM JIB BOOM UP/DOWN TOGGLE SWITCH...
  • Page 198 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models 6 - 19 6 - 20...
  • Page 199 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) 6 - 21 6 - 22...

  • Page 200: Electrical Schematic, S-80 And S-85 (Ce Deutz Td2011L04I Models (Before Serial Number 8111)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) C132PLI BK C28TTA RD/BK LS18A P26ESTP BK P24FS WH C9P-3 C9P-1 LS18 P25FS RD P25FS RD P24FS WH PBOX C9P-2 GROUND...
  • Page 201 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE ENABLE DRIVE MODE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 202 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04i Models (before serial number 8111) 6 - 23 6 - 24...
  • Page 203 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 25 6 - 26...

  • Page 204: Ground Control Box Terminal Strip Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (Before Serial Number 8111)

    TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE TIME DELAY, GLOW PLUG, 30 SECONDS LOAD SENSE MODULE CABLE HARNESS TO ES0504A RESTRAINT SWITCH PANEL 6 - 26 S-80 • S-85 • S-80X Part No. 122985...

  • Page 205: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (Before Serial Number 8111)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) ES0504A Part No. 122985 S-80 • S-85 • S-80X 6 - 27...
  • Page 206 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 27 6 - 28...

  • Page 207: Platform Control Box Wiring Diagram, S-80 And S-85 (Ce)

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 29 6 - 30...

  • Page 208: Platform Control Box Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (Before Serial Number 8111)

    SWITCH PANEL ES0504A BR BATGND (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 30 S-80 • S-85 • S-80X Part No. 122985...

  • Page 209: Platform Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (Before Serial Number 8111)

    NOTE: DASHED LINES INDICATE OPTIONS LED - PLATFORM OVERLOAD LED - CABLE TENSION PLATFORM ROTATE TOGGLE SWITCH ROCKER / STEER OPTION JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) LED - TILT ALARM Part No. 122985 S-80 • S-85 • S-80X 6 - 31...
  • Page 210 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111) 6 - 31 6 - 32...

  • Page 211: Deutz Td2011L04I Models (After Serial Number 8110)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 33 6 - 34...

  • Page 212: Deutz Td2011L04I Models (After Serial Number 8110)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) C28TTA RD/BK LS18A P26ESTP BK P24FS WH C9P-3 C9P-1 LS18 P25FS RD P25FS RD P24FS WH P24FS WH PBOX C9P-2 GROUND...
  • Page 213 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE ENABLE DRIVE MODE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 214 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 35 6 - 36...
  • Page 215 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 37 6 - 38...

  • Page 216: Ground Control Box Terminal Strip Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (After Serial Number 8110)

    TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE GLOW PLUG TIME DELAY LOAD SENSE MODULE LOAD SENSE TIME DELAY CABLE HARNESS TO ES0504D RESTRAINT SWITCH PANEL 6 - 38 S-80 • S-85 • S-80X Part No. 122985...

  • Page 217: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (After Serial Number 8110)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) ES0504D Part No. 122985 S-80 • S-85 • S-80X 6 - 39...
  • Page 218 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 39 6 - 40...
  • Page 219 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 41 6 - 42...

  • Page 220: Deutz Td2011L04I Models (After Serial Number 8110)

    TO PLATFORM (GROUND STUD) SWITCH PANEL CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 42 S-80 • S-85 • S-80X Part No. 122985...

  • Page 221: Platform Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Deutz Td2011L04I Models (After Serial Number 8110)

    PLATFORM OVERLOAD LIMIT SWITCH EMERGENCY STOP BUTTON ROCKER / STEER OPTION HORN BUTTON RESISTOR - 4700W AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH RPM SELECT TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 43...
  • Page 222 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110) 6 - 43 6 - 44...

  • Page 223: Electrical Schematic, S-80X

    Section 6 • Schematics February 2012 Electrical Schematic, S-80X, Deutz TD2011L04I Models 6 - 45 6 - 46...
  • Page 224 IGN / FUEL ON C24TSPS WH ENGINE FAULT BL/RD P24PWR RD TB21 C5-11 R21IGN WH B1BAT RD BAT2 APU RD CB20 CR39A CR15 CR17 ALTERNATOR EXCT 12V DC 12V DC REGULATOR ES504D 6 - 46 S-80 • S-85 • S-80X Part No. 122985...
  • Page 225 UP / DOWN ROTATE TS59 TB59 TB13 TB42 TB29 TB32 TB31 TB30 CR53 R14(A) CR52 CR34 CR68 TB36 TB37 TB44 TB18 CR69 TB15 TB17 TB43 TB14 TB118 J114 J133 J133 J134 Part No. 122985 S-80 • S-85 • S-80X 6 - 47...
  • Page 226 February 2012 Section 6 • Schematics Electrical Schematic, S-80X, Deutz TD2011L04I Models 6 - 47 6 - 48...

  • Page 227: Ground Control Box Terminal Strip Wiring Diagram, S-80X

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 49 6 - 50...
  • Page 228 TS61 TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE GLOW PLUG TIME DELAY RELAY CABLE HARNESS TO ES0504D RESTRAINT SWITCH PANEL 6 - 50 S-80 • S-85 • S-80X Part No. 122985...

  • Page 229: Ground Control Box Switch Panel Wiring Diagram, S-80X

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models ES0504D Part No. 122985 S-80 • S-85 • S-80X 6 - 51...
  • Page 230 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 51 6 - 52...

  • Page 231: Platform Control Box Wiring Diagram, S-80X

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 53 6 - 54...

  • Page 232: Deutz Td2011L04I Models

    BATTERY SWITCH BR BATGND (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 54 S-80 • S-85 • S-80X Part No. 122985...
  • Page 233 LED - ZONE A, 1000 LB CAPACITY EMERGENCY STOP BUTTON NOTE: DASHED LINES INDICATE OPTIONS HORN BUTTON ROCKER / STEER OPTION AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH RPM SELECT TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 55...
  • Page 234 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Deutz TD2011L04I Models 6 - 55 6 - 56...

  • Page 235: Electrical Schematic, S-80 And S-85 (Ansi / Csa / As)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 57 6 - 58...

  • Page 236: Electrical Schematic, S-80 And S-85 (Ansi / Csa / As Perkins 804D-33 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK P26ESTP BK P24FS WH C9P-3 P25FS RD P25FS RD P24FS WH P24FS WH...
  • Page 237 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE MODE DRIVE ENABLE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 238 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 59 6 - 60...

  • Page 239: And S-85 (Ansi / Csa / As), Perkins 804D-33 Models

    Section 6 • Schematics February 2012 Ground Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 61 6 - 62...
  • Page 240 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 16/22 CABLE 18/22 CABLE ENGINE 12V TO PLAT FUNCTIONS GROUND STUD CABLE RESTRAINT DRIVE LIGHT OPTION RELAY...
  • Page 241 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ES0503D Part No. 122985 S-80 • S-85 • S-80X 6 - 63...
  • Page 242 February 2012 Section 6 • Schematics Ground Control Switch Panel Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 63 6 - 64...
  • Page 243 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 65 6 - 66...

  • Page 244: Perkins 804D-33 Models

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ALC-500 CONTROL HARNESS TO PLATFORM SWITCH PANEL C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 J22-1,2,9,10,11 AND 12 GROUND...
  • Page 245 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models CONTROL HARNESS TO PLATFORM BOX TS15 TS14 ES0503D COMPONENT INDEX TILT ALARM JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)
  • Page 246 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models 6 - 67 6 - 68...

  • Page 247: Electrical Schematic, S-80 And S-85 (Ce)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 69 6 - 70...

  • Page 248: Electrical Schematic, S-80 And S-85 (Ce Perkins 804D-33 Models (Before Serial Number 8111)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) C132PLI BK C28TTA RD/BK LS18A P26ESTP BK P24FS WH C9P-3 C9P-1 LS18 P25FS RD P25FS RD P24FS WH PBOX C9P-2 GROUND...
  • Page 249 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE ENABLE DRIVE MODE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 250 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 71 6 - 72...
  • Page 251 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 73 6 - 74...

  • Page 252: Perkins 804D-33 Models (Before Serial Number 8111)

    PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE LOAD SENSE MODULE CABLE HARNESS TO ES0503A RESTRAINT SWITCH PANEL 6 - 74 S-80 • S-85 • S-80X Part No. 122985...

  • Page 253: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (Before Serial Number 8111)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) ES0503A Part No. 122985 S-80 • S-85 • S-80X 6 - 75...
  • Page 254 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 75 6 - 76...
  • Page 255 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 77 6 - 78...

  • Page 256: Platform Control Box Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (Before Serial Number 8111)

    SWITCH PANEL ES0503A BR BATGND (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 78 S-80 • S-85 • S-80X Part No. 122985...
  • Page 257 NOTE: DASHED LINES INDICATE OPTIONS LED - PLATFORM OVERLOAD LED - CABLE TENSION PLATFORM ROTATE TOGGLE SWITCH ROCKER / STEER OPTION LED - TILT ALARM JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION) Part No. 122985 S-80 • S-85 • S-80X 6 - 79...
  • Page 258 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111) 6 - 79 6 - 80...
  • Page 259 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 81 6 - 82...

  • Page 260: Electrical Schematic, S-80 And S-85 (Ce Perkins 804D-33 Models (After Serial Number 8110)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) C28TTA RD/BK LS18A P26ESTP BK P24FS WH C9P-3 C9P-1 LS18 P25FS RD P25FS RD P24FS WH P24FS WH PBOX C9P-2 GROUND...
  • Page 261 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE ENABLE DRIVE MODE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 262 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE) Perkins 804D-33 Models (after serial number 8110) 6 - 83 6 - 84...
  • Page 263 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 85 6 - 86...

  • Page 264: Ground Control Box Terminal Strip Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (After Serial Number 8110)

    TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE LOAD SENSE MODULE LOAD SENSE TIME DELAY CABLE HARNESS TO ES0503D RESTRAINT SWITCH PANEL 6 - 86 S-80 • S-85 • S-80X Part No. 122985...

  • Page 265: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (After Serial Number 8110)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) ES0503D Part No. 122985 S-80 • S-85 • S-80X 6 - 87...
  • Page 266 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 87 6 - 88...
  • Page 267 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 89 6 - 90...

  • Page 268: Platform Control Box Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (After Serial Number 8110)

    TO PLATFORM (GROUND STUD) SWITCH PANEL CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 90 S-80 • S-85 • S-80X Part No. 122985...

  • Page 269: Platform Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Perkins 804D-33 Models (After Serial Number 8110)

    PLATFORM OVERLOAD LIMIT SWITCH EMERGENCY STOP BUTTON ROCKER / STEER OPTION HORN BUTTON RESISTOR - 4700W AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH RPM SELECT TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 91...
  • Page 270 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110) 6 - 91 6 - 92...
  • Page 271 Section 6 • Schematics February 2012 Electrical Schematic, S-80X, Perkins 804D-33 Models 6 - 93 6 - 94...

  • Page 272: Electrical Schematic, S-80X Perkins 804D-33 Models

    IGN / FUEL ON C24TSPS WH ENGINE FAULT BL/RD P24PWR RD TB21 C5-11 R21IGN WH B1BAT RD BAT2 APU RD CB20 CR39A CR15 CR17 ALTERNATOR EXCT 12V DC 12V DC REGULATOR ES0503D 6 - 94 S-80 • S-85 • S-80X Part No. 122985...
  • Page 273 UP / DOWN ROTATE TS59 TB59 TB13 TB42 TB29 TB32 TB31 TB30 CR53 R14(A) CR52 CR34 CR68 TB36 TB37 TB44 TB18 CR69 TB15 TB17 TB43 TB14 TB118 J114 J133 J133 J134 Part No. 122985 S-80 • S-85 • S-80X 6 - 95...
  • Page 274 February 2012 Section 6 • Schematics Electrical Schematic, S-80X, Perkins 804D-33 Models 6 - 95 6 - 96...
  • Page 275 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 97 6 - 98...

  • Page 276: Ground Control Box Terminal Strip Wiring Diagram, S-80X Perkins 804D-33 Models

    PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH IGNITION START MODULE CABLE HARNESS TO ES0503D RESTRAINT SWITCH PANEL 6 - 98 S-80 • S-85 • S-80X Part No. 122985...
  • Page 277 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models ES0503D Part No. 122985 S-80 • S-85 • S-80X 6 - 99...
  • Page 278 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 99 6 - 100...
  • Page 279 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 101 6 - 102...

  • Page 280: Platform Control Box Wiring Diagram, S80X Perkins 804D-33 Models

    BATTERY SWITCH BR BATGND (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 102 S-80 • S-85 • S-80X Part No. 122985...

  • Page 281: Platform Control Box Switch Panel Wiring Diagram, S80X Perkins 804D-33 Models

    LED - ZONE A, 1000 LB CAPACITY EMERGENCY STOP BUTTON NOTE: DASHED LINES INDICATE OPTIONS HORN BUTTON ROCKER / STEER OPTION AUXILIARY TOGGLE SWITCH ENGINE START TOGGLE SWITCH RPM SELECT TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 103...
  • Page 282 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Perkins 804D-33 Models 6 - 103 6 - 104...
  • Page 283 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS) Continental TME27 Models 6 - 105 6 - 106...

  • Page 284: Continental Tme27 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK P24FS WH C9P-3 C9P-1 P25FS RD P25FS RD P24FS WH P24FS WH C9P-2...
  • Page 285 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS) Continental TME27 Models GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE MODE DRIVE ENABLE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 286 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 107 6 - 108...
  • Page 287 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 109 6 - 110...

  • Page 288: Ground Control Box Terminal Strip Wiring Diagram S-80 And S-85 (Ansi / Csa / As), Continental Tme27 Models

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 18/22 CABLE 16/22 CABLE ENGINE 12V TO PLAT FUNCTIONS GROUND STUD TS64 CABLE RESTRAINT LABEL DESCRIPTION...
  • Page 289 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models TO GROUND CONTROL BOX CONNECTIONS ES0505D Part No. 122985 S-80 • S-85 • S-80X 6 - 111...
  • Page 290 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 111 6 - 112...
  • Page 291 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 113 6 - 114...

  • Page 292: Platform Control Box Wiring Diagram, S-80 And S-85 (Ansi / Csa / As Continental Tme27 Models

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models ALC-500 CONTROL HARNESS TO PLATFORM SWITCH PANEL C1P-2 C28TTA RD/BK BATGND J3-1 BATGND C7P-3 J22-1,2,9,10,11 AND 12 GROUND...
  • Page 293 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models CONTROL HARNESS TO PLATFORM BOX TS15 TS14 ES0505D COMPONENT INDEX NOTE: DASHED LINES INDICATE OPTIONS CR27...
  • Page 294 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models 6 - 115 6 - 116...
  • Page 295 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 117 6 - 118...

  • Page 296: Electrical Schematic, S-80 And S-85 (Ce Continental Tme27 Models (Before Serial Number 8111)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) C132PLI BK C28TTA RD/BK P26ESTP BK P26ESTP BK LS18A LS18 P24FS WH C9P-3 C9P-1 P25FS RD P25FS RD P24FS WH P24FS WH...
  • Page 297 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE MODE DRIVE ENABLE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 298 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 119 6 - 120...
  • Page 299 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 121 6 - 122...

  • Page 300: Ground Control Box Terminal Strip Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (Before Serial Number 8111)

    PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS63 LOAD SENSE MODULE CABLE HARNESS TO ES0505A RESTRAINT SWITCH PANEL 6 - 122 S-80 • S-85 • S-80X Part No. 122985...

  • Page 301: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (Before Serial Number 8111)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) ES0505A Part No. 122985 S-80 • S-85 • S-80X 6 - 123...
  • Page 302 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 123 6 - 124...
  • Page 303 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 125 6 - 126...

  • Page 304: Platform Control Box Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (Before Serial Number 8111)

    SWITCH PANEL BR BATGND ES0505A (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 126 S-80 • S-85 • S-80X Part No. 122985...

  • Page 305: Platform Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (Before Serial Number 8111)

    TIME DELAY RELAY - 2 SECONDS, 30A LED - PLATFORM OVERLOAD LED - CABLE TENSION NOTE: DASHED LINES INDICATE OPTIONS LED - TILT ALARM ROCKER STEER OPTION LS18 PLATFORM OVERLOAD LIMIT SWITCH EMERGENCY STOP BUTTON Part No. 122985 S-80 • S-85 • S-80X 6 - 127...
  • Page 306 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111) 6 - 127 6 - 128...
  • Page 307 Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 129 6 - 130...

  • Page 308: Electrical Schematic, S-80 And S-85 (Ce Continental Tme27 Models (After Serial Number 8110)

    Section 6 • Schematics February 2012 Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK P26ESTP BK P24FS WH C9P-3 C9P-1 P25FS RD P25FS RD P24FS WH P24FS WH...
  • Page 309 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) GND BR C28TTA RD/BK P26ESTP BK P24FS WH TS15 TS14 J127 DRIVE MODE DRIVE ENABLE ROCKER / STEER OPTION C163PES-WH/BK C159STC-BL/WH...
  • Page 310 February 2012 Section 6 • Schematics Electrical Schematic, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 131 6 - 132...
  • Page 311 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 133 6 - 134...

  • Page 312: Ground Control Box Terminal Strip Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (After Serial Number 8110)

    TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS64 ENGINE FAULT CODE TEST TOGGLE SWITCH LOAD SENSE MODULE LOAD SENSE TIME DELAY CABLE HARNESS TO ES0505D RESTRAINT SWITCH PANEL 6 - 134 S-80 • S-85 • S-80X Part No. 122985...

  • Page 313: Ground Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (After Serial Number 8110)

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) ES0505D Part No. 122985 S-80 • S-85 • S-80X 6 - 135...
  • Page 314 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 135 6 - 136...
  • Page 315 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 137 6 - 138...

  • Page 316: Continental Tme27 Models (After Serial Number 8110)

    TO PLATFORM (GROUND STUD) SWITCH PANEL CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 138 S-80 • S-85 • S-80X Part No. 122985...

  • Page 317: Platform Control Box Switch Panel Wiring Diagram, S-80 And S-85 (Ce Continental Tme27 Models (After Serial Number 8110)

    ALC500 JOYSTICK CONTROLLER CARD EMERGENCY STOP BUTTON HORN BUTTON NOTE: DASHED LINES INDICATE OPTIONS AUXILIARY TOGGLE SWITCH ROCKER / STEER OPTION ENGINE START TOGGLE SWITCH FUEL SELECT TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 139...
  • Page 318 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110) 6 - 139 6 - 140...
  • Page 319 Section 6 • Schematics February 2012 Electrical Schematic, S-80X, Continental TME27 Models 6 - 141 6 - 142...

  • Page 320: Electrical Schematic, S-80X Continental Tme27 Models

    C127TSW GR BAT2 APU RD CR39A CR39B R21IGN WH C21RET WH CR17 510W R33STR BK R23PWR WH C38FP BL/WH C38RET BL EXCT HARNESS 12V DC 12V DC REGULATOR ES0505D 6 - 142 S-80 • S-85 • S-80X Part No. 122985...
  • Page 321 PLATFORM TB59 ROTATE TS59 TB29 TB32 TB31 TB30 TB13 TB42 CR53 R14(A) CR52 CR34 CR68 TB36 TB37 TB44 TB18 CR69 TB15 TB17 TB43 TB14 TB118 J114 J133 J133 J134 Part No. 122985 S-80 • S-85 • S-80X 6 - 143...
  • Page 322 February 2012 Section 6 • Schematics Electrical Schematic, S-80X, Continental TME27 Models 6 - 143 6 - 144...
  • Page 323 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-80X, Continental TME27 Models 6 - 145 6 - 146...

  • Page 324: Ground Control Box Terminal Strip Wiring Diagram, S-80X Continental Tme27 Models

    PRIMARY BOOM UP / DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH TS63 TS64 ENGINE FAULT CODE TEST TOGGLE SWITCH CABLE RESTRAINT ES0505D HARNESS TO SWITCH PANEL 6 - 146 S-80 • S-85 • S-80X Part No. 122985...
  • Page 325 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models ES0505D Part No. 122985 S-80 • S-85 • S-80X 6 - 147...
  • Page 326 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models 6 - 147 6 - 148...
  • Page 327 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-80X, Continental TME27 Models 6 - 149 6 - 150...

  • Page 328: Platform Control Box Wiring Diagram, S-80X Continental Tme27 Models

    SWITCH BATTERY BR BATGND (GROUND STUD) CR27 WH TS7 WH TS14 WH/RD C32BRK (SPLICE TO C32BRK, C1P-6) CR30 OR/RD C40LS (SPLICE TO C40LS, C2P-2) LIFT / DRIVE SELECT (OPTION) 6 - 150 S-80 • S-85 • S-80X Part No. 122985...
  • Page 329 LED - ZONE B, 500 LB CAPACITY LED - ZONE A, 1000 LB CAPACITY NOTE: DASHED LINES INDICATE OPTIONS. EMERGENCY STOP BUTTON ROCKER / STEER OPTION HORN BUTTON AUXILIARY TOGGLE SWITCH Part No. 122985 S-80 • S-85 • S-80X 6 - 151...
  • Page 330 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-80X, Continental TME27 Models 6 - 151 6 - 152...
  • Page 331 Section 6 • Schematics February 2012 Continental TME27 Engine Harness 6 - 153 6 - 154...

  • Page 332: Continental Tme27 Engine Harness

    RED/TAN 14 RED 14 RED 12 BAT + BROWN/YELLOW 16 RED 14 INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1 NOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER 6 - 154 S-80 • S-85 • S-80X Part No. 122985...

  • Page 333: Platform Level Cutout, Cte Option

    February 2012 Section 6 • Schematics Platform Level Cutout, CTE Option PLATFORM BOX C42LS OR/RD J2-4 C2P-4 CR21 CR20 GROUND GROUND BOX MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED Part No. 122985 S-80 • S-85 • S-80X 6 - 155...
  • Page 334 February 2012 Section 6 • Schematics Platform Level Cutout, CTE Option 6 - 155 6 - 156...
  • Page 335 Section 6 • Schematics February 2012 Continental Options Schematic 6 - 157 6 - 158...

  • Page 336: Continental Options Schematic

    P24FS WH P24FS WH C9P-2 10 A TS43 P134PWR RD CONTROL BOX TS49 TS48 HEATER WORK LIGHT DRIVE LIGHT THS1 PLATFORM BOX GROUND TB21 CR23 C26TSR GR/BK HARNESS ES0505C 6 - 158 S-80 • S-85 • S-80X Part No. 122985...

  • Page 337: Deutz And Perkins Options Schematic

    10 A TS43 P134PWR RD TS47 CONTROL BOX TS49 TS48 GENERATOR HEATER WORK LIGHT DRIVE LIGHT THS1 PLATFORM BOX GROUND TB21 TB45 C10-2 CR23 C10-4 C10-1 C10-3 CR46 ES0503D ES0504D Part No. 122985 S-80 • S-85 • S-80X 6 - 159...
  • Page 338 February 2012 Section 6 • Schematics Deutz and Perkins Options Schematic 6 - 159 6 - 160...
  • Page 339 Section 6 • Schematics February 2012 12 kW Hydraulic Generator Wiring Diagram 6 - 161 6 -162...

  • Page 340: Kw Hydraulic Generator Wiring Diagram

    8 GA 4 CONDUCTOR 8 GA 5 CONDUCTOR BRASS 120 VAC GFI GREEN 12GA 12 GA 3 CONDUCTOR 110 VAC ENCLOSURE SILVER BRASS WHITE GREEN GREEN BLACK ES0506B 12 GA 3 CONDUCTOR 6 - 162 S-80 • S-85 • S-80X Part No. 122985...

  • Page 341: Kw Hydraulic Generator Electrical Schematic

    CR50 E1NOT USED E2NOT USED E3NOT USED F1DIG IN 0 N.O. F2DIG IN 1 GENERATOR ON F3DIG IN 2 SX Controller PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD BR-2 (16-2) Part No. 122985 S-80 • S-85 • S-80X 6 - 163...
  • Page 342 February 2012 Section 6 • Schematics 12 kW Hydraulic Generator Electrical Schematic 6 - 163 6 - 164...
  • Page 343 Section 6 • Schematics February 2012 Belt Driven Generator Option 6 - 165 6 - 166...

  • Page 344: Belt Driven Generator Option

    RD 12GA R20BAT CR46 WH 12GA NEUTRAL NEUTRAL WH BR 12GA P20BAT BK 12GA LINE C45GEN TO GBOX BK/WH 14GA FIELD GND BR 220 VAC / 50 HZ with Regulator 6 - 166 S-80 • S-85 • S-80X Part No. 122985...

  • Page 345: Relay And Fuse Panel Legend

    CR17 HYDRAULIC OIL COOLER RELAY CR39 AUXILIARY PUMP RELAY CR15 CR39 FUSE, 30A, OIL COOLER FAN / HORN FUSE, 30A, ENGINE / AUXILIARY PUMP 02GND FUSE, 60A, GLOW PLUGS Part No. 122985 S-80 • S-85 • S-80X 6 - 167...
  • Page 346 February 2012 Section 6 • Schematics Relay and Fuse Panel Legend 6 - 167 6 - 168...
  • Page 347 Section 6 • Schematics February 2012 Hydraulic Schematic, 2WD Models 6 - 169 6 - 170...

  • Page 348: Hydraulic Schematic, 2Wd Models

    3300 psi / 228 bar LEFT RIGHT 3000 psi / 207 bar STEER CYLINDER 280 psi LEFT RIGHT 19 bar 0.070 inch 1.8 mm LEFT REAR HS0166C OSCILLATE CYLINDERS TRACTION MANIFOLD OSCILLATE VALVE 6 - 170 S-80 • S-85 • S-80X Part No. 122985...

  • Page 349: Hydraulic Schematic, 4Wd Models

    LEFT RIGHT 280 psi 19 bar 0.040 inch 0.040 inch 1 mm 1 mm 0.040 inch 1 mm HS0166C LEFT LEFT REAR FRONT OSCILLATE CYLINDERS TRACTION MANIFOLD OSCILLATE VALVE Part No. 122985 S-80 • S-85 • S-80X 6 - 171...
  • Page 350 February 2012 Section 6 • Schematics Hydraulic Schematic, 4WD Models 6 - 171 6 - 172...

  • Page 351: Kw Hydraulic Generator Hydraulic Schematic

    200 PSI / 13.8 BAR N.O. 270 PSI / 18.6 BAR @ 3.5 GPM / 13.25 L/min MTR B MTR A TANK 21CC 21 GPM / 79.5 L/min HS0166C GENERATOR 12.5 KW Part No. 122985 S-80 • S-85 • S-80X 6 - 173...
  • Page 352 February 2012 Section 6 • Schematics 12 kW Hydraulic Generator Hydraulic Schematic 6 - 173 6 - 174...
  • Page 353 Genie North America Phone 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 Genie Scandinavia Genie China Phone +46 31 57 51 00...

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