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Service and Repair Manual Serial Number Range ® This manual includes: from S8016H-13643 to Repair procedures S8016H-13999 Fault Codes ® from S8516H-13643 to Electrical and S8516H-13999 Hydraulic Schematics -80X ® from S80X16H-13643 to S80X16H-13999 from S80H-14000 from S85H-14000 from S80XH-14000 except S8516H-13685 except S8516H-13711 For detailed maintenance...
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March 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 3/2018 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...
Service and Repair Manual March 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Sequence number 2 Model year 2 Serial label (located under cover) 3 Facility code 3 Serial number (stamped on chassis) From September 1, 2016 1 Model 1 Serial label (located under cover) 2 Facility code...
March 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine 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.
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Service and Repair Manual March 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
March 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications...................
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March 2018 Table of Contents Platform Components ..................23 2-1 Platform ......................23 2-2 Platform Leveling Slave Cylinder ..............24 How to Remove the Platform Leveling Slave Cylinder ........24 How to Bleed the Slave Cylinder ..............24 2-3 Platform Rotator ..................... 25 How to Remove the Platform Rotator .............
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March 2018 Table of Contents Ground Controls ....................53 6-1 Control Relays ....................53 Hydraulic Pumps ....................54 7-1 Function Pump ....................54 7-2 Drive Pump ....................55 How to Prime the Drive Pump ................. 56 Manifolds ......................58 8-1 Function Manifold ................... 58 8-2 Valve Adjustments - Function Manifold............
March 2018 Service and Repair Manual Specifications Section 2 Specific ati ons Fluid capacities Machine Specifications Fuel tank, 35 gallons Tires and wheels Deutz and Perkins models 132.5 liters Rough Terrain and Non Marking Fuel tank, 30 gallons Tire size 18-625 FF Continental model 113.5 liters...
Service and Repair Manual March 2018 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position, 40 ft / 7.9 - 8.5 sec Genie specifications require hydraulic oils which are RT tires 12.2 m / 7.9 - 8.5 sec designed to give maximum protection to hydraulic systems, have the ability to perform over a wide Stowed position,...
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March 2018 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
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Service and Repair Manual March 2018 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...
March 2018 Service and Repair Manual Specifications Hydraulic Component Specifications UCON Hydrolube HP-5046 Fluid Properties Drive Pump Type: bi-directional variable displacement piston pump ISO Grade Displacement per revolution 0 to 2.8 cu in Viscosity index 0 to 46 cc Kinematic Viscosity Flow rate @ 2300 rpm 30.3 gpm cSt @ 149°F / 65°C...
March 2018 Service and Repair Manual Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 220.9 cu. in 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.78 x 4.92 inches Oil Pressure switch 96 x 125 mm...
Service and Repair Manual March 2018 Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...
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March 2018 Service and Repair Manual Specifications Perkins 404D-22T Engine Fuel injection system Injection pump make Zexel Displacement 134 cu in Injection pressure 2133 psi 2.2 liters 147 bar Number of cylinders Fuel requirement Bore and stroke 3.31 x 3.94 inches For fuel requirements, refer to the engine Operator's 84 x 100 mm Manual on your machine.
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Service and Repair Manual March 2018 Specifications GM 3.0L Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 183 cu. in Manual for your engine. 3.0 liters Battery – Engine starting and control system Number of cylinders Type 12V DC, Group 31 Bore and Stroke...
March 2018 Service and Repair Manual Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5, lubricated 480 ft-lbs (before SN 15-12988) 651 Nm 3/8-16 bolts, GR 8 35 ft-lbs* 47 Nm* (before SN 15-12988) *(use blue thread locking compound) 1-8 center bolt, GR 5, dull gray 615 ft-lbs (from SN 15-12988)
Service and Repair Manual March 2018 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...
March 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
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Service and Repair Manual March 2018 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
March 2018 Service and Repair Manual Repair Procedures Section 3 Repair Pr oc edures Machine Configuration: Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Key switch in the off position with the key Observe and Obey: removed ·...
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Service and Repair Manual March 2018 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
March 2018 Service and Repair Manual Platform Controls ALC-500 Circuit Board Platform Controls Note: When the ALC-500 circuit board is replaced, The platform control box contains one printed circuit the joystick controllers will need to be calibrated. board. The ALC-500 circuit board inside the Refer to Repair Procedure, How to Calibrate a platform control box controls all proportional Joystick.
Service and Repair Manual March 2018 Platform Controls How to Adj ust the Joystic k Max- out Setting How to Adjust the Joystick Joysticks Max-out Setting The max-out setting of a joystick controls the maximum speed of a joystick-controlled machine How to Calibrate a Joystick function.
March 2018 Service and Repair Manual Platform Controls How to Adj ust the Joystic k Ramp R ate Setting How to Adjust the Joystick Ramp Start the engine from the platform controls and press down the foot switch. Rate Setting Start a timer and activate the machine function The ramp rate setting of a joystick controls the time that needs to be adjusted.
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Service and Repair Manual March 2018 Platform Controls Start the engine from the platform controls and 14 Return the joystick to the neutral position and press down the foot switch. wait for approximately 10 seconds to allow the settings to be saved. Start a timer and simultaneously move the joystick in either direction full stroke.
March 2018 Service and Repair Manual Platform Controls How to Adj ust the Joystic k Thr eshol d Setting How to Adjust the Joystick Select a boom function joystick to set the threshold. Threshold Setting 10 Slowly move the joystick off center in either The threshold setting of a joystick is the minimum direction just until the function begins to move.
Service and Repair Manual March 2018 Platform Controls How to C alibr ate the Boom Angle Sens or How to Calibrate the Boom Angle Raise the primary boom to the fully elevated position. Sensor Note: Manually reduce the boom speed as it The boom angle sensor controls the maximum reaches the fully elevated position.
March 2018 Service and Repair Manual Platform Components Support and secure the platform to an appropriate lifting device. Platform Remove the platform mounting fasteners and remove the platform from the machine. How to Remove the Platform Crushing hazard. The platform Remove the cable clamp from the top of the could become unstable and fall platform mounting weldment.
Service and Repair Manual March 2018 Platform Components Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft Platform Leveling Cylinder metal drift to drive the rod-end pivot pin out. The slave cylinder and the rotator pivot are the two Crushing hazard.
March 2018 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the rotator. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.
Service and Repair Manual March 2018 Platform Components How to Bleed the Pl atfor m R otator How to Bleed the Platform Rotator Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the machine. Note: This procedure will require two people.
March 2018 Service and Repair Manual Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System (if equipped) Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic How to Calibrate the Platform connections very slowly to allow the oil pressure to dissipate Overload System (if equipped)
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Service and Repair Manual March 2018 Platform Components Move the platform up and down by hand, so it Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2 inches.
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March 2018 Service and Repair Manual Platform Components Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground controls. 11 Test all machine functions from the ground controls.
Service and Repair Manual March 2018 Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
March 2018 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.
Service and Repair Manual March 2018 Boom Components 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 running up the boom.
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March 2018 Service and Repair Manual Boom Components 12 Tag, disconnect and plug the hydraulic hoses 18 Place blocks between the upper and lower from the jib boom lift cylinder. Cap the fittings cable tracks and secure the upper and lower on the cylinder.
Service and Repair Manual March 2018 Boom Components How to R epair the C abl e Tr ac k How to Repair the Cable Track Boom Component damage hazard. The boom cable track can be How to Shi m the Boom damaged if it is twisted.
March 2018 Service and Repair Manual Boom Components How to R emove the Boom Place a block of wood measuring 4 x 4 x 60 How to Remove the Boom inches / 10 x 10 x 152 cm under the long link arm, across the turntable covers.
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Service and Repair Manual March 2018 Boom Components Slowly operate the overhead crane to apply 14 Using auxiliary power, activate the boom down tension to the lifting straps. Do not attempt to function so the cylinder will retract. Retract the lift the machine with the overhead crane.
March 2018 Service and Repair Manual Boom Components 20 Support the platform leveling master cylinder. Remove the master cylinder rod-end pivot pin Boom Lift Cylinder retaining fasteners. Place a rod through the pin and twist to remove. Carefully lower the master The boom lift cylinder raises and lowers the boom.
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Service and Repair Manual March 2018 Boom Components Support and secure both ends of the boom lift Use a slide hammer to remove the barrel-end cylinder to a second overhead crane or similar pivot pins. lifting device. Crushing hazard. The lift cylinder Remove the pin retaining fastener from the could become unbalanced and boom lift cylinder rod-end pivot pin.
March 2018 Service and Repair Manual Boom Components Fully loosen the lock nuts on the extend cables. Do not remove the nuts. Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube.
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Service and Repair Manual March 2018 Boom Components Remove the fasteners from the retaining 13 Lift up the extend cable mounting plate and blocks from the extension cylinder saddle. push the extend cables towards the platform to Remove the blocks. create slack in the cables.
March 2018 Service and Repair Manual Boom Components 22 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the Boom Extend and Retract Cables number 2 boom tube. How to Adj ust the Extend/R etrac t C abl es 23 Carefully support and slide the extension cylinder out of the boom.
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Service and Repair Manual March 2018 Boom Components 11 Locate the retract cable adjustment nut on the Locate the extend cable adjustment nuts on bottom of the number 1 boom tube at the the counterweight end of boom tube #1. Refer platform end of the boom.
March 2018 Service and Repair Manual Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom 17 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm Extend/Retract Cables is centered in the notch of the pivot plate.
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Service and Repair Manual March 2018 Boom Components Install the boom extend cable clevis pins and 17 Repeat steps 14 through 19 for the other boom rue rings to the pivot plate near the cable break retract cable. limit switch. 18 At the platform end of the boom, install the Install the boom extend cables to the lower retract cables, clevis pins and rue rings to the...
March 2018 Service and Repair Manual Boom Components Place a rod through the barrel-end pivot pin and twist to remove the pin. Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder. It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion.
Service and Repair Manual March 2018 Boom Components Referring to the illustration, hold the angle sensor/bracket assembly at an angle away Primary Boom Angle Sensor from the mounting plate and match up the hex shaft to the sensor. Rotate the assembly The primary boom angle sensor works in towards the mounting plate and install the conjunction with the boom extend limit switches,...
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March 2018 Service and Repair Manual Boom Components Turn the key switch to platform controls. Pull out the red Emergency Stop buttons at the ground and platform controls to the on position. 10 Using a volt meter set to DC volts, back probe the angle sensor harness connector.
Service and Repair Manual March 2018 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel and Service or Maintenance Manual for your machine, has a splined center to drive the pump.
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March 2018 Service and Repair Manual Engines Deutz TD2011L04i models: Carefully pull the pump and bell housing assembly away from the engine and secure it Tag and disconnect the wiring from the bell from moving. housing. Component damage hazard. Remove the U-bolt from the exhaust flex pipe Hoses can be damaged if they at the muffler.
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Service and Repair Manual March 2018 Engines Perkins 404TD-22 models: Tag and disconnect the wiring from the bell housing. Remove the fasteners supporting the muffler assembly from the bell housing. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns.
March 2018 Service and Repair Manual Engines How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the Install the flex plate onto the engine flywheel appropriate gap between coupler and pump with the raised spline towards the pump.
Service and Repair Manual March 2018 Engines How to i nstall the Pump and Bell H ousing Ass embl y Deutz Pump Mounting Plate How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C"...
March 2018 Service and Repair Manual Ground Controls Connect 12V DC to terminal 85 and a ground wire to terminal 86, then test the following Control Relays terminal combinations. Relays used for single function switching are single Test Desired result pole double throw (SPDT) relays.
Service and Repair Manual March 2018 Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...
March 2018 Service and Repair Manual Hydraulic Pumps Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Service and Repair Manual March 2018 Hydraulic Pumps How to Prime the Dri ve Pump How to Prime the Drive Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Component damage hazard. Remove the drive pump from the machine. The engine must not be started with the hydraulic tank shut-off Component damage hazard.
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March 2018 Service and Repair Manual This page intentionally left blank. Part No. 1287339GT S-80 • S-85 • S-80X...
Service and Repair Manual March 2018 Manifolds Function Manifold Components The function manifold assembly is located on the tank side tray, behind the ground control box. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Boom up 50-55 ft-lbs / 68-75 Nm Solenoid Valve, 2 position 3 way...
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March 2018 Service and Repair Manual Manifolds Part No. 1287339GT S-80 • S-85 • S-80X...
Service and Repair Manual March 2018 Manifolds How to Adj ust the Boom Down R elief Val ve 8-2 Valve Adjustments - How to Adjust the Boom Down Function Manifold Relief Valve Note: Perform this procedure with the boom in the How to Adj ust the System Reli ef Val ve stowed position.
March 2018 Service and Repair Manual Manifolds How to Adj ust the Boom Extend R elief Val ve How to Adjust the Boom Extend Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the boom extend relief valve.
Service and Repair Manual March 2018 Manifolds Brake / Two Speed Manifold Components The brake/two speed manifold is mounted inside the drive chassis. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Brake release 20-25 ft-lbs / 27-34 Nm Solenoid Valve, 2 position 3 way Two-speed motor shift 20-25 ft-lbs / 27-34 Nm...
March 2018 Service and Repair Manual Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine. Index Schematic Description Function Torque Item Counterbalance valve, 1000 psi Turntable rotate left 25-30 ft-lbs / 34-41 Nm Counterbalance valve, 1000 psi...
Service and Repair Manual March 2018 Manifolds Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator. Index Schematic Description Function Torque Item Counterbalance valve, 3300 psi Platform rotate right 37-44 ft-lbs / 50-60 Nm Counterbalance valve, 3300 psi Platform rotate left 37-44 ft-lbs / 50-60 Nm S-80 •...
March 2018 Service and Repair Manual Manifolds Platform Manifold Components, S-80 The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm Solenoid valve, 3 position 4 way Platform level up/down 30-35 ft-lbs / 41-47 Nm...
Service and Repair Manual March 2018 Manifolds Platform Manifold Components, S-85 The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm Solenoid valve, 3 position 4 way Platform level up/down 30-35 ft-lbs / 41-47 Nm...
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March 2018 Service and Repair Manual Manifolds Traction Manifold Components, 2WD The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index Schematic Description Function Torque Item Relief valve, 280 psi / 19.3 bar Charge pressure circuit 30-35 ft-lbs / 41-47 Nm Flow divider/combiner valve...
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Service and Repair Manual March 2018 Manifolds Traction Manifold Components, 4WD The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index Schematic Description Function Torque Item Relief valve, 280 psi / 19.3 bar Charge pressure circuit 35-40 ft-lbs / 48-54 Nm Flow divider/combiner valve...
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March 2018 Service and Repair Manual Manifolds Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Manifolds 8-10 Diverter Manifold Components (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Directional valve Diverter valve 80-90 ft-lbs / 108-122 Nm Orifice disc, 0.031 inch / 0.8 mm Delays shift to drive Solenoid Valve...
March 2018 Service and Repair Manual Manifolds 8-11 Valve Adjustments - Traction Manifold How to Adjust the Hot Oil Relief Valve Note: The pressure differential between the charge pump relief valve (located in the drive pump) and the hot oil shuttle relief valve (located in the traction manifold) is necessary to return hot oil from the closed loop drive circuit to the hydraulic tank for cooling.
Service and Repair Manual March 2018 Manifolds Val ve C oil Resistanc e Speci ficati ons 8-12 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically...
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March 2018 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Service and Repair Manual March 2018 Fuel and Hydraulic Tanks Tag, disconnect, drain and plug the supply and return fuel hoses. Cap the fittings on the fuel Fuel Tank tank. Remove the fuel tank retaining fasteners. How to Remove the Fuel Tank Remove the fuel tank from the machine.
March 2018 Service and Repair Manual Fuel and Hydraulic Tanks Close the two hydraulic tank valves located at the hydraulic tank (if equipped). Hydraulic Tank Component damage hazard. The primary functions of the hydraulic tank are to The engine must not be started cool, clean and de-aerate the hydraulic fluid during with the hydraulic tank shut-off operation.
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Service and Repair Manual March 2018 Fuel and Hydraulic Tanks Crushing hazard. The hydraulic 17 Clean up any oil that may have spilled. tank could become unbalanced 18 Open the hydraulic tank shutoff valves (if and fall if not properly supported equipped).
March 2018 Service and Repair Manual Turntable Rotation Components 10-1 Attach a suitable lifting device to the lifting eyes on the drive hub assembly. Turntable Rotation Drive Hub Assembly How to R emove the Tur ntabl e R otation Dri ve H ub As sembl y How to Remove the Turntable Rotation Drive Hub Assembly Note: When removing a hose assembly or fitting,...
Service and Repair Manual March 2018 Turntable Rotation Components How to R emove the Tur ntabl e R otation H ydr aulic M otor specification. Refer to Specifications, Machine How to Remove the Turntable Torque Specifications. Rotation Hydraulic Motor Adjust turntable rotation gear backlash. Refer Note: When removing a hose assembly or fitting, to Repair Procedure, How to Adjust the the O-ring (if equipped) on the fitting and/or hose...
March 2018 Service and Repair Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Bac klas h Clean up any oil that may have spilled. How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing...
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Service and Repair Manual March 2018 Turntable Rotation Components Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation gear into the turntable bearing ring gear). Loosen the lock nut on the adjustment bolt. Turn the adjustment bolt clockwise until it contacts the backlash pivot plate.
March 2018 Service and Repair Manual Steer Axle Components 11-1 Remove the lug nuts. Remove the tire and wheel assembly. Yoke and Drive Hub Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin. How to Remove the Yoke and Remove the drive motor mounting fasteners.
Service and Repair Manual March 2018 Steer Axle Components 11-2 11-3 Drive Motors Drive Hub How to Remove a Drive Motor How to Remove a Drive Hub Note: When removing a hose assembly or fitting, Component damage hazard. the O-ring (if equipped) on the fitting and/or hose Repairs to the motor should only end must be replaced.
March 2018 Service and Repair Manual Steer Axle Components 11-4 Steer Cylinders How to Remove a Steer Cylinder There are two identical steer cylinders that work in parallel. They are part of the same hydraulic circuit, but move in opposite directions. The tie rod cylinder maintains equal movement of the tires.
Service and Repair Manual March 2018 Non-steer Axle Components 12-2 12-1 Drive Hub Drive Motors How to Remove a Drive Hub How to Remove a Drive Motor This procedure is the same as the steer axle This procedure is the same as the steer axle procedure.
March 2018 Service and Repair Manual Oscillating Axle Components 13-1 Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to Oscillating Axle Cylinders remove the pin. The oscillating axle cylinders extend and retract Attach a lifting strap from an overhead crane to between the drive chassis and the oscillating axle.
Service and Repair Manual March 2018 Oscillating Axle Components 13-2 Start the engine from the ground controls. Oscillate Directional Valve With the engine running, manually activate the valve and observe the pressure reading on the How to Adj ust the Oscill ate R elief Val ve pressure gauge.
March 2018 Service and Repair Manual Oscillating Axle Components How to Set U p the Direc tional Val ve Li nkage How to Set Up the Directional Verify that the ground and drive chassis are completely level. Valve Linkage Loosen the jamb nuts and adjust the length of Note: Perform this procedure on a firm, level the rod by turning the clevis yoke until the surface.
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Service and Repair Manual March 2018 This page intentionally left blank. S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.
Service and Repair Manual March 2018 Control System Fault Codes How to R etrieve Contr ol System F ault Codes Control System Determine the error source: The red LED indicates the error source and will flash two separate codes. The first code will indicate the How to Retrieve Control System first digit of the two digit code, flashing once per second.
March 2018 Service and Repair Manual Control System Fault Codes Control System F ault C odes Error Source Error Type Condition Solution Name Name Primary Up / Value at 5.0 V Limited Speed and Direction frozen at Power up controller with Down Joystick zero and neutral, Alarm sounds.
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Service and Repair Manual March 2018 Control System Fault Codes Error Source Error Type Condition Solution Name Name Secondary Up / Fault Limited Speed and Direction frozen at Power up controller with zero and neutral, Alarm sounds. problem corrected. Down. Directional Valves Secondary Up / Value Too High...
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March 2018 Service and Repair Manual Control System Fault Codes Error Source Error Type Condition Solution Name Name Drive Joystick Value at 5.0 V Limited Speed and Direction frozen at Power up controller with zero and neutral, Alarm sounds. problem corrected. Value Too High Value Too Low Value at 0 V...
Service and Repair Manual March 2018 Fault Code Display - Deutz and Perkins Models How to R etrieve Ac ti ve Engine F ault Codes D eutz D 2.9 L4 and Per ki ns 404F- 22 Models How to Retrieve Active Engine With an active fault and the engine running: (preferred method) Fault Codes - Deutz D 2.9 L4 and...
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March 2018 Service and Repair Manual Fault Code Display - Deutz and Perkins Models Faul t Code Dis play - Flashi ng and Solid LED's - D eutz D 2.9 L4 and Per ki ns 404F- 22 Models Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models 1 Left green LED: Flashing, engine fault detected.
Service and Repair Manual March 2018 Fault Code Display - Deutz and Perkins Models Soft Key F unc tions and Ic ons - Deutz D 2.9 L4 and Per ki ns 404F-22 M odels Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models Next menu •...
March 2018 Service and Repair Manual Fault Code Display - Deutz and Perkins Models Main M enu Str ucture - Deutz D 2.9 L4 Models Main Menu Structure - Deutz D 2.9 L4 Models Part No. 1287339GT S-80 • S-85 • S-80X...
Service and Repair Manual March 2018 Fault Code Display - Deutz and Perkins Models Main M enu Str ucture - Per kins 404F-22 M odels Main Menu Structure - Perkins 404F-22 Models S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1231 Actuator error EGR-Valve; Power FMI = Failure Mode Identifier stage over temp due to high KWP = Keyword Protocol current SPN FMI Description...
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Service and Repair Manual March 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
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March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
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Service and Repair Manual March 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
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March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature exhaust KWP = Keyword Protocol gas mass flow; plausibility error SPN FMI Description 2659 12...
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Service and Repair Manual March 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of KWP = Keyword Protocol CAN-Receive-Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of 4766...
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March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
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Service and Repair Manual March 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523788 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of 523717...
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March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value FMI KWP Description exceeded 523922...
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Service and Repair Manual March 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
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March 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame A1DOC KWP Description 524115 9 1660 Timeout error of 524102 9 1674 Timeout error of...
Service and Repair Manual March 2018 Perkins 404F-22 Engine Fault Codes Description SPN = Suspect Parameter Number Engine Speed Sensor #2: Voltage FMI = Failure Mode Identifier Above Normal Description Engine Speed Sensor #2: Voltage Accelerator Pedal Position 2: Voltage Below Normal Above Normal Engine Speed Sensor#2: Abnormal...
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March 2018 Service and Repair Manual Perkins 404F-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Description Below Normal 3251 Particulate Trap Differential Pressure: 4201 Engine Speed Sensor #1: Abnormal Voltage Above Normal Frequency, Pulse \Nidth, or Period 3251...
Service and Repair Manual March 2018 Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.
March 2018 Service and Repair Manual Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...
Service and Repair Manual March 2018 Engine Relay Layout - Perkins 404D-22T Perkins 404D-22T Circuit Breakers See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10 See Elec Schem for circuits CB8A See Elec Schem for circuits CB8B See Elec Schem for circuits Fuses...
Service and Repair Manual March 2018 Engine Relay Layout - GM 3.0L GM 3.0L Fuses CB8A See Elec Schem for circuits CB8B See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits CB10 See Elec Schem for circuits See Elec Schem for circuits...
March 2018 Service and Repair Manual S-80X Ground Control Box Wiring Diagram...
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Service and Repair Manual March 2018 S-80X Ground Control Box Wiring Diagram Use this wiring diagram with each S-80X Ground Control Box Schematic S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual Ground Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80X - Deutz TD 2.9 L4 M odels (AN SI / CSA) Ground Control Box, S-80X Deutz TD2.9 L4 Models (ANSI / CSA) Refer to S-80X Ground Control Box Wiring Diagram for additional wiring. S-80 •...
March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80X - D eutz TD 2.9 L4 Models (AN SI / C SA) Platform Control Box, S-80X Deutz TD2.9 L4 Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Platform Control Box, S-80X - Deutz TD2.9 L4 Models (ANSI / CSA)
March 2018 Service and Repair Manual Ground Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80X - Deutz TD 2011L04i Models (AN SI / C SA) Ground Control Box, S-80X Deutz TD2011L04i Models (ANSI / CSA) Refer to S-80X Ground Control Box Wiring Diagram for additional wiring. S-80 •...
March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80X - D eutz TD 2011L04i Models (AN SI / C SA) Platform Control Box, S-80X Deutz TD2011L04i Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Platform Control Box, S-80X - Deutz TD2011L04i Models (ANSI / CSA)
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March 2018 Service and Repair Manual Electrical Schematic, S-80X - Perkins 404TD-22 Models (ANSI / CSA)
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Service and Repair Manual March 2018 Elec trical Schematic, S- 80X - Per ki ns 404D- 22T Model s (AN SI / C SA) Electrical Schematic, S-80X Perkins 404TD-22 Models (ANSI / CSA) S-80 • S-85 • S-80X Part No. 1287339GT...
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March 2018 Service and Repair Manual Electrical Schematic, S-80X Perkins 404TD-22 Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Electrical Schematic, S-80X - Perkins 404TD-22 Models (ANSI / CSA)
March 2018 Service and Repair Manual Ground Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80X - Per kins 404D-22T M odels ( ANSI / CSA) Ground Control Box, S-80X Perkins 404TD-22 Models (ANSI / CSA) Refer to S-80X Ground Control Box Wiring Diagram for additional wiring. S-80 •...
March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80X - Per ki ns 404D-22T Models (AN SI / CSA) Platform Control Box, S-80X Perkins 404TD-22 Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Platform Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA)
March 2018 Service and Repair Manual Ground Control Box, S-80X - GM 3.0L Models (ANSI / CSA)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80X - GM 3.0L M odels ( ANSI / C SA) Ground Control Box, S-80X GM 3.0L Models (ANSI / CSA) Refer to S-80X Ground Control Box Wiring Diagram for additional wiring. S-80 •...
March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80X - GM 3.0L M odels ( ANSI / CSA) Platform Control Box, S-80X GM 3.0L Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Platform Control Box, S-80X - GM 3.0L Models (ANSI / CSA)
March 2018 Service and Repair Manual Electrical Schematic, S-80 • S-85 - Perkins 404TD-22 Models (ANSI / CSA)
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Service and Repair Manual March 2018 Elec trical Schematic, S- 80 • S- 85 - Per kins 404D-22T M odels ( ANSI / CSA) Electrical Schematic, S-80 • S-85 Perkins 404TD-22 Models (ANSI / CSA) S-80 • S-85 • S-80X Part No.
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March 2018 Service and Repair Manual Electrical Schematic, S-80 • S-85 Perkins 404TD-22 Models (ANSI / CSA) Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Electrical Schematic, S-80 • S-85 - Perkins 404TD-22 Models (ANSI / CSA)
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March 2018 Service and Repair Manual Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (ANSI / CSA)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80 • S-85 - Per kins 404D- 22T Models (AN SI / C SA) Ground Control Box, S-80 • S-85 Perkins 404TD-22 Models (ANSI / CSA) S-80 • S-85 • S-80X Part No.
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March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80 • S- 85 - Per kins 404D-22T M odels ( ANSI / C SA) Platform Control Box, S-80 • S-85 Perkins 404TD-22 Models (ANSI / CSA) Part No. 1287339GT S-80 •...
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Service and Repair Manual March 2018 Platform Control Box, S-80X - Perkins 404TD-22 Models (ANSI / CSA)
March 2018 Service and Repair Manual Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (CE)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80 • S-85 - Per kins 404T D-22 Models (CE) Ground Control Box, S-80 • S-85 Perkins 404TD-22 Models (CE) S-80 • S-85 • S-80X Part No. 1287339GT...
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March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80 • S- 85 - Per kins 404TD-22 M odels (C E) Platform Control Box, S-80 • S-85 Perkins 404TD-22 Models (CE) Part No. 1287339GT S-80 • S-85 • S-80X...
March 2018 Service and Repair Manual Ground Control Box, S-80 • S-85 - Perkins 404TD-22 Models (AS)
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Service and Repair Manual March 2018 Ground C ontrol Box, S-80 • S-85 - Per kins 404T D-22 Models (AS) Ground Control Box, S-80 • S-85 Perkins 404TD-22 Models (AS) S-80 • S-85 • S-80X Part No. 1287339GT...
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March 2018 Service and Repair Manual Platfor m C ontrol Box, S-80 • S- 85 - Per kins 404TD-22 M odels ( AS) Platform Control Box, S-80 • S-85 Perkins 404TD-22 Models (AS) Part No. 1287339GT S-80 • S-85 • S-80X...
March 2018 Service and Repair Manual Deutz and Per ki ns Options Sc hematic Deutz and Perkins Options Schematic Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Deutz and Perkins Options Schematic...
March 2018 Service and Repair Manual Platform Level Cutout, CTE Option...
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Service and Repair Manual March 2018 Platfor m Level Cutout, CTE Opti on Platform Level Cutout, CTE Option S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual 12 kW Hydraulic Generator Electrical Schematic...
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Service and Repair Manual March 2018 12 kW H ydraulic Gener ator El ectric al Schematic 12 kW Hydraulic Generator Electrical Schematic S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual Hydraulic Schematic, 2WD Models...
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Service and Repair Manual March 2018 Hydraulic Schematic, 2WD M odels Hydraulic Schematic, 2WD Models S-80 • S-85 • S-80X Part No. 1287339GT...
March 2018 Service and Repair Manual Hydraulic Schematic, 4WD M odels Hydraulic Schematic, 4WD Models Part No. 1287339GT S-80 • S-85 • S-80X...
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Service and Repair Manual March 2018 Hydraulic Schematic, 4WD Models S-80 • S-85 • S-80X Part No. 1287339GT Ser vic e and R epair M anual March 2018...