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Section 4 • Repair Procedures

Part No. 122985

S-80 • S-85 • S-80X

4 - 23

February 2012

BOOM COMPONENTS

14 Using auxiliary power, activate the boom down

function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.

Crushing hazard. The boom lift
cylinder could fall if not properly
supported and secured to the
lifting device.

15 Using the overhead crane, carefully lower the

boom lift cylinder and allow it to rest on the
boom rest pad. Protect the cylinder rod from
damage.

16 Remove the boom end cover retaining

fasteners and remove the cover.

17 Tag, disconnect and plug the boom extension

cylinder hydraulic hoses. Cap the fittings on the
cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

18 Tag and disconnect the electrical connector for

the cable break limit switch.

19 Tag and disconnect all boom wire harness

electrical connectors located at the pivot end of
the boom.

20 Support the platform leveling master cylinder.

Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.

21 Tag, disconnect and plug the hydraulic hoses

from the bulkhead fittings at the pivot end of the
boom. Cap the bulkhead fittings.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

22 Remove the external snap rings from both boom

pivot pins at the short and long link arms. Do
not remove the pins.

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Summary of Contents for S-80

Page 1: ......

Page 2: ... accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex...

Page 3: ...t 3 1 3 51 4 Repair 4 3 to 4 6 4 18 6 Schem REFERENCEEXAMPLES 2 1_Section 2_Specifications Page 3 3_Section3_MaintenanceProcedurePage 4 48_Section4_RepairProcedurePage Fault Codes_Section 5 6 5_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update Revision History ...

Page 4: ...re Schematic Page Description REFERENCEEXAMPLES 2 1_Section 2_Specifications Page 3 3_Section3_MaintenanceProcedurePage 4 48_Section4_RepairProcedurePage Fault Codes_Section 5 6 5_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update ...

Page 5: ... load including occupants 500 lb 227 kg Maximum allowable inclination of the chassis 0 deg Gradeability N A Maximum allowable side force 150 lb 670 N Maximum number of platfrm occupants 2 Model year Manufacture date 01 05 06 2006 Maximum wind speed 28 mph 12 5 m s Maximum platform height 80 ft 24 4 m Maximum platform reach 71 ft 6 in 21 8 m Sequence number stamped on chassis Serial label located u...

Page 6: ...February2012 S 80 S 85 S 80X PartNo 122985 This page intentionally left blank iv ...

Page 7: ...s manual are also safety hazards when maintenance andrepairproceduresareperformed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a s...

Page 8: ...Note Used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and lighted tobacco away from fla...

Page 9: ...s 2 1 PerformanceSpecifications 2 2 Hydraulic Oil Specifications 2 2 HydraulicComponentSpecifications 2 3 Valve Coil Resistance Specifications 2 4 Continental TME27 Engine Specifications 2 5 Deutz TD2011L04i Engine Specifications 2 6 Perkins 804D 33 Engine Specifications 2 7 Machine Torque Specifications 2 8 ManifoldComponentSpecifications 2 8 Hydraulic Hose and Fitting Torque Specifications 2 9 S...

Page 10: ...9 A 6 Check the High Pressure Hydraulic Filter Condition Indicator 3 10 A 7 Perform 30 Day Service 3 10 A 8 Perform Engine Maintenance Deutz and Continental Models 3 11 A 9 Inspect the Fuel Filter Water Separator Diesel Models 3 11 A 10 Grease the Turntable Rotation Bearing and Rotate Gear 3 13 A 11 PerformEngineMaintenance 3 14 A 12 Replace the Drive Hub Oil 3 15 A 13 Perform Engine Maintenance P...

Page 11: ...Select Operation Gasoline LPG Models 3 31 B 17 Test the Drive Enable System 3 32 B 18 Test the Drive Brakes 3 33 B 19 Test the Drive Speed Stowed Position 3 33 B 20 Test the Drive Speed Raised or Extended Position 3 34 B 21 Test the Alarm Package if equipped and the Descent Alarm 3 35 B 22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 36 B 23 Perform Hydraulic Oil Analysis 3 37 B 24 In...

Page 12: ... Filter Elements 3 53 D 7 Replace the Drive Hub Oil 3 54 D 8 Perform Engine Maintenance Deutz Models 3 56 A ChecklistEProcedures E 1 Test or Replace the Hydraulic Oil 3 57 E 2 Perform Engine Maintenance Perkins Models 3 59 E 3 Perform Engine Maintenance Deutz and Perkins Models 3 59 E 4 Remove and Replace the Boom Extend Retract Cables 3 60 Section 4 Rev RepairProcedures Introduction 4 1 PlatformC...

Page 13: ... S 85 3 1 Jib Boom 4 16 3 3 Jib Boom Lift Cylinder 4 17 BoomComponents 4 1 CableTrack 4 18 4 2 Boom 4 21 4 3 Boom Lift Cylinder 4 24 4 4 Boom Extension Cylinders 4 25 4 5 Boom Extend Retract Cables 4 28 4 6 Platform Leveling Master Cylinder 4 32 Engines 5 1 RPM Adjustment 4 33 5 2 Flex Plate 4 33 GroundControls 6 1 ControlRelays 4 38 HydraulicPumps 7 1 Function Pump 4 39 7 2 Drive Pump 4 40 xi ...

Page 14: ... Manifold Components S 85 4 50 8 8 2WDTractionManifoldComponents 4 51 8 9 4WDTractionManifoldComponents beforeserialnumber8581 4 53 8 10 4WD Traction Manifold Components after serial number 8580 4 55 8 11 Drive Oil Diverter Manifold Components welder option 4 57 8 12 Valve Adjustments Traction Manifold 4 58 8 13 Valve Coils 4 59 Fuel and Hydraulic Tanks 9 1 Fuel Tank 4 61 9 2 HydraulicTank 4 62 Tu...

Page 15: ...riveMotor 4 72 13 2 DriveHub 4 72 OscillatingAxleComponents 14 1 Oscillate Axle Cylinders 4 73 14 2 Oscillate Directional Valve 4 74 Section 5 Rev FaultCodes Introduction 5 1 Fault Codes Control System 5 2 Engine Fault Codes Continental Models 5 7 Section 6 Rev Schematics Introduction 6 1 Electrical Symbols Legend 6 2 HydraulicSymbolsLegend 6 3 Connector Pin Legend View 1 6 6 Connector Pin Legend ...

Page 16: ...rialnumber8111 6 22 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE DeutzTD2011L04iModels beforeserialnumber8111 6 26 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE DeutzTD2011L04iModels beforeserialnumber8111 6 27 Platform Control Box Wiring Diagram S 80 and S 85 CE DeutzTD2011L04iModels beforeserialnumber8111 6 30 Platform Control Box Switch Panel Wiring Diagra...

Page 17: ...form Control Box Wiring Diagram S 80X DeutzTD2011L04iModels 6 54 Platform Control Box Switch Panel Wiring Diagram S 80X DeutzTD2011L04iModels 6 55 Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins804D 33Models 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 Perk...

Page 18: ...nd Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 86 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 87 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 90 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85...

Page 19: ...8111 6 118 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 122 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 123 Platform Control Box Wiring Diagram S 80 and S 85 CE Continental TME27 Models before serial number 8111 6 126 Platform Control Box Switch Panel W...

Page 20: ...el Wiring Diagram S 80X ContinentalTME27Models 6 147 Platform Control Box Wiring Diagram S 80X ContinentalTME27Models 6 150 Platform Control Box Switch Panel Wiring Diagram S 80X ContinentalTME27Models 6 151 ContinentalTME27EngineHarness 6 154 Platform Level Cutout CTE Option 6 155 Continental Options Schematic 6 158 Deutz and Perkins Options Schematic 6 159 12 kW Hydraulic Generator Wiring Diagra...

Page 21: ...dry 420 ft lbs 569 Nm Lug nut torque lubricated 320 ft lbs 434 Nm For operational specifications refer to the Operator sManual Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Fluid capacities Fuel tank 35 gallons Deutz and Perkins models 132 5 liters Continental models 30 gallons 113 5 liters LPG tank 33 5 pounds 15 2 kg Hydrauli...

Page 22: ...Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Performance Specifications Drive speed maximum Stowed position 40 ft 7 9 8 5 sec RT Tires 12 2 m 7 9 8 5 sec Stowed position 40 ft 11 13 sec Flotation Tires 12 2 m 11 13 sec Raised or extended position 40 ft 40 45 s...

Page 23: ...w rate 2300 rpm 0 to 23 gpm 0 to 87 L min Auxiliary pump Type fixed displacement gear pump Displacement static 0 151 cu in 2 47 cc Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in componentdamage Note Use Chevr...

Page 24: ...ems SJ 2 position 3 way solenoid valve 9 schematic items SK 3 position 4 way solenoid valve 7 2 schematic items SI and SL Solenoid valve NO Poppet 5 6 schematic items SP and SQ Functionmanifold System relief pressure 3200 psi measured at PTEST port 221 bar Boom down relief pressure 2400 psi measured at PTEST port 165 bar Boom extend relief pressure 2400 psi measured at PTEST port 165 bar Steer axl...

Page 25: ... in 0 46 mm Lubrication system Oil pressure 40 60 psi 2 8 4 1 bar Oil capacity 7 quarts including filter 6 65 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures my require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Fuel Requirement For fuel requirements refer to the engine Operator s Manual on y...

Page 26: ...te 200 minutes Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Deutz TD2011L04i Engine Displacement 189 6 cu in 3 1 liters Number of cylinders 4 Bore and stroke 3 7 x 4 409 inches 94 x 112 mm Horsepower Continuous 69 1 2500 rpm Net intermittent 72 8 2500 rpm Continuous 51 5 KW 2500 rpm Net intermittent 54 3 KW 2500 rpm Firing order 1 3 4 2 Lowidle 1300 rpm Frequency 331...

Page 27: ... x 4 72 inches 94 x 120 mm Horsepower 63 2600 rpm 47 KW 2600 rpm Firing order 1 3 4 2 Compression ratio 22 1 Compression pressure 300 to 500 psi 20 7 to 34 5 bar Pressure psi or bar of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Lowidle 1650 rpm Frequency 335 5 Hz Highidle 2300 rpm Frequency 467 7 Hz Governor mechanical all speed Valve clearance cold Intake 0 0098 in 0 25 mm...

Page 28: ...Drive motor and hubs Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs use blue thread locking compound 217 Nm Drive motor mounting bolts dry 110 ft lbs 149 Nm Drive motor mounting bolts lubricated 80 ft lbs use blue thread locking compound 108 Nm Drive hub oil plug O ring seal 13 ft lbs 18 Nm Continuous improvement of our products is a Genie policy Prod...

Page 29: ...Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number49612 ...

Page 30: ...AD in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm 20 80 9 100 11 3 110 12 4 140 15 8 130 14 7 28 90 10 1 120 13 5 120 13 5 160 18 140 15 8 ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm 18 13 17 6 17 23 18 24 25 33 9 21 28 4 24 14 19 19 25 7 20 27 1 27 36 6 24 32 5 16 23 31 2 31 42 33 44 7 44 59 6 38 51 5 24 26 35 2 35 47 4 37 50 1 49 66 4 43 58 3 14 37 50 1 49 66 4 50 67 8 70 94 7 61 82 7 2...

Page 31: ... between the non steer yellow arrow wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step in...

Page 32: ...use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year To account for repeated procedures the Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the...

Page 33: ...a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre deliveryPreparation The P...

Page 34: ...3 4 S 80 S 85 S80X PartNo 122985 Section 3 Scheduled Maintenance Procedures February2012 This page intentionally left blank ...

Page 35: ...B 2 Electrical wiring B 3 Key switch B 4 Exhaust system B 5 Engine air filter B 6 Oil cooler and fins Deutz models B 7 Brake configuration B 8 Tires wheels and lug nut torque B 9 Drive hub maintenance B 10 Engine RPM B 11 Engine maintenance B 12 Oscillate directional Control B 13 Ground control override B 14 Platform self leveling B 15 Engine idle select B 16 Fuel select operation B 17 Drive enabl...

Page 36: ...nance Deutz and Perkins models Perform every 7 years E 4 Replace the Boom Extend Retract Cables Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hour Inspection A B C D 2 Year or 2000 ...

Page 37: ...afe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate f...

Page 38: ...r every 8 hours whichever comes first Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are available in the DeutzTD2011OperationManual Deutz part number ...

Page 39: ...peration If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over Tip over hazard Failure to perform this procedure on a firm level surface will compromise the stability of the machine and could result in the machine tipping over 1 Start the engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block o...

Page 40: ...o high rpm rabbit symbol 4 Visually inspect the filter condition indicator Result The filter condition indicator should be operating with the plunger in the green area Result If the indicator displays the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See D 6 Replace the Hydraulic Filters A 7 Perform 30 Day Service The 30 day ma...

Page 41: ...t from moving Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury A 9 Inspect the Fuel Filter Water Separator Diesel Models Note Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator...

Page 42: ...he fuel filter water separator 7 Clean up any fuel that may have spilled 8 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel leak is discovered keep any additionalpersonnelfromentering the area and do not operate the machine Repair the leak immediately DeutzModels 1 Put on protective clothing and eye wear...

Page 43: ...osition and install the engine pivot plate retaining fastener A 10 Grease the Turntable Rotation Bearing and Rotate Gear 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 servic...

Page 44: ...ilable in the DeutzTD2011OperationManual Deutz part number 0312 3547 OR the Perkins804D 33OperationandMaintenance Manual PerkinspartnumberSEBU7853 00 OR the ContinentalTME27Owner sManual ContinentalpartnumberWM10303 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 1119...

Page 45: ...g plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Install the plugs 5 Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications 6 Repeat steps 1 through 4 for the other drive hub 7 Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications Turntable rotate drive hub Note W...

Page 46: ...table container Single fill port rotator a motor b fill port c drive hub mounting bolts d drive hub Dual fill port rotator a motor b drive hub c drive hub mounting bolts d fill ports 6 Install the drive hub assembly onto the machine Torque the drive hub mounting bolts to specification Refer to Section 2 Specifications 7 Fill the drive hub with oil Refer to Section 2 Specifications Apply pipe threa...

Page 47: ...oorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are available in the Perkins804D 33OperationandMaintenance Manual PerkinspartnumberSEBU7853 00 Perkins 804D 33 Operation and Maintenance Manual Genie part number To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the ma...

Page 48: ...wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight 4 Be sure that the battery separator wire connections are tight if equipped 5 Fully charge the battery s and allow the batt...

Page 49: ...istilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled a b B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation an...

Page 50: ... dielectric grease in the following locations All wire harness connectors to ground control box 9 Start the engine from the ground controls and raise the boom above the turntable covers 10 Inspect the turntable area for burnt chafed and pinched cables 11 Lower the boom to the stowed position and turn the engine off 12 Inspect the following areas for burnt chafed corroded pinched and loose wires Ca...

Page 51: ... to ground control 5 Check all machine function from the platform controls Result All machine functions should not operate 6 Turn the key switch to the off position Result The engine should stop and no functions shouldoperate B 4 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system i...

Page 52: ...rocedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poorengineperformanceandcomponentdamage Note Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner c...

Page 53: ... Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 3 Remove the fasteners from the engine side cover then remove the...

Page 54: ...arterly whichever comes first Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Bodily injury hazard An over inflated tire can explode and could resul...

Page 55: ... 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Install the plugs into the drive hub Torque to Specification Refer to Section 2 Specifications 5 Check the torque of the drive hub mounting fasteners Refer to Section 2 Specif...

Page 56: ... turntable rotate drive hub mounting fasteners Refer to Section 2 Specifications A B a c b d B 10 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Continentalmodels Note The eng...

Page 57: ...etracts when activating high idle Perkinsmodels 1 Connect a tachometer to the engine Start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confi...

Page 58: ...r 111332 Continental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury B 12 ...

Page 59: ...m the ground controls 3 At the ground controls operate each boom function through a partial cycle Result All boom functions should operate B 14 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe m...

Page 60: ...g activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Start the engine from the ground controls 4 Move and hold the function button in and move the idle switch to the high idle rabbit symbol position Result The engine rpm should change to high idl...

Page 61: ...nd warming the engine to normaloperatingtemperature 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and...

Page 62: ...the stowed position 1 Start the engine from the platform controls 2 Press down the foot switch 3 Rotate the turntable until the boom moves past one of the the non steer wheels Result The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown 4 Slowly move the drive control handle off center Result The drive function should not operate 5 Rotate the t...

Page 63: ...stance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 19 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operati...

Page 64: ... a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Performance...

Page 65: ...e on position at both the ground and platform controls Result Both flashing beacons should be on and flashing 2 Move and hold the function enable button to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down 3 Turn the key switch to platform controls Result The flashing ...

Page 66: ...ocedure with the engine off Note This procedure applies to diesel equipped machines only 1 Remove the cap from the fuel tank 2 Check for proper venting Result Air passes through the fuel tank cap Procced to step 4 Result If air does not pass through the cap clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild s...

Page 67: ...uarterly Replace the oil when it fails the test B 24 Inspect the Boom Extend Retract Cables Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or improper adjustment of the boom extend retra...

Page 68: ...hly inspect the above items Note A pulley groove gauge should be used to check the condition of the pulleys 6 Install the cover at the pivot end of the boom 7 Install the access panels on the sides of the boom 8 Start the engine from the ground controls and fully retract and lower the boom to the stowed position 9 Turn the key switch to the platform controls 10 Extend the boom approximately 2 feet...

Page 69: ...inental TME27 Owner s Manual Genie part number 111901 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out away from the machine and secure it from moving Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury C 2 Grease the Pla...

Page 70: ...r lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure 2 4 How to Calibrate the Platform Overload System if equipped Illustration 1 5 Carefully move the test weight to each remaining location Refer to Illustration 1 ...

Page 71: ...ivate the auxiliary power toggle switch 12 Using auxiliary power test all machine functions from the ground controls Result All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound 14 Start the ...

Page 72: ...flashing at both the ground and platform controls 27 Working from outside the platform and standing next to the platform rotator locate the orange wire which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire Tag and disconnect the connectors Refer to Illustration 2 28 Using a multimeter set to read resistance ohms secure...

Page 73: ...and secure Note Be sure the discharge slot is pointing down C 5 Replace the Fuel Filter Water Separator Element Diesel Models Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Regular replacement of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor enginepe...

Page 74: ...e the fuel filter water separator 7 Clean up any fuel that may have spilled 8 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel leak is discovered keep any additionalpersonnelfromentering the area and do not operate the machine Repair the leak immediately DeutzModels 1 Put on protective clothing and eye w...

Page 75: ...inal position and install the engine pivot plate retaining fastener C 6 Check the Safety Envelope Limit Switches and Angle Sensor S 80X Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the safety envelope system regularly is essential to safe machine operation Continued use of an improperly operating safety envelope coul...

Page 76: ...t switches LST3O and LST3S 6 Turn the key switch to the off position and push in the red Emergency Stop button Note The follwing step can be done using a measuring tape or a digital protractor Genie part number58377 7 MeasuringTape Measure the distance between the center of the pivot pins as shown 201 75 inches 512 cm 2 0 inch 5 cm DigitalProtractor Place the digital protractor on the turntable ch...

Page 77: ...latform capacity light will flash Result The primary boom does not stop after 10 degrees Calibrate the boom angle sensor Refer to Repair Procedure 1 2 How to Calibrate the Boom angle Sensor CHECKLIST C PROCEDURES 500 lbs 227 kg 1000 lbs 454 kg a b 6 Move the primary boom down joystick off center and retract the primary boom until the unrestricted platform capacity light stops flashing Result Prima...

Page 78: ...f the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad if it is less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag a boom 1 b boom 2 c boom 3 b c a 4 Extend and retract the boom through the entire range of motion to check for tight spots that may...

Page 79: ...lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis betweenthenon steerwheels 3 Lift the wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steerwheelhub 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage ...

Page 80: ...e pump b screwdriver c lift pump d free wheel valve D 3 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintainingpropertorqueontheturntablebearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operatingconditionandcomponentdamage 1 Start the en...

Page 81: ... Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform thi...

Page 82: ...t to zero the indicator 6 Fully extend the boom and lower to a horizontal position 7 Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced 8 Fully retract the boom and raise the boom to full height Visually inspect the the dial indicator to b...

Page 83: ...to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury D 6 Replace the Hydraulic Filters Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine ...

Page 84: ...em securely 16 Clean up any oil that may have spilled during the installationprocedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 18 Start the engine from the ground controls 19 Inspect the filter housings and related components to be sure that there are no leaks D 7 Replace the Drive Hub Oil Genie specifications require that ...

Page 85: ...with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotate drive motor Cap the fittings on the drive motor 3 Attach a suitable lifting device to the lifting eyes located near the drive motor 4 Remove the drive hub mounting bolts Carefully remove the turntable rotate drive hub...

Page 86: ... Engine specifications require that this procedure be performed every 1500 hours of operation Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are availa...

Page 87: ... specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank Refer to Repair Procedure 9 1 How to Remove the Fuel Tank open closed Checklist E Procedures 2 Models without hydraulic tank shutoff valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specification...

Page 88: ...hread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 17 Clean up any oil that may have spilled 18 Open the hy...

Page 89: ...tray anchor hole to secure the engine tray from moving could result in death or serious injury E 3 Perform Engine Maintenance Deutz and Perkins Models Engine specifications require that this procedure be performedevery3000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance p...

Page 90: ... boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Replacement of the boom extend retract cables is essential to good machine performance and safe machine operation The boom extend retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Replace the boom extend retract cables See Repair Procedure 4 5 How to ...

Page 91: ...property damage Note Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a da...

Page 92: ... Note When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated See 1 2 How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Push in the Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted ...

Page 93: ...rm should sound indicating successful joystick calibration Result The alarm does not sound Check the electrical connections or replace the joystick 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine fuction should operate while performing the joystick calibration procedure How to Adjust the Joystick Max out Setting The max ...

Page 94: ... Each time the drive enable toggle switch is momentarily moved the function speed will change in 2 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Result The ...

Page 95: ...the joystick is activated set the ramp rate Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time Note Each time the drive enable toggle switch is momentarily moved the time will change in 5 increments 13 Repeat steps 9 through 11 for each joystick controlled machine ...

Page 96: ...hould be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold 10 Slowly move the joystick off center in either direction just until the function begins to move ...

Page 97: ...2 times indicating that the machine is in Angle Sensor calibration mode 6 Start the engine from the platform controls and press down the foot switch 7 Momentarily activate the drive enable toggle switch to the right 1 time to set the stowed position Note The alarm will not sound indicating the setting 8 Raise the primary boom to the fully elevated position Note Manually reduce the boom speed as it...

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Page 99: ...itch Remove the cable from the back of the platform Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the platform control box mounting fasteners Lower the control box and set it aside Component damage hazard Cables can be damaged if they are kinked or pinched Note If your machine is equi...

Page 100: ...ocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to drive the rod end pivot pin out Crushing hazard The jib boom could fall when the slave cylinde...

Page 101: ...ue Specifications 1 Remove the platform See 2 1 How to Remove the Platform PLATFORM COMPONENTS 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or ...

Page 102: ... Lower the jib boom leveling arms Crushing hazard The platform rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications Refer to Section 2 Specifications How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move...

Page 103: ...ed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks 2 4 Platform Overload System How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine operation Con...

Page 104: ...overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds PLATFORM COMPONENTS 7 Move the platform up and down by ha...

Page 105: ...platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Te...

Page 106: ...b boom pivot pin Lay all hoses and cables to the side Component damage hazard Hoses and cables can become damaged if they are kinked or pinched 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gr...

Page 107: ...on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin ...

Page 108: ...r of the connectors to those on the control box to be sure they are installed in the correct location 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side Boom Components 6 S 80 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the ma...

Page 109: ...om Note Always replace the cotter pin with a new one 16 Remove the cable track guide fasteners from the cable track guides at the platform end of the boom Remove the cable track guides from the boom 17 Remove the cable clamp from the pivot end of the boom 18 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower c...

Page 110: ...ers from the 4 link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link secti...

Page 111: ...weight before removing the boom assembly will result in the machine tipping over Do not remove the boom without first removing the counterweight TIp over hazard When installing the boom onto the machine the boom assembly must be first installed prior to the installation of the counterweight If the counterweight is installed before the boom assembly the machine will tip over resulting in death or s...

Page 112: ...ps or chains to a 5 ton 5000 kg overhead crane Note A spreader bar and other hardware may be needed to safely remove the counterweight 9 Slowly operate the overhead crane to apply tension to the lifting straps Do not attempt to lift the machine with the overhead crane 10 Locate and remove the counterweight retaining fastener at the center of the counterweight Carefully lift the counterweight upwar...

Page 113: ...il can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 18 Tag and disconnect the electrical connector for the cable break limit switch 19 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom 20 Support the platform leveling master cylinder Remove the ...

Page 114: ...ily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All...

Page 115: ...vot pin bores will clear the boom linkage 10 Carefully remove the boom lift cylinder from the machine Crushing hazard The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 4 4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the...

Page 116: ... remove the cable guard 7 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube 8 Remove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the way 9 Remove the fasteners from the retaining blocks from the extension cylinder saddle Remove the blocks Note Access the fasteners through the access hole i...

Page 117: ...e lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 16 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 17 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder 18 Remove the exter...

Page 118: ... cylinder the overhead crane strap will need to be carefully adjusted for proper balancing 4 5 Boom Extend Retract Cables How to Adjust the Boom Extend Retract Cables The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Proper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine perf...

Page 119: ...ustment nuts have been replaced Do not re use the existing nuts 10 Extend the boom until there is approximately 3 feet 1 m of travel left Do not fully extend the boom 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom 12 Using a dial type torque wrench torque the retract cable adjustment nut to 32 36 ft lbs 43 49 Nm using gentle and s...

Page 120: ... cylinder See Section 4 4 How to Remove the Boom Extension Cylinder Boom extend cables 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft metal dr...

Page 121: ... old boom retract cable 14 Securely attach the rope to the same end of the new boom retract cable 15 At the pivot end of the boom carefully pull the rope with the new retract cable attached 16 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube Remove the rope 17 Repeat steps 14 through 19 for the other boom retract cable 18 At the platfor...

Page 122: ...aster cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fastener from the master cylinder barrel end pivot pin 5 Place a ...

Page 123: ...Adjust the Engine RPM Engines 5 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump Type B flex plates combines the pump coupler as part of the flex plate which is installed onto the engine flywheel Type B flexplate with coupler combined ...

Page 124: ...d disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump a b Deutzmodel 5 Tag and disconnect the wiring from the bell housing 6 Remove the U bolt from the exhaust flex pipe at the muffler Burn hazard Hot engine parts can cause severe burns 7 Remove the muffler bracket retaining fasteners from bell housing Remove the muffler and bracket assembly from the ...

Page 125: ...eat shield fasteners from the top of the muffler Burn Hazard Hot engine parts can cause severe burns 19 Remove the muffler retainer bracket fasteners 20 Remove the muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket 21 Remove the relay housing from the muffler mount Do not disconnect the relays 22 Disconnect and remove the ECM from the muffler mount 2...

Page 126: ...e pump mounting plate Apply Loctite removable thread sealant to the pump retaining fasteners Torque the pump retaining fasteners to 57 ft lbs 77 Nm Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged 5 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end ...

Page 127: ...37 February2012 ENGINES 1 2 3 4 5 6 Perkins Deutz and Continental Flex Plate 10 6 1 8 4 11 7 5 9 2 12 3 10 6 1 8 4 11 7 5 9 2 12 3 Deutz BF4L 2011 Pump Mounting Plate Perkins 804C 33 Pump Mounting Plate 1 8 6 10 11 12 3 5 9 2 7 4 Continental Pump Mounting Plate ...

Page 128: ...m an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 75 to 85 terminal 87 to 87a and 30 no continuity infinite terminal 87a to 30 continuity zero 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test th...

Page 129: ...ump after installing the pump See 7 2 How to Prime the Pump Hydraulic Pumps 7 1 Function Pump How to Remove the Function Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Close the two ...

Page 130: ...e performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifi...

Page 131: ...ponent damage hazard Be sure that the hydraulic tank shutoff valves if equipped are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur 1 Connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump 2 Continental models If equipped close the valve on ...

Page 132: ...ion 4 way SL Steering directional 20 25 ft lbs 27 34 Nm 9 Proportional valve SE Swing proportional 20 25 ft lbs 27 34 Nm 10 Solenoid valve 3 position 4 way SI Swing directional 26 30 ft lbs 35 41 Nm 11 Flow regulator valve SD Oscillate flow control 20 25 ft lbs 27 34 Nm 12 Relief valve 2400 psi 165 bar SN Boom down relief 20 25 ft lbs 27 34 Nm 13 Relief valve 2400 psi 165 bar SO Boom extend relief...

Page 133: ...Section 4 Repair Procedures PartNo 122985 S 80 S 85 S 80X 4 43 February2012 MANIFOLDS SK SP SQ SR SS SF SL SE SI SD SO ST SM SG SC SB SA SH SJ SN 1 14 1 2 3 4 8 9 10 11 13 12 16 17 18 19 20 15 7 6 5 ...

Page 134: ...ise to reduce the pressure Install the relief valve cap Componentdamagehazard Do not adjust the relief valve higher than specified 5 Repeat step 2 to confirm relief valve pressure 6 Remove the pressure gauge How to Adjust the Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the diagnostic nipple located...

Page 135: ... high idle position and activate and hold the boom extend toggle switch with the boom fully extended Observe the pressure reading on the pressure gauge Refer to Section 2 Hydraulic Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item SO on the function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockw...

Page 136: ...de the drive chassis Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way BA Brake release 20 25 ft lbs 27 34 Nm 2 Solenoid valve 2 position 3 way BC Two speed motor shift 20 25 ft lbs 27 34 Nm 3 Check valve BB Brake release circuit 20 25 ft lbs 27 34 Nm 4 Orifice 0 025 inch 0 63 mm BD Turntable rotation brake release BD BA BC BB 3 4 1 2 ...

Page 137: ...ontrol side of the machine Index Schematic No Description Item Function Torque 1 Counterbalance valve 1000 psi RA Turntable rotate left 25 30 ft lbs 34 41 Nm 2 Counterbalance valve 1000 psi RB Turntable rotate right 25 30 ft lbs 34 41 Nm 3 Shuttle valve 2 position 3 way RD Turntable rotation brake release 8 10 ft lbs 10 15 Nm 4 Orifice 0 030 inch 0 8 mm RC Brake release circuit MANIFOLDS 1 2 RA RD...

Page 138: ...d Components The platform rotate manifold is mounted on the platform rotator Index Schematic No Description Item Function Torque 1 Counterbalance valve 3300 psi PA Platform rotate right 37 44 ft lbs 50 60 Nm 2 Counterbalance valve 3300 psi PB Platform rotate left 37 44 ft lbs 50 60 Nm 2 1 PB PA MANIFOLDS ...

Page 139: ...osition 4 way EF Platform rotate CW CCW 30 35 ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 4 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Needle valve EA Platform level 20 25 ft lbs 27 34 Nm 6 Pressure comp flow control valve EE P...

Page 140: ... ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Solenoid valve 3 position 4 way EH Jib Up Down 30 35 ft lbs 41 47 Nm 4 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 6 Needle valve EA Platform level 20 25 ft lbs 27 34 Nm 7 Pressure co...

Page 141: ... 3 bar DE Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow Divider Combiner Valve DB Controls flow to drive motors in forward and reverse 90 100 ft lbs 120 133 Nm 3 Check Valve DC Drive circuit 30 35 ft lbs 41 47 Nm 4 Check Valve DD Drive circuit 30 35 ft lbs 41 47 Nm 5 Shuttle Valve 3 position 3 way DF Controls flow to drive motors in forward and reverse 50 55 ft lbs 67 73 Nm 6 Orifice Plug 0...

Page 142: ...Section 4 Repair Procedures 4 52 S 80 S 85 S 80X PartNo 122985 February2012 MANIFOLDS DE DB DC DD DF DA 6 2 5 3 4 1 ...

Page 143: ...mbiner valves 2 and 13 80 90 ft lbs 108 122 Nm 6 Check valve DD Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm DL Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm DA Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm DN Equalizes pressure on both sides of flow divider combiner val...

Page 144: ...Section 4 Repair Procedures 4 54 S 80 S 85 S 80X PartNo 122985 February2012 MANIFOLDS DE DB DF DC DK DD DL DA DN DG DH DJ DM DP 9 8 7 10 11 13 6 5 3 2 4 1 14 12 ...

Page 145: ...er combiner valves 2 and 13 80 90 ft lbs 108 122 Nm 6 Check valve DD Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm DL Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm DA Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm DN Equalizes pressure on both sides of flow divider combine...

Page 146: ...Section 4 Repair Procedures 4 56 S 80 S 85 S 80X PartNo 122985 February2012 MANIFOLDS DE DB DF DC DD DK DL DA DN DG DH DJ DM DP 9 8 7 10 11 13 6 5 3 2 4 1 14 12 ...

Page 147: ...ion Item Function Torque 1 Directional Valve CU Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice disc 0 031 inch 0 8 mm CV Delays shift to drive 3 Solenoid valve CW Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve CX Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Pressure switch CZ Power to relay 16 ft lbs 22 Nm 6 Connector For pressure switch 11 ft lbs 15 Nm 7 Check valve CY Prevents...

Page 148: ...ressure gauge to the diagnostic nipple on the drive pump 2 Start the engine from the platform controls and allow the engine to run at low idle Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple located on the traction manifold 4 Start the engine from the platform controls and drive the machine slowly ...

Page 149: ...ritical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate ...

Page 150: ... the coil Note The battery should read 9V DC or more when measured across the terminals 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA a multimeter b 9V DC battery c 10 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 Connect the negative lead to the other termi...

Page 151: ...nk 3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to capacity specifications Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel 4 Tag disconnect drain and plug the supply and return fuel hoses Cap t...

Page 152: ...ring installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See 9 1 How to Remove the Fuel Tank 2 Close the two hydraulic tank valves located at the hydraulic tank if equipped Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur If the tank valves are clos...

Page 153: ...solvent 11 Rinse out the inside of the tank using a mild solvent 12 Install the suction strainers using pipe thread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until the level is within the...

Page 154: ...ction 2 Machine Torque Specifications 8 Adjust turntable rotation gear backlash See 10 1 How to Adjust the Turntable Rotation Gear Backlash 10 1 Turntable Rotation Drive Hub Assembly How to Remove the Turntable Rotation Drive Hub Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to speci...

Page 155: ...the hydraulic hoses from the drive motor Cap the fittings on the motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the hydraulic tube that connects from the counterbalance manifold to the brake Cap the fittings on the brake and manifold ...

Page 156: ... a backlash pivot plate b adjustment bolt with lock nut c backlash pivot plate mounting bolts 3 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 4 Loosen the lock nut on the adjustment bolt 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 6 Turn the adjustment bolt one half tu...

Page 157: ...yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out 9 Remove the yoke and hub assembly from the machine Crushing hazard The yoke and hub assembly may become unbalanced and fall if not properly supported and secured to the lifting jack when it is removed from the machine How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block t...

Page 158: ...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 11 2 Steer Cylinder 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...

Page 159: ...he yoke Remove the yoke from the drive hub Refer to Section 2 Specifications Note Replace the thrust washer when installing the yoke and drive hub assembly onto the axle 4WD Steer Axle Components 12 1 Yoke and Drive Hub How to Remove the Yoke and Drive Hub Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connectio...

Page 160: ...he fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the axles 2 Remove the drive motor access covers from both sides of the inner axle 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard...

Page 161: ...ivot pins Remove the pivot pin from each end of the steer cylinder 4 Remove the steer cylinder from the machine 12 3 Drive Hub How to Remove a Drive Hub Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Spec...

Page 162: ...r Axle Components 13 1 Drive Motor How to Remove a Drive Motor This procedure is the same as the steer axle procedure See 12 2 How to Remove a Drive Motor 13 2 Drive Hub How to Remove a Drive Hub This procedure is the same as the steer axle procedure See 12 3 How to Remove a Drive Hub ...

Page 163: ...rque Specifications 1 Rotate the turntable until the boom is between the steer tires 2 Remove the fasteners from the drive chassis cover at the steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow th...

Page 164: ...nning manually activate the valve and observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 6 Turn the engine off 7 Locate the relief valve on the function manifold item SC 8 Loosen the jam nut on the relief valve 9 Turn the valve clockwise to increase the pressure or counterclockwise to decrease the pressure Tip over hazard Do not adjust the relief valve higher than...

Page 165: ...pe level on the turntable rotate bearing plate at the non steer end Confirm whether the drive chassis is completely level 7 If the drive chassis is not level start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Loosen the jamb nuts and adjust the length of the rod by turning t...

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Page 167: ...hes and other jewelry Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Two persons will be required to safely perform some troubleshooting procedures Fault Codes Observe and Obey Troubleshootingandrepairproceduresshallbe completed by a person tra...

Page 168: ...printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap 3 Determine the error source The red LED indidates the error source and will flash two separate codes The first code will indicate the first digit of the two digit cod...

Page 169: ...onal Alarmsounds problem has been Valves indicating a fault correted 23 Primary 12 Value too high Valve is operating Cycle power off Up Down 15 Value too low outside of limits then on after Flow Valve Alarmsounds problem has been indicating a fault corrected 17 Notcalibrated Normalfunction Calibratevalve exceptthreshold threshold for one or both directions is zero 24 Anglesensor 11 Value at 5V Red...

Page 170: ...l Alarmsounds problem has been Valves indicating a fault correted 33 Primary 12 Value too high Valve is operating Cycle power off Ext Ret 15 Value too low outside of limits then on after Flow Alarmsounds problem has been Valve indicating a fault corrected 17 Notcalibrated Normalfunction Calibratevalve exceptthreshold threshold for one or both directions is zero 34 Ext Ret 31 Invalid setup Limit Sw...

Page 171: ...Flow Valve Frozen at zero problem has been and neutral correted Alarmsounds indicating a fault 17 Notcalibrated Normalfunction Calibratevalve exceptthreshold threshold for one or both directions is zero 44 DriveEnable 21 Fault Driveenable Cycle power off Override overridedirection then on after Switch is frozen at problem has been neutral corrected 51 DriveJoystick 11 Value at 5V Limited speed Cyl...

Page 172: ...at zero and then on after neutral problem has been Alarmsounds correted indicating a fault 55 High Drive 21 Fault Motorspeed Cycle power off MotorSpeed in the low state then on after Valve Alarmsounds problem has been indicating a fault corrected 61 SteerJoystick 11 Value at 5V Limited speed Cylcle power off 12 Value too high and direction then on after 15 Value too low Frozen at zero problem has ...

Page 173: ...eck engine light should begin to blink 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1654 three times After the fault codes the check engine light will blink a code 1654 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will...

Page 174: ...210 F and RPM 1000 BP 2229 BP Pressure High Y Y BP pressure 16 psi 129 BP Pressure Low Y Y BP pressure 8 3 psi Battery 563 Voltage High Y Y Voltage 18 vdc Voltage 562 Voltage Low Y Y Voltage 9 5 vdc and RPM 1500 5V 643 5VE1 High Voltage Y 5VE1 5 4 vdc External 642 5VE1 Low Voltage Y 5VE1 4 6 vdc TPS 123 TPS1 High Voltage Y TPS1 voltage 4 8 vdc 122 TPS1 Low Voltage Y TPS1 voltage 0 2 vdc 223 TPS2 H...

Page 175: ...AL High LPG AL_BM 30 and RPM between 0 9999 and MAP between 0 99 psi 1162 AL Low LPG AL_BM 30 and RPM between 0 9999 and MAP between 0 99 psi Closed 1155 CL High Gasoline Bank 1 CL_BM 40 and RPM between 0 9999 Loop and MAP between 0 99 psi 1156 CL Low Gasoline Bank 1 CL_BM 40 and RPM between 0 9999 and MAP between 0 99 psi 1151 CL High LPG CL_BM 35 and RPM between 0 9999 and MAP between 0 99 psi 1...

Page 176: ... low side 4 vdc and battery voltage 16 vdc Power 686 Relay Control Ground Short Relay 685 Relay Coil Short Control 687 Relay Coil Short to Pwr Coil Tach 2618 Tach Output Ground Short Does not turn on MIL Output 2619 Tach Output Short to Pwr Does not turn on MIL EPR 1171 EPR Delivery Pressure Y Y MJ actual commanded press 4 in H20 Diagnostics than expected LPG 1172 EPR Delivery Pressure Y Y MJ actu...

Page 177: ... ms 16 Never Crank Synced Cranking revs without sync 4 revs at Start and RPM 90 rpm Internal 606 COP Failure Y Y Processor 1612 RTI 1 Loss Y Y Diagnostics 1613 RTI 2 Loss Y Y 1614 RTI 3 Loss Y Y 1615 A D Loss Y Y 1616 Invalid Interrupt Y Y 601 Flash Checksum Invalid Y Y 604 RAM Failure Y Y J1939 1625 Shutdown Request Number of shutdown requests 1 Network 1626 CAN Tx Failure TX error counter 100 16...

Page 178: ...5 12 S 80 S 85 S 80X PartNo 122985 February2012 Section 5 Fault Codes This page intentionally left blank ...

Page 179: ...nance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section ElectricalSchematics Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry HydraulicSchematics Bodily injury hazard Sprayin...

Page 180: ... KS1 GROUND PLATFORM Power relay PR1 Toggle switch SPDT TS2 START ENGINE Toggle switch DPDT TS6 UP DOWN PLATFORM LEVEL Gauge sending unit HM Hour meter N O OTS2 Oil temperature switch normally open N O CTS1 Coolant temperature switch normally open Oil pressure switch normally closed N C OPS1 BLK FS1 Foot switch Pump Aux Auxiliary pump FAN Hydraulic oil cooling fan G1 Gauge Tilt sensor LED L3 Limit...

Page 181: ...s valve relief setting 25 psi 1 7 bar Motor 2 speed bi directional Pump bi directional variable displacement E Pump prime mover engine or motor Directional valve mechanically activated o Relief valve with pressure setting 200 psi 13 8 bar Orifice with size 035 0 89 mm Solenoid operated 3 position 4 way directional valve Directional valve pilot operated 2 position 2 way Flow divider combiner valve ...

Page 182: ...February2012 Section 6 Schematics 6 4 S 80 S 85 S 80X PartNo 122985 This page intentionally left blank ...

Page 183: ...Section 6 Schematics February2012 6 5 6 6 Connector Pin Legend View 1 ...

Page 184: ...K C28TTA P134PWR B RD RD BK BL BK C36STC C37STCC BL BK BL C3PBF C1PBU C2PBD COLOR RD WH RD RD BK C5TRR C9PERF C4TRL C6TRF C7PBE C8PBR BK WH BK WH BK RD WH BK C40LS OR WH RD 1 3 2 4 C7 DTP06 4S P22PWR PLUG BATGND P23PWR CIRCUIT PIN COLOR BR WH BK C7 C1 GRAY C3 GREEN PLUG PLUG SNSR GND P109ANG C2 DT06 12SB C2 BLACK 1 3 2 4 5 BL RD OR OR BK GR C39LP C42LS C46HRN C41RPM C40LS COLOR OR RD 7 8 11 9 GR W...

Page 185: ... C9PERF C8PBR 3 4 5 7 8 6 C3PBF 2 1 PIN CIRCUIT WH WH WH BK BL BK WH BK WH RD BK BK WH BK RD BL RD OR RD OR BK RD BK RD WH RD COLOR OR 18 19 20 C29MS C32BRK C36STC BL WH RD RD WH R23PWR C38RET C21RET R21IGN C41RPM R33STR C38FP C127TSW C39LP C26TSR C35RPM C14 GRAY J22 OR BK 6 C44JD GR BK 10 C14PLU C15PLD OR 9 11 8 7 GR COLOR GND C18PRR C43JU C17PRL GND GR GR BK BR BR 5 4 2 3 1 J22 DT04 12PA GND GND...

Page 186: ...February2012 Section 6 Schematics 6 8 Connector Pin Legend View 2 6 7 ...

Page 187: ...Section 6 Schematics February2012 6 9 Electrical Schematic S 80 and S 85 ANSI CSA AS DeutzTD2011L04iModels 6 10 ...

Page 188: ... C5 22 C5 18 D13 D12 C116HYD WH R116HYD OR A C B R33STR BK BL RD P22PWR BK C132PLI BL WH P134PWR RD CB2 15AMP C28TTA RD BK 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD P24FS WH P26ESTP BK OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY ...

Page 189: ... C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB59 L46 L47 C3 11 C42LS O...

Page 190: ...February2012 Section 6 Schematics 6 12 Electrical Schematic S 80 and S 85 ANSI CSA AS DeutzTD2011L04iModels 6 11 ...

Page 191: ...Section 6 Schematics February2012 6 13 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS DeutzTD2011L04IModels 6 14 ...

Page 192: ...DOWN TURNTABLE ROTATE CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLAT...

Page 193: ...RD TB134D WH KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR HM BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D BK WH TB34D BK RD TB35D D64 D13 D68 GR TB43...

Page 194: ...February2012 Section 6 Schematics 6 16 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS DeutzTD2011L04IModels 6 15 ...

Page 195: ...Section 6 Schematics February2012 6 17 6 18 Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS DeutzTD2011L04IModels ...

Page 196: ...65TRS WH RD C2P 10 SNSR GND BR JC3 5 C159STC BL WH C1P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE ...

Page 197: ... C9 1 RD LS18 BK C7P 1 WH C7P 2 RD RD RD ES0504D CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW ...

Page 198: ...February2012 Section 6 Schematics 6 20 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Deutz TD2011L04I Models 6 19 ...

Page 199: ...Section 6 Schematics February2012 6 21 Electrical Schematic S 80 and S 85 CE DeutzTD2011L04iModels beforeserialnumber8111 6 22 ...

Page 200: ...WR BK C132PLI BL WH P134PWR RD CB2 15AMP 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D39 C133PLS GR BK L4 CR15 NO GLOW PLUG GLOW PLUG CONTROL RELAY RD RPM MODULE J144 8 J1...

Page 201: ... P24FS WH C3 4 C3 5 C3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO...

Page 202: ...February2012 Section 6 Schematics 6 24 Electrical Schematic S 80 and S 85 CE DeutzTD2011L04iModels beforeserialnumber8111 6 23 ...

Page 203: ...Section 6 Schematics February2012 6 25 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE DeutzTD2011L04IModels beforeserialnumber8111 6 26 ...

Page 204: ...S PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLAT PLATFORM LEVEL UP LOOSE CABLE LED HORN PRESSURE COMP ENABLE KEY SW...

Page 205: ... KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR G6 BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D WH ISM 10 BK RD TB35D D64 D13 D68 GR TB43D GR BK TB44D ...

Page 206: ...February2012 Section 6 Schematics 6 28 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE DeutzTD2011L04IModels beforeserialnumber8111 6 27 ...

Page 207: ...Section 6 Schematics February2012 6 29 Platform Control Box Wiring Diagram S 80 and S 85 CE DeutzTD2011L04IModels beforeserialnumber8111 6 30 ...

Page 208: ...R WH C4P BR C3P GN C2P BK C1P GY C2PBD RD BK C3P 2 C3PBF RD WH C3P 3 C36STC BL C1P 10 C5TRR WH BK C3P 5 C4TRL WH C3P 4 TS2 C33STR BK C1P 7 C32BRK WH RD C1P 6 C29MS RD WH C1P 3 TS1 C27AUX RD C1P 1 TS6 C34SA BK WH C1P 8 C37STCC BL BK C1P 11 J2 C40LS OR C2P 2 C7PBE BK C3P 7 C1PBU RD C3P 1 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C6TRF WH RD C3P 6 C9PERF BK RD C3P 9 C42LS OR RD C2P 4 C31EDC WH BK C1P 5 C3...

Page 209: ... 5 OR J1 13 1 CONTROL HARNESS TO PLATFROM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFOR...

Page 210: ...February2012 Section 6 Schematics 6 32 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE DeutzTD2011L04IModels beforeserialnumber8111 6 31 ...

Page 211: ...Section 6 Schematics February2012 6 33 Electrical Schematic S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 34 ...

Page 212: ...P22PWR BK C132PLI BL WH P134PWR RD CB2 15AMP 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD P24FS WH OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D39 C133PLA GR BK L4 CR15 NO GLOW PLUG GLOW PLUG CONTROL RELAY RD RPM MOD...

Page 213: ...3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB59 L46 L47 C3 1...

Page 214: ...February2012 Section 6 Schematics 6 36 Electrical Schematic S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 35 ...

Page 215: ...Section 6 Schematics February2012 6 37 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 38 ...

Page 216: ...LATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLAT PLATFORM LEVEL UP LOOSE CABLE LED HORN PRESSURE COMP ENABLE KEY SWITCH POWER LIFT SPEED REDUCTION KE...

Page 217: ...KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR G6 BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D WH ISM 10 BK RD TB35D D64 D13 D68 GR TB43D GR BK TB44D 2...

Page 218: ...February2012 Section 6 Schematics 6 40 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 39 ...

Page 219: ...Section 6 Schematics February2012 6 41 Platform Control Box Wiring Diagram S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 42 ...

Page 220: ... WH C1P 8 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PBE BK C3P 7 C40LS OR C2P 2 1 11 P2 P22PWR BK C7P 1 H1 C133PLA GR BK C3P 12 TS4...

Page 221: ...L WH J1 5 BR J1 14 OR J1 13 1 1 ROCKER STEER OPTION H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OP...

Page 222: ...February2012 Section 6 Schematics 6 44 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE DeutzTD2011L04I Models after serial number 8110 6 43 ...

Page 223: ...Section 6 Schematics February2012 6 45 Electrical Schematic S 80X DeutzTD2011L04IModels 6 46 ...

Page 224: ... 10 START RELAY TACHOMETER START INPUT AUXILIARY GROUND BATTERY KEY POWER KEY BYPASS IGN FUEL ON ENGINE FAULT IGN START MODULE L2 BL RD HM C27AUX RD C41RPM OR BK P23PWR WH C33STR BK C33STR BK C27AUX RD P24PWR RD C21IGN WH C24TSPS WH F7 20A D22 12V DC 12V DC B2 B1 BAT BAT STA IND REGULATOR EXCT ALTERNATOR FB FB C41RPM OR BK P134FB RD P134FB RD CR17 NO 30 87 86 85 R116HYD OR C116HYD WH CR5 NO R46HRN...

Page 225: ...ER BK RD R14 A 5W TS62 TURNTABLE ROTATE C4TRL WH CW CCW TB13 C5TRR WH BK C6TRF WH RD C13DRE BL RD TB42 P134PWR RD C40LS OR C42LS OR RD P109ANG GR WH SNSR GND BR C123PBS RD BK GND BR C6 24 C6 11 C5 24 C5 23 C6 36 C6 37 C5 20 C5 21 C118LS OR TB118 C6 31 C6 3 C6 2 C6 1 C6 12 P210PWR BK P134PWR RD C6 21 C6 30 C6 38 C6 16 BL RD C211PLO BL BK S212PLO GR BK GR WH J133 J133 BK RD OR WH 1 4 5 2 BL 3 6 BR B...

Page 226: ...February2012 Section 6 Schematics 6 48 Electrical Schematic S 80X DeutzTD2011L04IModels 6 47 ...

Page 227: ...Section 6 Schematics February2012 6 49 6 50 Ground Control Box Terminal Strip Wiring Diagram S 80X DeutzTD2011L04IModels ...

Page 228: ...CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLATFORM PLATFORM LEVEL UP UNUSED LOOSE CABLE LED HORN PRESSURE COMP ENABLE KEY SWITCH POWER LIFT SPEED REDUCTION KEY SWITCH POWER A PRI BOOM RETRACT ENGINE RPM GLOW PLUG RD C5 1 KEY BYPASS BATTERY KEY PWR ENG FAULT IGN FUEL ON WH TB23C 6 8 7 WH L2 10 WH C5 3 9 U1 TACHOMETER START INPUT AUX ON GROUND START RELAY OR BK TB41...

Page 229: ...RD TB1D RD BK CR52 30 RD WH R14 WH TB4D WH BK TB5D WH RD R14 A BK CR53 30 BK WH TB8D BK RD TB9D GN BK TB18D GN TB17D OR BK TB15D OR TB14D WH TB23D RD R16 RD R16 RD TS61 2 RD TS51 1 BR CR34 85 BR HM BR L46 BR GND STUD 6 4 5 3 2 1 WH ISM 10 RD CB2 1 RD P1 2 WH C32 6 WH TS51 2 WH KS1 1 RD L45 4 3 2B 1B 2A 1A 6 4 1 3 3 2 1 4 5 6 1 2 3 6 5 4 1 2 3 3 2 1 1 2 3 1 TO GROUND CONTROL BOX CONNECTIONS L46 L2 ...

Page 230: ...February2012 Section 6 Schematics 6 52 Ground Control Box Switch Panel Wiring Diagram S 80X DeutzTD2011L04IModels 6 51 ...

Page 231: ...Section 6 Schematics February2012 6 53 Platform Control Box Wiring Diagram S 80X DeutzTD2011L04IModels 6 54 ...

Page 232: ...P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS6 C34SA BK WH C1P 8 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PB...

Page 233: ...WH J8 6 WH J8 2 GR J8 5 BR J8 8 RD BK BK BK RD RD ES0504D CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM L50 LED ZONE B 500 LB CAPACITY L51 LED ZONE A 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWIT...

Page 234: ...February2012 Section 6 Schematics 6 56 Platform Control Box Switch Panel Wiring Diagram S 80X DeutzTD2011L04IModels 6 55 ...

Page 235: ...Section 6 Schematics February2012 6 57 Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins804D 33Models 6 58 ...

Page 236: ...HYD WH R116HYD OR A C B R33STR BK BL RD P22PWR BK C177LS BL RD P134PWR RD CB2 15AMP C28TTA RD BK 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD P24FS WH P26ESTP BK OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D40 P109LS...

Page 237: ... C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB59 L46 L47 C3 11 C42LS O...

Page 238: ...February2012 Section 6 Schematics 6 60 Electrical Schematic S 80 and S 85 ANSI CSA AS Perkins804D 33Models 6 59 ...

Page 239: ...Section 6 Schematics February2012 6 61 Ground Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins804D 33Models 6 62 ...

Page 240: ...URNTABLE ROTATE CCW PRI BOOM FLOW PRI BOOM DOWN TURNTABLE ROTATE CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTA...

Page 241: ...RD TB134D WH KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR HM BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D BK WH TB34D BK RD TB35D D64 D13 D68 GR TB43...

Page 242: ...February2012 Section 6 Schematics 6 64 Ground Control Switch Panel Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins804D 33Models 6 63 ...

Page 243: ...Section 6 Schematics February2012 6 65 6 66 Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins804D 33Models ...

Page 244: ...L WH C1P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS6 C34SA BK WH C1P 8 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P...

Page 245: ...18 BK C7P 1 WH C7P 2 RD RD RD ES0503D CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS6 GLOW PLUG TOGGLE...

Page 246: ...February2012 Section 6 Schematics 6 68 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Perkins804D 33Models 6 67 ...

Page 247: ...Section 6 Schematics February2012 6 69 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 70 ...

Page 248: ...PLI BL WH P134PWR RD CB2 15AMP 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D39 C133PLS GR BK L4 CR15 NO GLOW PLUG GLOW PLUG CONTROL RELAY RD C6 24 R34SA BK WH C5 3 F17 20A...

Page 249: ...BK P24FS WH C3 4 C3 5 C3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 ...

Page 250: ...February2012 Section 6 Schematics 6 72 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 71 ...

Page 251: ...Section 6 Schematics February2012 6 73 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 74 ...

Page 252: ...CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLAT PLATFORM LEVEL UP LOO...

Page 253: ...KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR G6 BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D WH ISM 10 BK RD TB35D D64 D13 D68 GR TB43D GR BK TB44D 2...

Page 254: ...February2012 Section 6 Schematics 6 76 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 75 ...

Page 255: ...Section 6 Schematics February2012 6 77 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 78 ...

Page 256: ...R WH C4P BR C3P GN C2P BK C1P GY C2PBD RD BK C3P 2 C3PBF RD WH C3P 3 C36STC BL C1P 10 C5TRR WH BK C3P 5 C4TRL WH C3P 4 TS2 C33STR BK C1P 7 C32BRK WH RD C1P 6 C29MS RD WH C1P 3 TS1 C27AUX RD C1P 1 TS6 C34SA BK WH C1P 8 C37STCC BL BK C1P 11 J2 C40LS OR C2P 2 C7PBE BK C3P 7 C1PBU RD C3P 1 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C6TRF WH RD C3P 6 C9PERF BK RD C3P 9 C42LS OR RD C2P 4 C31EDC WH BK C1P 5 C3...

Page 257: ... 5 OR J1 13 1 CONTROL HARNESS TO PLATFROM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFOR...

Page 258: ...February2012 Section 6 Schematics 6 80 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models before serial number 8111 6 79 ...

Page 259: ...Section 6 Schematics February2012 6 81 6 82 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 ...

Page 260: ...32PLI BL WH P134PWR RD CB2 15AMP 7 WH GR BK TB28 12 8 TB134 RD PLAT GND KS1 TB22 P1 RD 6 1 4 3 5 C46HRN GR H1 P3 HORN RD P23PWR WH WH TB23 D2 FS1 BK C9P 1 P2 CR39A NO C5 5 D51 R21ING WH P25FS RD P24FS WH OIL COOLER TEMP SWITCH OPTION OIL COLLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D39 C133PLS GR BK L4 CR15 NO GLOW PLUG GLOW PLUG CONTROL RELAY RD C6 24 R34SA BK WH C...

Page 261: ...3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB59 L46 L47 C3 1...

Page 262: ...February2012 Section 6 Schematics 6 84 Electrical Schematic S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 83 ...

Page 263: ...Section 6 Schematics February2012 6 85 6 86 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 ...

Page 264: ...CTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLAT PLATFORM LEVEL UP LOOSE CABLE LED HORN PRESSURE COMP ENABLE ...

Page 265: ...KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR G6 BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D WH ISM 10 BK RD TB35D D64 D13 D68 GR TB43D GR BK TB44D 2...

Page 266: ...February2012 Section 6 Schematics 6 88 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 87 ...

Page 267: ...Section 6 Schematics February2012 6 89 Platform Control Box Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 90 ...

Page 268: ... WH C1P 8 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PBE BK C3P 7 C40LS OR C2P 2 1 11 P2 P22PWR BK C7P 1 H1 C133PLA GR BK C3P 12 TS4...

Page 269: ... WH J1 5 BR J1 14 OR J1 13 1 1 ROCKER STEER OPTION H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH CR27 LIFT DRIVE SELECT BRAKE CIRCUIT OPT...

Page 270: ...February2012 Section 6 Schematics 6 92 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE Perkins 804D 33 Models after serial number 8110 6 91 ...

Page 271: ...Section 6 Schematics February2012 6 93 Electrical Schematic S 80X Perkins804D 33Models 6 94 ...

Page 272: ...START RELAY TACHOMETER START INPUT AUXILIARY GROUND BATTERY KEY POWER KEY BYPASS IGN FUEL ON ENGINE FAULT IGN START MODULE L2 BL RD HM C27AUX RD C41RPM OR BK P23PWR WH C33STR BK C33STR BK C27AUX RD P24PWR RD C21IGN WH C24TSPS WH F7 20A D22 12V DC 12V DC B2 B1 BAT BAT STA IND REGULATOR EXCT ALTERNATOR FB FB C41RPM OR BK P134FB RD P134FB RD CR17 NO 30 87 86 85 R116HYD OR C116HYD WH CR5 NO R46HRN GR ...

Page 273: ...ER BK RD R14 A 5W TS62 TURNTABLE ROTATE C4TRL WH CW CCW TB13 C5TRR WH BK C6TRF WH RD C13DRE BL RD TB42 P134PWR RD C40LS OR C42LS OR RD P109ANG GR WH SNSR GND BR C123PBS RD BK GND BR C6 24 C6 11 C5 24 C5 23 C6 36 C6 37 C5 20 C5 21 C118LS OR TB118 C6 31 C6 3 C6 2 C6 1 C6 12 P210PWR BK P134PWR RD C6 21 C6 30 C6 38 C6 16 BL RD C211PLO BL BK S212PLO GR BK GR WH J133 J133 BK RD OR WH 1 4 5 2 BL 3 6 BR B...

Page 274: ...February2012 Section 6 Schematics 6 96 Electrical Schematic S 80X Perkins804D 33Models 6 95 ...

Page 275: ...Section 6 Schematics February2012 6 97 6 98 Ground Control Box Terminal Strip Wiring Diagram S 80X Perkins804D 33Models ...

Page 276: ... EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLATFORM PLATFORM LEVEL UP UNUSED LOOSE CABLE LED HORN PRESSURE COMP ENABLE KEY SWITCH POWER LIFT SPEED REDUCTION KEY SWITCH POWER A PRI BOOM RETRACT ENGINE RPM GLOW PLUG RD C5 1 KEY BYPASS BATTERY KEY PWR ENG FAULT IGN FUEL ON WH TB23C 6 8 7 WH L2 10 WH C5 3 9 U1 TACHOMETER START INPUT AUX...

Page 277: ...D TB1D RD BK CR52 30 RD WH R14 WH TB4D WH BK TB5D WH RD R14 A BK CR53 30 BK WH TB8D BK RD TB9D GN BK TB18D GN TB17D OR BK TB15D OR TB14D WH TB23D RD R16 RD R16 RD TS61 2 RD TS51 1 BR CR34 85 BR HM BR L46 BR GND STUD 6 4 5 3 2 1 WH ISM 10 RD CB2 1 RD P1 2 WH C32 6 WH TS51 2 WH KS1 1 RD L45 4 3 2B 1B 2A 1A 6 4 1 3 3 2 1 4 5 6 1 2 3 6 5 4 1 2 3 3 2 1 1 2 3 1 TO GROUND CONTROL BOX CONNECTIONS L46 L2 T...

Page 278: ...February2012 Section 6 Schematics 6 100 Ground Control Box Switch Panel Wiring Diagram S 80X Perkins804D 33Models 6 99 ...

Page 279: ...Section 6 Schematics February2012 6 101 Platform Control Box Wiring Diagram S 80X Perkins804D 33Models 6 102 ...

Page 280: ...P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS6 C34SA BK WH C1P 8 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PB...

Page 281: ...8 6 WH J8 2 GR J8 5 BR J8 8 RD BK BK BK RD RD ES0503D CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM L50 LED ZONE B 500 LB CAPACITY L51 LED ZONE A 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH T...

Page 282: ...February2012 Section 6 Schematics 6 104 Platform Control Box Switch Panel Wiring Diagram S 80X Perkins804D 33Models 6 103 ...

Page 283: ...Section 6 Schematics February2012 6 105 Electrical Schematic S 80 and S 85 ANSI CSA AS ContinentalTME27Models 6 106 ...

Page 284: ...B39 D4 C39LP BL RD P134PWR RD C41RPM OR BK C27AUX FE RD C27AUX RD TB41 C27AUX RD P134PWR RD P23PWR WH C5 7 C6 24 C6 28 C5 6 C5 1 C5 5 C5 19 C5 11 C5 2 C5 10 C5 9 C5 13 C5 8 C41RPM OR BK C39LP BL RD C35RPM BK RD C108ESL BL WH C127TSW GR 6 11 8 9 10 7 2 5 1 4 3 R21IGN WH C21RET WH R33STR BK R23PWR WH C38FP BL WH C38RET BL BK 12GA CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 HARNESS F17 20 A B1BAT RD...

Page 285: ... WH C3 4 C3 5 C3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB...

Page 286: ...February2012 Section 6 Schematics 6 108 Electrical Schematic S 80 and S 85 ANSI CSA AS ContinentalTME27Models 6 107 ...

Page 287: ...Section 6 Schematics February2012 6 109 6 110 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 ANSI CSA AS ContinentalTME27Models ...

Page 288: ...ND STUD 3 2 1 TS64 BL RD C5 10 BL RD TS53 1 D11 RD BK C7B 1 GR BK TB133C WH TS51 5 RD TS53 2 BR GND STUD BR GND BL WH TB132C BK TB22C GR C5 8 RD TB20A RD TB20B BK C5 5 PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW PRI BOOM FLOW PRI BOOM DOWN TURNTABLE ROTATE CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 1...

Page 289: ...2A 1B 2B 3 4 RD L45 WH KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR HM BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D BL RD TB39D BK RD TB35D D11 D13 D...

Page 290: ...February2012 Section 6 Schematics 6 112 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models 6 111 ...

Page 291: ...Section 6 Schematics February2012 6 113 Platform Control Box Wiring Diagram S 80 and S 85 ANSI CSA AS ContinentalTME27Models 6 114 ...

Page 292: ...65TRS WH RD C2P 10 SNSR GND BR JC3 5 C159STC BL WH C1P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE ...

Page 293: ...18 BK C9 1 BK J3 3 TS7 TS8 TS14 TS1 TS9 L48 P2 BL RD C2P 1 D10 RD RD BK RD D43 ES0505D 1 CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITC...

Page 294: ...February2012 Section 6 Schematics 6 116 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 ANSI CSA AS Continental TME27 Models 6 115 ...

Page 295: ...Section 6 Schematics February2012 6 117 6 118 Electrical Schematic S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 ...

Page 296: ...6 28 C5 6 C5 1 C5 5 C5 19 C5 11 C5 2 C5 10 C5 9 C5 13 C5 8 C41RPM OR BK C39LP BL RD C35RPM BK RD C108ESL BL WH C127TSW GR 6 11 8 9 10 7 2 5 1 4 3 R21IGN WH C21RET WH R33STR BK R23PWR WH C38FP BL WH C38RET BL BK 12GA CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 HARNESS F17 20 A B1BAT RD P24PWR RD R21IGN WH P20BAT RD BAT2 APU F7 20 A R6 510W 12V DC 12V DC B2 B1 BAT BAT EXCT STA IND REGULATOR M1 SW4 ...

Page 297: ...K P24FS WH C3 4 C3 5 C3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 N...

Page 298: ...February2012 Section 6 Schematics 6 120 6 119 Electrical Schematic S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 ...

Page 299: ...Section 6 Schematics February2012 6 121 6 122 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 ...

Page 300: ... H6 WH TS51 5 RD TS53 2 BR GND STUD BR GND BL WH TB132C BK TB22C GR C5 8 RD TB20A RD TB20B BK C5 5 PRI BOOM EXT TURNTABLE ROTATE FLOW TURNTABLE ROTATE CCW PRI BOOM FLOW PRI BOOM DOWN TURNTABLE ROTATE CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR STEER CW STEER CCW GAS LP...

Page 301: ... 3 4 RD L45 WH KS1 1 WH TS51 2 WH C32 6 RD P1 2 RD CB2 1 RD C32 7 1 2 3 5 4 6 BR GND STUD BR L46 BR HM BR CR34 85 RD TS51 1 RD TS61 2 RD R16 RD R16 WH TB23D OR TB14D OR BK TB15D GR TB17D GR BK TB18D RD TB27D BK RD TB9D BK WH TB8D BK TB7D WH RD R14 A WH BK TB5D WH TB4D RD WH R14 RD BK TB2D RD TB1D BL BK TB59D BK TB22D WH TB21D OR RD TB155D RD TB20D BK TB33D BL RD TB39D BK RD TB35D D11 D13 D68 GR TB...

Page 302: ...February2012 Section 6 Schematics 6 124 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 6 123 ...

Page 303: ...Section 6 Schematics February2012 6 125 Platform Control Box Wiring Diagram S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 6 126 ...

Page 304: ...5TRS WH RD C2P 9 P109ANG GR WH C4P BR C3P GN C2P BK C1P GY C2PBD RD BK C3P 2 C3PBF RD WH C3P 3 C36STC BL C1P 10 C5TRR WH BK C3P 5 C4TRL WH C3P 4 TS2 C33STR BK C1P 7 C32BRK WH RD C1P 6 C29MS RD WH C1P 3 TS1 C27AUX RD C1P 1 C37STCC BL BK C1P 11 J2 C40LS OR C2P 2 C7PBE BK C3P 7 C1PBU RD C3P 1 C13DRE BL RD C4P 1 C8PBR BK WH C3P 8 C6TRF WH RD C3P 6 C9PERF BK RD C3P 9 C42LS OR RD C2P 4 C31EDC WH BK C1P ...

Page 305: ...YSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS3 FUEL SELECT TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS14 DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENAB...

Page 306: ...February2012 Section 6 Schematics 6 128 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE ContinentalTME27Models beforeserialnumber8111 6 127 ...

Page 307: ...Section 6 Schematics February2012 6 129 6 130 Electrical Schematic S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 ...

Page 308: ... C28TTA RD BK C5 7 B1BAT RD B1BAT RD F17 20A F7 20A C6 24 C6 28 C5 6 C5 1 C5 5 C5 15 C5 17 C5 19 C5 11 C41RPM OR BK C5 10 C5 9 C5 13 C5 8 C5 2 C39LP BL RD C35RPM BK RD C108ESL BL WH C127TSW GR R21ING WH R21RET WH R33STR BK R23PWR WH C38FP BL WH C38RET BL 6 11 8 9 10 7 2 5 1 4 3 BK 12GA VEHICLE INTERFACE 1 HARNESS CONTINENTAL TME27 ENGINE C27AUX RD P134PWR RD P23PWR WH M4 RD 12GA WH 14GA M3 Y74 V15...

Page 309: ...C3 6 C1 10 C1 11 C1 3 C1 6 C1 5 C1 4 C144DER BL WH LED BL RD C4 3 C4 2 C4 7 C4 8 J1 J1 J1 J3 H1 RD BK C29MS RD WH C143DEL BL BK C2 2 C7 3 1 C30EDC WH C31EDC WH BK D29 U4 C6 9 C6 8 C6 7 C27AUX FE RD RIGHT LEFT BK RD YL OR BR BL J114 C123PBS RD BK P109ANG GN WH SNSR GND BR 6 5 4 3 1 2 1 4 2 3 5 6 J127 10 9 J1 TB40 C6TRF WH RD C44JD GR BK C43JU GR L46 L47 LOOSE CABLE LED D30 13 NO 14 TB59 L46 L47 C3 ...

Page 310: ...February2012 Section 6 Schematics 6 132 Electrical Schematic S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 6 131 ...

Page 311: ...Section 6 Schematics February2012 6 133 6 134 Ground Control Box Terminal Strip Wiring Diagram S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 ...

Page 312: ...CCW PRI BOOM FLOW PRI BOOM DOWN TURNTABLE ROTATE CW PRI BOOM UP JIB BOOM DOWN BOOM RETRACTED LS PRI BOOM EXT RET FLOW POWER TO PLATFORM BRAKE REVERSE EDC LEVEL SENSOR ALARM START 12V IGNITION SUPPLY JIB BOOM UP AC GENERATOR OPTION STEER CW STEER CCW RPM SIGNAL BOOM ANGLE STOWED LS DRIVE ENABLE LS AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V...

Page 313: ... RD BK CR52 30 RD WH R14 WH TB4D WH BK TB5D WH RD R14 A BK CR53 30 BK WH TB8D BK RD TB9D GN BK TB18D GN TB17D OR BK TB15D OR TB14D WH TB23D RD R16 RD R16 RD TS61 2 RD TS51 1 BR CR34 85 BR HM BR L46 BR GND STUD 6 4 5 3 2 1 RD C32 7 RD CB2 1 RD P1 2 WH C32 6 WH TS51 2 WH KS1 1 RD L45 4 3 2B 1B 2A 1A 6 4 1 3 3 2 1 4 5 6 1 2 3 6 5 4 1 2 3 3 2 1 1 2 3 1 TO GROUND CONTROL BOX CONNECTIONS L46 L2 TS52 CB2...

Page 314: ...February2012 Section 6 Schematics 6 136 Ground Control Box Switch Panel Wiring Diagram S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 6 135 ...

Page 315: ...Section 6 Schematics February2012 6 137 Platform Control Box Wiring Diagram S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 6 138 ...

Page 316: ...RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PBE BK C3P 7 C40LS OR C2P 2 1 11 P2 P22PWR BK C7P 1 H1 C133PLA GR BK C3P 12 TS47 C45GEN GR WH C2P 7 ...

Page 317: ... RD ES0505D CONTROL HARNESS TO PLATFORM BOX H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS3 FUEL SELECT TOGGLE SWITCH TS4 RPM SELECT TOGGLE SWITCH TS7 PLATFORM ROT...

Page 318: ...February2012 Section 6 Schematics 6 140 Platform Control Box Switch Panel Wiring Diagram S 80 and S 85 CE ContinentalTME27 Models after serial number 8110 6 139 ...

Page 319: ...Section 6 Schematics February2012 6 141 6 142 Electrical Schematic S 80X ContinentalTME27Models ...

Page 320: ... RD 12V DC B1 B2 C5 7 C6 28 D13 D12 P22PWR BK P134PWR RD 15 AMP CB2 C28TTA RD BK GR BK TB28 TB134 PLAT GRD KS1 TB22 P1 1 4 C46HRN GR H1 P3 HORN P23PWR WH TB23 D2 FS1 C9P 1 P2 NO P25FS RD P24FS WH P26ESTP BK HYD OIL COOLER TEMP SWITCH OPTION HYD OIL COOLER FAN OPTION ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY D40 L48 C32 C6 24 20A 20A F17 F7 C9P 3 C9P 2 GROUND P134FB RD TB133 TB132 ...

Page 321: ...PER BK RD R14 A 5W TS62 TURNTABLE ROTATE C4TRL WH CW CCW TB13 C5TRR WH BK C6TRF WH RD C13DRE BL RD TB42 P134PWR RD C40LS OR C42LS OR RD P109ANG GR WH SNSR GND BR C123PBS RD BK GND BR C6 24 C6 11 C5 24 C5 23 C6 36 C6 37 C5 20 C5 21 C118LS OR TB118 C6 31 C6 3 C6 2 C6 1 C6 12 P210PWR BK P134PWR RD C6 21 C6 30 C6 38 C6 16 BL RD C211PLO BL BK S212PLO GR BK GR WH J133 J133 BK RD OR WH 1 4 5 2 BL 3 6 BR ...

Page 322: ...February2012 Section 6 Schematics 6 144 Electrical Schematic S 80X ContinentalTME27Models 6 143 ...

Page 323: ...Section 6 Schematics February2012 6 145 6 146 Ground Control Box Terminal Strip Wiring Diagram S 80X ContinentalTME27Models ...

Page 324: ...ELECT RPM TACH SIGNAL LIMIT SWITCH LST20 DRIVE ENABLE AUXILIARY POWER FORWARD EDC DRIVE SPEED PLATFORM ROTATE CCW PLATFORM LEVEL DOWN PLATFORM ROTATE CW 12V BATT SUPPLY KEYSWITCH PWR TO PLATFORM PLATFORM LEVEL UP LOOSE CABLE LED HORN PRESSURE COMP ENABLE KEY SWITCH POWER BOOM SPEED REDUCTION KEY SWITCH POWER A PRI BOOM RETRACT ENGINE RPM 16 22 CABLE C5 B C D A 12V TO PLATFORM 3 ENGINE HARNESS 18 2...

Page 325: ... RD TB1D RD BK CR52 30 RD WH R14 WH TB4D WH BK TB5D WH RD R14 A BK CR53 30 BK WH TB8D BK RD TB9D GN BK TB18D GN TB17D OR BK TB15D OR TB14D WH TB23D RD R16 RD R16 RD TS61 2 RD TS51 1 BR CR34 85 BR HM BR L46 BR GND STUD 6 4 5 3 2 1 WH ISM 10 RD CB2 1 RD P1 2 WH C32 6 WH TS51 2 WH KS1 1 RD L45 4 3 2B 1B 2A 1A 6 4 1 3 3 2 1 4 5 6 1 2 3 6 5 4 1 2 3 3 2 1 1 2 3 1 TO GROUND CONTROL BOX CONNECTIONS L46 L2...

Page 326: ...February2012 Section 6 Schematics 6 148 Ground Control Box Switch Panel Wiring Diagram S 80X ContinentalTME27Models 6 147 ...

Page 327: ...Section 6 Schematics February2012 6 149 Platform Control Box Wiring Diagram S 80X ContinentalTME27Models 6 150 ...

Page 328: ...1P GY C2P BK C3P GR C4P BR C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 TS1 C27AUX RD C1P 1 C29MS RD WH C1P 3 C32BRK WH RD C1P 6 TS2 C33STR BK C1P 7 C4TRL WH C3P 4 C5TRR WH BK C3P 5 C36STC BL C1P 10 C3PBF RD WH C3P 3 J2 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C31EDC WH BK C1P 5 C42LS OR RD C2P 4 C9PERF BK RD C3P 9 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DRE BL RD C4P 1 C1PBU RD C3P 1 C7PBE BK C3P 7 C40LS OR C...

Page 329: ... WH J8 2 GR J8 5 BR J8 8 RD BK BK BK RD RD TS3 BL RD C2P 1 D10 ES0505D H1 COMPONENT INDEX TILT ALARM JC3 JOYSTICK DRIVE STEER JC7 JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE L1 LED DRIVE ENABLE L47 LED CABLE TENSION L48 LED TILT ALARM L50 LED ZONE B 500 LB CAPACITY L51 LED ZONE A 1000 LB CAPACITY P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS1 AUXILIARY TOGGLE SWITCH TS4 RPM SELECT T...

Page 330: ...February2012 Section 6 Schematics 6 152 6 151 Platform Control Box Switch Panel Wiring Diagram S 80X ContinentalTME27Models ...

Page 331: ...Section 6 Schematics February2012 6 153 6 154 Continental TME27 Engine Harness ...

Page 332: ...EN 18 PURPLE LT BLUE 18 DK GREEN ORANGE 18 EGO 2 EGO 4 EGO 3 EGO 1 3 5 4 1 2 LT GREEN BLACK 18 TX DK GREEN 18 BLK LT GREEN 18 LT GREEN RED 18 B C 5V D RTN COMM ORANGE 18 A RX OIL PRESSURE SWITCH DK BLUE YELLOW 18 PINK DK GREEN 16 PINK DK GREEN 16 YELLOW BLACK 18 BLACK LT GREEN 18 PINK DK GREEN 16 YELLOW RED 18 BLACK LT GREEN 18 PINK DK GREEN 16 BLACK LT GREEN 18 BLACK LT GREEN 18 YELLOW LT GREEN 1...

Page 333: ...85 S 80X 6 155 Platform Level Cutout CTE Option Y19 MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED PLATFORM LEVEL DOWN GROUND CR21 NO C15PLD OR BK C14PLU OR C42LS OR RD TS9 3 TS9 1 C2P 4 J2 4 J22 8 C4 2 TB14 TB15 C4 3 GROUND BOX PLATFORM BOX CR20 NO C15PLD OR BK C14PLU OR J22 7 Y20 PLATFORM LEVEL UP ...

Page 334: ...February2012 Section 6 Schematics 6 156 Platform Level Cutout CTE Option 6 155 ...

Page 335: ...Section 6 Schematics February2012 6 157 Continental Options Schematic 6 158 ...

Page 336: ... RD P24FS WH P26ESTP BK P25FS RD P24FS WH P26ESTP BK F18 10 A TS49 WORK LIGHT WH WH BK BK L30 L30 PLATFORM BOX GROUND TS48 DRIVE LIGHT F19 10A C4 9 C49LITE WH BK L29 L29 CR23 TB21 CONTINENTAL TME27 ENGINE VEHICLE INTERFACE 1 HARNESS C26TSR GR BK 12 G2 G3 G1 VOLT METER OIL PRESSURE GAUGE C25PSR BL BK COOLANT TEMP GAUGE WORK LIGHTS DRIVE LIGHTS ES0505C TS43 CONTROL BOX HEATER R22 10W R21 10W THS1 NC...

Page 337: ...H P26ESTP BK F18 10 A TS49 WORK LIGHT WH WH BK BK L30 L30 PLATFORM BOX GROUND TS48 DRIVE LIGHT TS47 GENERATOR TB45 C2 7 C6 39 C45GEN GR WH Y29 HYDRAULIC GENERATOR OPTION CR46 BELT DRIVEN GENERATOR OPTION F19 10A C4 9 C49LITE WH BK L29 L29 CR23 TB21 G2 G1 G3 VOLT METER OIL PRESSURE GAUGE C26TSR WH RD WORK LIGHTS DRIVE LIGHTS ES0503D ES0504D C25PSR WH BK C10 2 C10 3 C10 1 C10 4 COOLANT TEMP GAUGE TS...

Page 338: ...February2012 Section 6 Schematics 6 160 Deutz and Perkins Options Schematic 6 159 ...

Page 339: ...Section 6 Schematics February2012 6 161 6 162 12 kW Hydraulic Generator Wiring Diagram ...

Page 340: ...HITE RED 8 GA 4 CONDUCTOR 208 VAC OUTLET SILVER GREEN L1 L2 L3 NEUTRAL BUSS BAR 12 5 KW HYDRAULIC GENERATOR NEMA 4 CONTROL BOX 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI BRASS SILVER 120 VAC GFI GREEN 12GA BLACK 12GA 110 VAC GFI BRASS BLACK GREEN WHITE X Y Z 8 GA 5 CONDUCTOR 20 AMP CIRCUIT BREAKER GROUND STUD ON PANEL 12 GA 3 CONDUCTOR 1 2 3 N 5 4 6 BLACK 12GA 12 GA 3 CONDUCTOR ENCLOSURE ES05...

Page 341: ...C5 24 D98 D99 C57 BK 2 Y75 Y75 C57 RD 1 PRESSURE SWITCH 200 PSI OMRON RELAY SX Controller BYPASS COIL 3 1 2 A B C 124 ohms 124 ohms 1k ohms V150HG GR BK V151HG GR RS232TxD A1BATTERY A2SENSOR POWER 5 VDC A3BATTERY B1VALVE 0 FWD COIL B2VALVE 1 NC B3DIGITAL OUTPUT BYPASS C1TxD C2RxD C3 BOOT D1ANALOG 0 JOYSTICK D2ANALOG 1 NC D3C41 RPM E1NOT USED E2NOT USED E3NOT USED F1DIG IN 0 F2DIG IN 1 GENERATOR ON...

Page 342: ...February2012 Section 6 Schematics 6 164 6 163 12 kW Hydraulic Generator Electrical Schematic ...

Page 343: ...Section 6 Schematics February2012 6 165 Belt Driven Generator Option 6 166 ...

Page 344: ...NEUTRAL WH GND GR GND BR P20BAT TG3 TG1 TG4 TG2 CR46 CB2 12 5A LINE BK FIELD BK WH GND BR NEUTRAL WH R20BAT RD C45GEN TO GBOX FIELD GR NEUTRAL WH NEU LINE GND LINE BK 30A CB6 87A 87 85 86 30 87A 87 85 86 30 VOLTAGE REGULATOR BELT DRIVEN GENERATOR BATTERY LINE FIELD CB6 30A CB4 VOLTAGE REGULATOR BK WH 14GA BK 12GA 5 5 4 3 2 1 VOLTAGE REGULATOR 3 4 1 PIN 2 WH 12GA COLOR NEUTRAL CIRCUIT RD 12GA BR 12...

Page 345: ...0A ENGINE RPM SOLENOID F22 FUSE 60A GLOW PLUGS 1 2 5 6 3 4 7 8 F22 F7 F17 CB20 CR1 CR39 CR3 CR5 CR17 R21IGN 02GND B1BAT P24PWR CR15 CR2 CR4 Perkins 804D 33 LABEL DESCRIPTION CR1 START RELAY CR2 IGNITION FUEL RELAY CR3 HIGH IDLE RELAY CR5 HORN RELAY CR15 GLOW PLUG RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39 AUXILIARY PUMP RELAY F7 FUSE 30A OIL COOLER FAN HORN F17 FUSE 30A ENGINE AUXILIARY PUMP CR4 E...

Page 346: ...February2012 Section 6 Schematics 6 168 Relay and Fuse Panel Legend 6 167 ...

Page 347: ...Section 6 Schematics February2012 6 169 6 170 Hydraulic Schematic 2WD Models ...

Page 348: ...EL CYLINDERS PRIMARY LIFT CYLINDER 15 gpm 57 L min UP 8 gpm 30 L min DOWN STEER CYLINDER RIGHT LEFT OSCILLATE VALVE OSCILLATE CYLINDERS LEFT RIGHT BOOM EXTEND RETRACT 16 gpm 61 L min EXTEND 7 gpm 26 5 L min RETRACT OIL COOLER HIGH PRESSURE FILTER FUNCTION MANIFOLD 9 FUNCTION PUMP 38cc 250 psi 17 bar 2900 psi 200 bar E E F F D A B B A A G C C G G G 3 5 gpm 13 L min BA BC BB BD SA SB SC SD SE SG SI ...

Page 349: ...LIC ROTARY COUPLER BRAKE 2 SPEED MANIFOLD DRIVE PUMP RETURN FILTER TRACTION MANIFOLD PLATFORM ROTATE SLAVE CYLINDER MASTER CYLINDER TURNTABLE ROTATE 3 gpm 11 4 L min PLATFORM MANIFOLD AUXILIARY PUMP PLATFORM LEVEL CYLINDERS PRIMARY LIFT CYLINDER 15 gpm 57 L min UP 8 gpm 30 L min DOWN STEER CYLINDERS RIGHT LEFT OSCILLATE VALVE OSCILLATE CYLINDERS LEFT RIGHT BOOM EXTEND RETRACT 16 gpm 61 L min EXTEN...

Page 350: ...February2012 Section 6 Schematics 6 172 Hydraulic Schematic 4WD Models 6 171 ...

Page 351: ... Generator Hydraulic Schematic OIL COOLER 0 031 inch 0 79 mm WELDER MANIFOLD DRIVE PUMP B A 3 5 GPM 13 25L min PMP B CLR PMP A 270 PSI 18 6 BAR 3 5 GPM 13 25 L min MTR B MTR A G1 G2 21 GPM 79 5 L min G2 G1 21CC TANK 1 3 GENERATOR 12 5 KW HYDRAULIC ROTARY COUPLER PRESSURE SWITCH 200 PSI 13 8 BAR N O CASE CY CX CU CV CW CZ HS0166C ...

Page 352: ...February2012 Section 6 Schematics 6 174 12 kW Hydraulic Generator Hydraulic Schematic 6 173 ...

Page 353: ... 5600 Fax 55 22 4082 5630 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Scandinavia Phone 46 31 57 51 00 Fax 46 31 57 51 04 Genie France Phone 33 2 37 26 09 99 Fax 33 2 37 26 09 98 Genie Iberica Phone 34 93 572 5090 Fax 34 93 572 5091 Genie Germany Phone 0800 180 9017 Phone 49 4221 491 810 Fax 49 4221 491 820 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Mexico City Phone 5...

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