Genie S-80 Service And Repair Manual Download

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Service and Repair Manual

October 2016

Repair Procedures

S-80 • S-85 • S-80X

Part No. 1269074

Section 3

Repair Pr oc edures

Observe and Obey:



Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.



Immediately tag and remove from service a
damaged or malfunctioning machine.



Repair any machine damage or malfunction
before operating the machine.

Before Repairs Start:



Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.



Be sure that all necessary tools and parts are
available and ready for use.



Use only Genie approved replacement parts.



Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

Machine Configuration:



Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:

•

Machine parked on a firm, level surface

•

Key switch in the off position with the key

removed

•

The red Emergency Stop button in the off

position at both the ground and platform
controls

•

Wheels chocked

•

All external AC power supply disconnected

from the machine

•

Boom in the stowed position

•

Turntable secured with the turntable rotation

lock

Summary of Contents for S-80

Page 1: ... Electrical and Hydraulic Schematics S 85 from S80X15 12264 to S80X16H 13999 from S8015D 101 to S8016D 339 S 80X from S80X15D 101 to S80X16D 339 from S80H 14000 from S85H 14000 from S80XH 14000 from S80D 340 from S85D 340 from S80XD 340 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1269074 Rev A3 October 2016 ...

Page 2: ...O 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestio...

Page 3: ...air Procedures Added 4 7 Primary Boom Angle Sensor S80X A2 9 2016 Introduction Serial Number Legend A3 10 2016 Repair Schematics Hydraulic Drive Manifolds Hydraulic Schematics Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...al Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label located under cover 6 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis ...

Page 5: ...jury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations ...

Page 6: ... crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from fl...

Page 7: ...hine Specifications 1 Performance Specifications 2 Hydraulic Specification 2 Hydraulic Component Specifications 5 Manifold Component Specifications 6 Continental TME27 Engine Specifications 7 Deutz TD2011L04i Engine Specifications 8 Deutz TD 2 9 Engine Specifications 9 Perkins 804D 33 Engine Specifications 10 Perkins 404F 22T Engine Specifications 11 Machine Torque Specifications 12 Hydraulic Hose...

Page 8: ...e Joystick Ramp Rate Setting 21 How to Adjust the Joystick Threshold Setting 22 How to Calibrate the Boom Angle Sensor 23 Platform Components 25 2 1 Platform 25 2 2 Platform Leveling Slave Cylinder 26 How to Remove the Platform Leveling Slave Cylinder 26 How to Bleed the Slave Cylinder 26 2 3 Platform Rotator 27 How to Remove the Platform Rotator 27 How to Bleed the Platform Rotator 28 2 4 Platfor...

Page 9: ... 5 Boom Extend Retract Cables 43 How to Adjust the Extend Retract Cables 43 How to Replace the Boom Extend Retract Cables 45 4 6 Platform Leveling Master Cylinder 47 4 7 Primary Boom Angle Sensor S 80X 48 Engines 50 5 1 RPM Adjustment 50 5 2 Flex Plate 50 How to Remove the Flex Plate 50 How to Install the Flex Plate 53 How to install the Pump and Bell Housing Assembly 54 Ground Controls 55 6 1 Con...

Page 10: ...ifold Components 63 8 4 Turntable Rotation Manifold Components 64 8 5 Platform Rotate Manifold Components 65 8 6 Platform Manifold Components S 80 66 8 7 Platform Manifold Components S 85 67 8 8 2WD Traction Manifold Components 68 8 9 4WD Traction Manifold Components 69 8 10 Drive Oil Diverter Manifold Components welder option 71 8 11 Valve Adjustments Traction Manifold 72 8 12 Valve Coils 73 Valv...

Page 11: ...draulic Motor 79 How to Adjust the Turntable Rotation Gear Backlash 80 Steer Axle Components 82 11 1 Yoke and Drive Hub 82 11 2 Drive Motors 83 11 3 Drive Hubs 83 11 4 Steer Cylinders 84 Non steer Axle Components 85 12 1 Drive Motor 85 12 2 Drive Hub 85 Oscillating Axle Components 86 13 1 Oscillate Axle Cylinders 86 13 2 Oscillate Directional Valve 87 How to Adjust the Oscillate Relief Valve 87 Ho...

Page 12: ... 404F 22 Models 95 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 and Perkins 404F 22 Models 96 Soft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 97 Main Menu Structure Deutz D 2 9 L4 Models 98 Main Menu Structure Perkins 404F 22 Models 99 Deutz D 2 9 L4 Engine Fault Codes 100 Perkins 404F 22 Engine Fault Codes 111 Continental TME27 Engine Fault Codes 113 How to Re...

Page 13: ...SI CSA 137 Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA 141 Platform Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA 143 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA 146 Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA 150 Platform Control Box S 80X Deutz TD2011L04i Models ANSI CSA 151 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA 154 Ground Contro...

Page 14: ...Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA 191 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA 194 Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA 198 Platform Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA 199 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA 202 Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA 206 Platfor...

Page 15: ...x S 80 S 85 Continental TME27 Models CE 247 Electrical Schematics S 80 S 85 AS Models 249 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS 250 Ground Control Box S 80 S 85 Deutz TD2011L04i Models AS 254 Platform Control Box S 80 S 85 Deutz TD2011L04i Models AS 255 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS 258 Ground Control Box S 80 S 85 Perkins 804D 33 Models AS 262 Platfo...

Page 16: ......

Page 17: ...eter 22 5 in 57 cm Wheel width 14 in 35 6 cm Lugs and Lug Nut Torque Wheel lugs 11 3 4 16 Lug nut torque dry 420 ft lbs 569 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Fluid capacities Fuel tank Deutz and Perkins models 35 gallons 132 5 liters Fuel tank Continental model 30 gallons 113 5 liters LPG tank 33 5 lbs 15 2 kg Hydraulic tank 40 gallons 151 4 liters Hydraulic system including tank 50 g...

Page 18: ...ications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 ...

Page 19: ...20 F 49 C Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375...

Page 20: ...above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C ...

Page 21: ...mp Type fixed displacement gear pump Displacement per revolution 0 15 cu in 2 47 cc Function manifold System relief valve pressure maximum 3200 psi 221 bar Primary boom extend relief pressure measured at PTEST port 2400 psi 165 bar Platform Manifold and Oscillate Valve Platform level flow regulator Platform rotate flow regulator 0 6 gpm 2 3 L min 0 3 gpm 1 1 L min Oscillate relief pressure 950 psi...

Page 22: ...ecifications 6 S 80 S 85 S 80X Part No 1269074 Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm ...

Page 23: ...rs Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 7 psi 0 55 bar Fuel pump F...

Page 24: ...s 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Instal...

Page 25: ...86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation tor...

Page 26: ... 0 25 mm Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 10 6 quarts 10 liters Oil viscosity requirements Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Injection system Injection pump make Zexel Injection pump pressur...

Page 27: ...ments 22 F to 86 F 30 C to 30 C 5W 20 CJ4 4 F to 104 F 20 C to 40 C 10W 40 CJ4 Above 5 F 15 C 15W 40 CJ4 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 14 2 psi 1 bar Fuel injection system I...

Page 28: ... bolts GR 8 from SN 15 12988 dull gray use blue thread locking compound 35 ft lbs 47 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate drive hub mounting bolts lubricated 80 ft lbs 108 Nm Backlash plate mounting bolts lubricated 280 ft lbs 379 Nm Drive motors and hubs Drive hub mounting bolts lubricated 180 ft lbs 217 Nm Drive motor mounting bolts dry 1...

Page 29: ... 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O ...

Page 30: ...ted and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex n...

Page 31: ...ct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fi...

Page 32: ...l on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a fi...

Page 33: ...lert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not ...

Page 34: ... ALC 500 Circuit Board Note When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated Refer to Repair Procedure How to Calibrate a Joystick How to R emove the ALC 500 Circuit Boar d How to Remove the ALC 500 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid re...

Page 35: ...trols 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for ...

Page 36: ...ugh 7 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the machine function time with the function times listed in Refer to Specifications Performance Specifications Determine whether the function time need...

Page 37: ...p button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 6 times Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and ...

Page 38: ... the Joystick Thr eshol d Setting How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key ...

Page 39: ... in memory Note Do not operate any machine function during the 10 second waiting time 14 Cycle the red Emergency Stop button off then back on How to C alibr ate the Boom Angle Sensor How to Calibrate the Boom Angle Sensor The boom angle sensor controls the maximum angle that the boom can attain Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop butto...

Page 40: ...vate the drive enable toggle switch to the right 1 time to set the elevated position Result The alarm will sound indicating that the angle sensor has been calibrated 10 Release the joystick and the foot switch and wait for 10 seconds Result The alarm will sound indicating that the settings have been saved and is leaving calibration mode 11 Cycle the red Emergency Stop button off then back on Start...

Page 41: ...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 42: ...e blocks 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 cyl...

Page 43: ...cifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 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...

Page 44: ...ners torque the fasteners to specifications How to Bleed the Pl atfor m R otator How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold t...

Page 45: ... 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 Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is...

Page 46: ...tform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note 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 ...

Page 47: ...a suitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate no...

Page 48: ... from the jib boom pivot pin Lay all hoses and cables to the side Component damage hazard Cables and hoses can be 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 diss...

Page 49: ... 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 half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove ...

Page 50: ...onnectors 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 6 S 80 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazar...

Page 51: ...ew 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 cable tracks are not properly secured together ...

Page 52: ...lacement cable track section to the existing cable track using the snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 2 Boom How to Shi m the Boom How to Shim the Boom 1 Measure each wear pad Boom wear pad specifications Boom number one Minimum Bottom wea...

Page 53: ...ath or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Remove the cable track Refer to Repair Procedure How to Remove the Cable Track 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers 4 Place a block of wood measuring 4 x 4 x 60 inch...

Page 54: ...taining fasteners Use a soft metal drift to remove the pin Crushing hazard The boom could fall if not properly supported when the lift cylinder rod end pivot pin is removed 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 ...

Page 55: ...le of supporting it Crushing hazard The boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed Crushing hazard The long and short link arms may fall if not properly supported when the boom pivot pins are removed 4 3 Boom Lift Cylinder The boom lift cylinder raises and lowers the boom The boom lift cylinder is equipped with counterbalance valves to preve...

Page 56: ...er 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 7 Remove the pin retaining fasteners from the boom lift cylinder barrel end pivot pins Do not remove the pins 8 Use a slide hammer to remove the barre...

Page 57: ... fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position 2 Remove the boom end cover retaining fasteners and remove the cover 3 Remove ...

Page 58: ...bly on top of the extend cylinder 14 Locate the lower extend cable bracket on the bottom of the number 3 boom tube 15 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 16 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 17 Secure the ...

Page 59: ...t the Extend R etract C abl es 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 performance and safe machine operation The boom extend and retract functions should operate smo...

Page 60: ...m Illustration 1 1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom 12 Using a dial type torque wrench torque the retract cable adjustment nut to 32 36 ft lbs 43 49 Nm using gentle and steady torque 13 Retract and extend the boom approximately 3 feet 1...

Page 61: ...fer to Repair Procedure 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 drif...

Page 62: ...iscard the old boom retract cable 14 Securely attach the rope to the same end of the new boom retract cable 15 At the pivot end of the boom carefully pull the rope with the new retract cable attached 16 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube Remove the rope 17 Repeat steps 14 through 19 for the other boom retract cable 18 At t...

Page 63: ... pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder 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 re...

Page 64: ...iming link Remove the cover to gain access to the sensor 4 Locate and disconnect the angle sensor harness connector 5 Remove the angle sensor mounting bracket retaining fasteners and set aside to be reused Remove the angle sensor and bracket assembly 6 Remove the angle sensor from the mounting bracket and install the new angle sensor using the same fasteners 7 Referring to the illustration hold th...

Page 65: ...d re install the cover removed in step 3 If the voltage is not between 2 16V dc and 2 2V dc remove the mounting bracket assembly remove the sensor from the hex key and rotate the assembly to index the sensor and obtain the correct voltage If the voltage was less then 2 16V dc rotate the assembly approximately 60 from the mounting plate If the voltage was more than 2 2V dc rotate the assembly appro...

Page 66: ...s the pump coupler as part of the flex plate which is installed onto the engine flywheel Type B flexplate with coupler combined How to R emove the Flex Pl ate How to Remove the Flex Plate Note Perform this procedure with the engine off and cool to the touch 1 Open the engine side turntable cover 2 Tag and disconnect the battery cables from the battery s Electrocution burn hazard Contact with elect...

Page 67: ...g engine fasteners 3 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Perkins 804D models 1 Tag and disconnect the wiring from the bell housing 2 Remove the exhaust pipe clamp at the ...

Page 68: ...t shield fasteners from the top of the muffler Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 3 Remove the muffler retainer bracket fasteners 4 Remove the muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket 5 Remove the relay housing from the muffler mount Do not disconnect the relays 6 Discon...

Page 69: ... in sequence to 40 ft lbs 54 Nm Deutz Perkins and Continental Flex Plate 2 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 3 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm 4 Install the pump onto the pump mounting plate Apply Loc...

Page 70: ...s Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm Continental model Torque the pump mounting plate fasteners in sequence to 23 ft lbs 31 2 Nm Component damage hazard When installi...

Page 71: ...nect all the wiring from the relay to be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 75 to 85Ω terminal 87 to 87a and 30 no continuity infinite Ω terminal 87a to 30 continuity zero Ω 3...

Page 72: ...th the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydrau...

Page 73: ...n the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves open closed Component damage haz...

Page 74: ...ion 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 the LPG tank then disconnect the hose from the tank Move the fuel select toggle switch to the LPG pos...

Page 75: ...on 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 76: ...Service and Repair Manual October 2016 Manifolds 60 S 80 S 85 S 80X Part No 1269074 ...

Page 77: ...duce the pressure Install the relief valve cap Tip over hazard 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 Adj ust the Boom Down R elief Val ve How to Adjust the Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate ...

Page 78: ...ols 3 Hold the function enable rpm select toggle switch to the high idle position and activate and hold the boom extend toggle switch with the boom fully extended Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Specifications 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap on the function manifold 5 Adjust the internal hex socket ...

Page 79: ...nted inside the drive chassis Index No Description Schematic 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 ...

Page 80: ...tor at the ground control side of the machine Index No Description Schematic 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 ...

Page 81: ...Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator Index No Description Schematic Item Function Torque 1 Counterbalance valve 3300 psi PA Platform rotate right 37 44 ft lbs 50 60 Nm 2 Counterbalance valve 3300 psi PB Platform rotate left 37 44 ft lbs 50 60 Nm ...

Page 82: ...noid valve 3 position 4 way EF Platform rotate CW CCW 30 35 ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 4 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Needle valve EA Platform level 20 25 ft lbs 27 34 Nm 6 Pressure comp flow cont...

Page 83: ...lenoid 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 comp flow control valve...

Page 84: ...80 psi 19 3 bar DA 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 DE Controls flow to drive motors in forward and reverse 50 55 ft lbs 67 73 Nm 6 Orifi...

Page 85: ...er valves 2 and 13 80 90 ft lbs 108 122 Nm 6 Check valve HF Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm HG Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm HH Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm HI Equalizes pressure on both sides of flow divider combiner valve 1...

Page 86: ...Service and Repair Manual October 2016 Manifolds 70 S 80 S 85 S 80X Part No 1269074 ...

Page 87: ...cription Schematic 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 va...

Page 88: ...essure 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 i...

Page 89: ...ll rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Val ve C oil Resistance Speci fications Valve Coil Resistance Specification Note The following coil resistance specificati...

Page 90: ... on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 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 4 Con...

Page 91: ...pped 2 Remove the fuel filler cap from the tank 3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Specifications Machine 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 disco...

Page 92: ...n during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank Refer to Repair Procedure 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 shut off valves in the closed position or component damage will occur...

Page 93: ...ean them using a mild solvent 11 Rinse out the inside of the tank using a mild solvent 12 Install the suction strainers using pipe thread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until t...

Page 94: ...ed locked 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Loosen the backlash pivot plate and adjustment bolts 4 Attach a suitable lifting device to th...

Page 95: ...ving a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittin...

Page 96: ...s mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear Note Perform this procedure with the boom between the non steer end tires and with the machine on a firm and level surface 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad...

Page 97: ... adjustment bolt clockwise until it contacts the backlash pivot plate 6 Turn the adjustment bolt one half turn counterclockwise Tighten the lock nut on the adjustment bolt 7 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt Then torque the mounting fasteners on the backlash pivot plate Refer to Specifications Machine Torque Specifications 8 Rotate the tu...

Page 98: ...5 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 6 Remove the lug nuts Remove the tire and wheel assembly 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 10 Remove the pin re...

Page 99: ...llow oil to squirt or spray 4 Remove the drive motor mounting fasteners 5 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 11 3 Drive Hubs How to Remove a Drive Hub Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer...

Page 100: ...be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow o...

Page 101: ...12 1 Drive Motor How to Remove a Drive Motor This procedure is the same as the steer axle procedure Refer to Repair Procedure How to Remove a Drive Motor 12 2 Drive Hub How to Remove a Drive Hub This procedure is the same as the steer axle procedure Refer to Repair Procedure How to Remove a Drive Hub ...

Page 102: ... Torque 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...

Page 103: ...g manually activate the valve and observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component 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 rel...

Page 104: ...kage clevis yoke from the axle 6 Place a bubble type level on the turntable rotate bearing plate at the non steer end Confirm whether the drive chassis is completely level 7 If the drive chassis is not level start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Loosen the jamb ...

Page 105: ...ocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necess...

Page 106: ...hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code ...

Page 107: ...roblem has been corrected 15 Value too low Alarm sounds indicating a fault 17 Not calibrated Normal function except threshold for one or both directions is zero Calibrate valve threshold 24 Angle sensor 11 Value at 5V Reduced speed function Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not calibrated Ca...

Page 108: ...wering Check and service ext ret and fully stowed switches 500lb Mode Operates normally 41 Turntable Rotate Joystick 11 Value at 5V Limited speed and direction frozen at zero and neutral Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 42 Turntable Rotate Directional Valve...

Page 109: ...rected 51 Drive Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after problem has been corrected 12 Value too high 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 53 Drive Flow Valve EDC 12 Value too high Limited speed and direction Frozen at zero and neutral ALarm sounds indicating a fault ...

Page 110: ...lue 21 Fault Direction frozen at zero and neutral AB Power up controller with problem corrected 57 Foot switch ECU Power Crosscheck 12 Value too high Direction frozen at zero and neutral AB Power up controller with problem corrected 15 Value too low 61 Steer Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after ...

Page 111: ...h an engine fault LED located at the platform control box If an engine fault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm When operating from the platform if the red Emergency Stop button is pushed in the active fault code s will be erased from the display Start the engine from the ground control box and operate vari...

Page 112: ...rvice Flashing with right flashing amber LED engine soot level over 140 Engine shut down Contact service 4 Right green LED Flashing engine fault detected Contact service Solid fault acknowledged Contact service 5 Right amber LED Perkins models Solid with left amber LED on solid regeneration has been inhibited and engine soot level is between 80 100 Regeneration is required Flashing with left amber...

Page 113: ...oft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 1 Next menu Exit Back one screen Decrease brightness 2 Brightness Contrast Scroll up Increase Increase brightness 3 Regeneration forced Scroll down Decrease Decrease contrast 4 Regeneration inhibited Select Next Main menu Increase contarst Note Regeneration initiate inhibit and soot only apply to the Perkins 404F 22 models ...

Page 114: ...ervice and Repair Manual October 2016 Fault Code Display Deutz and Perkins Models 98 S 80 S 85 S 80X Part No 1269074 Main M enu Str ucture Deutz D 2 9 L4 Models Main Menu Structure Deutz D 2 9 L4 Models ...

Page 115: ...ober 2016 Service and Repair Manual Fault Code Display Deutz and Perkins Models Part No 1269074 S 80 S 85 S 80X 99 Main M enu Str ucture Per kins 404F 22 M odels Main Menu Structure Perkins 404F 22 Models ...

Page 116: ...EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressure warning threshold exceeded...

Page 117: ... load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low battery voltag...

Page 118: ... 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR Setpoint 59...

Page 119: ...Timeout Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal range check ...

Page 120: ... 1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank...

Page 121: ... 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Function Mode C...

Page 122: ...detection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail pressure...

Page 123: ... KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value pr...

Page 124: ...23936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calibration injec...

Page 125: ...ual value downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator due to overlo...

Page 126: ...imeout error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame SCR2 524117 ...

Page 127: ...Accelerator Pedal1 Low Idle Switch Voltage Below Normal 638 6 Engine Fuel Rack Actuator Current Above Normal 639 14 J1939 Network 1 Special Instruction SPN FMI Description 723 3 Engine Speed Sensor 2 Voltage Above Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period 723 10 Engine Speed Sensor 2 Abnormal Rate of Change 733 3 En...

Page 128: ...tem Timeout 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 3719 16 Particulate Trap 1 Soot Load Percent High moderate severity 2 4016 6 High Current Auxiliary Power Relay 1 Current Above Normal 4201 3 Engine Speed Sensor 1 Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor 1 Voltage Below Normal 4201 8 Engine Speed Sensor 1 Abnormal Frequency Pulse Nidth or Period ...

Page 129: ...check 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 wi...

Page 130: ...AT 200 F and RPM 1000 127 IAT higher than expected 2 Y IAT 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 Voltage 563 Voltage High Y Y Voltage 18 vdc 562 Voltage Low Y Y Voltage 9 5 vdc and RPM 1500 5V External 643 5VE1 High Voltage Y 5VE1 5 4 vdc 642 5VE1 Low Voltage Y 5VE1 4 6 vdc TPS 123 TPS1 High Voltage Y TPS1 voltage 4 8...

Page 131: ...d RPM between 0 9999 and MAP between 0 99 psi 1161 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 Loop 1155 CL High Gasoline Bank 1 CL_BM 40 and RPM between 0 9999 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 3...

Page 132: ...d RPM between 0 9999 and MAP between 0 99 psi 1161 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 Loop 1155 CL High Gasoline Bank 1 CL_BM 40 and RPM between 0 9999 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 3...

Page 133: ...trol Coil 686 Relay Control Ground Short 685 Relay Coil Short 687 Relay Coil Short to Pwr Tach Output 2618 Tach Output Ground Short Does not turn on MIL 2619 Tach Output Short to Pwr Does not turn on MIL EPR Diagnostics LPG 1171 EPR Delivery Pressure than expected Y Y MJ actual commanded press 4 in H20 1172 EPR Delivery Pressure than expected Y Y MJ actual commanded press 4 in H20 1173 EPR Comm Lo...

Page 134: ... re syncs 1 within a time window of 800 ms 16 Never Crank Synced at Start Cranking revs without sync 4 revs and RPM 90 rpm Internal Process or Diagnostics 606 COP Failure Y Y 1612 RTI 1 Loss Y Y 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 Network 1625 Shutdown Request Number of shutdown requests 1 162...

Page 135: ...he safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings wa...

Page 136: ...erminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally ...

Page 137: ... Shuttle valve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator Solenoid operated proportional valve Pressure reducing valve Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid op...

Page 138: ...COOLER FAN HORN F17 FUSE 30A ENGINE AUXILIARY PUMP F20 FUSE 20A ENGINE RPM SOLENOID F22 FUSE 60A GLOW PLUGS Deutz TD2 9 L4 Label Description CR2 ENGINE IGNITION RELAY CR5 HORN RELAY CR6 FUEL PUMP RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39 VDROP RELAY F7 FUSE 20A B1BAT P116PWR F17 FUSE 20A B1BAT P24PWR F20 FUSE 20A B1BAT P35PWR Perkins 404F 22T Label Description CR4A LOW RPM RELAY CR4B HIGH RPM REL...

Page 139: ...GINE RPM SOLENOID RELAY CR5 HORN RELAY CR15 GLOW PLUG RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39 AUXILIARY PUMP RELAY F7 FUSE 30A OIL COOLER FAN HORN F17 FUSE 30A ENGINE AUXILIARY PUMP F20 FUSE 60A GLOW PLUGS Continental TME27 LABEL DESCRIPTION CR1 START RELAY CR2 IGNITION FUEL RELAY CR5 HORN RELAY CR17 HYDRAULIC OIL COOLER RELAY CR39A AUXILIARY PUMP RELAY CR39B AUXILIARY PUMP ENGINE CUTOUT RELAY ...

Page 140: ...2SC Green Pin Circuit Color 1 C1PBU RD 2 C2PBD RD BK 3 C3PBF RD WH 4 C4TRL WH 5 C5TRR WH BK 6 C6TRF WH RD 7 C7PBE BK 8 C8PBR BK WH 9 C9PERF BK RD 10 C132PLI2 BL CE 11 C59CNK BL BK 12 C133PLA BL WH CE 12 P109LS BL WH S 80X C4 DT06 12SD Brown Pin Circuit Color 1 C13DRE BL RD 2 C14PLU OR 3 C15PLD OR BK 4 V155PCE OR RD 5 C17PRL GR 6 C18PRR GR BK 7 C43JU GR WH 8 C44JD RD OR 9 C49DLITE OR GR 10 SPARE LT...

Page 141: ...D BR 2 GND BR 3 C18PRR GR BK 4 C17PRL GR 5 C43JU GR 6 C44JD GR BK 7 C14PLU OR 8 C15PLD OR BK 9 GND BR 10 GND BR 11 GND BR 12 GND BR J3 ALC500 Power Valve Input Pin Circuit Color 1 GND BR 2 P24FS WH 3 P26ESTP BK 4 P24FS WH J1 ALC500 Input Pin Circuit Color 1 C165TRS WH RD 2 C164PES RD WH 3 C163PLS WH BK 4 C160JPL WH RD 5 C159STC BL WH 6 C144DER BL WH 7 C143DEL BL BK 8 C29MS RD WH 9 P109ANG GR WH 10...

Page 142: ...169LED2 BL 6 P109LS GR WH 7 C177LS BL RD 8 SNSR GND BR 9 NC 10 C169LED1 GR J144 Engine Plug Deutz 2011L04i Pin Circuit Color 1 C41RPM OR BK 2 C107AF WH 3 C26TSR WH RD 4 C24TS WH 5 C25PSR WH BK 6 C24PS WH 7 R21IGN WH 14 8 GND BR 9 10 Engine Plug Continental TME27 Pin Circuit Color 1 R23PWR WH 2 C21RET WH 3 C38RET BL 4 C38FP BL WH 5 R33STR BK 14 6 C41RPM OR BK 7 R21IGN WH 8 C35RPM BK RD 9 C108ESL BL...

Page 143: ...C33STR BK C33STR BK 6 C27AUX RD C27AUX RD C27AUX RD 7 C46HRN GR C46HRN GR C46HRN GR 8 C127TSW GR 9 C35RPM BK RD 10 C39LP BL RD 11 R21IGN WH 14 R21IGN WH 14 R21IGN WH 14 12 13 C108ESL BL WH 14 15 C24TSPS WH C24TSPS WH P24PWR RD 16 17 R24PWR RD 18 C35RPM BK RD C35RPM BK RD 19 V155PCE OR RD V155PCE OR RD V155PCE OR RD 20 C31EDC WH BK C31EDC WH BK C31EDC WH BK 21 C30EDC WH C30EDC WH C30EDC WH 22 C34SA...

Page 144: ...Service and Repair Manual October 2016 128 Continental TME27 Engine Harness ...

Page 145: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 129 Continental TME27 Engine Harness ...

Page 146: ...Service and Repair Manual October 2016 130 S 80 S 85 S 80X Part No 1269074 S 80X Ground Control Box Wiring Diagram Use this wiring diagram with each S 80X Ground Control Box Schematic ...

Page 147: ...October 2016 Service and Repair Manual 131 S 80X Ground Control Box Wiring Diagram ...

Page 148: ...Service and Repair Manual October 2016 132 Deutz TD2 9 L4 Engine Harness ...

Page 149: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 133 Deutz TD2 9 L4 Engine Harness ...

Page 150: ...Service and Repair Manual October 2016 134 S 80 S 85 S 80X Part No 1269074 Perkins 404F 22T Engine Harness ...

Page 151: ...October 2016 Service and Repair Manual 135 Perkins 404F 22T Engine Harness ...

Page 152: ...Service and Repair Manual October 2016 136 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 153: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 137 Electrical Schematic S 80X D eutz TD 2 9 L4 Models AN SI C SA Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 154: ...Service and Repair Manual October 2016 138 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 155: ...October 2016 Service and Repair Manual 139 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 156: ...Service and Repair Manual October 2016 140 Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 157: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 141 Ground C ontrol Box S 80X D eutz TD 2 9 L4 Models AN SI CSA ...

Page 158: ...Service and Repair Manual October 2016 142 S 80 S 85 S 80X Part No 1269074 Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 159: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 143 Platfor m C ontrol Box S 80X D eutz TD 2 9 L4 Models AN SI C SA Platform Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 160: ...Service and Repair Manual October 2016 144 Platform Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 161: ...October 2016 Service and Repair Manual 145 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 162: ...Service and Repair Manual October 2016 146 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80X D eutz TD 2011L04i M odels ANSI C SA Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 163: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 147 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 164: ...Service and Repair Manual October 2016 148 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 165: ...October 2016 Service and Repair Manual 149 Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 166: ...r 2016 150 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80X D eutz TD 2011L04i Models AN SI C SA Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 167: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 151 Platfor m C ontrol Box S 80X D eutz TD 2011L04i Models AN SI C SA Platform Control Box S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 168: ...Service and Repair Manual October 2016 152 Platform Control Box S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 169: ...October 2016 Service and Repair Manual 153 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 170: ...Service and Repair Manual October 2016 154 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80X Per ki ns 404F 22T Models AN SI C SA Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 171: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 155 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 172: ...Service and Repair Manual October 2016 156 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 173: ...October 2016 Service and Repair Manual 157 Ground Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 174: ...er 2016 158 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80X Per kins 404F 22T M odels ANSI CSA Ground Control Box S 80X Perkins 404F 22T Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 175: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 159 Platfor m C ontrol Box S 80X Per ki ns 404F 22T Model s AN SI C SA Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 176: ...Service and Repair Manual October 2016 160 Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 177: ...October 2016 Service and Repair Manual 161 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 178: ...Service and Repair Manual October 2016 162 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80X Per ki ns 804D 33 Models AN SI C SA Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 179: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 163 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 180: ...Service and Repair Manual October 2016 164 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 181: ...October 2016 Service and Repair Manual 165 Ground Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 182: ...ber 2016 166 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80X Per kins 804D 33 M odels ANSI CSA Ground Control Box S 80X Perkins 804D 33 Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 183: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 167 Platfor m C ontrol Box S 80X Per ki ns 804D 33 M odels AN SI CSA Platform Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 184: ...Service and Repair Manual October 2016 168 Platform Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 185: ...October 2016 Service and Repair Manual 169 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 186: ...Service and Repair Manual October 2016 170 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80X C ontinental TME27 Models AN SI C SA Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 187: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 171 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 188: ...Service and Repair Manual October 2016 172 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 189: ...October 2016 Service and Repair Manual 173 Ground Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 190: ... 2016 174 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80X C onti nental TM E27 Models AN SI CSA Ground Control Box S 80X Continental TME27 Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 191: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 175 Platfor m C ontrol Box S 80X C ontinental TME27 Models AN SI C SA Platform Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 192: ...Service and Repair Manual October 2016 176 Platform Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 193: ...October 2016 Service and Repair Manual 177 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 194: ...Service and Repair Manual October 2016 178 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Deutz TD 2 9 L4 Models AN SI CSA Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 195: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 179 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 196: ...Service and Repair Manual October 2016 180 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 197: ...October 2016 Service and Repair Manual 181 Ground Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 198: ...Service and Repair Manual October 2016 182 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 D eutz TD2 9 L4 M odels ANSI CSA Ground Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 199: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 183 Platfor m C ontrol Box S 80 S 85 Deutz TD 2 9 L4 M odels ANSI CSA Platform Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 200: ...Service and Repair Manual October 2016 184 Platform Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 201: ...October 2016 Service and Repair Manual 185 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 202: ...rvice and Repair Manual October 2016 186 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Deutz TD 2011L04i Models AN SI C SA Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 203: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 187 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 204: ...Service and Repair Manual October 2016 188 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 205: ...October 2016 Service and Repair Manual 189 Ground Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 206: ...Service and Repair Manual October 2016 190 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 D eutz TD2011L04i M odels ANSI CSA Ground Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 207: ...ober 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 191 Platfor m C ontrol Box S 80 S 85 Deutz TD 2011L04i M odels AN SI CSA Platform Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 208: ...Service and Repair Manual October 2016 192 Platform Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 209: ...October 2016 Service and Repair Manual 193 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 210: ...ervice and Repair Manual October 2016 194 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Per kins 404F 22T M odels ANSI CSA Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 211: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 195 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 212: ...Service and Repair Manual October 2016 196 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 213: ...October 2016 Service and Repair Manual 197 Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 214: ...Service and Repair Manual October 2016 198 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 Per kins 404F 22T M odels ANSI C SA Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 215: ...tober 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 199 Platfor m C ontrol Box S 80 S 85 Per kins 404F 22T M odels ANSI CSA Platform Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 216: ...Service and Repair Manual October 2016 200 Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 217: ...October 2016 Service and Repair Manual 201 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 218: ...Service and Repair Manual October 2016 202 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Per kins 804D 33 M odels ANSI CSA Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 219: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 203 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 220: ...Service and Repair Manual October 2016 204 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 221: ...October 2016 Service and Repair Manual 205 Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 222: ...Service and Repair Manual October 2016 206 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 Per kins 804D 33 Models AN SI C SA Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 223: ...tober 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 207 Platfor m C ontrol Box S 80 S 85 Per kins 804D 33 M odels ANSI C SA Platform Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 224: ...Service and Repair Manual October 2016 208 Platform Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 225: ...October 2016 Service and Repair Manual 209 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 226: ...vice and Repair Manual October 2016 210 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Conti nental TM E27 M odels AN SI CSA Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 227: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 211 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 228: ...Service and Repair Manual October 2016 212 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 229: ...October 2016 Service and Repair Manual 213 Ground Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 230: ...rvice and Repair Manual October 2016 214 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 C onti nental TM E27 M odels ANSI C SA Ground Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 231: ...ber 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 215 Platfor m C ontrol Box S 80 S 85 Conti nental TM E27 M odels ANSI CSA Platform Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 232: ...Service and Repair Manual October 2016 216 Platform Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 233: ...October 2016 Service and Repair Manual 217 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 234: ...Service and Repair Manual October 2016 218 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Deutz TD 2 9 L4 Models CE Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 235: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 219 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 236: ...Service and Repair Manual October 2016 220 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 237: ...October 2016 Service and Repair Manual 221 Ground Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 238: ...Service and Repair Manual October 2016 222 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 D eutz TD2 9 L4 M odels C E Ground Control Box S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 239: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 223 Platfor m C ontrol Box S 80 S 85 Deutz TD 2 9 L4 M odels CE Platform Control Box S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 240: ...Service and Repair Manual October 2016 224 Platform Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 241: ...October 2016 Service and Repair Manual 225 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 242: ...Service and Repair Manual October 2016 226 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Deutz TD 2011L04i Models CE Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 243: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 227 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 244: ...Service and Repair Manual October 2016 228 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 245: ...October 2016 Service and Repair Manual 229 Ground Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 246: ...Service and Repair Manual October 2016 230 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 D eutz TD2011L04i M odels C E Ground Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 247: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 231 Platfor m C ontrol Box S 80 S 85 Deutz TD 2011L04i M odels CE Platform Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 248: ...Service and Repair Manual October 2016 232 Platform Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 249: ...October 2016 Service and Repair Manual 233 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 250: ...Service and Repair Manual October 2016 234 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Per kins 804D 33 M odels C E Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 251: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 235 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 252: ...Service and Repair Manual October 2016 236 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 253: ...October 2016 Service and Repair Manual 237 Ground Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 254: ...Service and Repair Manual October 2016 238 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 Per kins 804D 33 Models CE Ground Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 255: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 239 Platfor m C ontrol Box S 80 S 85 Per kins 804D 33 M odels C E Platform Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 256: ...Service and Repair Manual October 2016 240 Platform Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 257: ...October 2016 Service and Repair Manual 241 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 258: ...Service and Repair Manual October 2016 242 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Conti nental TM E27 M odels CE Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 259: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 243 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 260: ...Service and Repair Manual October 2016 244 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 261: ...October 2016 Service and Repair Manual 245 Ground Control Box S 80 S 85 Continental TME27 Models CE ...

Page 262: ...Service and Repair Manual October 2016 246 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 C onti nental TM E27 M odels C E Ground Control Box S 80 S 85 Continental TME27 Models CE ...

Page 263: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 247 Platfor m C ontrol Box S 80 S 85 Conti nental TM E27 M odels CE Platform Control Box S 80 S 85 Continental TME27 Models CE ...

Page 264: ...Service and Repair Manual October 2016 248 Platform Control Box S 80 S 85 Continental TME27 Models CE ...

Page 265: ...October 2016 Service and Repair Manual 249 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 266: ...Service and Repair Manual October 2016 250 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Deutz TD 2011L04i Models AS Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 267: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 251 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 268: ...Service and Repair Manual October 2016 252 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 269: ...October 2016 Service and Repair Manual 253 Ground Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 270: ...Service and Repair Manual October 2016 254 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 D eutz TD2011L04i M odels AS Ground Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 271: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 255 Platfor m C ontrol Box S 80 S 85 Deutz TD 2011L04i M odels AS Platform Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 272: ...Service and Repair Manual October 2016 256 Platform Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 273: ...October 2016 Service and Repair Manual 257 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 274: ...Service and Repair Manual October 2016 258 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Per kins 804D 33 M odels AS Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 275: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 259 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 276: ...Service and Repair Manual October 2016 260 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 277: ...October 2016 Service and Repair Manual 261 Ground Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 278: ...Service and Repair Manual October 2016 262 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 Per kins 804D 33 Models AS Ground Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 279: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 263 Platfor m C ontrol Box S 80 S 85 Per kins 804D 33 M odels AS Platform Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 280: ...Service and Repair Manual October 2016 264 Platform Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 281: ...October 2016 Service and Repair Manual 265 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 282: ...Service and Repair Manual October 2016 266 S 80 S 85 S 80X Part No 1269074 Electrical Schematic S 80 S 85 Conti nental TM E27 M odels AS Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 283: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 267 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 284: ...Service and Repair Manual October 2016 268 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 285: ...October 2016 Service and Repair Manual 269 Ground Control Box S 80 S 85 Continental TME27 Models AS ...

Page 286: ...Service and Repair Manual October 2016 270 S 80 S 85 S 80X Part No 1269074 Ground C ontrol Box S 80 S 85 C onti nental TM E27 M odels AS Ground Control Box S 80 S 85 Continental TME27 Models AS ...

Page 287: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 271 Platfor m C ontrol Box S 80 S 85 Conti nental TM E27 M odels AS Platform Control Box S 80 S 85 Continental TME27 Models AS ...

Page 288: ...Service and Repair Manual October 2016 272 Platform Control Box S 80 S 85 Continental TME27 Models AS ...

Page 289: ...October 2016 Service and Repair Manual 273 Continental Options Schematic ...

Page 290: ...Service and Repair Manual October 2016 274 S 80 S 85 S 80X Part No 1269074 Continental Options Schematic Continental Options Schematic ...

Page 291: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 275 Deutz and Perki ns Options Schematic Deutz and Perkins Options Schematic ...

Page 292: ...Service and Repair Manual October 2016 276 Deutz and Perkins Options Schematic ...

Page 293: ...October 2016 Service and Repair Manual 277 Platform Level Cutout CTE Option ...

Page 294: ...Service and Repair Manual October 2016 278 S 80 S 85 S 80X Part No 1269074 Platfor m Level Cutout CTE Opti on Platform Level Cutout CTE Option ...

Page 295: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 279 12 kW H ydraulic Gener ator Wiring Diagram 12 kW Hydraulic Generator Wiring Diagram ...

Page 296: ...Service and Repair Manual October 2016 280 12 kW Hydraulic Generator Wiring Diagram ...

Page 297: ...October 2016 Service and Repair Manual 281 12 kW Hydraulic Generator Electrical Schematic ...

Page 298: ...Service and Repair Manual October 2016 282 S 80 S 85 S 80X Part No 1269074 12 kW H ydraulic Gener ator El ectrical Schematic 12 kW Hydraulic Generator Electrical Schematic ...

Page 299: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 283 Belt Driven Gener ator Opti on Belt Driven Generator Option ...

Page 300: ...Service and Repair Manual October 2016 284 Belt Driven Generator Option ...

Page 301: ...October 2016 Service and Repair Manual 285 Hydraulic Schematic 2WD Models ...

Page 302: ...Service and Repair Manual October 2016 286 S 80 S 85 S 80X Part No 1269074 Hydraulic Schematic 2WD M odels Hydraulic Schematic 2WD Models ...

Page 303: ...October 2016 Service and Repair Manual Part No 1269074 S 80 S 85 S 80X 287 Hydraulic Schematic 4WD M odels Hydraulic Schematic 4WD Models ...

Page 304: ...Service and Repair Manual October 2016 288 Hydraulic Schematic 4WD Models S 80 S 85 S 80X Part No 1269074 Ser vice and R epair M anual October 2016 ...

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