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Terex Genie S-80 Service And Repair Manual Download Page 6

Service and Repair Manual

 

March 2018

 

Safety Rules

 

 

 

vi 

S®-

80 • S®

-85

 

• S®

-80X 

Part No. 1269074GT 

 

 

Personal 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. 

  

Read each procedure thoroughly. This 

manual and the decals on the machine, 

use signal words to identify the following: 

 

Safety alert symbol—used to alert 

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 avoided, 

may cause minor or moderate 

injury. 

 

Indicates a potentially hazardous 

situation which, if not avoided, 

may result in property damage. 

 

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

 

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 flammable and 

combustible materials like battery gases 

and engine fuels. Always have an 

approved fire extinguisher within easy 

reach. 

 

Be sure that all tools and working areas 

are properly maintained and ready for 

use. Keep work surfaces clean and free of 

debris that could get into machine 

components and cause damage. 

 

Be sure any forklift, overhead crane or 

other lifting or supporting device is fully 

capable of supporting and stabilizing the 

weight to be lifted. Use only chains or 

straps that are in good condition and of 

ample capacity. 

 

Be sure that fasteners intended for one 

time use (i.e., cotter pins and self-locking 

nuts) are not reused. These components 

may fail if they are used a second time. 

 

Be sure to properly dispose of old oil or 

other fluids. Use an approved container. 

Please be environmentally safe. 

 

Be sure that your workshop or work area 

is properly ventilated and well lit. 

 

Summary of Contents for Genie S-80

Page 1: ...hematics S 85 from S8515 12264 to S8516H 13642 S 80X from S80X15 12264 to S80X16H 13642 includes S8516H 13685 and S8516H 13711 from S8015D 101 to S8016D 339 from S80X15D 101 to S80X16D 339 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine from S80D 340 from S85D 340 from S80XD 340 Part No 1269074GT Rev A4 March 2018 ...

Page 2: ...SO 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 suggesti...

Page 3: ...Sensor S80X A2 9 2016 Introduction Serial Number Legend A3 10 2016 Repair Schematics Hydraulic Drive Manifolds Valve Coil resistance Hydraulic Schematics A4 3 2018 Schematics Update Electrical Schematics AddSerial Breaks 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 Sec...

Page 4: ...al Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 1 Sequence number 2 Serial label located under cover 3 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 1 Serial label located under cover 2 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: ...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 and Fitting Torque Specifications 13 Torque Procedure 14 Section 3 Repair Procedures 16 Introduction 16 Platform Controls 18 1 1 ALC 500 Circuit Board 18 How to Remove...

Page 8: ... Lift Cylinder 32 Boom Components 33 4 1 Cable Track 33 How to Remove the Cable Track S 80 33 How to Repair the Cable Track 35 4 2 Boom 35 How to Shim the Boom 35 How to Remove the Boom 36 4 3 Boom Lift Cylinder 38 4 4 Boom Extension Cylinder 40 4 5 Boom Extend Retract Cables 42 How to Adjust the Extend Retract Cables 42 How to Replace the Boom Extend Retract Cables 44 4 6 Platform Leveling Master...

Page 9: ...nts 63 8 5 Platform Rotate Manifold Components 64 8 6 Platform Manifold Components S 80 65 8 7 Platform Manifold Components S 85 66 8 8 2WD Traction Manifold Components 67 8 9 4WD Traction Manifold Components 68 8 10 Drive Oil Diverter Manifold Components welder option 70 8 11 Valve Adjustments Traction Manifold 71 8 12 Valve Coils 72 Valve Coil Resistance Specifications 72 Fuel and Hydraulic Tank...

Page 10: ...o Retrieve Control System Fault Codes 90 Control System Fault Codes 91 Fault Code Display Deutz and Perkins Models 94 How to Retrieve Active Engine Fault Codes Deutz D 2 9 L4 and Perkins 404F 22 Models 94 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 and Perkins 404F 22 Models 95 Soft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 96 Main Menu Structure Deutz D 2 9 ...

Page 11: ...I CSA 136 Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA 140 Platform Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA 141 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA 144 Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA 148 Platform Control Box S 80X Deutz TD2011L04i Models ANSI CSA 149 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA 152 Ground Control...

Page 12: ...Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA 189 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA 192 Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA 196 Platform Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA 197 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA 200 Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA 204 Platfor...

Page 13: ...ox S 80 S 85 Continental TME27 Models CE 245 Electrical Schematics S 80 S 85 AS Models 247 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS 248 Ground Control Box S 80 S 85 Deutz TD2011L04i Models AS 252 Platform Control Box S 80 S 85 Deutz TD2011L04i Models AS 253 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS 256 Ground Control Box S 80 S 85 Perkins 804D 33 Models AS 260 Platf...

Page 14: ......

Page 15: ...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 16: ...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 17: ...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 18: ...ystem is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently 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 Sh...

Page 19: ...per revolution 0 to 2 8 cu in 0 to 46 cc Flow rate 2300 rpm 30 3 gpm 114 7 L min Drive pressure maximum 3750 psi 259 bar Charge Pump Type gerotor Displacement per revolution 0 85 cu in 13 9 cc Flow rate 2300 rpm 9 gpm 34 L min Charge pressure 2300 rpm Neutral position 310 psi 21 4 bar Function pump Type variable displacement piston pump Displacement per revolution 0 to 2 3 cu in 0 to 38 cc Flow ra...

Page 20: ... Brake release pressure Wheel drive hubs 240 psi 16 5 bar Drive Motors Displacement per revolution high speed 0 9 cu in 14 7 cc Displacement per revolution low speed 2 7 cu in 45 cc Hydraulic Filters High pressure filter Beta 3 200 High pressure filter bypass pressure 102 psi 7 bar Medium pressure filter Beta 3 200 Medium pressure filter bypass pressure 51 psi 3 5 bar Hydraulic tank return filter ...

Page 21: ...s 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 Handbook on your machine Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 7 psi 0 55 bar Fuel Pump ...

Page 22: ... 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 Handbook on your machine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Insta...

Page 23: ...6 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 Handbook on your machine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation to...

Page 24: ...5 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 Handbook on your machine Injection system Injection pump make Zexel Injection pump pressure ...

Page 25: ...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 Handbook on your machine Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 14 2 psi 1 bar Fuel injection system...

Page 26: ... 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 27: ... 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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...primary boom up down and turntable rotate left right joystick controller 1 1 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 bo...

Page 33: ...ctions or replace the joystick 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine function should operate while performing the joystick calibration procedure How to Adj ust the Joystick Max out Setting How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick contr...

Page 34: ... not operate any machine function during the 10 second waiting time Function speeds factory settings Boom up 89 to 93 seconds Boom down 90 to 94 seconds Boom extend 73 to 79 seconds Boom retract 79 to 84 seconds Turntable rotate 360 boom fully stowed 95 to 103 seconds Drive speeds factory settings Stowed high speed 7 9 to 8 5 seconds Non stowed 40 to 45 seconds How to Adj ust the Joystick Ram p R ...

Page 35: ...ive enable toggle switch is momentarily moved the time will change in 10 increments 13 Repeat steps 9 through 11 for each joystick controlled machine function 14 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 Note Do not operate any machine funct...

Page 36: ...e 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 11 Slowly move the joys...

Page 37: ...ause and the alarm should sound 12 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 Man...

Page 38: ...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 39: ...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 cylinder rod...

Page 40: ...ifications 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 41: ...ners torque the fasteners to specifications How to Bleed the Pl atform 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 th...

Page 42: ...nspect the bleed screws for leaks 2 4 Platform Overload System if equipped How to Calibrate the Platform Overload System if equipped Proper 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 compromised...

Page 43: ...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 in between adjustments Note There may be a 2 second delay before the overload indicator lights flash and ...

Page 44: ...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 45: ... 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 46: ... 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 47: ...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 48: ...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 49: ...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 Shim the Boom How to Shim the Boom 1 Measure each wear pad Boom wear pad specifications Boom number one Minimum Bottom wear...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ... 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 55: ...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 56: ...ust 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 s...

Page 57: ...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 58: ...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 59: ...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 60: ... 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 61: ...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 62: ...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 63: ...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 64: ... housing 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 ...

Page 65: ...eat 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 Disc...

Page 66: ...equence 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 Loctite ...

Page 67: ...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 68: ...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 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test th...

Page 69: ...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 70: ...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 71: ...losed 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 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 switc...

Page 72: ...osition 4 way SL Steering directional 20 25 ft lbs 27 34 Nm 9 Proportional solenoid 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 ...

Page 73: ...March 2018 Service and Repair Manual Manifolds Part No 1269074GT S 80 S 85 S 80X 59 ...

Page 74: ...re 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 Dow n R elief Valve 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 the boom down r...

Page 75: ...trols 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 socke...

Page 76: ...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 77: ...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 78: ...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 79: ... 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 control ...

Page 80: ...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 boom 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 E...

Page 81: ...80 psi 19 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 Orifi...

Page 82: ...er 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 valve 1...

Page 83: ...March 2018 Service and Repair Manual Manifolds Part No 1269074GT S 80 S 85 S 80X 69 ...

Page 84: ...ion 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 valve C...

Page 85: ...ssure 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 in...

Page 86: ...rcuits could result in death or serious injury Remove all 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 Valve C oil Resistance Speci ficati ons Valve Coil Resistance Speci...

Page 87: ... 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 88: ...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 89: ...r 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 If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open clos...

Page 90: ... 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 hydraulic tank shutoff valves ...

Page 91: ...ons 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 the lifting eyes on the drive hub assembly 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts 5 Remove the backlash pivot plate mounting bolts Carefully remove the ...

Page 92: ...c 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 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...

Page 93: ...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 94: ... 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 95: ...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 96: ...to squirt or spray 3 Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 11 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 hose end must be replaced All connections must be torqued to specification during installation Refer to Specif...

Page 97: ...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 98: ...12 1 Drive Motors 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 99: ...ecifications 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 the oil p...

Page 100: ...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 101: ...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 102: ...Service and Repair Manual March 2018 88 S 80 S 85 S 80X Part No 1269074GT This page intentionally left blank ...

Page 103: ...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 104: ...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 105: ...h problem corrected 15 Value Too Low 17 Not calibrated Normal function except threshold for one or both directions is zero Calibrate valve threshold 24 Angle sensor 11 Value at 5 0 V Reduced function speed Retract before lowering required Dual capacity models Power up controller with problem corrected 12 Value Too High 15 Value Too Low 16 Value at 0 V 17 Not calibrated Calibrate angle sensor 31 In...

Page 106: ... Direction frozen at zero and neutral Alarm sounds Power up controller with problem corrected 12 Value Too High 15 Value Too Low 16 Value at 0 V 17 Not calibrated Initiate 1 second beep of Alarm Calibrate Joystick 42 Turntable Rotate Directional Valves 21 Fault Limited Speed and Direction frozen at zero and neutral Alarm sounds Power up controller with problem corrected 17 Not calibrated Normal fu...

Page 107: ...tral Alarm sounds Power up controller with problem corrected 55 Propel High Motor Speed Valve 21 Fault Motor speed frozen in the low state Power up controller with problem corrected 56 Platform Level Valve 21 Fault Direction frozen at zero and neutral Power up controller with problem corrected 57 Foot switch ECU Power Crosscheck 12 Value Too High Direction frozen at zero and neutral Power up contr...

Page 108: ...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 109: ...vice 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 110: ...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 111: ...arch 2018 Service and Repair Manual Fault Code Display Deutz and Perkins Models Part No 1269074GT S 80 S 85 S 80X 97 Main M enu Str ucture Deutz D 2 9 L4 Model s Main Menu Structure Deutz D 2 9 L4 Models ...

Page 112: ...rvice and Repair Manual March 2018 Fault Code Display Deutz and Perkins Models 98 S 80 S 85 S 80X Part No 1269074GT Main M enu Str ucture Perkins 404F 22 M odels Main Menu Structure Perkins 404F 22 Models ...

Page 113: ...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 114: ... 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 115: ... 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 116: ...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 117: ... 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 118: ... 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 119: ...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 120: ... 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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...on The 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...

Page 127: ...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 128: ...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 129: ...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 130: ...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 131: ... 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 132: ...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 133: ...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 separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally ...

Page 134: ... 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 135: ...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 136: ...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 137: ...RD 2 C40LS OR 3 C41RPM OR BK 4 C42LS OR RD 5 C46HRN GR 6 P134PWR GR BK 7 C45GEN GR WH 8 C123PBS GR RD 9 P109ANG OR WH 10 SNSR GND LT BR 11 PLUG 12 PLUG C3 DT06 12SC 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 Brow...

Page 138: ...6 27 28 C28TTA RD BK 29 30 C211LO BL BK S 80X 31 C118LSR OR 32 33 C123PBS RD BK 34 SNSR GND BR 35 P109ANG GR WH 36 C36STC BL 37 C37STCC BL BK 38 C212LO GR BK S 80X 39 C45GEN GR WH 40 C40LS OR C7 DTP06 4S 12V Power to Platform Pin Circuit Color 1 P22PWR BK 2 P23PWR WH 3 BATGND BR 4 PLUG C9 FS DT04 4P Footswitch Pin Circuit Color 1 P26ESTP BK 2 P24FS WH 3 P25FS RD 4 PLUG J22 Platform Manifold Pin Ci...

Page 139: ...F RD WH 9 C4TRL WH 10 C5TRR WH BK 11 C6TRF WH RD 12 C7PBE BK 13 C8PBR BK WH 14 C9PERF BK RD 15 C30EDC WH 16 C31EDC WH BK 17 C36STC BL 18 C37STCC BL BK 19 C32BRK WH RD 20 C29MS RD WH J8 S 80X Model Pin Circuit Color 1 P109LS GR WH 2 C184PL WH 3 NC 4 NC 5 C169LED2 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 C10...

Page 140: ...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 141: ...March 2018 Service and Repair Manual 127 Continental TME27 Engine Harness ...

Page 142: ...Service and Repair Manual March 2018 128 S 80 S 85 S 80X Part No 1269074GT Continental TME27 Engine Harness ...

Page 143: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 129 S 80X Ground Control Box Wiring Diagram Use this wiring diagram with each S 80X Ground Control Box Schematic ...

Page 144: ...Service and Repair Manual March 2018 130 S 80X Ground Control Box Wiring Diagram ...

Page 145: ...March 2018 Service and Repair Manual 131 Deutz TD2 9 L4 Engine Harness ...

Page 146: ...Service and Repair Manual March 2018 132 S 80 S 85 S 80X Part No 1269074GT Deutz TD2 9 L4 Engine Harness ...

Page 147: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 133 Perkins 404F 22T Engine Harness ...

Page 148: ...Service and Repair Manual March 2018 134 Perkins 404F 22T Engine Harness ...

Page 149: ...March 2018 Service and Repair Manual 135 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 150: ...Service and Repair Manual March 2018 136 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic 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 151: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 137 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 152: ...Service and Repair Manual March 2018 138 Electrical Schematic S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 153: ...March 2018 Service and Repair Manual 139 Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 154: ...ch 2018 140 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80X Deutz TD 2 9 L4 Models AN SI CSA Ground Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 155: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 141 Platform 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 156: ...Service and Repair Manual March 2018 142 Platform Control Box S 80X Deutz TD2 9 L4 Models ANSI CSA ...

Page 157: ...March 2018 Service and Repair Manual 143 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 158: ...Service and Repair Manual March 2018 144 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80X D eutz TD 2011L04i M odels ANSI C SA Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 159: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 145 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 160: ...Service and Repair Manual March 2018 146 Electrical Schematic S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 161: ...March 2018 Service and Repair Manual 147 Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 162: ...2018 148 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80X Deutz TD 2011L04i Models AN SI C SA Ground Control Box S 80X Deutz TD2011L04i Models ANSI CSA Refer to S 80X Ground Control Box Wiring Diagram for additional wiring ...

Page 163: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 149 Platform 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 164: ...Service and Repair Manual March 2018 150 Platform Control Box S 80X Deutz TD2011L04i Models ANSI CSA ...

Page 165: ...March 2018 Service and Repair Manual 151 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 166: ...Service and Repair Manual March 2018 152 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80X Perki ns 404F 22T Models AN SI C SA Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 167: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 153 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 168: ...Service and Repair Manual March 2018 154 Electrical Schematic S 80X Perkins 404F 22T Models ANSI CSA ...

Page 169: ...March 2018 Service and Repair Manual 155 Ground Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 170: ... 2018 156 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80X Perkins 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 171: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 157 Platform C ontrol Box S 80X Perki ns 404F 22T Models AN SI C SA Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 172: ...Service and Repair Manual March 2018 158 Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 173: ...March 2018 Service and Repair Manual 159 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 174: ...Service and Repair Manual March 2018 160 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80X Perki ns 804D 33 Models AN SI C SA Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 175: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 161 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 176: ...Service and Repair Manual March 2018 162 Electrical Schematic S 80X Perkins 804D 33 Models ANSI CSA ...

Page 177: ...March 2018 Service and Repair Manual 163 Ground Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 178: ...h 2018 164 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80X Perkins 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 179: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 165 Platform C ontrol Box S 80X Perki ns 804D 33 M odels AN SI CSA Platform Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 180: ...Service and Repair Manual March 2018 166 Platform Control Box S 80X Perkins 804D 33 Models ANSI CSA ...

Page 181: ...March 2018 Service and Repair Manual 167 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 182: ...Service and Repair Manual March 2018 168 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80X C ontinental TME27 Models AN SI C SA Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 183: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 169 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 184: ...Service and Repair Manual March 2018 170 Electrical Schematic S 80X Continental TME27 Models ANSI CSA ...

Page 185: ...March 2018 Service and Repair Manual 171 Ground Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 186: ...018 172 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80X Conti nental TM E27 M odels 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 187: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 173 Platform C ontrol Box S 80X C ontinental TME27 Models AN SI C SA Platform Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 188: ...Service and Repair Manual March 2018 174 Platform Control Box S 80X Continental TME27 Models ANSI CSA ...

Page 189: ...March 2018 Service and Repair Manual 175 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 190: ...Service and Repair Manual March 2018 176 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Deutz TD 2 9 L4 M odels AN SI CSA Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 191: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 177 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 192: ...Service and Repair Manual March 2018 178 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 193: ...March 2018 Service and Repair Manual 179 Ground Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 194: ...Service and Repair Manual March 2018 180 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 D eutz TD2 9 L4 M odels ANSI C SA Ground Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 195: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 181 Platform 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 196: ...Service and Repair Manual March 2018 182 Platform Control Box S 80 S 85 Deutz TD2 9 L4 Models ANSI CSA ...

Page 197: ...March 2018 Service and Repair Manual 183 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 198: ...rvice and Repair Manual March 2018 184 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Deutz TD 2011L04i Models AN SI C SA Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 199: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 185 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 200: ...Service and Repair Manual March 2018 186 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 201: ...March 2018 Service and Repair Manual 187 Ground Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 202: ...Service and Repair Manual March 2018 188 S 80 S 85 S 80X Part No 1269074GT 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 203: ...rch 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 189 Platform 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 204: ...Service and Repair Manual March 2018 190 Platform Control Box S 80 S 85 Deutz TD2011L04i Models ANSI CSA ...

Page 205: ...March 2018 Service and Repair Manual 191 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 206: ...ervice and Repair Manual March 2018 192 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Perkins 404F 22T M odels ANSI CSA Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 207: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 193 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 208: ...Service and Repair Manual March 2018 194 Electrical Schematic S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 209: ...March 2018 Service and Repair Manual 195 Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 210: ...Service and Repair Manual March 2018 196 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 Perkins 404F 22T M odels ANSI C SA Ground Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 211: ...arch 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 197 Platform C ontrol Box S 80 S 85 Perkins 404F 22T M odels ANSI CSA Platform Control Box S 80 S 85 Perkins 404F 22T Models ANSI CSA ...

Page 212: ...Service and Repair Manual March 2018 198 Platform Control Box S 80X Perkins 404F 22T Models ANSI CSA ...

Page 213: ...March 2018 Service and Repair Manual 199 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 214: ...Service and Repair Manual March 2018 200 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Perkins 804D 33 M odels ANSI CSA Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 215: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 201 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 216: ...Service and Repair Manual March 2018 202 Electrical Schematic S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 217: ...March 2018 Service and Repair Manual 203 Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 218: ...Service and Repair Manual March 2018 204 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 Perkins 804D 33 Models AN SI C SA Ground Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 219: ...arch 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 205 Platform C ontrol Box S 80 S 85 Perkins 804D 33 M odels ANSI C SA Platform Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 220: ...Service and Repair Manual March 2018 206 Platform Control Box S 80 S 85 Perkins 804D 33 Models ANSI CSA ...

Page 221: ...March 2018 Service and Repair Manual 207 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 222: ...ice and Repair Manual March 2018 208 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic 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 223: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 209 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 224: ...Service and Repair Manual March 2018 210 Electrical Schematic S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 225: ...March 2018 Service and Repair Manual 211 Ground Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 226: ...rvice and Repair Manual March 2018 212 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 C onti nental TME27 M odels ANSI C SA Ground Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 227: ...ch 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 213 Platform 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 228: ...Service and Repair Manual March 2018 214 Platform Control Box S 80 S 85 Continental TME27 Models ANSI CSA ...

Page 229: ...March 2018 Service and Repair Manual 215 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 230: ...Service and Repair Manual March 2018 216 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Deutz TD 2 9 L4 M odels CE Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 231: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 217 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 232: ...Service and Repair Manual March 2018 218 Electrical Schematic S 80 S 85 Deutz TD2 9 L4 Models CE ...

Page 233: ...March 2018 Service and Repair Manual 219 Ground Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 234: ...Service and Repair Manual March 2018 220 S 80 S 85 S 80X Part No 1269074GT 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 235: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 221 Platform 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 236: ...Service and Repair Manual March 2018 222 Platform Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 237: ...March 2018 Service and Repair Manual 223 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 238: ...Service and Repair Manual March 2018 224 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Deutz TD 2011L04i Models CE Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 239: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 225 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 240: ...Service and Repair Manual March 2018 226 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models CE ...

Page 241: ...March 2018 Service and Repair Manual 227 Ground Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 242: ...Service and Repair Manual March 2018 228 S 80 S 85 S 80X Part No 1269074GT 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 243: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 229 Platform 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 244: ...Service and Repair Manual March 2018 230 Platform Control Box S 80 S 85 Deutz TD2011L04i Models CE ...

Page 245: ...March 2018 Service and Repair Manual 231 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 246: ...Service and Repair Manual March 2018 232 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Perkins 804D 33 M odels C E Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 247: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 233 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 248: ...Service and Repair Manual March 2018 234 Electrical Schematic S 80 S 85 Perkins 804D 33 Models CE ...

Page 249: ...March 2018 Service and Repair Manual 235 Ground Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 250: ...Service and Repair Manual March 2018 236 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 Perkins 804D 33 Models CE Ground Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 251: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 237 Platform C ontrol Box S 80 S 85 Perkins 804D 33 M odels C E Platform Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 252: ...Service and Repair Manual March 2018 238 Platform Control Box S 80 S 85 Perkins 804D 33 Models CE ...

Page 253: ...March 2018 Service and Repair Manual 239 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 254: ...Service and Repair Manual March 2018 240 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Conti nental TM E27 M odels CE Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 255: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 241 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 256: ...Service and Repair Manual March 2018 242 Electrical Schematic S 80 S 85 Continental TME27 Models CE ...

Page 257: ...March 2018 Service and Repair Manual 243 Ground Control Box S 80 S 85 Continental TME27 Models CE ...

Page 258: ...Service and Repair Manual March 2018 244 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 C onti nental TME27 M odels C E Ground Control Box S 80 S 85 Continental TME27 Models CE ...

Page 259: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 245 Platform C ontrol Box S 80 S 85 Conti nental TM E27 M odels C E Platform Control Box S 80 S 85 Continental TME27 Models CE ...

Page 260: ...Service and Repair Manual March 2018 246 Platform Control Box S 80 S 85 Continental TME27 Models CE ...

Page 261: ...March 2018 Service and Repair Manual 247 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 262: ...Service and Repair Manual March 2018 248 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Deutz TD 2011L04i Models AS Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 263: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 249 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 264: ...Service and Repair Manual March 2018 250 Electrical Schematic S 80 S 85 Deutz TD2011L04i Models AS ...

Page 265: ...March 2018 Service and Repair Manual 251 Ground Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 266: ...Service and Repair Manual March 2018 252 S 80 S 85 S 80X Part No 1269074GT 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 267: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 253 Platform 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 268: ...Service and Repair Manual March 2018 254 Platform Control Box S 80 S 85 Deutz TD2011L04i Models AS ...

Page 269: ...March 2018 Service and Repair Manual 255 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 270: ...Service and Repair Manual March 2018 256 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Perkins 804D 33 M odels AS Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 271: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 257 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 272: ...Service and Repair Manual March 2018 258 Electrical Schematic S 80 S 85 Perkins 804D 33 Models AS ...

Page 273: ...March 2018 Service and Repair Manual 259 Ground Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 274: ...Service and Repair Manual March 2018 260 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 Perkins 804D 33 Models AS Ground Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 275: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 261 Platform C ontrol Box S 80 S 85 Perkins 804D 33 M odels AS Platform Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 276: ...Service and Repair Manual March 2018 262 Platform Control Box S 80 S 85 Perkins 804D 33 Models AS ...

Page 277: ...March 2018 Service and Repair Manual 263 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 278: ...Service and Repair Manual March 2018 264 S 80 S 85 S 80X Part No 1269074GT Electrical Schem atic S 80 S 85 Conti nental TM E27 M odels AS Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 279: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 265 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 280: ...Service and Repair Manual March 2018 266 Electrical Schematic S 80 S 85 Continental TME27 Models AS ...

Page 281: ...March 2018 Service and Repair Manual 267 Ground Control Box S 80 S 85 Continental TME27 Models AS ...

Page 282: ...Service and Repair Manual March 2018 268 S 80 S 85 S 80X Part No 1269074GT Ground C ontrol Box S 80 S 85 C onti nental TME27 M odels AS Ground Control Box S 80 S 85 Continental TME27 Models AS ...

Page 283: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 269 Platform 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 284: ...Service and Repair Manual March 2018 270 Platform Control Box S 80 S 85 Continental TME27 Models AS ...

Page 285: ...March 2018 Service and Repair Manual 271 Continental Options Schematic ...

Page 286: ...Service and Repair Manual March 2018 272 S 80 S 85 S 80X Part No 1269074GT Continental Options Schem atic Continental Options Schematic ...

Page 287: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 273 Deutz and Perki ns Options Schem atic Deutz and Perkins Options Schematic ...

Page 288: ...Service and Repair Manual March 2018 274 Deutz and Perkins Options Schematic ...

Page 289: ...March 2018 Service and Repair Manual 275 Platform Level Cutout CTE Option ...

Page 290: ...Service and Repair Manual March 2018 276 S 80 S 85 S 80X Part No 1269074GT Platform Level Cutout CTE Opti on Platform Level Cutout CTE Option ...

Page 291: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 277 12 kW Hydraulic Gener ator Wiring Diagram 12 kW Hydraulic Generator Wiring Diagram ...

Page 292: ...Service and Repair Manual March 2018 278 12 kW Hydraulic Generator Wiring Diagram ...

Page 293: ...March 2018 Service and Repair Manual 279 12 kW Hydraulic Generator Electrical Schematic ...

Page 294: ...Service and Repair Manual March 2018 280 S 80 S 85 S 80X Part No 1269074GT 12 kW Hydraulic Gener ator El ectrical Schematic 12 kW Hydraulic Generator Electrical Schematic ...

Page 295: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 281 Belt Driven Gener ator Opti on Belt Driven Generator Option ...

Page 296: ...Service and Repair Manual March 2018 282 Belt Driven Generator Option ...

Page 297: ...March 2018 Service and Repair Manual 283 Hydraulic Schematic 2WD Models ...

Page 298: ...Service and Repair Manual March 2018 284 S 80 S 85 S 80X Part No 1269074GT Hydraulic Schem atic 2WD M odels Hydraulic Schematic 2WD Models ...

Page 299: ...March 2018 Service and Repair Manual Part No 1269074GT S 80 S 85 S 80X 285 Hydraulic Schem atic 4WD M odels Hydraulic Schematic 4WD Models ...

Page 300: ...Service and Repair Manual March 2018 286 Hydraulic Schematic 4WD Models S 80 S 85 S 80X Part No 1269074GT Service and R epair M anual March 2018 ...

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