Checklist A Procedures

Transcription

Introduction
February 2012
Introduction
Important
Serial Number Information
Read, understand and obey the safety rules and
operating instructions in the Genie S-80 and
S-85 Operator's Manual before attempting any
maintenance or repair procedure.
Genie offers the following Service
Manuals for these models:
Title
This manual provides detailed scheduled maintenance
information for the machine owner and user. It also
provides troubleshooting fault codes and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However, several
procedures require specialized skills, tools, lifting
equipment and a suitable workshop. In these instances,
we strongly recommend that maintenance and repair be
performed at an authorized Genie dealer service center.
Compliance
Part No.
Genie S-80 and S-85 Service Manual
(from serial number 101 to 785) .......... 34032
(from serial number 786 to 965) .......... 52270
(from serial number 966 to 3081) ........ 72062
(from serial number 3082 to 3737) ...... 77832
(from serial number 5381 to 7999) ... 122149
Machine Classification
Group B/Type 3 as defined by ISO 16368
Genie S-80, S-85 and S-80X Service Manual
(from serial number 8000)
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 suggestions for improvement. All
communications will be carefully considered for future
printings of this and all other manuals.
111165 Rev C February 2012
Fifth Edition, Third Printing
"Genie" and "S" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
ii
Copyright © 2011 by Terex Corporation
Printed on recycled paper
Printed in U.S.A.
S-80 • S-85
Part No. 111165
February 2012
Revision History
Revision
Date
Section
Procedure / Schematic Page / Description
C
2/2012
Introduction
Revision History Added
3 - Maint.
3-1
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Part No. 111165
S-80 • S-85
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iii
February 2012
REVISION HISTORY, CONTINUED
Revision
Date
Section
Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
Fault Codes_Section 5.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
iv
S-80 • S-85
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Part No. 111165
February 2012
Introduction
Serial Number Legend
Model: S-80
S8006-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: E0180
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg
S80
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 6 in/ 18.3 m
06 - 12345
Sequence
number
Model
Maximum platform reach : 34 ft 3 in/ 10.4 m
Gradeability: N/A
Model year
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Terex South Dakota, Inc.
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201
USA
Sequence number
(stamped on chassis)
Serial label
(located under cover)
PN - 77055
Part No. 111165
S-80 • S-85
v
Section 1 • Safety Rules
February 2012
Safety Rules
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.
Danger
Read each procedure thoroughly. This
manual and the decals on the machine use
signal words to identify the following:
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 and Genie S-85
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
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.
Do Not Perform Maintenance
Unless:
Indicates an 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.
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
may result in minor or moderate
injury.
You have the appropriate tools, lifting
equipment and a suitable workshop.
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.
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Part No. 111165
February 2012
Section 1 - Safety Rules
SAFETY RULES
Workplace Safety
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.
Part No. 111165
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Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Revision History .......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 1
Safety Rules
General Safety Rules .................................................................................................. vi
Section 2
Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 1
Hydraulic Specifications ........................................................................................ 2 - 2
Manifold Component Specifications ....................................................................... 2 - 3
GM 3.0L EFI Engine Specifications ....................................................................... 2 - 4
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 5
Deutz F4L-913 Engine Specifications .................................................................... 2 - 7
Deutz BF4L-2011 Engine Specifications ................................................................ 2 - 8
Perkins 804C-33 Engine Specifications ............................................................... 2 - 10
Machine Torque Specifications ............................................................................ 2 - 11
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12
SAE and Metric Torque Specifications ................................................................. 2 - 13
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Part No. 111165
February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
A-1
Inspect the Manuals and Decals .................................................................. 3 - 7
A-2
Perform Pre-operation Inspection ................................................................. 3 - 8
A-3
Perform Function Tests ................................................................................ 3 - 8
A-4
Perform Engine Maintenance ....................................................................... 3 - 9
A-5
Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10
A-6
Grease the Extendable Axles ..................................................................... 3 - 11
A-7
Test the Oscillate Axle ............................................................................... 3 - 11
A-8
Test the Extendable Axles ......................................................................... 3 - 12
A-9
Perform 30 Day Service ............................................................................. 3 - 13
A-10 Perform Engine Maintenance - Deutz Models ............................................. 3 - 13
A-11 Inspect the Fuel Filter/Water Separator - Deutz and Perkins Models .......... 3 - 14
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15
A-13 Perform Engine Maintenance ..................................................................... 3 - 15
A-14 Perform Engine Maintenance- Deutz Models .............................................. 3 - 16
A-15 Replace the Drive Hub Oil .......................................................................... 3 - 17
A-16 Perform Engine Maintenance - GM, Ford and Perkins Models .................... 3 - 18
Checklist B Procedures
Part No. 111165
B-1
Inspect the Battery(s) ................................................................................. 3 - 19
B-2
Inspect the Electrical Wiring ....................................................................... 3 - 20
B-3
Test the Key Switch ................................................................................... 3 - 22
B-4
Check the Exhaust System ....................................................................... 3 - 22
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February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
B-5
Inspect the Engine Air Filter ....................................................................... 3 - 23
B-6
Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 24
B-7
Confirm the Proper Brake Configuration ...................................................... 3 - 25
B-8
Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 26
B-9
Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 27
B-10 Check and Adjust the Engine RPM ............................................................ 3 - 28
B-11 Perform Engine Maintenance ..................................................................... 3 - 30
B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 31
B-13 Test the Ground Control Override ............................................................... 3 - 31
B-14 Test the Platform Self-leveling ................................................................... 3 - 32
B-15 Test the Engine Idle Select Operation ........................................................ 3 - 32
B-16 Test the Fuel Select Operation - GM and Ford Models ............................... 3 - 33
B-17 Test the Drive Enable System ................................................................... 3 - 34
B-18 Test the Drive Brakes ................................................................................ 3 - 35
B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 36
B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 36
B-21 Test the Alarm Package (if equipped) ........................................................ 3 - 37
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38
B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 39
B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 40
Checklist C Procedures
x
C-1
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 41
C-2
Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 42
C-3
Test the Platform Overload System (if equipped) ....................................... 3 - 42
C-4
Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 45
C-5
Replace the Fuel Filter/ Water Separator Element Deutz and Perkins Models ......................................................................... 3 - 45
C-6
Perform Engine Maintenance - GM and Ford Models ................................. 3 - 47
S-80 • S-85
Part No. 111165
February 2012
TABLE OF CONTENTS
Section 3
Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1
Check the Boom Wear Pads ...................................................................... 3 - 48
D-2
Check the Extendable Axle Wear Pads ...................................................... 3 - 49
D-3
Check the Free-wheel Configuration ........................................................... 3 - 50
D-4
Check the Turntable Rotation Bearing Bolts ............................................... 3 - 51
D-5
Inspect the Turntable Bearing Wear ........................................................... 3 - 52
D-6
D-7
Replace the Hydraulic Filter Elements ........................................................ 3 - 55
D-8
Replace the Drive Hub Oil .......................................................................... 3 - 56
D-9
Perform Engine Maintenance - Deutz Models ............................................. 3 - 58
Checklist E Procedures
Section 4
E-1
Test or Replace the Hydraulic Oil ............................................................... 3 - 59
E-2
Perform Engine Maintenance - Perkins Models .......................................... 3 - 61
E-3
Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 61
E-4
Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1
ALC-500 Circuit Board .................................................................................. 4 - 2
1-2
Joysticks ..................................................................................................... 4 - 3
Platform Components
Part No. 111165
2-1
Platform ....................................................................................................... 4 - 8
2-2
Platform Leveling Slave Cylinder .................................................................. 4 - 9
S-80 • S-85
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TABLE OF CONTENTS
Section 4
Repair Procedures, continued
2-3
Platform Rotator ......................................................................................... 4 - 10
2-4
Calibrate the Platform Overload System .................................................... 4 - 12
Jib Boom Components, S-85
3-1
Jib Boom .................................................................................................... 4 - 15
3-3
Jib Boom Lift Cylinder ................................................................................ 4 - 16
Boom Components
4-1
Cable Track ................................................................................................ 4 - 17
4-2
Boom ......................................................................................................... 4 - 20
4-3
Boom Lift Cylinder ...................................................................................... 4 - 23
4-4
Boom Extension Cylinders ......................................................................... 4 - 25
4-5
Platform Leveling Master Cylinder .............................................................. 4 - 27
Engines
5-1
RPM Adjustment ........................................................................................ 4 - 28
5-2
Flex Plate ................................................................................................... 4 - 28
Ground Controls
6-1
Control Relays ............................................................................................ 4 - 34
6-2
Power Relay ............................................................................................... 4 - 35
6-3
Terminal Strip ............................................................................................. 4 - 35
Hydraulic Pumps
xii
7-1
Function Pump ........................................................................................... 4 - 36
7-2
Drive Pump ................................................................................................ 4 - 37
S-80 • S-85
Part No. 111165
February 2012
TABLE OF CONTENTS
Section 4
Manifolds
8-1
Function Manifold Components - View 1 .................................................... 4 - 39
8-2
Function Manifold Components - View 2 .................................................... 4 - 40
8-3
Valve Adjustments - Function Manifold ...................................................... 4 - 45
8-4
Brake/Two-speed Manifold Components
(before serial number 5002) ........................................................................ 4 - 47
8-5
Brake/Two-speed Manifold Components
(after serial number 5001) ........................................................................... 4 - 48
8-6
Turntable Rotation Manifold Components ................................................... 4 - 49
8-7
Jib Boom Select Manifold Components, S-85 ............................................ 4 - 50
8-8
Axle Select Manifold Components .............................................................. 4 - 51
8-9
2WD Traction Manifold Components
8-10 2WD Traction Manifold Components
8-13 Drive Oil Diverter Manifold Components ..................................................... 4 - 61
8-14 Valve Adjustments - Drive Manifold ........................................................... 4 - 62
8-15 Valve Coils ................................................................................................. 4 - 63
Fuel and Hydraulic Tanks
Part No. 111165
9-1
Fuel Tank ................................................................................................... 4 - 66
9-2
Hydraulic Tank ........................................................................................... 4 - 67
S-80 • S-85
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TABLE OF CONTENTS
Section 4
Turntable Rotation Components
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 69
2WD Steer Axle Components
11-1 Yoke and Hub ............................................................................................ 4 - 72
11-2 Steer Cylinder ............................................................................................ 4 - 73
11-3 Tie Rod Cylinder ......................................................................................... 4 - 74
12-1 Yoke and Drive Hub ................................................................................... 4 - 75
12-2 Drive Motor ................................................................................................ 4 - 76
12-3 Drive Hub ................................................................................................... 4 - 77
12-4 Steer Cylinders ........................................................................................... 4 - 77
12-5 Tie Rod Cylinder ......................................................................................... 4 - 78
Non-steer Axle Components
13-1 Drive Motor ................................................................................................ 4 - 79
13-2 Drive Hub ................................................................................................... 4 - 79
Oscillating Axle Components
14-1 Oscillate Axle Cylinders ............................................................................. 4 - 80
14-2 Valve Adjustments - Oscillate Directional Valve ......................................... 4 - 81
Extendable Axle Components
15-1 Extendable Axles ....................................................................................... 4 - 83
15-2 Axle Extension Cylinder ............................................................................. 4 - 85
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Part No. 111165
February 2012
TABLE OF CONTENTS
Section 5
Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes- Control System ................................................................................. 5 - 2
Engine Fault Codes- GM and Ford Models ............................................................. 5 - 6
Section 6
Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend - Rev A ........................................................................ 6 - 2
Hydraulic Symbols Legend - Rev A ........................................................................ 6 - 3
Ford LRG-425 Engine Wiring Harness .................................................................... 6 - 6
GM 3.0L Engine Wiring Harness ............................................................................ 6 - 7
Electrical Schematic, S-80
Deutz F4L 913 Models ......................................................................................... 6 - 10
Ground Control Box Wiring Diagram, S-80
Deutz F4L 913 Models ......................................................................................... 6 - 14
Platform Control Box Wiring Diagram, S-80
Deutz F4L 913 Models ......................................................................................... 6 - 15
Deutz BF4L2011 Models ...................................................................................... 6 - 18
Deutz BF4L 2011 Models ..................................................................................... 6 - 22
Deutz BF4L 2011 Models ..................................................................................... 6 - 23
Part No. 111165
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TABLE OF CONTENTS
Section 6
Schematics, continued
GM 3.0L Models .................................................................................................. 6 - 26
GM 3.0L Models .................................................................................................. 6 - 30
GM 3.0L Models .................................................................................................. 6 - 31
Perkins 804-33 Models ........................................................................................ 6 - 34
Perkins 804-33 Models ........................................................................................ 6 - 38
Perkins 804-33 Models ........................................................................................ 6 - 39
Ford LRG-425 Models .......................................................................................... 6 - 42
Ford LRG-425 Models .......................................................................................... 6 - 46
Ford LRG-425 Models .......................................................................................... 6 - 47
Deutz F4L 913 Models ......................................................................................... 6 - 50
Deutz F4L 913 Models ......................................................................................... 6 - 54
Deutz F4L 913 Models ......................................................................................... 6 - 55
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February 2012
TABLE OF CONTENTS
Section 6
Deutz BF4L2011 Models ...................................................................................... 6 - 58
Deutz BF4L2011 Models ...................................................................................... 6 - 62
Deutz BF4L2011 Models ...................................................................................... 6 - 62
GM 3.0L Models .................................................................................................. 6 - 66
GM 3.0L Models .................................................................................................. 6 - 70
GM 3.0L Models .................................................................................................. 6 - 71
Perkins 804-33 Models ........................................................................................ 6 - 74
Perkins 804-33 Models ........................................................................................ 6 - 78
Perkins 804-33 Models ........................................................................................ 6 - 79
Part No. 111165
S-80 • S-85
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February 2012
TABLE OF CONTENTS
Section 6
Ford LRG-425 EFI Models ................................................................................... 6 - 82
Connector Pin Legend - View 1 ............................................................................ 6 - 90
Connector Pin Legend - View 2 ............................................................................ 6 - 91
Dual Battery Option ............................................................................................. 6 - 94
Belt Drive Generator Option ................................................................................. 6 - 95
CE Option ............................................................................................................ 6 - 98
Platform Level Cutout, CTE Option ...................................................................... 6 - 99
12 kW Hydraulic Generator Wiring Diagram ......................................................... 6 - 102
12 kW Hydraulic Welder Option ........................................................................... 6 - 103
Hydraulic Schematic, 2WD Models ..................................................................... 6 - 106
Hydraulic Schematic, 4WD Models ..................................................................... 6 - 107
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Part No. 111165
February 2012
Section 2 • Specifications
Specifications
Machine Specifications
Performance Specifications
Tires and wheels
Drive speed, maximum
Tire size
15-22.5 SAT
385/65-22.5
Tire ply rating
Overall tire diameter
16
43.5 in
110.5 cm
Stowed position
40 ft / 7.9-8.5 sec
12.2 m / 7.9-8.5 sec
Raised or extended position
Braking distance, maximum
Tire pressure
100 psi
6.9 bar
High range on paved surface
Wheel diameter
22.5 in
57 cm
Gradeability
Wheel width
Wheel lugs
Lug nut torque, dry
Lug nut torque, lubricated
11.75 in
29.8 cm
10 @ 3/4 -16
420 ft-lbs
569 Nm
310 ft-lbs
420 Nm
40 ft / 40-45 sec
12.2 m / 40-45 sec
3 ft
90 cm
Refer to the Operator’s Manual
Boom function speeds, maximum
from platform controls
Jib boom up (S-85)
60 to 70 seconds
Jib boom down (S-85)
40 to 50 seconds
Boom up
89 to 93 seconds
Boom down
90 to 94 seconds
Boom extend
73 to 79 seconds
Boom retract
79 to 84 seconds
Fluid capacities
Fuel tank
LPG tank
Hydraulic tank
Hydraulic system
(including tank)
30 gallons
114 liters
33.5 pounds
15.2 kg
45 gallons
170 liters
57 gallons
215 liters
Turntable rotation drive hub
40 fl oz
1.2 liters
Rexroth drive hubs
61 fl oz
1.8 liters
51 fl oz
1.5 liters
Bonfiglioli drive hubs
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil
API service classification GL5
For operational specifications, refer to the
Part No. 111165
Turntable rotate, 360°
boom fully stowed
boom raised or extended
Platform rotate, 160°
95 to 103 seconds
210 to 250 seconds
8 to 12 seconds
Platform level up
50 to 60 seconds
Platform level down
40 to 50 seconds
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
S-80 • S-85
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February 2012
SPECIFICATIONS
Hydraulic Oil Specifications
Hydraulic Component
Specifications
Hydraulic Oil Specifications
Hydraulic oil type
Viscosity grade
Viscosity index
Chevron Rykon MV equivalent
Multi-viscosity
200
Cleanliness level, minimum
Water content, maximum
15/13
200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
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, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Drive pump
Type: bi-directional variable displacement piston pump
Flow rate @ 2300 rpm
0 to 30.3 gpm
0 to 114.7 L/min
Drive pressure, maximum
4200 psi
290 bar
Charge pump
Type:
gerotor
Displacement
0.85 cu in
13.9 cc
8 gpm
30.3 L/min
Optional fluids
Biodegradable
Fire resistant
Mineral based
Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Continued use of Chevron Aviation
A hydraulic oil when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage.
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
below 0°F / -18°C.
Charge pressure @ 2300 rpm
Neutral position
320 psi
22 bar
Function pump
Type:
two-section tandem gear pump
Displacement - Pump 1 (inner)
1.4 cu in
22.9 cc
12.7 gpm
48 L/min
Displacement - Pump 2 (outer)
0.24 cu in
4 cc
2.25 gpm
8.5 L/min
Auxiliary pump
Type:
Displacement - static
fixed displacement gear pump
0.151 cu in
2.47 cc
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
2-2
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
Function manifold
System relief pressure
(measured at PTEST port)
2900 psi
200 bar
Boom down relief pressure
2100 psi
145 bar
Boom extend
2500 psi
172 bar
Steer/axle extend
flow regulator
3.5 gpm
13.2 L/min
Oscillate relief pressure
850 psi
58.6 bar
Drive manifold
Hot oil relief pressure
280 psi
19.3 bar
Brake release pressure
Rexroth hubs
217.5 psi
15 bar
189 psi
13 bar
Bonfiglioli hubs
Drive motors
Displacement per revolution, variable
(2 speed motor)
0.9 to 2.7 cu in
14.7 to 45 cc
Valve Coil Resistance
Specifications
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
Valve coil resistance specifications
Proportional solenoid valve
(schematic items K and W)
4.8 Ω
2 position 3 way solenoid valve
(schematic items D, R, X, TT and UU)
6.3 Ω
(schematic items G)
3.3 Ω
(schematic items A, E, N and S)
6.3 Ω
(schematic items AK, AM, VV and WW)
6.3 Ω
(schematic item G)
3.3 Ω
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
10 micron with
25 psi / 1.7 bar bypass
Part No. 111165
S-80 • S-85
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February 2012
SPECIFICATIONS
GM 3.0L EFI Engine
Starter motor
181 cu in
3 liters
Displacement
4
Number of cylinders
Bore & stroke
Horsepower
Intermittent
Continuous
Intermittent
Continuous
4 x 3.6 inches
101.6 x 91.44 mm
67 @ 2300 rpm
60 @ 2300 rpm
50 kW @ 2300 rpm
45 kW @ 2300 rpm
1-3-4-2
Low idle
Frequency
1650 rpm
386.1 Hz
High idle
Frequency
2300 rpm
538.2 Hz
Current draw, normal load
400A
Current draw, maximum load
600A
Current draw, minimum
100A
Type
Compression pressure - minimum
Pressure (psi or bar) of lowest cylinder
must be at least 75% of highest cylinder
100 psi
6.9 bar
12V DC
Group
31
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
1
1000A
200 minutes
Electronic fuel pump
Fuel pressure, static
9.25:1
Compression ratio
Fuel flow rate
9 to 11 psi
0.6 to 0.76 bar
0.3 gpm
1.14 L/min
Ignition system
Zero lash + 1 full turn
Lubrication system
Oil pressure - minimum
(operating temp. @ 2000 rpm)
18 psi
1.24 bar
Oil capacity
(including filter)
5 quarts
4.7 liters
Spark plug type
AC ACMR-43-LTS
Spark plug gap
0.040 in
1.01 mm
Engine coolant
Capacity
Oil viscosity requirements
Alternator
Extreme operating temperatures may require the use of
alternative engine oil. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Output
Fan belt deflection
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
2-4
350 rpm
Batteries
Firing order
Valve clearances
Normal engine cranking speed
12 quarts
11.4 liters
66A, 12V DC
1 /2
inch
12 mm
Genie policy. Product specifications are
subject to change without notice.
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
Ford LRG-425 EFI Engine
Displacement
Oil pressure switch specifications
153 cu in
2.5 liters
4
Number of cylinders
Bore & stroke
3.78 x 3.4 in
96.01 x 86.36 mm
Torque
8-18 ft-lbs
11-24 Nm
Oil pressure switch point
3-5 psi
0.21-0.34 bar
Starter motor
Normal engine cranking speed
Horsepower
Continuous
Intermittent
Continuous
Intermittent
60 @ 2500 rpm
70 @ 2500 rpm
44.7kW @ 2500 rpm
52 kW @ 2500 rpm
Firing order
1-3-4-2
Low idle
Frequency
1600 rpm
396.8 Hz
High idle
Frequency
2500 rpm
620 Hz
200 to 250 rpm
140-200A
Current draw, maximum load
800A
Current draw, no load
70A
Maximum circuit voltage drop
while starting (normal temperature)
0.5V DC
Batteries
Type
12V DC
Group
31
9.4:1
Compression ratio
Quantity
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder.
Valve clearances collapsed tappet
0.035 to 0.055 in
0.889 to 1.397 mm
Oil pressure
(operating temp. @ 2000 rpm)
Oil capacity
(including filter)
40 to 60 psi
2.75 to 4.1 bar
5 quarts
4.7 liters
200 minutes
Fuel flow rate
64 psi
4.4 bar
0.58 gpm
2.18 L/min
Fuel requirement
Unit ships with 5W-30.
alternative engine oils. For oil requirements, refer to the
Part No. 111165
1000A
Electronic fuel pump
Fuel pressure, static
Lubrication system
1
Ignition system
Spark plug type
Motorcraft AWSF-52C
Spark plug gap
0.042 to 0.046 in
1.07 to 1.18 mm
Spark plug torque
S-80 • S-85
5 to 10 ft-lbs
7 to 14 Nm
2-5
February 2012
SPECIFICATIONS
Engine coolant
Capacity
11.5 quarts
10.9 liters
Coolant temperature switch
Torque
Temperature switch point
8-18 ft-lbs
11-24 Nm
230° F
112° C
Alternator
Output
95A, 13.8V DC
2-6
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
Deutz F4L-913 Engine
Displacement
Injection system
249.3 cu in
4.085 liters
Horsepower
Firing order
Compression ratio
IMSA
Injection pump pressure
8702 psi
600 bar
Injector opening pressure
3626 psi
250 bar
4
Number of cylinders
Bore and stroke
Injection pump make
4.02 x 4.92 inches
102.1 x 125 mm
76 @ 2300 rpm
57 kW @ 2300 rpm
1-3-4-2
18:1
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Low idle - no load
Frequency
1300 rpm
385.7 Hz
High idle - no load
Frequency
2300 rpm
570.4 Hz
Fuel requirement
Batteries
Type
12V DC
Group
31
Quantity
1
Alternator
1000A
200 minutes
55A, 12V DC
Valve clearance, cold
Fan belt deflection
Intake
0.006 in
0.15 mm
Exhaust
0.006 in
0.15 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
3/8
to 1/2 inch
9 to 12 mm
Genie policy. Product specifications are
subject to change without notice.
40 to 60 psi
2.75 to 4.14 bar
14.3 quarts
13.5 liters
Units ship with 15W-40.
alternative engine oil. For oil requirements, refer to the
Part No. 111165
S-80 • S-85
2-7
February 2012
SPECIFICATIONS
Deutz BF4L-2011 Engine
Displacement
Lubrication system
189.6 cu in
3.1 liters
4
Number of cylinders
Bore and stroke
3.7 x 4.409 inches
94 x 112 mm
Horsepower
Continuous
Net intermittent
Continuous
Net intermittent
Firing order
69.1 @ 2500 rpm
72.8 @ 2500 rpm
51.5 KW @ 2500 rpm
54.3 KW @ 2500 rpm
1-3-4-2
Low idle
Frequency
1500 rpm
382.5 Hz
High idle
Frequency
2350 rpm
599.25 Hz
Compression ratio
17.5:1
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.
Governor
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
40 to 60 psi
2.8 to 4.1 bar
11 quarts
10.4 liters
Extreme operating temperatures my require the use of
Oil temperature switch
Torque
Oil temperature switch point
8-18 ft-lbs
11-24 Nm
275°F
135°C
Oil pressure switch
Torque
Oil pressure switch point
8-18 ft-lbs
11-24 Nm
7 psi
0.48 bar
centrifugal mechanical
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
2-8
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
Fuel injection system
Injection pump make
Bosch
Injection pump pressure, maximum15,000 psi/1034 bar
3046 psi
210 bar
Fuel Requirement
Starter motor
Cranking speed
140-200A
200-250 rpm
Batteries
Type
12V DC
Group
31
Quantity
1
Alternator output
Fan belt deflection
1000A
200 minutes
80A @ 14V DC
3/8
to 1/2 inch
9 to 12 mm
Part No. 111165
S-80 • S-85
2-9
February 2012
SPECIFICATIONS
Perkins 804C-33 Engine
Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio
201 cu in
3.3 liters
4
3.70 x 4.72 inches
94 x 120 mm
63 @ 2600 rpm
47 KW @ 2600 rpm
1-3-4-2
Injection system
Injection pump make
Injection pump pressure
22:1
300 to 500 psi
20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must be
within 50 psi / 3.45 bar of highest cylinder
Low idle
Frequency
1650 rpm
335.5 Hz
High idle
Frequency
2300 rpm
467.67 Hz
Governor
Extreme operating temperatures my require the use of
mechanical all speed
0.0098 in
0.25 mm
Exhaust
0.0098 in
0.25 mm
Lubrication system
40-60 psi
2.8-4.1 bar
Oil capacity
(including filter)
10.6 quarts
10 liters
~2000 psi
~138 bar
Engine coolant
Capacity
12.5 quarts
11.8 liters
Batteries
Type
Quantity
Alternator output
Oil pressure @ 2000 rpm
1707 to 1849 psi
117.7 to 127.5 bar
Fuel Requirement
Group
Intake
Zexel
Fan belt deflection
12V DC
31
1
1000A
200 minutes
90A, 12V DC
3/8 to 1/2 in
9 to 12 mm
2 - 10
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
Machine Torque Specifications
Manifold Component
Specifications
Platform rotator
1-8 center bolt, GR 5, lubricated
3/8
-16 bolts, GR 8
*(use blue thread locking compound)
480 ft-lbs
651 Nm
35 ft-lbs*
47 Nm*
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
Rotate drive hub mounting bolts, lubricated
Backlash plate mounting bolts, lubricated
180 ft-lbs
244 Nm
80 ft-lbs
108 Nm
Plug torque
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
14 ft-lbs / 18.9 Nm
SAE No. 6
23 ft-lbs / 31.2 Nm
SAE No. 8
36 ft-lbs / 48.8 Nm
SAE No. 10
62 ft-lbs / 84.1 Nm
SAE No. 12
84 ft-lbs / 113.9 Nm
280 ft-lbs
379 Nm
Drive motor and hubs
Drive hub mounting bolts, dry
Drive hub mounting bolts, lubricated
210 ft-lbs
284 Nm
185 ft-lbs*
247 Nm
Drive motor mounting bolts, dry
110 ft-lbs
149 Nm
Drive motor mounting bolts, lubricated
80 ft-lbs*
108 Nm
Drive hub oil plug, O-ring seal
13 ft-lbs
18 Nm
Part No. 111165
S-80 • S-85
2 - 11
February 2012
SPECIFICATIONS
Seal-Lok® fittings
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
SAE Dash size
Torque
-4
14 ft-lbs / 18.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
36 ft-lbs / 48.8 Nm
-10
62 ft-lbs / 84.1 Nm
-12
84 ft-lbs / 113.9 Nm
-16
125 ft-lbs / 169.5 Nm
-20
151 ft-lbs / 204.7 Nm
-24
184 ft-lbs / 250 Nm
3 Be sure that the face seal O-ring is seated 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 per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok® Fittings
(tube fitting - installed into Steel)
(hose end)
SAE Dash size
Torque
SAE Dash size
Torque
-4
15 ft-lbs / 20.3 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
30 ft-lbs / 40 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 55 Nm
-10
100 ft-lbs / 135.6 Nm
-10
60 ft-lbs / 80 Nm
-12
135 ft-lbs / 183 Nm
-12
85 ft-lbs / 115 Nm
-16
200 ft-lbs / 271 Nm
-16
110 ft-lbs / 150 Nm
-20
250 ft-lbs / 334 Nm
-20
140 ft-lbs / 190 Nm
-24
305 ft-lbs / 414 Nm
-24
180 ft-lbs / 245 Nm
2 - 12
S-80 • S-85
Part No. 111165
February 2012
SPECIFICATIONS
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Grade 5
SIZE THREAD
LUBED
20
28
1/4
DRY
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(mm)
5
6
7
LUBED
LUBED
DRY
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Part No. 111165
S-80 • S-85
2 - 13
February 2012
This page intentionally left blank.
2 - 14
S-80 • S-85
Part No. 111165
February 2012
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Symbols Legend
Scheduled maintenance inspections shall be
completed daily, quarterly, six months, annually
and every two years as specified on the
Maintenance Inspection Report. The frequency
and extent of periodic examinations and tests
may also depend on national regulations.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial machine damage.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used to
indicate the presence of a
which, if not avoided, may result
in minor or moderate injury.
Repair any machine damage or malfunction
before operating machine.
Use only Genie approved replacement parts.
which, if not avoided, may result in
property damage.
Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
•
Machine parked on a firm, level surface
•
Boom in the stowed position
•
Turntable rotated with the boom between
the non-steer (yellow arrow) wheels
•
Turntable secured with the turntable
rotation lock pin
•
Key switch in the off position with the
key removed
•
Wheels chocked
•
All external AC power supply disconnected
from the machine
Part No. 111165
Note: Used to indicate operation or maintenance
information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-80 • S-85
3-1
February 2012
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation Report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
To account for repeated procedures, the
Scheduled Maintenance Procedures Section and
the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection
Indicates that a warm engine will be
required to perform this procedure.
Checklist
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that dealer service is required
to perform this procedure.
Six month or every 500 hours
Annual or every 1000 hours
Two year or every 2000 hours
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
3-2
S-80 • S-85
Part No. 111165
Pre-Delivery Preparation
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Make copies of this form to use for each Pre-Delivery
Preparation.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it is
put into service.
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing
the Pre-operation Inspection, the Maintenance items
and the Function Tests.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair, place
a check in the R box.
Scheduled maintenance inspections shall be performed
by qualified service technicians, according to the
manufacturer's specifications and the requirements
listed in the responsibilities manual.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA
500 Oak Wood Road
PO Box 1150
Watertown, SD 57201-6150
(605) 882-4000
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
Y
N
R
February 2012
3-4
S-80 • S-85
Part No. 111165
February 2012
Maintenance Inspection Report
Model
Checklist A
Serial number
A-1 Inspect the manuals
and decals
B-1 Battery(s)
Date
A-2 Pre-operation
inspection
B-3 Key switch
Hour meter
A-3 Function tests
Y N R
A-4 Engine maintenance
Checklist B
B-2 Electrical wiring
B-4 Exhaust system
B-5 Engine air filter
Machine owner
A-5 Filter condition indicator
B-6 Oil cooler and finsDeutz models
A-6 Grease Axles
B-7 Brake configuration
A-7 Oscillate axle
A-8 Extendable axles
B-8 Tires, wheels and
lug nut torque
Perform after 40 hours:
B-9 Drive hub maintenance
A-9 30 day service
B-10 Engine RPM
B-11 Engine maintenance
A-10 Engine maintenance Deutz models
B-12 Oscillate directional
Control
Perform every 100 hours:
B-13 Ground control
override
Inspector signature
Inspector title
Inspector company
Instructions
• Make copies of this report to use for
each inspection.
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
A-11 Inspect filter/separator Diesel models
B-14 Platform self-leveling
A-12 Grease rotation
bearing
B-15 Engine idle select
A-13 Engine maintenance
B-17 Drive enable system
B-18 Drive brakes
A-14 Engine maintenance Deutz models
B-19 Drive speed-stowed
B-16 Fuel select operation
Six Month or 500 hour
Inspection:
A+B+C
B-20 Drive speed-raised
or extended
A-15 Replace Drive Hub oil
B-21 Alarm package
Annual or 1000 hour
Inspection:
A+B+C+D
B-22 Fuel and hydraulic tank
venting systems
2 Year or 2000 hour
Inspection:
A+B+C+D+E
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
A-16 Engine maintenance GM, Ford and Perkins
models
Y N R
B-23 Hydraulic oil analysis
B-24 Engine maintenance GM and Ford models
Comments
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 111165
S-80 • S-85
3-5
February 2012
MAINTENANCE INSPECTION REPORT
Model
Checklist C
Serial number
C-1 Engine maintenance Deutz and Perkins
models
E-1 Hydraulic oil
Hour meter
C-2 Grease platform
overload (if equipped)
E-3 Grease axle bearings,
2WD models
C-3 Test the platform
overload (if equipped)
Machine owner
Date
Y N R
E-4 Engine maintenance Deutz and Perkins
models
C-5 Replace filter/separator Deutz and Perkins
models
Inspector signature
Inspector title
C-6 Engine maintenance GM and Ford models
Inspector company
Instructions
• Make copies of this report to use for
each inspection.
Checklist D
Quarterly or 250 hour
Inspection:
Y N R
D-1 Boom wear pads
D-2 Axle wear pads
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily or 8 hour
Inspection:
Y N R
E-2 Engine maintenance Perkins models
C-4 Air filter element
Checklist E
A
A+B
Six Month or 500 hour
Inspection:
A+B+C
D-3 Free-wheel
configuration
D-4 Turntable rotation
bearing bolts
D-5 Turntable bearing wear
D-6 Engine maintenance Deutz and Perkins
models
D-7 Replace hydraulic filters
Annual or 1000 hour
Inspection:
A+B+C+D
D-8 Drive hub oil
2 Year or 2000 hour
Inspection:
A+B+C+D+E
D-9 Engine maintenance Deutz models
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
Comments
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6
S-80 • S-85
Part No. 111165
February 2012
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes
first.
Maintaining the operator’s and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each machine
and should be stored in the container provided in
the platform. An illegible or missing manual will not
provide safety and operational information
necessary for a safe operating condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.
3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and in
good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie if replacement manuals or decals are
needed.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or is illegible. Remove the machine
from service until the manual is replaced.
Part No. 111165
S-80 • S-85
3-7
February 2012
CHECKLIST A PROCEDURES
A-2
Perform Pre-operation
Inspection
A-3
Perform Function Tests
first.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong
with a machine before the operator performs the
function tests. The pre-operation inspection also
serves to determine if routine maintenance
procedures are required.
first.
Completing the function tests is essential to safe
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
3-8
S-80 • S-85
Part No. 111165
February 2012
To access the engine:
A-4
Perform Engine Maintenance
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Engine specifications require that this procedure be
first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
Required maintenance procedures and additional
engine information are available in the:
Deutz 913 Operator Handbook
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
GM 3.0L Operator Handbook
(GM part number 36100007) OR the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).
Genie part number
62446
Genie part number
84794
Genie part number
Genie part number
101095
84792
Perkins 804C-33 Operation and Maintenance Manual
Genie part number
111332
Part No. 111165
S-80 • S-85
3-9
February 2012
Tank return filter:
A-5
Check the Hydraulic Filter
Condition Indicators
3 Open the ground control side turntable cover and
inspect the filter condition indicator gauge.
first.
Maintaining the hydraulic filters in good condition is
essential to good system performance and safe
machine operation. The filter condition indicators
will show when the hydraulic flow is bypassing a
clogged filter. If the filters are not frequently
checked and replaced, impurities will remain in the
hydraulic system and cause component damage.
Note: There are three hydraulic filters located on
the machine: one tank return filter, one medium
pressure filter and one high pressure filter. The tank
return and high pressure filter have a condition
indicator on them. The medium pressure filter does
not have a filter condition indicator.
1 Start the engine from the platform controls.
Result: The needle on the gauge should be
operating in the green area.
Result: If the needle is in the red area, this
indicates that the hydraulic filter is being
bypassed and the filter should be replaced. See
D-7, Replace the Hydraulic Filter Elements.
High pressure filter:
Note: The high pressure filter is located to the left
of the medium pressure filter below the hydraulic
pumps. A filter condition indicator is located on the
top of the high pressure filter.
4 Open the engine side turntable cover and
Inspect the filter condition indicator.
Result: The filter condition indicators should be
operating with the plungers in the green area.
Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter should be
replaced. See D-7, Replace the Hydraulic Filter
Elements.
2 Change the engine idle to high rpm (rabbit
symbol).
a
a
3 - 10
filter condition indicator gauge
S-80 • S-85
Part No. 111165
February 2012
A-6
Grease the Extendable Axles
A-7
Test the Oscillate Axle
first.
first.
Proper lubrication of the extendable axle wear pads
is essential to smooth operation and minimum wear
of the wear pads.
Proper axle oscillation is essential to safe machine
operation. If the axle oscillation system is not
operating correctly, the stability of the machine is
compromised and it may tip over.
Tip-over hazard. Failure to perform
this procedure on a firm, level
surface will compromise the
stability of the machine and could
result in the machine tipping over.
Before serial number 4952:
1 Spread a liberal coating of grease on the top of
the inner axle extension and bottom of the outer
axle.
2 Drive the right steer tire up onto a
6 inch / 15 cm block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
2 Repeat for each axle.
After serial number 4951:
1 Locate the grease fitting on the platform side of
the non-steer extendable axle and behind the
drive motor on the steer extendable axle.
3 Drive the left steer tire up onto a 6 inch / 15 cm
block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
2 Pump grease into each fitting until grease is
visible between the axle and wear pads.
3 Repeat for each axle.
4 Drive both steer tires up onto a
6 inch / 15 cm block or curb.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Part No. 111165
Result: The non-steer tires should stay in firm
contact with the ground.
Note: If the chassis does not remain level during
the test, refer to Repair Procedure 14-2, How to Set
Up the Directional Valve Linkage.
S-80 • S-85
3 - 11
February 2012
6 Move and hold the function enable switch to
either side and activate the boom retract
function.
A-8
Test the Extendable Axles
first.
Tip-over hazard. Do not raise or
extend the boom unless both axles
are fully extended. If the axle
extension system is not operating
correctly, the stability of the
machine is compromised and it
may tip over.
Note: Be sure the axles are retracted before
performing this procedure.
Result: The boom should retract.
7 Turn the key switch to platform controls.
8 Press down the foot switch and move the drive
control handle in the forward direction and
activate the axle extend function.
Result: The machine will drive forward and the
axles should extend.
Note: The axle extend function will only work while
the machine is moving.
Note: The steer function will override the axle
extend or the axle retract function.
1 Turn the key switch to ground control and pull
out the red Emergency Stop buttons to the on
position at both the ground and platform
controls.
2 Start the engine from the ground controls.
either side and activate the boom up function.
Result: The boom should raise to 5° above
horizontal and then stop. The boom should not
raise above the limit switch unless both axles
are extended.
9 Turn the key switch to ground controls.
10 At the ground controls, hold the function enable
switch to either side and activate the boom up
and boom down function.
Result: The boom should raise and lower
normally.
11 At the ground controls, move and hold the
function enable switch to either side and
activate the boom extend and boom retract
function.
Result: The boom should extend and retract
normally.
either side and activate the boom down
function.
Result: The boom should lower and return to the
stowed position.
either side and activate the boom extend
function.
Result: The boom will extend approximately
1 foot / 30 cm and then stop. The boom should
not extend farther unless both axles are
extended.
3 - 12
S-80 • S-85
Part No. 111165
February 2012
A-9
Perform 30 Day Service
A-10
Perform Engine Maintenance Deutz Models
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the
maintenance tables for continued scheduled
maintenance.
1 Perform the following maintenance procedures:
•
A-12
Grease the Turntable Rotation Bearing
and Rotate Gear
•
B-8
Inspect the Tires, Wheels and
Lug Nut Torque
•
B-9
Check the Drive Hub Oil Level and
Fastener Torque
•
D-4
Check the Turnable Rotation Bearing
Bolts
•
D-7
Replace the Hydraulic Filter Elements
Engine specifications require that this one-time
procedure be performed after 50 hours of operation.
Required maintenance procedures for
commissioning new and overhauled engines and
additional engine information are available in the
(Deutz part number 0297 9929).
Genie part number
62446
Genie part number
84794
from moving.
Part No. 111165
S-80 • S-85
3 - 13
February 2012
A-11
Inspect the Fuel Filter/Water
Separator - Deutz and Perkins
Models
a
b
e
d
c
performed every 100 hours or monthly, whichever
comes first.
Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
perform this procedure can lead to poor engine
performance and/or hard starting, and continued
use may result in component damge. Extremely
dirty conditions may require this procedure be
performed more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
1 Open the turntable cover at the engine side of
the machine. Locate the fuel filter/water
separator.
2 Inspect the filter bowl for water.
a
b
c
d
e
4 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
5 Clean up any fuel that may have spilled.
Note: If the fuel filter/water separator is completely
drained, you must prime the fuel filter/water
separator before starting the engine.
See C-5, Replace The Fuel Filter/Water Separator
Element, for instructions on how to prime the fuel
filter/water separator.
6 Start the engine from the ground controls and
check the fuel filter/water separator and vent
plug for leaks.
Result: Water is not visible in the filter bowl.
Result: There is water present. Proceed
to step 3.
3 Loosen the vent plug located on the head of the
fuel filter/water separator.
3 - 14
head bolt
vent plug
drain plug
filter bowl
separator head
S-80 • S-85
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Part No. 111165
February 2012
A-12
Grease the Turntable Rotation
Bearing and Rotate Gear
A-13
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the platform end of
the tank side bulkhead.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments
of 4 to 5 inches / 10 to 13 cm at a time and
repeat this step until the entire bearing has been
greased.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
or equivalent
performed every 100 hours.
Genie part number
62446
Genie part number
84794
Genie part number
Genie part number
101095
84792
Genie part number
111332
Part No. 111165
S-80 • S-85
3 - 15
February 2012
from moving.
A-14
performed every 125 hours of operation.
Required maintenance procedures for
commissioning new and overhauled engines and
additional engine information are available in the
Genie part number
62446
Genie part number
84794
from moving.
3 - 16
S-80 • S-85
Part No. 111165
February 2012
6 Repeat steps 1 through 4 for the other drive hub.
A-15
Replace the Drive Hub Oil
7 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
Turntable rotate drive hub:
Manufacture specifications require that this onetime procedure be performed after the first 150
hours.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil after the initial 150 hours of
use may cause the machine to perform poorly and
continued use may cause component damage.
Drive hubs:
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
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.
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
3 Attach a suitable lifting device to the lifting eyes
located near the drive motor.
2 Remove both plugs and drain the oil into a
suitable container.
4 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a
b
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device.
a
a. models with pipe plugs
b.
models with o-ring plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Install the plugs.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs into
the drive hub. Torque to Specification. Refer to
Section 2, Specifications.
Part No. 111165
S-80 • S-85
3 - 17
February 2012
5 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
A-16
Perform Engine Maintenance GM, Ford and Perkins Models
a
b
c
a
b
c
motor
drive hub
drive hub mounting bolts
6 Install the drive hub assembly onto the machine.
Torque the drive hub mounting bolts to
specification. Refer to Section 2, Specifications.
7 Fill the drive hub with oil from the side plug hole
until the oil level is even with the bottom of the
hole. Apply pipe thread sealant to the plug.
Install the plug.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 10-1, How to Adjust the
Turntable Rotation Gear Backlash.
engine information are available in the
Genie part number
101095
Genie part number
84792
Genie part number
from moving.
3 - 18
S-80 • S-85
Part No. 111165
February 2012
Checklist B Procedures
3 Be sure that the battery hold downs and cable
connections are tight.
B-1
Inspect the Battery(s)
4 Be sure that the battery separator wire
connections are tight (if equipped).
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good engine
performance and operational safety. Improper fluid
levels or damaged cables and connections can
result in engine component damage and hazardous
conditions. A single battery configuraton is
standard. A dual battery option is available, where
one battery is used to start the engine and the other
is used to power the control system and auxiliary
power unit. The two batteries are charged by the
alternator through a battery separator.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
5 Fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 8.
8 Perform an equalizing charge, OR fully charge
the battery(s) and allow the battery(s) to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
Part No. 111165
S-80 • S-85
3 - 19
February 2012
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
•
Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
•
Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific
gravity of 1.277 or greater. The battery is fully
charged. Proceed to step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.
B-2
Inspect the Electrical Wiring
comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.
1 Open the turntable cover at the engine side of
the machine.
2 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
a
b
engine tray anchor hole
engine tray retaining fastener
3 Locate the engine tray anchor hole on the
turntable.
3 - 20
S-80 • S-85
Part No. 111165
February 2012
4 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
the bolt into the engine pivot plate
to secure it from moving could
5 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
•
Engine wiring harness
•
Battery area wiring
13 Inspect for a liberal coating of dielectric grease
in the following location:
•
All wire harness connectors to
platform control box
14 Remove the engine tray retaining fastener from
the engine tray anchor hole at the pivot end of
the engine tray.
15 Swing the engine tray in towards the machine.
16 Install the engine tray retaining fasteners.
6 Open the turntable cover at the ground controls
side of the machine.
the bolt into the engine pivot plate
•
Inside the ground control box
•
Hydraulic manifold wiring
•
Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric grease
in the following locations:
•
All wire harness connectors to
ground control box
raise the secondary boom above the turntable
covers.
10 Inspect the turntable area for burnt, chafed and
pinched cables.
11 Lower the secondary boom to the stowed
position and turn the engine off.
•
Cable track on the boom
•
Cables on the boom and jib boom
•
Jib boom/platform rotate manifold
•
Inside of the platform control box
Part No. 111165
S-80 • S-85
3 - 21
February 2012
B-3
Test the Key Switch
B-4
Check the Exhaust System
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause a
hazardous operating situation.
comes first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
Bodily injury hazard. Do not
inspect while the engine is running.
Remove the key to secure from
operation.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check all machine function from the platform
controls.
from moving.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no functions
should operate.
2 Be sure that all nuts and bolts are tight.
3 Inspect all welds for cracks.
3 - 22
S-80 • S-85
Part No. 111165
February 2012
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
B-5
Inspect the Engine Air Filter
5 Swing the engine pivot plate in towards the
machine.
6 Install the bolts that were just removed into the
original holes to secure the engine pivot plate.
the bolts into the engine pivot plate
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
a
b
c
a
b
c
Part No. 111165
S-80 • S-85
clamp
canister end cap
dust discharge valve
3 - 23
February 2012
2 Release the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
B-6
Check the Oil Cooler and
Cooling Fins - Deutz Models
3 Remove the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
comes first.
5 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
Replace the filter if needed.
6 Install the filter element.
7 Install the air filter canister end cap and secure
the end cap latches.
Note: Be sure the discharge slot is pointing down.
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating a
machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
Oil cooler:
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
3 - 24
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Part No. 111165
February 2012
3 Remove the fasteners from the engine side
cover, then remove the cover.
B-7
Confirm the Proper
Brake Configuration
4 Inspect the oil cooler for leaks and physical
damage.
a
b
c
comes first.
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
a
b
c
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
oil cooler
cylinder head cooling fins
fan blower fins
5 Clean the oil cooler of debris and foreign
material.
disengaged position
Cooling and fan blower fins:
6 Inspect the fan blower fins for physical damage.
engaged position
7 Clean the fan blower fins of debris and foreign
material.
8 Inspect the head cooling passages and fins for
physical damage or foreign material, using a
flashlight.
9 Clean the cylinder head cooling passages of
debris and foreign material.
10 Install the engine side cover.
11 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
Part No. 111165
S-80 • S-85
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February 2012
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the bottom
of the drive pump.
b
a
c
d
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
B-8
Inspect the Tires, Wheels
and Lug Nut Torque
comes first.
Maintaining the tires and wheels in good
condition, including proper wheel fastener torque, is
essential to safe operation and good performance.
Tire and/or wheel failure could result in a machine
tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
Bodily injury hazard. An overinflated tire can explode and could
Note: The free-wheel valve should always remain
closed.
Tip-over hazard. Do not use
temporary flat tire repair products.
Note: The tires on some machines are foam filled
and do not need air added to them.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
4 Check the pressure in each air-filled tire. Add air
as necessary. Refer to Section 2,
Specifications.
3 - 26
S-80 • S-85
Part No. 111165
February 2012
B-9
Check Drive Hub Oil Level and
Fastener Torque
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
Drive hubs:
fasteners. Refer to Section 2, Specifications.
6 Repeat steps 1 through 5 for the other drive
hubs.
1 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
1 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
a
a
b
b
a
b.
2 Remove the plug located at 90 degrees and
check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
a
b
plug
drive hub
2 If necessary, add oil until the oil level is even
with the bottom of the plug hole. Refer to
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
Part No. 111165
S-80 • S-85
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February 2012
B-10
Check and Adjust the
Engine RPM
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
GM models:
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM.
If rpm adjustment or service is required, please
contact the Genie Service Department or your local
GM dealer.
Ford models:
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM.
If rpm adjustment or service is required, please
contact Genie Service Department or your local
Ford dealer.
Deutz F4L 913 models:
1 Connect a tachometer to the engine. Start the
engine from the ground controls and check the
rpm. Refer to Section 2, Specifications.
a
b
primary idle adjustment screw
secondary idle adjustment screw
3 Turn the secondary adjustment screw
counterclockwise until the adjustment screw is
loose. Tighten the locknut.
Note: Be sure the adjustment screw is loosened
until there is no spring tension felt.
4 Remove the primary idle adjustment screw cap
from the primary idle adjustment screw on the
injection pump. Loosen the locknut.
5 Adjust the primary idle adjustment screw until
low idle is 1250 rpm. Tighten the locknut.
6 Install the primary idle adjustment screw cap
and tighten. Do not over tighten.
7 Loosen the secondary idle adjustment screw
locknut.
Skip to step 10 if the low idle rpm is correct.
2 Remove the secondary idle adjustment screw
cap from the secondary idle adjustment screw
on the injection pump. Loosen the locknut.
3 - 28
S-80 • S-85
Part No. 111165
February 2012
8 Adjust the secondary adjustment screw until the
low idle meets specification. Tighten the
locknut.
9 Install the secondary idle adjustment screw cap
and tighten. Do not over tighten.
10 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustment
step 11.
Perkins models:
2 Loosen the low idle lock nut. Turn the low idle
adjustment screw clockwise to increase the rpm
or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
11 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
Deutz BF4L 2011 models:
Perkins models
a
solenoid boot
b
yoke lock nut
c
low idle adjustment screw
d
low idle lock nut
e
yoke
f
high idle adjustment nut
2 Loosen the locknut on the low idle adjustment
screw.
3 Adjust the low idle adjustment screw until low
idle meets specification. Tighten the locknut.
4 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
3 Move the function enable/rpm select toggle
switch to the high idle (rabbit symbol) position.
If the high idle is correct, disregard adjustment
step 5.
If high idle rpm is correct, disregard adjustment
step 4.
Part No. 111165
S-80 • S-85
3 - 29
February 2012
B-11
from moving.
comes first.
Genie part number
62446
Genie part number
84794
Genie part number
Genie part number
101095
84792
Genie part number
111332
3 - 30
S-80 • S-85
Part No. 111165
February 2012
B-12
Check the Oscillate Directional
Valve Linkage
comes first.
B-13
Test the Ground Control
Override
comes first.
Proper axle oscillation is essential to safe machine
operation. If the oscillate directional valve linkage is
not operating correctly, the stability of the machine
is compromised and it may tip over.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow ground
personnel to operate the machine from the ground
controls whether or not the red Emergency Stop
button at the platform controls is in the on or off
position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Remove the drive chassis cover from the
non-steer end of the machine.
1 Push in the red Emergency Stop button at the
platform controls to the off position.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for
the following:
Note: Perform this test only on models equipped
with an oscillating axle.
3 At the ground controls, operate each boom
function through a partial cycle.
• Lock nut is tight against yoke
Result: All boom functions should operate.
• Yoke clevis pins are installed
Note: The boom will not raise past horizontal and
the boom will not extend more than 12 inches /
30.5 cm unless both axles are fully extended.
• Cotter pins are installed through clevis pins
• Linkage is properly attached to
directional valve
Part No. 111165
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February 2012
B-14
Test the Platform Self-leveling
comes first.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is
essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder
located at the base of the boom.
A platform self-leveling failure creates an unsafe
working condition for platform and ground
personnel.
2 Hold the function enable toggle switch to either
side and adjust the platform to a level position
using the platform level toggle switch.
3 Raise and lower the boom through a full cycle.
B-15
Test the Engine Idle Select
Operation
comes first.
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are three settings.
Low idle (turtle symbol) allows the operator to
control individual boom functions only.
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions
simultaneously. This setting maintains a
consistent high idle.
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal
machine operation. This setting activates high idle
only when the foot switch is pressed down.
Result: The platform should remain level at
all times to within ±5 degrees.
Note: The boom will not raise past horizontal and
the boom will not extend more than
12 inches / 30.5 cm unless both axles are fully
extended.
controls.
4 Move and hold the function enable toggle switch
in the high idle (rabbit symbol) position.
Result: The engine rpm should change to high
idle.
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Part No. 111165
February 2012
5 Release the function enable toggle switch.
Result: The engine rpm should change to low
idle.
B-16
Test the Fuel Select Operation GM and Ford Models
7 At the platform controls, move the engine idle
select toggle switch to high idle (rabbit symbol).
Do not press down the foot switch.
idle.
8 Move the engine idle select toggle switch to low
idle (turtle symbol).
Result: The engine rpm should change to low
idle.
9 Move the engine idle select toggle switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine rpm should not change to
high idle.
10 Press down the foot switch.
idle.
comes first.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made whether the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
Note: Perform this test after checking the gasoline
and LPG fuel levels, and warming the engine to
normal operating temperature.
1 Move the fuel select toggle switch to gasoline
and then move the engine idle select switch to
foot switch activated high idle (rabbit and foot
switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Part No. 111165
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February 2012
4 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button in to
the off position.
B-17
Test the Drive Enable System
5 Move the fuel select toggle switch to LPG.
comes first.
6 Start the engine and allow it to run at low idle.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Note: The engine may hesitate momentarily and
then continue to run on the selected fuel if the fuel
source is switched while the engine is running.
Proper drive enable system operation is
essential to safe machine operation. When the
boom is past the non-steering wheels, drive
movement is stopped and the
indicator light turns on. The drive
enable switch must be held to
either side to reactivate the drive
function and should alert the
operator that the machine may
move in the opposite direction that the drive and
steer controls are moved. An improperly functioning
drive enable system may allow the machine to be
moved into an unsafe position.
Note: Perform this procedure with the boom in the
stowed position.
2 Press down the foot switch.
3 Rotate the turntable until the boom moves past
one of the the non-steer wheels.
Result: The drive enable indicator light should
turn on and remain on while the
boom is anywhere in the range
shown.
4 Slowly move the drive control
handle off center.
Result: The drive function should not operate.
3 - 34
S-80 • S-85
Part No. 111165
February 2012
5 Rotate the turntable until the boom moves past
the other non-steer wheel.
Result: The drive enable
indicator light should come on
and remain on while the boom
is anywhere in the range shown.
6 Move and hold the drive enable toggle switch to
either side and slowly move the drive control
handle off center.
Result: The drive function should operate.
Collision hazard. Always use the
color-coded direction arrows on the
platform controls and the drive
chassis to identify the direction of
travel.
B-18
Test the Drive Brakes
comes first.
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
See B-7, Confirm the Proper Brake
Configuration.
Note: When the drive enable system is in use, the
machine may drive in the opposite direction that the
drive and steer control handle is moved.
Note: Select a test area that is firm, level and free
of obstructions.
Blue
Note; Perform this procedure with the boom in the
stowed position.
1 Mark a test line on the ground for reference.
Yellow
3 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
when crossing the test line.
4 Bring the machine to top drive speed before
reaching the test line. Release the drive
controller when your reference point on the
machine crosses the test line.
5 Measure the distance between the test line and
your machine reference point. Refer to
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Part No. 111165
S-80 • S-85
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February 2012
B-19
Test the Drive Speed Stowed Position
B-20
Test the Drive Speed Raised or Extended Position
comes first.
comes first.
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire
proportionally controlled speed range.
Proper drive function movement is essential to safe
machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation,
jerking and unusual noise over the entire
proportionally controlled speed range.
Note: Select a test area that is firm, level and free
of obstructions.
Select a test area that is firm, level and free of
obstructions.
stowed position.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
3 Extend the axles.
4 Move the engine idle select toggle switch to
foot switch activated high idle (rabbit and foot
switch symbol).
patch of a tire) as a visual reference for use
when crossing the start and finish lines.
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
5 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Performance
Specifications.
5 Press down the foot switch and raise the boom
10° above horizontal.
6 Choose a point on the machine (i.e. contact
patch of a tire), as a visual reference for use
start line.
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
3 - 36
S-80 • S-85
Part No. 111165
February 2012
8 Continue at full speed and note the time when
Specifications.
Setting.
9 Press down the foot switch and lower the boom
to the stowed position.
B-21
Test the Alarm Package
(if equipped) and the Descent
Alarm
comes first.
The alarm package includes:
10 Extend the boom 3 feet / 90 cm.
patch of a tire), as a visual reference for use
start line.
13 Continue at top speed and note the time when
Specifications.
Setting.
•
Travel alarm
•
Flashing beacons
Alarms and beacons are installed to alert operators
and ground personnel of machine proximity and
motion. The alarm package is installed on the
turntable rear cover. Beacons are installed on both
turntable covers.
Note: The alarms and beacons will operate with the
engine running or not running.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on
controls.
Result: Both flashing beacons should be on and
flashing.
2 Move and hold the function enable toggle switch
to either side and activate the boom toggle
switch in the down position, hold for a moment
and then release it.
Result: The descent alarm should sound when
the toggle switch is held down.
Part No. 111165
S-80 • S-85
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February 2012
B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Result: The flashing beacons should be on
and flashing.
4 Press down the foot switch. Move the boom
controller to the down position, hold for a
moment and then release it.
Result: The descent alarm should sound when
the controller is held down.
5 Press down the foot switch. Move the drive
controller off center, hold for a moment and then
release it. Move the drive controller off center in
the opposite direction, hold for a moment and
then release it.
Result: The travel alarm should sound when the
drive controller is moved off center in either
direction.
comes first. Perform this procedure more often if
dusty conditions exist.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the caps be inspected
more often.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Procced to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank cap venting, air
should pass freely through the cap.
3 - 38
S-80 • S-85
Part No. 111165
February 2012
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
B-23
Perform Hydraulic Oil Analysis
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
comes first.
6 Check for proper venting.
Result: Air passes through the hydraulic tank
cap. Procced to step 8.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
8 Install the breather cap onto the hydraulic tank.
Part No. 111165
Replacement or testing of the hydraulic oil is
service life. Dirty oil and suction strainers may
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more frequently.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
S-80 • S-85
3 - 39
February 2012
B-24
Perform Engine Maintenance GM and Ford Models
(Ford part number FPP 194-302).
Genie part number
Genie part number
101095
84792
tray out away from the machine and secure.
3 - 40
S-80 • S-85
Part No. 111165
February 2012
Checklist C Procedures
C-1
Perform Engine Maintenance Deutz and Perkins Models
from moving.
Genie part number
62446
Genie part number
84794
Genie part number
111332
Part No. 111165
S-80 • S-85
3 - 41
February 2012
CHECKLIST C PROCEDURES
C-2
Grease the Platform Overload
Mechanism (if equipped)
C-3
Test the Platform Overload
System (if equipped)
performed every 500 hours or six months,
whichever comes first. Perform this procedure more
often if dusty conditions exist.
whichever comes first.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
Testing the platform overload system regularly is
essential to safe machine operation. Continued use
of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
Note: Perform this procedure with the machine on a
firm, level surface.
2 Thoroughly pump grease into each grease
fitting.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
or equivalent
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
3 - 42
S-80 • S-85
Part No. 111165
February 2012
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity
one of the locations shown.
Refer to Illustration 1.
6 Using a suitable lifting device, place an
additional 50 lbs / 23 kg of weight onto the
platform.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Illustration 1
Part No. 111165
overload indicator lights flash and the alarm
sounds.
S-80 • S-85
3 - 43
February 2012
8 Test all machine functions from the platform
controls.
14 Start the engine and test all machine functions
from the ground controls.
Result: All platform control functions should not
operate.
Result: All ground control functions should
operate normally.
15 Turn the key switch to platform control.
10 Test all machine functions from the ground
controls.
controls.
Result: All ground control functions should not
operate.
11 Activate the auxiliary power toggle switch.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System (if
equipped).
Note: The engine will turn off when the auxiliary
power is activated.
12 Using auxiliary power, test all machine functions
from the ground controls.
17 Using a suitable lifting device, remove the
remaining test weights from the platform.
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
should turn off at both the ground and platform
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.
3 - 44
S-80 • S-85
Part No. 111165
February 2012
C-4
Replace the Engine Air Filter
Element - Deutz and Perkins
Models
C-5
Replace the Fuel Filter/Water
Separator Element Deutz and Perkins Models
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
Regular replacement of the fuel filter/water
separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
engine performance and/or hard starting, and
continued use may result in component damge.
Extremely dirty conditions may require this
procedure be performed more often.
1 Release the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
2 Remove the filter element.
3 Use a damp cloth to wipe the filter sealing
surface and the inside of the outlet tube. Make
sure that all contaminant is removed before the
filter is inserted.
Perform this procedure with the engine off.
4 Check new filter element gasket for damage
before installing.
1 Open the engine side turntable cover and locate
the fuel filter/water separator.
5 Install the new filter element.
6 Install the end cap on the canister and secure.
Note: Be sure the discharge slot is pointing down.
Part No. 111165
Note: The fuel filter/water separator is located near
the hydraulic pump.
2 Disconnect and plug the fuel supply hose from
the fuel tank to the fuel filter/water separator
head.
S-80 • S-85
3 - 45
February 2012
8 Apply a thin layer of oil onto the element gasket.
Install the filter/bowl assembly onto the filter
head. Tighten the drain plug and vent plug.
3 Loosen the vent plug located on the fuel filter/
water separator head.
Component damage hazard. The
drain plug and vent plug can be
damaged if they are overtightened.
a
d
9 Install the fuel supply hose from the fuel tank to
the fuel filter/water separator. Tighten the
clamp.
c
10 Clean up any diesel fuel that may have spilled
during the installation procedure.
b
11 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
filter element.
a
b
c
d
vent plug
drain plug
filter bowl
separator head
Bleed the fuel system:
Note: Before bleeding the system, fill the fuel tank.
4 Place a suitable container under the filter bowl.
Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel.
12 Loosen the vent plug located on the
fuel filter/water separator head.
5 Rotate the filter bowl counterclockwise and
remove it from the element.
13 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the vent
plug. Tighten the vent plug.
6 Rotate the filter element counterclockwise and
remove it from the filter head.
14 Loosen the air vent screw, located on top of the
fuel injection pump.
7 Install the filter bowl onto the new filter element.
15 Tighten the air vent screw when air stops
coming through the air vent.
16 Clean up any diesel fuel that may have spilled
during the bleeding procedure and dispose of
properly.
17 Start the engine from ground controls and check
for leaks.
3 - 46
S-80 • S-85
Part No. 111165
February 2012
C-6
Perform Engine Maintenance GM and Ford Models
(Ford part number FPP 194-302).
Genie part number
Genie part number
101095
84792
Part No. 111165
S-80 • S-85
3 - 47
February 2012
Checklist D Procedures
4 Extend and retract the boom through the entire
range of motion to check for tight spots that
may cause binding or scraping of the boom.
D-1
Check the Boom Wear Pads
Note: Always maintain squareness between the
outer and inner
boom tubes.
performed every 1000 hours or annually, whichever
comes first.
Boom wear pad specifications
Boom number one
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in
component damage and unsafe operating
conditions.
5 /8
Side wear pads
(extension end of boom)
inch
15.9 mm
Boom number two
1/2 inch
12.7 mm
Top and bottom wear pads
2 Raise the end of the boom to a comfortable
working height (chest high), then extend the
boom 1 foot / 30 cm.
5 /8
Side wear pads
inch
15.9 mm
Top, bottom and side wear pads
(pivot end of boom)
1/2 inch
12.7 mm
Boom number three
3 Measure each wear pad. Replace the wear pad if
it is less than specification. If the wear pad is
still within specification, shim as necessary to
obtain zero clearance and zero drag.
1/2 inch
12.7 mm
(pivot end of boom)
a
3 - 48
1/2 inch
12.7 mm
Note: If the wear pads are still within specification,
refer to Repair Procedure 4-2, How to Shim the
Boom.
a
b
c
Minimum
b
c
boom 1
boom 2
boom 3
S-80 • S-85
Part No. 111165
February 2012
CHECKLIST D PROCEDURES
3 Extend and retract the axles through the entire
range of motion to check for tight spots that
may cause binding or scraping of the axle
tubes.
D-2
Check the Extendable Axle
Wear Pads
outer and inner axle tubes.
comes first.
Maintaining the axle wear pads in good condition is
essential to safe machine operation. Wear pads are
placed on axle tube surfaces to provice a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in component
damage and unsafe operating conditions.
Axle wear pad specifications
Minimum
Outer axle
(both ends of axle)
1/2 inch
12.7 mm
Extendable inner axle
(both ends of axle)
1/2 inch
12.7 mm
Note: If the wear pads are not worn below
specification but are still within specification, refer
to Repair Procedure 15-1, How to Shim an
Extendable Axle.
extend the axles.
2 Measure each wear pad.
If the wear pad is not less than specification,
shim as necessary to obtain zero clearance and
zero drag. Refer to Repair Procedure 15-1, How
to Shim an Extendable Axle.
Replace the wear pad if it is less than
specification. It is recommended to replace both
inner and outer wear pads. Refer to Repair
Procedure 15-1, How to Remove an Inner Axle.
Part No. 111165
S-80 • S-85
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February 2012
5 Manually rotate each non-steer wheel.
D-3
Check the Free-wheel
Configuration
Result: Each non-steer wheel should rotate with
minimum effort.
comes first.
Proper use of the free-wheel configuration is
essential to safe machine operation. The free-wheel
configuration is used primarily for towing. A
machine configured to free-wheel without operator
knowledge could result in death or serious injury
and property damage.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the blocks.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury and
property damage.
Steer wheels: 4WD models
7 Chock the non-steer wheels to prevent the
machine from rolling.
Collision hazard. Select a work site
that is firm and level.
8 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the steer wheels.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
9 Lift the wheels off the ground and then place
blocks under the drive chassis for support.
Non-steer wheels: All models
1 Chock the steer wheels to prevent the machine
from rolling.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each steer wheel
hub.
disengaged position
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer wheels.
3 Lift the wheels off the ground and place blocks
under the drive chassis for support.
engaged position
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
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S-80 • S-85
Part No. 111165
February 2012
11 Manually rotate each steer wheel.
D-4
Check the Turntable Rotation
Bearing Bolts
Result: Each steer wheel should rotate with
minimum effort.
12 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks.
Collision hazard. Failure to
re-engage the drive hubs could
result in death or serious injury and
property damage.
All models:
13 Turn the valve in a clockwise direction to be
sure it is fully closed.
Note: The free-wheel valve is located on the bottom
of the drive pump, and should always remain
closed.
comes first.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
extend the axles.
2 Turn the key switch to ground controls.
3 Raise the boom and place a safety chock on the
lift cylinder rod. Carefully lower the boom onto
the lift cylinder safety chock.
Crushing hazard. Keep hands
away from cylinder and all moving
parts when lowering the boom.
b
c
a
d
a
b
c
d
Part No. 111165
Note: The lift cylinder safety chock is available
through Genie Service Parts.
drive pump
screwdriver
lift pump
free-wheel valve
S-80 • S-85
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February 2012
4 Remove the center turntable cover retaining
fasteners. Remove the cover.
5 Confirm that each turntable mounting bolt is
torqued in sequence to specification. Refer to
20
24
28
1
5
9
comes first.
13
16
12
8
17
21
25
4
30
29
26
3
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
7
11
15
22
18
14
10
6
27 23
2
19
Bolt torque sequence
6 Install the center turntable cover and tighten the
retaining fasteners.
7 Raise the boom and remove the safety chock.
8 Lower the boom to the stowed position.
9 Confirm that each bearing mounting bolt under
the drive chassis is torqued in sequence to
10
1
D-5
Inspect for Turntable Bearing
Wear
15
firm, level surface and the boom in the stowed
position.
1 Grease the turntable bearing. See A-12, Grease
the Turntable Rotation Bearing and Rotate Gear.
2 Torque the turntable bearing bolts to
specification. See D-4, Check the Turntable
Rotation Bearing Bolts.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
7
13
6
12
18
4
3
17
11
5
14
8
16
2
9
Bolt torque sequence
3 - 52
S-80 • S-85
Part No. 111165
February 2012
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more than
1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero" position.
a
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
b
11 Lower the boom to the stowed position and turn
the machine off.
c
12 Remove the dial indicator from the machine.
d
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the
indicator.
6 Fully extend the boom and lower to a horizontal
position.
Part No. 111165
S-80 • S-85
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February 2012
D-6
from moving.
Genie part number
62446
Genie part number
84794
Genie part number
111332
3 - 54
S-80 • S-85
Part No. 111165
February 2012
5 Install the new filter and tighten it securely by
hand. Clean up any oil that may have spilled
during the installation procedure.
D-7
Replace the Hydraulic Filter
Elements
oil filter.
Genie specifications requires that this procedure be
come first. Perform this procedure more often if
dusty conditions exist.
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
Hydraulic return filter:
Medium and high pressure filters:
Note: The medium pressure filter is for the charge
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating
axle circuit.
7 Open the engine side turntable cover and locate
the two filters mounted below the hydraulic
pumps.
Note: The medium pressure filter is located on the
right. The high pressure filter is located on the left
with the condition indicator.
8 Place a suitable container under the filters.
9 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housings.
10 Remove the filter element from the housings.
1 Open the ground controls side turntable cover
and locate the hydraulic return filter mounted on
the hydraulic tank.
11 Inspect the housing seals and replace them if
necessary.
2 Place a suitable container under the hydraulic
tank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket of
the new oil filter.
Part No. 111165
S-80 • S-85
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February 2012
12 Install the new medium and high pressure filter
elements into the housings and tighten them
securely.
D-8
Replace the Drive Hub Oil
13 Clean up any oil that may have spilled during the
installation procedure.
oil filter housings.
comes first.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
use may cause component damage.
16 Inspect the filter housings and related
components to be sure that there are no leaks.
Drive hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a
b
a
b.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Install the plugs.
3 - 56
S-80 • S-85
Part No. 111165
February 2012
6 Repeat steps 1 through 4 for the other drive hub.
bolts. Refer to Section 2, Specifications.
5 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
a
b
c
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
located near the drive motor.
4 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
rotate drive hub assembly could
properly supported by the lifting
device.
a
b
c
motor
drive hub
6 Install the drive hub assembly onto the machine.
Torque the drive hub mounting bolts to
7 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the
plug.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 10-1, How to Adjust the
Turntable Rotation Gear Backlash.
Part No. 111165
S-80 • S-85
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February 2012
D-9
performed every 1500 hours of operation.
Genie part number
62446
Genie part number
84794
3 - 58
S-80 • S-85
Part No. 111165
February 2012
Checklist E Procedures
2 Models without hydraulic tank shutoff valves:
Remove the drain plug from the hydraulic tank
and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
E-1
Test or Replace the
Hydraulic Oil
Models with hydraulic tank shutoff valves:
Close the two hydraulic tank valves located at
the hydraulic tank.
performed every 2000 hours or every two years,
engine must not be started with the
hydraulic tank shutoff valves in the
CLOSED position or component
Replacement or testing of the hydraulic oil is
service life. Dirty oil and suction strainers may
use may cause component damage. Extremely
dirty conditions may require oil changes to be
performed more frequently.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
open
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.
stowed position.
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation. Refer
to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
1 Remove the fuel tank. Refer to Repair Procedure
9-1, How to Remove the Fuel Tank.
closed
3 Remove the drain plug from the hydraulic tank
4 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank
shutoff valves.
5 Disconnect and plug the T-fitting located at the
return filter with the two hoses connected to it.
Cap the fitting on the return filter housing.
6 Disconnect and plug the supply hose for the
auxiliary power unit. Cap the fitting on the
hydraulic tank.
Part No. 111165
S-80 • S-85
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February 2012
CHECKLIST E PROCEDURES
7 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
hold down straps from the hydraulic tank.
18 Open the hydraulic tank shutoff valves (if
equipped).
Component damage hazard.
Be sure to open the two hydraulic
tank shutoff valves and prime the
pump after installing the hydraulic
tank. Refer to Repair Procedure
7-2, How to Prime the Pump.
8 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an appropriate
lifting device.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank may become unbalanced and
fall if it is not properly supported
and secured to the lifting device.
10 Remove the suction strainers from the tank and
clean them using a mild solvent.
11 Rinse out the inside of the tank using a mild
solvent.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
19 Operate all machine functions through a full
cycle and check for leaks.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
17 Clean up any oil that may have spilled.
3 - 60
S-80 • S-85
Part No. 111165
February 2012
E-2
Perform Engine Maintenance Perkins Models
E-3
Grease the Steer Axle
Wheel Bearings, 2WD Models
performed every 2000 hours or 2 years, whichever
comes first.
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
Genie part number
111332
1 Loosen the wheel lug nuts. Do not remove them.
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support.
from moving.
4 Remove the lug nuts. Remove the tire and wheel
assembly.
Part No. 111165
2 Block the non-steering wheels. Center a lifting
jack under the steer axle.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
S-80 • S-85
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February 2012
Skip to step 10 if there is no movement.
14 Pack both bearings with clean, fresh grease.
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
15 Place the large inner bearing into the rear of the
hub.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
16 Install a new bearing grease seal into the hub by
pressing it evenly into the hub until it is flush.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
Note: Always replace the bearing grease seal when
removing the hub.
8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
17 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue to step 11 to grease
the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
seat the bearings.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
11 Remove the castle nut.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
12 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
13 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the rear
bearing.
24 Center a lifting jack under the steer axle.
25 Raise the machine approximately
6 inches / 15 cm. Remove the blocks from
under the drive chassis.
26 Lower the machine
3 - 62
S-80 • S-85
Part No. 111165
February 2012
E-4
Genie part number
62446
Genie part number
84794
Genie part number
111332
from moving.
Part No. 111165
S-80 • S-85
3 - 63
February 2012
3 - 64
S-80 • S-85
Part No. 111165
February 2012
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Perform disassembly procedures to the point where
repairs can be completed. Then to re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
before operating the machine.
Before Repairs Start:
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
operating instructions in the Genie S-80 and
Genie S-85 Operator’s Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
which, if not avoided, could result
in death or serious injury.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbol—used to
indicate the presence of a
which, if not avoided, may result
in minor or moderate injury.
repair procedure with the machine in the
following configuration:
•
Machine parked on a firm, level surface
•
Boom in the stowed position
•
Turntable rotated with the boom between
the non-steering wheels
•
Turntable secured with the turntable
rotation lock pin
•
Key switch in the off position with the
key removed
•
Wheels chocked
•
All external AC power supply disconnected
from the machine
Part No. 111165
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-80 • S-85
4-1
February 2012
Platform Controls
The platform control box contains one printed
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall
Effect technology and require no adjustment. The
operating parameters of the joysticks are stored in
memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. See 1-2,
How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its
entire range of motion.
1-1
ALC-500 Circuit Board
Note: When the ALC-500 circuit board is replaced,
the joystick controllers will need to be calibrated.
See 1-2, How to Calibrate a Joystick.
How to Remove the ALC-500
Circuit Board
1 Push in the Emergency Stop button to the off
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.
a
with electrically charged circuits
injury. Remove all rings, watches
and other jewelry.
4 Attach a grounded wrist strap to the ground
screw inside the platform control box.
c
d
a
b
c
d
4-2
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.
b
ALC-500 circuit board
drive/steer joystick controller
boom extend/retract
joystick controller
boom up/down and turntable rotate
left/right joystick controller
S-80 • S-85
Part No. 111165
February 2012
PLATFORM CONTROLS
5 Carefully disconnect the wire connectors from
the circuit board.
6 Remove the ALC-500 circuit board mounting
fasteners.
7 Carefully remove the ALC-500 circuit board
from the platform control box.
1-2
Joysticks
How to Calibrate a Joystick
The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function
will operate.
Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set.
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Press down the foot switch and select a joystick
to calibrate.
4 Move the joystick full stroke in either direction
and hold for 5 seconds.
5 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds and
return the joystick to the neutral position.
Result: The alarm should sound indicating
successful joystick calibration.
6 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
Part No. 111165
S-80 • S-85
4-3
February 2012
PLATFORM CONTROLS
7 Momentarily activate the drive enable toggle
switch in the right direction 4 times.
How to Adjust the Joystick
Max-out Setting
The max-out setting of a joystick controls the
maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum
performance. The max-out settings on the joystick
can be changed to compensate for hydraulic pump
wear to maintain peak performance from the
machine.
stowed position.
Note: If a max-out adjustment has been made to
any joystick function other than the limited drive
speed (raised or extended), the limited drive speed
must be checked. Refer to steps 14 thru 19.
controls.
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
Result: There should be a pause and the alarm
should sound 4 times indicating that the
machine is in max-out calibration mode.
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
table below and determine whether the function
time needs to increase or decrease.
11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle
time. Momentarily move the drive enable toggle
switch in the right direction to increase the time
or momentarily move the drive enable toggle
switch in the left direction to decrease the time.
Note: Each time the drive enable toggle switch is
momentarily moved, the time will change in 2%
increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
Result: The alarm should sound indicating that
the settings have been saved 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.
4-4
S-80 • S-85
Part No. 111165
February 2012
PLATFORM CONTROLS
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
boom fully stowed
78 to 86 seconds
Drive speeds (factory settings)
Stowed- high speed
Non-stowed
7.9 to 8.5 seconds
40 to 45 seconds
Ramp Rate Setting
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum
output, when moved out of the neutral position.
The ramp rate settings of a joystick can be
changed to compensate for hydraulic pump wear to
maintain peak performance from the machine.
stowed position.
controls.
start the engine.
machine is in ramp rate calibration mode.
Part No. 111165
S-80 • S-85
4-5
February 2012
PLATFORM CONTROLS
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how
long it takes the function to reach maximum
speed. This is the ramp rate.
10 Compare the function ramp rate time with the
table below and determine whether the ramp
rate time needs to increase or decrease.
11 While the joystick is activated, set the ramp
rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time
or momentarily move the drive enable toggle
switch in the left direction to decrease the time.
Ramp rate (factory settings)
Boom up/down and turntable rotate
accelerate
decelerate
3 seconds
1 second
Boom extend/retract
accelerate
decelerate
4 seconds
1 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed
4 seconds
0.5 second
0.75 second
1 second
1 second
1 second
4 seconds
Note: Each time the drive enable toggle switch is
momentarily moved, the time will change in 5%
increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
back on.
4-6
S-80 • S-85
Part No. 111165
February 2012
PLATFORM CONTROLS
Threshold Setting
10 Slowly move the joystick off center in either
direction just until the function begins to move.
The threshold setting of a joystick is the minimum
output at which a function proportional valve can
open and allow the function to operate.
11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
move the drive enable toggle switch to either
side to set the threshold.
stowed position.
Result: The alarm should sound indicating a
successful calibration.
controls.
12 Repeat steps 9 through 11 for each boom
joystick controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
start the engine.
back on.
machine is in threshold calibration mode.
9 Select a boom function joystick to set the
threshold.
Part No. 111165
S-80 • S-85
4-7
February 2012
Platform Components
7 Support and secure the platform to an
appropriate lifting device.
2-1
Platform
8 Remove the platform mounting fasteners and
remove the platform from the machine.
How to Remove the Platform
1 Remove the cable clamp from the top of the
platform mounting weldment.
2 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side. Do
not disconnect the wiring.
Crushing hazard. The platform
could become unstable and fall
when it is removed from the
machine if not properly supported.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
5 Tag and disconnect the foot switch wiring from
the foot switch. Remove the cable from the
back of the platform.
and other jewelry.
6 Remove the platform control box mounting
fasteners. Lower the control box and set it
aside.
Cables can be damaged if they are
kinked or pinched.
Note: If your machine is equipped with an airline to
platform option, the airline must be disconnected
from the platform before removal.
4-8
S-80 • S-85
Part No. 111165
February 2012
PLATFORM COMPONENTS
2-2
Platform Leveling Slave Cylinder
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-end pivot pin is removed if not
properly supported.
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
5 Remove the external snap rings from the barrelend pivot pin.
6 Use a soft metal drift to drive the barrel-end
pivot pin out.
Leveling Slave Cylinder
7 Carefully pull the cylinder out of the primary
boom to access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no
air in the closed loop.
from the slave 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 oil to
squirt or spray.
to
Section 2, Hydraulic Hose and Fitting Torque
Specifications.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the primary boom slightly and place
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.
Part No. 111165
How to Bleed the Slave Cylinder
Note: Do not start the engine. Use auxiliary power
for this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
S-80 • S-85
4-9
February 2012
PLATFORM COMPONENTS
from the platform rotator manifold. Cap the
fittings on the rotator.
2-3
Platform Rotator
gradually. Do not allow oil to squirt
or spray.
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
How to Remove the
Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
S-85:
3
Support the jib boom leveling arms and the
platform mounting weldment with an appropriate
lifting device. Do not apply any lifting pressure.
4 Remove the mounting bolts from the platform
mounting weldment. Remove the center bolt
and slide the platform mounting weldment off of
the platform rotator.
mounting weldment could become
unbalanced and fall if not properly
supported when removed from the
machine.
to
Specifications.
5 Support the platform rotator with an appropriate
1 Remove the platform. See 2-1,
How to Remove the Platform.
7 Remove the pivot pin retaining fasteners from
both the slave cylinder rod-end pivot pin and
the rotator pivot pin.
4 - 10
S-80:
6 Support the rod end of the platform leveling
slave cylinder. Protect the cylinder rod from
damage.
S-80 • S-85
Part No. 111165
February 2012
PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins.
Remove the platform rotator from the machine.
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator fasteners,
torque the fasteners to specifications. Refer to
S-85:
6 Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
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 the switch to
the right position until the platform is fully
rotated to the right.
7 Support the jib boom leveling arms.
2 Place a suitable container underneath the
platform rotator.
8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
3 Open the top bleed screw on the rotator, but do
not remove it.
Bodily injury hazard. The jib boom
leveling arms may fall if not
properly supported.
9 Lower the jib boom leveling arms.
rotator may become unbalanced
and fall if not properly supported.
squirt or spray.
Note: When installing the platform rotator fasteners,
torque the fasteners to specifications. Refer to
Part No. 111165
S-80 • S-85
4 - 11
February 2012
PLATFORM COMPONENTS
side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
screw. Close the bleed screw.
2-4
Platform Overload System
How to Calibrate the Platform
Overload System (if equipped)
Crushing hazard. Keep clear of the
platform during rotation.
5 Open the bottom bleed screw on the rotator, but
do not remove it.
squirt or spray.
side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
screw. Close the bleed screw.
Crushing hazard. Keep clear of the
platform during rotation.
7 Clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks.
4 - 12
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 and it could tip over.
firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
S-80 • S-85
Part No. 111165
February 2012
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring
adjustment nut in a clockwise direction in 10°
increments until the overload indicator light
turns off, and the alarm does not sound.
Proceed to step 8.
alarm is sounding. Repeat this procedure
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
platform overload indicator light and alarm
responds.
Result: The overload indicator lights are off at
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
alarm is sounding. Repeat this procedure
responds.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure
responds.
controls.
Result: All platform control functions should not
operate.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
platform overload indicator lights and alarm
responds.
Part No. 111165
S-80 • S-85
4 - 13
February 2012
PLATFORM COMPONENTS
controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
overload indicator lights and alarm turn off.
controls.
operate normally.
14 Turn the key switch to platform control.
controls.
Result: All platform control functions should
operate normally.
4 - 14
S-80 • S-85
Part No. 111165
February 2012
Jib Boom Components, S-85
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
3-1
Jib Boom
squirt or spray.
How to Remove the Jib Boom
stowed position.
Specifications.
1 Remove the platform. See 2-1, How to Remove
the Platform.
Note: Models equipped with platform overoad
system: If the platform overload components are
disassembled and/or removed from the platform
support, the platform overload system will need to
be calibrated. See 2-4, How to Calibrate the
Platform Overload System.
2 Models equipped with platform overload
system: Tag and disconnect the electrical
connector from the platform load sense module.
3 Remove the hose and cable cover from the side
of the jib boom.
4 Remove the hose and cable clamp from the jib
boom pivot pin. Lay all hoses and cables to the
side.
6 Attach a lifting strap from an overhead crane to
the jib boom assembly.
7 Place blocks under the platform leveling cylinder
for support. Protect the cylinder rod from
damage.
8 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly attached to the overhead
crane.
9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
10 Use a soft metal drift to remove the pin and
carefully remove the jib boom assembly from
the primary boom.
Component damage hazard. Hoses
and cables can become damaged
if they are kinked or pinched.
Part No. 111165
S-80 • S-85
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
4 - 15
February 2012
JIB BOOM COMPONENTS, S-85
2 Tag, disconnect and plug the jib boom lift
cylinder.
3-2
Jib Boom Lift Cylinder
squirt or spray.
How to Remove the Jib Boom
Lift Cylinder
stowed position.
Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib 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.
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 the pin.
the lug at the rod end of the jib boom lift
cylinder.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall if not properly supported
when removed from the machine.
4 - 16
S-80 • S-85
Part No. 111165
February 2012
Boom Components
S-80:
4-1
Cable Track
The boom cable track guides cables and hoses
running up the boom. It can be repaired link by link
without removing the cables and hoses that run
through it. Removing the entire boom cable track is
necessary when performing major repairs that
involve removing the boom.
from the counterbalance valve manifold located
on the platform rotator. Cap the fittings on the
manifold.
squirt or spray.
How to Remove the Cable Track
Specifications.
from the platform leveling slave cylinder at the
union and connect the hoses from the cylinder
together using a connector.
squirt or spray.
1 Open the platform control box.
2 Tag and disconnect the foot switch wiring from
the terminal strip inside the platform control box.
3 Loosen the squeeze connector and remove the
foot switch cable from the control box.
4 Disconnect the wire connectors from the bottom
of the platform control box.
Note: When installing the wire connectors to the
bottom of the platform control box, match the color
of the connectors to those on the control box to be
sure they are installed in the correct location.
5 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side.
Part No. 111165
S-85:
8 Remove the hose and cable cover from the side
of the jib boom.
from the jib boom/platform rotate select
manifold. Cap the fittings on the manifold.
10 Tag, disconnect and plug the wiring from the jib
boom/platform rotate select manifold.
S-80 • S-85
4 - 17
February 2012
BOOM COMPONENTS
from the jib boom lift cylinder. Cap the fittings
on the cylinder.
squirt or spray.
the cable track.
19 Remove the mounting fasteners that attach the
lower cable track to the boom.
20 Remove the cable track from the machine and
place it on a structure capable of supporting it.
All models:
12 From the ground controls, raise the boom to a
horizontal position.
13 Remove the fasteners from the drive speed limit
switch bracket (LS1RS) mounted on the side of
the boom at the platform end of the boom. Do
not remove the limit switch from the bracket.
Crushing hazard. The cable track
if not properly attached to the
overhead crane.
Cables and hoses can be
damaged if they are kinked or
pinched.
cable track can be damaged if it is
twisted.
14 Remove the cotter pin from the upper cable
track at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
15 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.
16 Remove the cable clamp from the pivot end of
the boom.
17 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, the cable track
4 - 18
S-80 • S-85
Part No. 111165
February 2012
BOOM COMPONENTS
5 Remove the upper rollers from the replacement
section of cable track.
How to Repair the Cable Track
The boom cable track can be
damaged if it is twisted.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Note: A cable track repair kit is available through
the Genie Industries Service Parts Department,
part no. 77896. The kit includes a 4-link section of
cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Carefully remove the snap rings from each end
of the damaged section of cable track.
3 Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
track to be replaced. Remove the rollers.
Hoses and cables can be damaged
if they are kinked or pinched.
7 Connect the ends of the replacement 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 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
track.
and cables can be damaged if they
are kinked or pinched.
Part No. 111165
S-80 • S-85
4 - 19
February 2012
BOOM COMPONENTS
4-2
Boom
How to Remove the Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
How to Shim the Boom
1 Measure each wear pad.
Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
minimum specification, perform the following
procedure. Refer to Section 3, D-1, Check the
Boom Wear Pads.
2 Extend the boom until the wear pads are
accessible.
Specifications.
3 Loosen the wear pad mounting fasteners.
4 Install the new shims under the wear pad to
5 Tighten the mounting fasteners.
6 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
binding or scraping.
outer and inner boom tubes.
stowed position.
1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Remove the platform rotator and leveling slave
cylinder. See 2-3, How to Remove the Platform
Rotator.
3 Remove the cable track. See 4-1, How to
Remove the Cable Track.
4 S-85: Remove the jib boom. See 3-1,
How to Remove the Jib Boom.
4 - 20
S-80 • S-85
Part No. 111165
February 2012
BOOM COMPONENTS
5 Raise the boom to a horizontal position high
enough that the boom lift cylinder rod end can
clear the boom lift cylinder mounting boss.
11 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
6 Remove the turntable end cover.
squirt or spray.
7 Remove the pin retaining fasteners from the
master cylinder rod-end pivot pin.
8 Place a rod through the pin and twist to remove
the pin. Lower the rod end of the master
cylinder.
12 Attach an overhead 5 ton / 5000 kg crane to the
center point of the boom.
13 Attach a similar lifting device to the boom lift
cylinder for support.
14 Place support blocks under the boom lift
cylinder, across the turntable.
9 Remove the fasteners from the boom angle limit
switches (LS2RO and LS2RS) mounted to the
inside of both turntable riser side plates at the
pivot end of the boom. Do not disconnect the
wiring.
10 Remove the fasteners from the boom extend
limit switch (LS1RO) mounted next to the boom
extension cylinder at the pivot end of the boom.
Do not disconnect the wiring.
15 Remove the pin retaining fastener from the
boom lift cylinder rod-end pin. Use a soft metal
drift to remove the pin.
Crushing hazard. The boom lift
cylinder could fall if not properly
supported.
16 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
boom pivot pin.
18 Use a soft metal drift to remove the boom pivot
pin. Carefully remove the boom from the
machine.
Crushing hazard. The boom could
properly supported by the overhead
crane.
Part No. 111165
S-80 • S-85
4 - 21
February 2012
BOOM COMPONENTS
How to Disassemble the Boom
Note: Complete disassembly of the boom is only
necessary if the outer or inner boom tubes must be
replaced. The extension cylinder can be removed
without completely disassembling the boom. See 44, How to Remove the Boom Extension Cylinders.
6 Support and slide the number 2 and 3 boom
tubes out of the number 1 boom tube. Place the
number 2 and 3 boom tubes on blocks for
support.
Crushing hazard. The number 2
and 3 boom tubes could become
unbalanced and fall when they are
removed from the number 1 boom
tube if they are not properly
supported.
1 Remove the boom. See 4-2, How to Remove the
Boom.
2 Remove the external snap rings from the
extension cylinder pivot pin at the pivot end of
the number 1 boom tube. Use a soft metal drift
to remove the pin.
3 Remove and label the wear pads from the top,
side, and bottom of the number 1 boom tube at
the platform end of the boom.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
7 Tag and remove the wear pads from the top,
side, and bottom of the number 2 boom tube at
the platform end of the boom.
Note: Note the location and quantity of shims used
with each wear pad.
8 Remove the trunnion pin retaining fasteners at
the base end of the number 2 boom tube. Use a
slide hammer to remove the trunnion pins.
4 Remove the two wear pad stop bolts from each
side of the number 1 boom tube (located on the
outside).
the number 3 boom tube at the platform end of
the boom for support.
the number 2 and number 3 boom tubes at the
platform end of the boom for support.
10 Support and slide the number 3 boom tube out
of the number 2 boom tube. Place the number 3
boom tube on blocks for support.
Crushing hazard. The number 3
boom tube could become
unbalanced and fall when removed
from the number 2 boom tube if not
properly supported.
4 - 22
S-80 • S-85
Part No. 111165
February 2012
BOOM COMPONENTS
extension cylinder pivot pin at the platform end
of the number 3 boom tube. Use a soft metal
12 Support and slide the extension cylinder out of
the pivot end of the number 3 boom tube. Place
the extension cylinder on blocks for support.
4-3
Boom Lift Cylinder
How to Remove the Boom
Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
Crushing hazard. The extension
and fall when it is removed from
the number 3 boom tube if not
properly supported.
Specifications.
1 Raise the boom to a horizontal position high
enough that the boom lift cylinder rod end can
clear the boom lift cylinder mounting boss.
2 Remove the center turntable cover fasteners.
Remove the cover.
3 Place support blocks under the boom lift
cylinder across the turntable side plates.
4 Attach an overhead 5 ton / 5000 kg crane to the
boom for support. Do not lift the boom.
Part No. 111165
S-80 • S-85
4 - 23
February 2012
BOOM COMPONENTS
5 Support the rod end of the boom lift cylinder with
an overhead crane or similar lifting device.
8 Remove the mounting fasteners from the
barrel-end cylinder pivot pin retaining plates.
and fall when it is disconnected
from the machine if not properly
supported.
9 With the lift cylinder being supported by the
overhead crane, pull the cylinder toward the
platform and remove it from the machine.
6 Tag, disconnect and plug the boom lift cylinder
hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
Crushing hazard. The lift cylinder
if not properly supported.
cables and hydraulic hoses can be
damaged if the lift cylinder is
pulled across them.
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin, and lower the lift
cylinder onto the blocks. Protect the cylinder
rod from damage.
and fall when it is disconnected
from the machine if not properly
supported.
4 - 24
S-80 • S-85
Part No. 111165
February 2012
BOOM COMPONENTS
4-4
Boom Extension Cylinders
The extension cylinder consists of two cylinders
that are fastened together. The first cylinder
extends and retracts the number 2 boom tube. The
second cylinder extends and retracts the number 3
boom tube. The extension cylinders are equipped
with counterbalance valves to prevent movement in
the event of a hydraulic line failure.
How to Remove the
Boom Extension Cylinders
3 Place a 4 in x 4 in x 6 ft / 10 cm x 10 cm x
1.8 m block on top of the number 3 boom tube
and place one end of the block against the
weldment at the platform end of the boom.
4 Retract the boom until the number 2 boom tube
is fully retracted into the number 1 boom tube.
Note: The number 3 boom tube will remain
extended approximately 6 feet / 1.8 m.
extension cylinder pivot pin at the platform end.
Use a soft metal drift to remove the pin.
6 Remove the turntable end cover.
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
Specifications.
7 Support the rod end of the master cylinder with a
lifting device.
master cylinder rod-end pivot pin. Place a rod
through the pin and twist to remove the pin.
the machine if not properly
supported.
Note: Use the platform level toggle switch with
auxiliary power to relieve pressure on the master
cylinder barrel-end pivot pin.
1 Raise the boom to a horizontal position, fully
extend the boom and fully lower the platform.
2 Remove the 2 bolts that are located on each
side of the number 3 boom tube near the
platform end of the number 2 boom tube.
Part No. 111165
S-80 • S-85
4 - 25
February 2012
BOOM COMPONENTS
9 Lay the master cylinder down. Protect the
cylinder rod from damage.
extension cylinder pivot pin at the pivot end of
the boom. Use a soft metal drift to remove the
pin through the access holes in the turntable
riser.
11 Using auxiliary power, move the boom
extend/retract toggle switch in the extend
direction and extend the extension cylinder out
the pivot end of the boom approximately
1 foot / 30 cm.
14 Remove the trunnion pin access covers from
both sides of the number 1 boom tube at the
pivot end of the boom.
15 Remove the trunnion pin retaining fastener and
use a slide hammer to remove the pins.
16 Slide the cylinder out to access the wear pads
on the bottom rod support bracket. Remove the
wear pads.
17 Support and slide the extension cylinder out of
the pivot end of the boom.
the machine if not properly
supported.
12 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
the end of the extension cylinder and lift slightly
to relieve the pressure on the trunnion pins.
4 - 26
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.
Note: During re-assembly of the boom, fully retract
the boom after installing all pins. Install the two top
¼-20 fasteners through the access holes located
mid-section of the number 1 boom. Then extend the
boom and install the two lower ¼-20 fasteners in
the number 3 boom tube.
S-80 • S-85
Part No. 111165
February 2012
BOOM COMPONENTS
master cylinder barrel-end pivot pin.
4-5
Platform Leveling
Master Cylinder
5 Place a rod through the barel-end pivot pin and
twist to remove the pin.
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed loop hydraulic
circuit that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the pivot end of the boom.
Leveling Master Cylinder
Specifications.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible.
the lug on the rod end of the master cylinder.
rod-end pivot pin.
8 Place a rod through the rod-end pivot pin and
twist to remove the pin.
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.
squirt or spray.
Part No. 111165
9 Remove the master cylinder from the machine.
S-80 • S-85
Crushing hazard. The master
and fall if it is not properly
supported by the lifting device
4 - 27
February 2012
Engines
5-1
RPM Adjustment
5-2
Flex Plate
Refer to Maintenance Procedure B-10,
Check and Adjust the Engine RPM.
The flex plate couples the engine to the pump. The
flex plate is bolted to the engine flywheel and has a
cut-out in the center for the pump coupler.
a
b
c
d
e
f
a
b
c
d
e
f
4 - 28
S-80 • S-85
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.185 inch / 4.7 mm gap - Deutz Engines
0.15 inch / 3.8 mm gap - GM Engines
0.25 inch / 6.35 mm gap - Ford Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.3 inch / 7.6 mm gap - Perkins 704-30 Engine
Part No. 111165
February 2012
ENGINES
9 Support the drive pump with an appropriate
How to Remove the Flex Plate
Note: Perform this procedure with the engine off
and cool to the touch.
10 Remove all of the remaining bell housing to
engine fasteners. Carefully pull the pump away
from the engine and secure it from moving.
1 Open the engine side turntable cover.
can be damaged if they are kinked
or pinched
2 Tag and disconnect the battery cables from the
battery(s).
and other jewelry.
3 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
11 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
Ford models:
5 Tag and disconnect the wire harness from the
oxygen sensor on the exhaust pipe.
6 Remove the exhaust pipe heat shield fasteners
from the top of the muffler.
Burn hazard. Hot engine parts can
cause severe burns.
7 Remove the muffler retainer bracket fasteners.
8 Remove the muffler fasteners securing the
muffler to the exhaust manifold. Remove the
muffler from the bracket.
a
b
engine tray anchor hole
engine tray retaining fastener
9 Remove the muffler bracket retaining fasteners.
Remove the muffler bracket from the engine.
4 Tag and disconnect the wiring plug at the
electronic displacement controller (EDC),
located on the drive pump.
GM models:
10 Close the shutoff valve on the Liquid Petroleum
Gas (LPG) tank by turning it clockwise
(if equipped).
5 Remove the fasteners securing the muffler to
the exhaust manifold.
cause severe burns.
6 Remove muffler mounting bracket fasteners.
Remove the muffler and bracket assembly from
the engine.
7 Remove the hose clamp securing the air filter
assembly to the air inlet tube.
8 Remove the air cleaner bracket fasteners.
Remove the air cleaner and bracket assembly
from the engine.
Part No. 111165
11 Tag and disconnect the wiring from the LPG
solenoid.
12 Remove the engine starter retaining fasteners
and remove the starter from the engine. Do not
disconnect the wiring.
13 Remove the dipstick tube bracket fasteners.
the lifting eyes on the engine.
15 Remove the bell housing to engine tray
fasteners.
S-80 • S-85
4 - 29
February 2012
ENGINES
16 Raise the engine slightly using the overhead
crane. Do not apply any lifting pressure.
lifting device. Remove all of the remaining bell
housing engine fasteners.
18 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
flywheel.
Deutz BF4L-2011 models:
5 Tag and disconnect the wiring from the bell
housing.
6 Remove the U-bolt from the exhaust flex pipe at
the muffler.
or pinched
cause severe burns.
19 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine fly wheel.
7 Remove the muffler bracket retaining fasteners
from bell housing. Remove the muffler and
bracket assembly from the engine.
Deutz F4L-913 models:
housing engine fasteners.
5 Tag and disconnect the wiring from the bell
housing.
6 Remove the exhaust tailpipe and air inlet tube
U-bolts from the air cleaner mounting bracket.
cause severe burns.
7 Remove the fuel filter/water separator retaining
fasteners. Remove the filter/separator from the
engine. Do not disconnect the fuel hoses.
8 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
assembly from the engine.
from moving.
or pinched
flywheel.
housing to engine fasteners.
from moving.
or pinched
4 - 30
S-80 • S-85
Part No. 111165
February 2012
ENGINES
5 Install the pump onto the bell housing/mounting
plate. Torque the pump retaining fasteners to
57 ft-lbs / 83 Nm.
How to Install the Flex Plate
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Ford models: Torque the flex plate mounting
bolts in sequence to 14 ft-lbs / 19 Nm. Then
torque the flex plate mounting bolts in sequence
to 20 ft-lbs / 27 Nm.
GM models: Torque the flex plate mounting
Deutz models: Torque the flex plate mounting
Perkins models: Torque the flex plate
mounting bolts in sequence to 13 ft-lbs / 18 Nm.
Then torque the flex plate mounting bolts in
sequence to 19 ft-lbs / 26 Nm.
3 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.
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
a
b
c
d
not force the drive pump during
installation or the flex plate teeth
may become damaged.
6 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.
7 Install the pump and bellhousing assembly onto
the engine. Apply Loctite® removable thread
sealant to the mounting screws.
Perkins 704 models
Torque the bellhousing mounting bolts in
sequence to 14 ft-lbs / 19.1 Nm.
Deutz 913, Perkins 804 and GM models
sequence to 28 ft-lbs / 38 Nm.
Deutz 2011 Models
sequence to 46.7 ft-lbs / 63.3 Nm.
Ford Models
sequence to 37 ft-lbs / 50.1 Nm.
e
Component damage hazard. When
installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
not force the drive pump during
installation or the flex plate teeth
may become damaged.
f
a
b
c
d
e
f
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.185 inch / 4.7 mm gap - Deutz Engines
0.15 inch / 3.8 mm gap - GM Engines
0.25 inch / 6.35 mm gap - Ford Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.3 inch / 7.6 mm gap - Perkins 704-30 Engine
Part No. 111165
S-80 • S-85
4 - 31
February 2012
ENGINES
6
1
8
3
1
C
C
10
8
C
4
5
6
4
11
7
C
C
C
C
C
2
12
C
C
Deutz F4L-913
Flex Plate
3
C
7
C
5
1
9
2
3
6
Deutz BF4L-2011
Pump Plate
1
6
5
4
2
Ford, Perkins and
Deutz BF4L-2011
Flex Plate
1
3
11
12
2
5
1
2
7
GM Flex Plate
6
C
6
C
8
C
C
1
10
8
4
3
C
C
4
3
11
C
12
9
5
7
2
C
5
C
2
9
Deutz F4L-913 and Perkins 704-30
Pump Plate
4 - 32
9
Perkins 804C-33 and GM
Pump Plate
5
2
5
7
3
4
4
4
3
1
6
8
10
Ford Pump Plate
S-80 • S-85
Part No. 111165
February 2012
Part No. 111165
S-80 • S-85
4 - 33
February 2012
Ground Controls
6-1
Control Relays
Relays used for single function switching are single
pole double throw (SPDT) relays.
How to Test a Single Pole Double
Throw Relay
and other jewelry.
1 Tag and disconnect all the wiring from the relay
to be tested.
terminal no. 87a - N.C.
terminal no. 85 - coil negative (-)
terminal no. 30 - common
terminal no. 86 - coil positive (+)
terminal no. 87 - N.O.
Control Relay Schematic
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
terminal 85 to 86 with resistor
terminal 87 to 87a and 30
terminal 87a to 30
Desired result
75 to 85Ω
no continuity
(infinite Ω)
continuity
(zero Ω)
3 Connect 12V DC to terminal 85 and a ground
wire to terminal 86, then test the following
terminal combinations.
Test
terminal 87 to 87a and 30
terminal 87 to 30
4 - 34
Desired result
no continuity
(infinite Ω)
continuity
(zero Ω)
S-80 • S-85
Part No. 111165
February 2012
GROUND CONTROLS
6-2
Power Relay
6-3
Terminal Strip
and other jewelry.
How to Remove a Terminal Strip
Section
could cause death or serious
and other jewelry.
Note: The power relay is mounted on the Auxiliary
Power Unit.
How to Test the Power Relay
1 Disconnect the battery(s) from the machine.
Electrocution/burn hazard.
Disconnect the ground cable from
the battery before performing this
procedure.
1 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Test
Desired result
2 small posts
12 to 16Ω
2 large posts
no continuity
(infinite Ω)
Any small post to
any large post
no continuity
(infinite Ω)
2 Label the wiring from the terminal strip section to
be removed.
3 Use a small flat blade screwdriver to push in and
release the wire from the terminal strip.
4 Locate the removal tab on the bottom or top of
the terminal strip section.
5 Use a small flat blade screwdriver to gently pry
up on the tab of the terminal strip section and
remove it.
2 Connect 12V DC to one of the small posts and a
ground wire to the other small post, then test
the following terminal combination.
Test
Desired result
continuity (zero Ω)
2 large posts
b
a
a
b
a
b
Part No. 111165
solenoid activate coil terminal
(small post)
high amp power contact terminal
S-80 • S-85
4 - 35
February 2012
Hydraulic Pumps
from the function pump. Cap the fittings on the
pump.
7-1
Function Pump
squirt or spray.
How to Remove the Function
Pump
When removing a hose assembly or fitting, the Oring (if equipped) on the fitting and/or the hose end
must be replaced. All connections must be torqued
to specification during installation. Refer to Section
2, Hydraulic Hose and Fitting Torque
Specifications.
3 Remove the pump mounting fasteners.
Carefully remove the pump.
the hydraulic tank.
tank valves (if equipped) and
prime the pump after installing the
pump. See 7-2, How to Prime the
Pump.
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
condition.
open
4 - 36
closed
S-80 • S-85
Part No. 111165
February 2012
HYDRAULIC PUMPS
7-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local
authorized service center.
the hydraulic tank.
How to Remove the Drive Pump
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
condition.
open
closed
Specifications.
1 Disconnect the wire harness at the electronic
displacement controller (EDC), located on the
drive pump.
Part No. 111165
S-80 • S-85
4 - 37
February 2012
HYDRAULIC PUMPS
from the drive and function pumps. Cap the
fittings on the pumps.
How to Prime the Pump
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves (if equipped) are in the
open position before priming the
pump. The engine must not be
started with the hydraulic tank
shutoff valves in the closed
position or component damage will
occur.
squirt or spray.
4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
fasteners.
1 Connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
2 GM and Ford models: Close the valve on the
LPG tank, then disconnect the hose from the
tank. Move the fuel select toggle switch to the
LPG position.
Deutz and Perkins models: Disconnect the
engine wiring harness from the fuel solenoid at
the injector pump.
6 Remove the drive pump assembly from the
machine.
tank valves and prime the pump
after installing the pump.
Note: Before installing the pump, verify proper
pump coupler spacing. See 5-2, Flex Plate.
3 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
pressure reaches 300 psi / 20.7 bar.
4 GM and Ford models: Connect the LPG hose
to the LPG tank and open the valve on the tank.
Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
check for hydraulic leaks.
4 - 38
S-80 • S-85
Part No. 111165
February 2012
Manifolds
8-1
Function Manifold Components - View 1
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index
No.
Description
1
Solenoid valve, 3 position 4 way ...... A ........... Platform rotate left/right ..................... 25-30 ft-lbs / 34-41 Nm
2
Check valve, 30 psi / 2 bar ................ B ........... Platform rotate circuit
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
3
Check valve, 30 psi / 2 bar ................ C ........... Platform rotate circuit
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
4
Solenoid valve, 2 position 3 way ...... D ........... Boom retract ..................................... 33-37 ft-lbs / 45-50 Nm
5
Solenoid valve, 3 position 4 way ...... E ........... Turntable rotate left/right .................. 25-30 ft-lbs / 34-41 Nm
6
Relief valve, 2500 psi / 172 bar ........ F ........... Boom extend/retract circuit ............... 20-25 ft-lbs / 27-34 Nm
7
Solenoid valve, 2 position 3 way ...... G ........... Boom extend .................................... 50-55 ft-lbs / 68-75 Nm
8
Check valve ....................................... H ........... Differential sensing circuit,
turntable rotate left/right ...................... 8-10 ft-lbs / 10-15 Nm
9
Differential sensing valve .................. I ............ Boom extend/retract circuit
(prevents overflowing
the proportional valve) ..................... 30-35 ft-lbs / 41-47 Nm
10
Differential sensing valve .................. J ............ Turntable rotate left/right circuit
11
Proportional solenoid valve .............. K ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
12
Check valve ....................................... L ........... Differential sensing circuit,
platform level down ............................. 8-10 ft-lbs / 10-15 Nm
13
Check valve ....................................... M .......... Differential sensing circuit,
platform level up .................................. 8-10 ft-lbs / 10-15 Nm
14
Solenoid valve, 3 position 4 way ....... N ........... Platform level up/down ..................... 25-30 ft-lbs / 34-41 Nm
15
Differential sensing valve .................. O ........... Boom up/down circuit
16
Counterbalance valve ....................... P ........... Platform level down circuit ............... 35-40 ft-lbs / 47-54 Nm
17
Counterbalance valve ....................... Q ........... Platform level up circuit .................... 35-40 ft-lbs / 47-54 Nm
18
Solenoid valve, 2 position 3 way ...... R ........... Boom down ....................................... 33-37 ft-lbs / 45-50 Nm
19
Solenoid valve, 3 position 4 way ...... S ........... Steer left/right and
axle extend/retract ............................ 35-40 ft-lbs / 47-54 Nm
20
Relief valve, 2900 psi / 200 bar ........ T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
Schematic
Item
Function
Torque
This list continues. Please turn the page.
Part No. 111165
S-80 • S-85
4 - 39
February 2012
MANIFOLDS
2
B
1
A
3
C
D
E
33
32
31
30
F
AG
AE
G
AD
H
J
28
27
26
25
5
6
AF
I
29
4
7
8
9
10
AC
K
O
AB
L
AA
M
Z
N
Y
P
Q
11
12
13
14
15
16
17
R
X
24
4 - 40
W
23
U
V
22
21
S-80 • S-85
T
S
18
19
20
Part No. 111165
February 2012
MANIFOLDS
Function Manifold Components - View 1, continued
Index
No.
Description
Schematic
Item
Function
Torque
21
Check valve ....................................... U ........... Blocks flow from auxiliary pump
to function pump ............................... 30-35 ft-lbs / 41-47 Nm
22
Priority flow regulator valve,
3.5 gpm / 13.2 L/min .......................... V ........... Steer circuit ....................................... 30-35 ft-lbs / 41-47 Nm
23
Proportional solenoid valve .............. W .......... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
24
Solenoid valve, 2 position 3 way ...... X ........... Boom up ........................................... 33-37 ft-lbs / 45-50 Nm
25
Check valve ....................................... Y ........... Blocks flow from function pump
to auxiliary pump .............................. 30-35 ft-lbs / 41-47 Nm
26
Check valve ....................................... Z ........... Hydraulic oil cooler bypass .............. 30-35 ft-lbs / 41-47 Nm
27
Check valve ....................................... AA ......... Boom up/down circuit ......................... 8-10 ft-lbs / 10-15 Nm
28
Needle valve ..................................... AB ......... Platform level circuit ......................... 30-35 ft-lbs / 41-47 Nm
29
Proportional solenoid valve .............. AC ........ Turntable rotate circuit ...................... 20-30 ft-lbs / 27-47 Nm
30
Differential sensing valve .................. AD ........ Meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
31
Check valve ....................................... AE ......... Differential sensing circuit,
boom extend/retract ............................ 8-10 ft-lbs / 10-15 Nm
32
Flow regulator valve,
0.1 gpm / 0.37 L/min .......................... AF ......... Bleeds off differential
sensing valves to tank ...................... 20-25 ft-lbs / 27-34 Nm
33
0.6 gpm / 2.27 L/min .......................... AG ........ Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm
Part No. 111165
S-80 • S-85
4 - 41
February 2012
MANIFOLDS
2
B
1
A
3
C
D
E
33
32
31
30
F
AG
AE
G
AD
H
J
28
27
26
25
5
6
AF
I
29
4
7
8
9
10
AC
K
O
AB
L
AA
M
Z
N
Y
P
Q
11
12
13
14
15
16
17
R
X
24
4 - 42
W
23
U
V
22
21
S-80 • S-85
T
S
18
19
20
Part No. 111165
February 2012
MANIFOLDS
8-2
Function Manifold Components - View 2
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index
No.
1
2
Description
Schematic
Item
Function
Check valve, 30 psi / 2 bar ................ AH ........ Platform rotate circuit
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... (prevents hydraulic hoses
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... from draining back to tank)
12345678901234567890123456789012123456789012345678901234567
Torque
............... 20-25 ft-lbs / 27-34 Nm
0.3 gpm / 1.14 L/min .......................... AJ ......... Dump circuit source from
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
.......................................................................... charge pump ....................................
12345678901234567890123456789012123456789012345678901234567
12345678901234567890123456789012123456789012345678901234567
20-25 ft-lbs / 27-34 Nm
3
Solenoid valve, 2 position 2 way ...... AK ......... Allows boom functions to
operate with the boom in
the stowed position ........................... 26-30 ft-lbs / 34-41 Nm
4
Check valve, 30 psi / 2 bar ................ AI .......... Blocks flow from charge pump
to auxiliary pump .............................. 20-25 ft-lbs / 27-34 Nm
5
Check valve, 30 psi / 2 bar ................ AL ......... Blocks flow from auxiliary pump
to charge pump ................................. 20-25 ft-lbs / 27-34 Nm
6
Pressure Switch, 180 psi / 12.4 bar .. AY ......... Axle extend pressure switch ............ 26-30 ft-lbs / 34-41 Nm
7
Solenoid valve, 2 position 3 way ...... AM ........ Provides pilot signal to redirect
steer flow to axle extension system .. 26-30 ft-lbs / 34-41 Nm
8
Directional valve, 2 position 2 way,
pilot operated .................................... AN ........ Dump valve that allows boom
functions to operate when
axles are fully extended ............. 90-100 ft-lbs / 122-136 Nm
9
Relief valve, 2100 psi / 145 bar ........ AO ........ Boom down ....................................... 20-25 ft-lbs / 27-34 Nm
Part No. 111165
S-80 • S-85
4 - 43
February 2012
MANIFOLDS
AH
AJ
AK
AI
AL
AY
AO
9
4 - 44
2
3
4
5
6
AM
AN
8
1
7
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-3
Valve Adjustments Function Manifold
How to Adjust the Boom Down
Relief Valve
stowed position.
How to Adjust the System
Relief Valve
stowed position.
gauge to the diagnostic nipple (PTEST port) on the
function manifold.
3 Hold the function enable/rpm select toggle
switch to the high idle position and activate and
hold the boom retract toggle switch with the
boom fully retracted. Observe the pressure
reading on the pressure gauge. Refer to
Section 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item T) on the
function manifold.
5 Adjust the internal hex socket. Turn it clockwise
to increase pressure or counterclockwise to
decrease pressure. Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
function manifold.
hold the boom down toggle switch with the
boom fully lowered. Observe the pressure
relief valve and remove the cap (item AO) on
the function manifold.
to increase pressure or counterclockwise to
decrease pressure. Install the relief valve cap.
specified.
6 Repeat steps 2 through 5 and confirm relief
valve pressure.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
Part No. 111165
S-80 • S-85
4 - 45
February 2012
MANIFOLDS
How to Adjust the Boom Extend
Relief Valve
stowed position.
function manifold.
hold the boom extend toggle switch with the
boom fully extended. Observe the pressure
relief valve and remove the cap (item F) on the
function manifold.
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
specified.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
4 - 46
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-4
Brake/Two-Speed Manifold Components
(from serial number 4436 to 4617 and before 4212)
The brake/two-speed manifold is mounted on the engine tray.
Index
No.
Description
Schematic
Item
Function
1
Check valve ....................................... SS ......... Brake circuit ........................................ 8-10 ft-lbs / 10-15 Nm
2
Solenoid valve, 2 position 3 way ...... TT ......... Brake release ................................. 25-30 ft-lbs / 34-41 Nm
3
Solenoid valve, 2 position 3 way ...... UU ........ 2-Speed wheel motors
(energized in high range to
destroke the drive motor
swash plates) .................................. 25-30 ft-lbs / 34-41 Nm
Torque
1
2
SS
Part No. 111165
S-80 • S-85
3
TT
UU
4 - 47
February 2012
MANIFOLDS
8-5
Brake / Two Speed Manifold Components
(from serial number 4212 to 4435 and after 4617)
The brake/two speed manifold is mounted inside the drive chassis.
Index
No.
Description
1
Solenoid valve, 2 position 3 way ... EA ........... Releases brakes ............................. 47-52 ft-lbs / 64-70 Nm
2
Solenoid valve, 2 position 3 way ... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm
3
Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm
4
Orifice, 0.042 inch / 1.07 mm ......... ED ........... Controls flow to tank
Schematic
Item
1
Torque
2
EA
4
Function
EB
ED
EC
3
4 - 48
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-6
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side
of the machine.
Index
No.
Description
Schematic
Item
1
Shuttle valve, 2 position 3 way ......... PP ......... Turntable rotation brake release ........ 8-10 ft-lbs / 10-15 Nm
2
Counterbalance valve ....................... QQ ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm
3
Counterbalance valve ....................... RR ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm
1
2
PP
Part No. 111165
Function
Torque
3
QQ
S-80 • S-85
RR
4 - 49
February 2012
MANIFOLDS
8-7
Jib Boom Select Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index
No.
Description
Schematic
Item
1
Solenoid valve, 2 position 3 way ...... VV ......... Platform rotate select .......................... 8-10 ft-lbs / 11-14 Nm
2
Solenoid valve, 2 position 3 way ...... WW ....... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
3
Orifice Plug, 0.035 inch / 0.89 mm .... XX ......... Jib boom circuit
1
2
VV
4 - 50
Function
Torque
3
WW
S-80 • S-85
XX
Part No. 111165
February 2012
MANIFOLDS
8-8
Axle Select Manifold Components
The axle select manifold is mounted next to the drive manifold at the non-steer end of the machine.
Index
No.
Description
Schematic
Item
Function
Torque
1
Directional valve, pilot operated
2 position 3 way ................................ FA ......... Directs flow from steer cylinders
to axle extend circuit ......................... 30-35 ft-lbs / 41-47 Nm
2
Pressure reducing valve,
1000 psi / 69 bar ............................... FB ......... Limits pressure to tie rod cylinder
during axle extension ....................... 30-35 ft-lbs / 41-47 Nm
3
2 position 3 way ................................ FC ......... Directs flow from steer cylinders
to axle retract circuit .......................... 30-35 ft-lbs / 41-47 Nm
4
2 position 2 way ................................ FD ......... Locks out steer cylinders during
5
2 position 2 way ................................ FE ......... Locks out steer cylinders during
Part No. 111165
S-80 • S-85
4 - 51
February 2012
MANIFOLDS
1
2
FA
3
FB
FC
FD
FE
4 - 52
S-80 • S-85
4
5
Part No. 111165
February 2012
MANIFOLDS
8-9
(before serial number 3853)
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index
No.
Description
1
Relief valve, 280 psi / 19.3 bar ......... BF ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2
Flow divider/combiner valve ............. BG ........ Controls flow to drive motors
in forward and reverse .............. 90-100 ft-lbs / 122-136 Nm
3
Orifice - plug, 0.070 inch / 1.77 mm .. BH ........ Equalizes flow across flow
divider/combiner valve (item BG)
4
Shuttle valve ...................................... BI .......... Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 68-75 Nm
5
Diagnostic nipple ............................................. Testing
Part No. 111165
Schematic
Item
Function
S-80 • S-85
Torque
4 - 53
February 2012
MANIFOLDS
1
2
BF
BG
BH
BI
3
4
5
4 - 54
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-10
(after serial number 3852)
Index
No.
Description
1
Relief Valve, 280 psi / 19.3 bar ......... BX ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2
Flow Divider / Combiner Valve ......... BY ......... Controls flow to drive motors in
.......................................................................... forward and reverse ................... 90-100 ft-lbs / 120-133 Nm
3
Check Valve, 5 psi / 0.34 bar ............ BZ ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4
Check Valve, 5 psi / 0.34 bar ............ CA ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5
Shuttle Valve, 3 position 3 way ......... CB ........ Controls flow to drive motors in
.......................................................................... forward and reverse ......................... 50-55 ft-lbs / 67-73 Nm
6
Schematic
Item
Function
Torque
Orifice Plug, 0.070 inch / 1.78 mm .... CC ........ Equalizes flow across flow combiner/
valve BY
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.......................................................................... divider
1234567890123456789012345678901212345678901234567890123456
Part No. 111165
S-80 • S-85
4 - 55
February 2012
MANIFOLDS
1
BX
BY
BZ
CA
CB
CC
4 - 56
S-80 • S-85
2
3
4
5
6
Part No. 111165
February 2012
MANIFOLDS
8-11
(before serial number 3835)
Index
No.
Description
Schematic
Item
1
Relief valve, 280 psi / 19.3 bar ......... BJ ......... Charge pressure circuit .................... 20-25 ft-lbs / 27-34 Nm
2
Check valve, 5 psi / 0.34 bar ............. BK ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
3
Flow divider/combiner valve ............. BL ......... Controls flow to flow
90-100 ft-lbs /
divider/combiner valves BQ and BW ................. 122-136 Nm
4
Check valve, 5 psi / 0.34 bar ............. BM ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
5
Check valve, 5 psi / 0.34 bar ............. BN ........ Drive motor anti-cavitation ............... 30-35 ft-lbs / 41-47 Nm
6
Shuttle valve ...................................... BO ........ Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 68-75 Nm
7
Check valve, 5 psi / 0.34 bar ............. BP ......... Drive motor anti-cavitation ............... 30-35 ft-lbs / 41-47 Nm
8
Flow divider/combiner valve ............. BQ ........ Controls flow to steer end
drive motors in forward
90-100 ft-lbs /
and reverse ........................................................ 122-136 Nm
Function
Torque
9
Check valve, 5 psi / 0.34 bar ............. BR ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
10
2 gpm / 7.6 L/min ............................... BS ......... Equalizes pressure on both sides
of flow divider/combiner valve BQ .... 30-35 ft-lbs / 41-47 Nm
11
2 gpm / 7.6 L/min ............................... BT ......... Equalizes pressure on both sides
of flow divider/combiner valve BL .... 30-35 ft-lbs / 41-47 Nm
12
2 gpm / 7.6 L/min ............................... BU ........ Equalizes pressure on both sides
of flow divider/combiner valve BW ... 30-35 ft-lbs / 41-47 Nm
13
Check valve, 5 psi / 0.34 bar ............. BV ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
14
Flow divider/combiner valve ............. BW ........ Controls flow to non-steer end
90-100 ft-lbs /
and reverse ........................................................ 122-136 Nm
Part No. 111165
S-80 • S-85
4 - 57
February 2012
MANIFOLDS
1
2
BJ
14
13
12
11
10
9
8
BK
BW
STEER END
BV
BU
BT
BS
BR
BQ
BL
BO
BP
7
4 - 58
BM
BN
6
5
S-80 • S-85
3
4
NON-STEER END
Part No. 111165
February 2012
MANIFOLDS
8-12
(after serial number 3834)
Index
No.
Description
1
Relief valve, 280 psi / 19.3 bar ......... CD ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
2
Flow divider/combiner valve ............. CE ........ Controls flow to non-steer end
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3
Check valve ....................................... CF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
4
Check valve ....................................... CG ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
5
Flow divider/combiner valve ............. CH ........ Controls flow to flow
divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6
Check valve ....................................... CI .......... Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
7
Orifice, 0.040 inch / 1 mm .................. CJ ......... Equalizes pressure on both sides
of flow divider/combiner valve 5
8
Orifice, 0.040 inch / 1 mm .................. CK ........ Equalizes pressure on both sides
9
Orifice, 0.040 inch / 1 mm .................. CL ......... Equalizes pressure on both sides
10
Check valve ....................................... CM ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
11
Check valve ....................................... CN ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm
12
Shuttle valve, 3 position 3 way ......... CO ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13
Flow divider/combiner valve ............. CP ........ Controls flow to steer end
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14
Check valve ....................................... CQ ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm
Part No. 111165
Schematic
Item
Function
S-80 • S-85
Torque
4 - 59
February 2012
MANIFOLDS
CD
CE
CF
CG
14
13
CQ
CH
CP
CI
12
11
10
1
2
3
4
5
6
CO
CN
CM
CL
9
4 - 60
CK
CJ
7
8
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-13
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
No.
Description
1
Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
Schematic
Item
Function
Torque
2
Orifice disc, 0.030 inch / 0.080 cm . 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
Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
5
CY
CU
CV
CW
CX
Part No. 111165
S-80 • S-85
1
2
3
4
4 - 61
February 2012
MANIFOLDS
drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
8-14
Valve Adjustments Traction Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the traction
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap (item BJ). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
6 Repeat steps 4 and 5 until a pressure differential
(between the charge pump reading and the hot
oil shuttle relief valve) of 40 psi / 14.5 bar is
obtained.
Note: The following procedure will require two
people.
connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
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 - 62
S-80 • S-85
Part No. 111165
February 2012
MANIFOLDS
8-15
Valve Coils
Valve Coil Resistance
Specifications
How to Test a Coil
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite resistance
indicates the coil has failed.
Since coil resistance is sensitive to temperature,
resistance values outside specification can produce
erratic operation. When coil resistance decreases
below specification, amperage increases. As
resistance rises above specification, voltage
increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
and other jewelry.
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
Proportional solenoid valve
(schematic items K and W)
4.8 Ω
(schematic items D, R, X, TT and UU)
6.3 Ω
(schematic items G)
3.3 Ω
(schematic items A, E, N and S)
6.3 Ω
(schematic items AK, AM, VV and WW)
6.3 Ω
(schematic item G)
3.3 Ω
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to be
tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 111165
S-80 • S-85
4 - 63
February 2012
MANIFOLDS
How to Test a Coil Diode
a
d
10 W
RESISTOR
c
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 Connect the negative lead to the other terminal
on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
4 - 64
9V
BATTERY
b
a
b
c
d
1 Test the coil for resistance. Refer to, How to
Test a Coil.
Note: The battery should read 9V DC or more when
measured across the terminals.
b
+
c
and other jewelry.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
AMMETER
COIL
+
Genie incorporates spike suppressing diodes in all
of its directional valve coils except proportional
valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following the
interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.
multimeter
9V DC battery
10Ω resistor
coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
S-80 • S-85
Part No. 111165
February 2012
Part No. 111165
S-80 • S-85
4 - 65
February 2012
Fuel and Hydraulic Tanks
9-1
Fuel Tank
4 Tag, disconnect, drain and plug the supply and
return fuel hoses. Cap the fittings on the fuel
tank.
How to Remove the Fuel Tank
5 Remove the fuel tank retaining fasteners.
fuels are combustible. Remove the
fuel tank in an open, wellventilated area away from heaters,
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
6 Remove the fuel tank from the machine.
The fuel tank is plastic and may
become damaged if allowed to fall.
When installing the plastic fuel
tank, do not overtighten the
retaining fasteners.
Note: Clean the fuel tank and inspect for damage
before installing it onto the machine.
1 Turn the manual fuel shutoff valve to the
closed position (if equipped).
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
capacity specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand operated pump
suitable for use with gasoline and diesel fuel.
4 - 66
S-80 • S-85
Part No. 111165
February 2012
FUEL AND HYDRAULIC TANKS
3 Close the two hydraulic tank valves located at
the hydraulic tank (if equipped).
9-2
Hydraulic Tank
engine must not be started with the
hydraulic tank shutoff valves in the
CLOSED position or component
condition.
The primary functions of the hydraulic tank are to
cool, clean and de-aerate the hydraulic fluid during
operation. The tank utilizes internal suction
strainers for the pump supply hoses and has an
external return filter equipped with a filter condition
indicator.
How to Remove the
Hydraulic Tank
The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system.
open
to
Specifications.
closed
4 Remove the drain plug from the hydraulic tank
5 Tag, disconnect and plug the two suction hoses
that are attached to the hydraulic tank.
6 Tag and disconnect and plug the hose from the
return filter. Cap the fitting on the return filter
housing.
1 Lower and retract the boom to the stowed
position.
2 Remove the fuel tank. See 9-1, How to Remove
the Fuel Tank.
7 Tag and disconnect and plug the supply hose for
the auxiliary power unit. Cap the fitting on the
hydraulic tank.
8 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
hold down straps from the hydraulic tank.
Part No. 111165
S-80 • S-85
4 - 67
February 2012
FUEL AND HYDRAULIC TANKS
9 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
10 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and secured to the overhead
crane.
11 Remove the suction strainers from the tank and
clean them using a mild solvent.
12 Rinse out the inside of the tank using a mild
solvent.
13 Install the suction strainers using pipe thread
sealant on the threads.
14 Install the drain plug using pipe thread sealant
on the threads.
15 Install the hydraulic tank onto the machine.
16 Install the two suction hoses and the supply
hose for the auxiliary power unit.
17 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
19 Open the hydraulic tank shutoff valves
(if equipped).
tank shutoff valves (if equipped)
and prime the pump after installing
the hydraulic tank.
Note: Always use pipe thread sealant when
installing the drain plug and strainers.
4 - 68
S-80 • S-85
Part No. 111165
February 2012
Turntable Rotation Components
10-1
Turntable Rotation Drive Hub
Assembly
How to Remove the Turntable
Rotation Drive Hub Assembly
to
Specifications.
a
b
a
b
c
c
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
on the drive hub assembly.
5 Remove the backlash pivot plate mounting
bolts. Carefully remove the drive hub assembly
from the machine.
unlocked
rotation drive hub assembly could
become unbalanced and fall when
it is removed from the machine if
not properly supported.
locked
from the drive motor. Cap the fittings on the
motor.
or spray.
3 Loosen the backlash pivot plate and adjustment
bolts.
When installing the drive hub assembly:
6 Install the drive hub. Apply removable thread
locking compound to fastener threads.Torque
the backlash pivot plate mounting fasteners to
specification. Refer to Section 2, Machine
Torque Specifications.
7 Install the brake and then the motor onto the
drive hub. Apply removable thread locking
compound to fastener threads.Torque the motor/
brake mounting fasteners to specification. Refer
to Section 2, Machine Torque Specifications.
8 Adjust turntable rotation gear backlash.
See 10-1, How to Adjust the Turntable Rotation
Gear Backlash.
Part No. 111165
S-80 • S-85
4 - 69
February 2012
TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable
Rotation Hydraulic Motor
a
Specifications.
b
c
motor.
or spray.
a
b
c
motor
drive hub with brake
3 Remove the hydraulic tube that connects from
the counterbalance manifold to the brake. Cap
the fittings on the brake and manifold.
or spray.
4 Remove the motor/brake mounting fasteners.
Carefully remove the motor from the brake.
4 - 70
S-80 • S-85
Part No. 111165
February 2012
TURNTABLE ROTATION COMPONENTS
How to Adjust the Turntable
Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor pinion gear and the turntable bearing
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.
2 Loosen the backlash pivot plate mounting
fasteners.
b
a
b
c
Part No. 111165
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt one half turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
a
3 Push the backlash pivot plate towards the
turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
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 Section 2,
Specifications.
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
c
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
S-80 • S-85
4 - 71
February 2012
11-1
Yoke and Hub
How to Remove the Hub
and Bearings
How to Remove the Yoke
and Hub
2 Block the non-steer wheels and center a lifting
jack of ample capacity under the steer axle.
1 Remove the pin retaining fasteners from both
the steering cylinder and the tie rod cylinder
pivot pins. Use a soft metal drift to remove the
pins.
6 inches / 15 cm and place blocks under the
chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
2 Loosen the wheel lug nuts. Do not remove
them.
3 Block the non-steer wheels and center a lifting
5 Remove the dust cap, cotter pin and castle nut.
Note: Always replace the cotter pin with a new one
when installing the castle nut.
6 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
7 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the rear
bearing.
wheel assembly.
yoke pivot pins.
7 Support and secure the yoke and hub assembly
to a lifting jack.
8 Use a slide hammer to remove the upper yoke
pivot pin, then use a soft metal drift to drive the
lower yoke pivot pin down and out.
9 Remove the yoke and hub assembly from the
machine.
Crushing hazard. The yoke and
hub assembly may become
supported and secured to the
lifting jack when it is removed from
the machine.
4 - 72
S-80 • S-85
Part No. 111165
February 2012
2WD STEER AXLE COMPONENTS
How to Install the Hub and
Bearings, 2WD Models
11-2
Steer Cylinder
Note: When replacing a wheel bearing, both the
inner and outer bearings including the pressed-in
races must be replaced.
How to Remove a
Steer Cylinder
1 Be sure that both bearings are packed
with clean, fresh grease.
There are two identical steer cylinders that
work in parallel. They are part of the same hydraulic
circuit, but move in opposite directions. The tie rod
cylinder maintains equal movement of the tires.
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub
until it is flush.
4 Slide the hub onto the yoke spindle.
not apply excessive force or
damage to the lip of the seal may
occur.
5 Place the outer bearing into the hub.
Specifications.
from the steer cylinder. Cap the fittings on the
cylinder.
squirt or spray.
6 Install the washer and castle nut.
seat the bearing.
8 Loosen the castle nut one turn, and then torque
9 Install a new cotter pin. Bend the cotter pin
to secure the castle nut.
steer cylinder pivot pins. Remove the pivot pin
from each end of the steer cylinder.
3 Remove the steer cylinder from the machine.
Note: Always use a new cotter pin when installing a
castle nut.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
Part No. 111165
S-80 • S-85
4 - 73
February 2012
11-3
Tie Rod Cylinder
How to Perform the Toe-in
Adjustment
How to Remove the
Tie Rod Cylinder
Note: Perform this procedure on a firm, level
surface. Block the non-steer tires and be sure that
the machine is in the stowed position.
Specifications.
1 Straighten the steer wheels.
2 Measure the steer tires, front to front and back
to back, using a measuring fixture.
from the tie rod cylinder. Cap the fittings on the
cylinder.
squirt or spray.
2 Support and secure the tie rod cylinder to a
lifting jack.
3 Remove the pin retaining fasteners from each tie
rod cylinder pivot pin.
4 Remove the pivot pin from each end of the tie
rod cylinder.
5 Remove the tie rod cylinder from the machine.
Crushing hazard. The tie rod
cylinder may become unbalanced
and secured to the lifting jack
when it is removed from the
machine.
3 Center a lifting jack of ample capacity under the
steer axle and raise the machine until the steer
tires are off the ground.
4 Loosen the jam nut on the adjustable end
of the tie rod cylinder.
adjustable end of the tie rod cylinder. Remove
the pivot pin.
6 Slide the tie rod cylinder off of the yoke and
adjust it by turning the end.
Note: One half turn on the adjustable end equals
approximately
1
/8 inch / 3.2 mm change in the front and rear
measurements.
7 Slide the tie rod cylinder onto the yoke. Install
the pivot pin and the pin retaining fastener.
8 Tighten the jam nut against the tie rod cylinder.
9 Lower the machine and repeat step 2.
If further adjustment is needed, repeat
this procedure beginning with step 3.
Toe-in specification
4 - 74
S-80 • S-85
0 ± 1/8 inch / 6.35 mm
Part No. 111165
February 2012
wheel assembly.
12-1
Yoke and Drive Hub
7 Remove the hydraulic hose clamp retaining
fastener from the top of the yoke pivot pin.
How to Remove the Yoke
and Drive Hub Assembly
8 Remove the drive motor mounting fasteners.
Specifications.
1 Remove the pin retaining fasteners from both
the steer cylinder and the tie rod cylinder pivot
pins. Remove the pins.
9 Slide the drive motor shaft out of the drive hub
and remove the drive motor from the machine.
upper and lower yoke pivot pins.
11 Support and secure the yoke and drive hub
assembly to a lifting jack.
12 Use a slide hammer to remove the upper yoke
pivot pin. Use a soft metal drift to drive the
lower yoke pivot pin down and out.
drive motor.
squirt or spray.
4 Block the non-steer wheels, and center a lifting
Part No. 111165
Crushing hazard. The yoke and
drive hub assembly could become
unbalanced and fall when the yoke
pivot pins are removed if not
properly supported and secured to
the lifting jack.
13 Place the yoke and drive hub assembly on a flat
surface with the drive hub facing down.
14 Remove the drive hub mounting fasteners that
attach the drive hub to the yoke. Remove the
yoke from the drive hub. Refer to
Note: Replace the thrust washer when installing the
yoke and drive hub assembly onto the axle.
S-80 • S-85
4 - 75
February 2012
drive motor.
12-2
Drive Motor
or spray.
How to Remove a Drive Motor
Repairs to the motor should only
be performed by an authorized
Sauer dealer.
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
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.
to
Specifications.
1 Extend the axles.
2 Remove the drive motor access covers from
both sides of the inner axle.
4 - 76
S-80 • S-85
Part No. 111165
February 2012
12-3
Drive Hub
12-4
Steer Cylinders
How to Remove a Drive Hub
How to Remove a Steer Cylinder
Specifications.
There are two identical steer cylinders that
work in parallel. They are part of the same hydraulic
circuit, but move in opposite directions. The tie rod
cylinder maintains equal movement of the tires.
1 Remove the drive motor. See 12-2, How to
Remove a Drive Motor.
3 Center a lifting jack of ample capacity under the
non-steer axle.
Specifications.
from the steer cylinder. Cap the fittings on the
cylinder.
squirt or spray.
5 Remove the wheel lug nuts, then the tire and
wheel assembly.
6 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
lifting jack.
7 Remove the drive hub mounting fasteners that
attach the drive hub to the axle. Remove the
drive hub.
Crushing hazard. The drive
hub could become unbalanced
and secured to the lifting jack
2 Remove the hose bracket mounting fastener on
the steer cylinder barrel-end pivot pin.
steer cylinder pivot pins. Remove the pivot pin
from each end of the steer cylinder.
4 Remove the steer cylinder from the machine.
Note: Do not re-use the drive hub mounting
fasteners. Genie specifications require the use of
new fasteners.
Part No. 111165
S-80 • S-85
4 - 77
February 2012
12-5
Tie Rod Cylinder
How to Perform the Toe-in
Adjustment
This procedure is the same as the 2WD procedure.
See 11-3, How to Perform the Toe-in Adjustment.
How to Remove the
Tie Rod Cylinder
This procedure is the same as the 2WD procedure.
See 11-3, How to Remove the Tie Rod Cylinder.
4 - 78
S-80 • S-85
Part No. 111165
February 2012
Non-steer Axle Components
13-1
Drive Motor
13-2
Drive Hub
How to Remove a Drive Motor
How to Remove a Drive Hub
This procedure is the same as the steer axle
procedure. See 12-2, How to Remove a Drive
Motor.
This procedure is the same as the steer axle
procedure. See 12-3, How to Remove a Drive Hub.
Part No. 111165
S-80 • S-85
4 - 79
February 2012
Oscillating Axle Components
3 Tag, disconnect and plug the oscillating axle
cylinder.
14-1
Oscillate Axle Cylinders
or spray.
The oscillating axle cylinders extend and retract
between the drive chassis and the axle to maintain
a level chassis while driving over uneven terrain.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic hose failure.
How to Remove an Oscillate Axle
Cylinder
Note: Perform this procedure on firm, level surface
with the boom in the stowed position.
Specifications.
rod-end pivot pin. Use a soft metal drift to
remove the pin.
the barrel end of the oscillating cylinder.
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
7 Remove the cylinder from the machine.
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.
4 - 80
S-80 • S-85
Crushing hazard. The oscillate
and fall if not properly attached to
the overhead crane when
removed from the machine.
Part No. 111165
February 2012
OSCILLATING AXLE COMPONENTS
8 Loosen the jam nut on the relief valve.
14-2
Oscillate Directional Valve
9 Turn the valve clockwise to increase the
pressure or counterclockwise to decrease the
pressure.
How to Adjust the Oscillate
Relief Valve Pressure
Tip-over hazard. Do not adjust the
relief valve higher than specified.
1 Remove the drive chassis cover from the nonsteer end of the machine.
gauge to the diagnostic nipple located near the
oscillate directional valve.
3 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis.
10 Tighten the jam nut.
11 Start the engine and manually activate the valve
to confirm the valve pressure.
Result: Pressure is between 800 to 900 psi / 55
to 65 bar.
Result: Pressure is less than 800 psi / 55 bar or
more than 900 psi / 65 bar. Repeat this
procedure beginning with step 5.
4 Start the engine from the ground control.
5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge. Refer to Section 2,
Specifications.
12 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
13 Install the cover on the non-steer end of the
drive chassis.
6 Turn the engine off.
7 Locate the relief valve on the directional valve.
a
a
Part No. 111165
relief valve
S-80 • S-85
4 - 81
February 2012
OSCILLATING AXLE COMPONENTS
How to Set Up the Directional
Valve Linkage
8 Verify that the ground and drive chassis are
completely level.
Note: Perform this procedure on a firm, level
surface.
9 Adjust the length of the rod by turning the clevis
yoke until the clevis yoke can be pinned to the
axle.
1 Lower the boom to the stowed position.
10 Install the shoulder bolt and nut.
2 Use a "bubble type" level to be sure the surface
the machine is on is completely level.
11 Measure the distance between the drive chassis
and the non-steer axle on both sides (from the
inside of the drive chassis).
3 Check the tire pressure in all four tires and add
air if needed to meet specification.
Result: The measurements should be equal.
Note: If the distance is not equal and the
adjustment to the linkage was completed with the
ground and drive chassis level, consult Genie
Industries Service Department.
4 Remove the drive chassis cover from the
non-steer end of the machine.
5 Disconnect the linkage 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.
4 - 82
S-80 • S-85
Part No. 111165
February 2012
Extendable Axle Components
Top and bottom wear pads:
15-1
Extendable Axles
The extendable axles are used to widen the foot
print of the drive chassis for stability.
How to Shim an Extendable Axle
Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
minimum specification, perform the following
procedure. Refer to Maintenance Procedure D-2,
Check the Extendable Axle Wear Pads.
1 Extend the axles.
Side wear pads:
2 Loosen the side wear pad mounting fasteners
on the outer axle.
3 Install the new shims under the wear pads to
4 Use a round punch to align the shim to the wear
pad. Tighten the mounting fasteners.
5 Extend and retract the axle through an entire
binding or scraping.
inner and outer axle tubes.
Part No. 111165
1 Center a lifting jack of sufficient capacity under
the outer axle that needs to be shimmed. Do not
raise the machine.
2 Block the wheels at the opposite end of the
machine.
3 Raise the machine just until the weight of the
machine is relieved off of the inner axle. Do not
raise the wheels off of the ground.
4 Remove the drive chassis cover.
5 Loosen the wear pad mounting fasteners from
the top and bottom wear pads on both the inner
and outer axles.
6 Install the new shims under the wear pads of the
inner and outer axle to obtain zero clearance
and zero drag.
7 Use a round punch through the wear pad
mounting holes to align the shims with the wear
pad. Install the wear pad retaining fasteners.
8 Extend and retract the axle through an entire
binding or scraping of the axle tubes.
inner and outer axle tubes.
S-80 • S-85
4 - 83
February 2012
EXTENDABLE AXLE COMPONENTS
How to Remove an Inner Axle
7 Place blocks under the axle extension cylinder
for support.
8 Remove the external snap ring from the axle
extension cylinder pivot pin. Use a soft metal
stowed position and boom between the non-steer
end tires.
10 Remove all wear pads from the outer axle.
Steer end:
1 Extend the axles.
the inner axle for support.
Note: Pay careful attention to the quantity and
location of shims used when removing the wear
pads.
11 Carefully remove the inner axle from the outer
axle.
3 2WD models: Remove the yoke and hub
assembly. See 11-1, How to Remove the Yoke
and Hub.
4WD models: Remove the yoke and drive hub.
See 12-1, How to Remove the Yoke and Drive
Hub Assembly.
4 4WD models: Remove the hose bracket from
the steer cylinder barrel-end pivot pin.
5 Remove the remaining steer cylinder pivot pin.
Remove the steer cylinder and lay off to the
side.
or pinched.
6 Remove the steer cylinder mounting lug from the
inner axle.
4 - 84
Crushing hazard. The inner axle
if not properly supported when it is
removed from the outer axle.
Non-steer end:
13 Block the steer tires and center a lifting jack
under the outer axle.
15 Remove the lug nuts. Remove the tire and wheel
assembly.
16 Remove the drive motor covers from both sides
of the inner axle.
S-80 • S-85
Part No. 111165
February 2012
17 Tag, disconnect and plug the hydraulic hoses at
the drive motor. Cap the fittings on the drive
motor.
15-2
Axle Extension Cylinder
or spray.
How to Remove the Axle
Extension Cylinder
for support.
19 Remove the external snap rings from the axle
extension cylinder pivot pin of the inner axle to
be removed. Use a soft metal drift to remove
the pin.
20 Attach a strap from a lifting device through the
inner axle close to the drive hub for support.
21 Remove all wear pads from the outer axle.
stowed position and boom between the non-steer
end tires.
1 Extend the axles.
Steer end:
3 Remove the engine side yoke and hub.
Note: Pay careful attention to the location and
number of shims used when removing the wear
pads.
2WD models: Remove the yoke and hub
assembly. See 11-1, How to Remove the Yoke
and Hub.
22 Carefully remove the inner axle from the outer
axle.
Crushing hazard. The inner axle
if not properly supported when it is
removed from the outer axle.
4WD models: Remove the yoke and drive hub.
See 12-1, How to Remove the Yoke and Drive
Hub Assembly.
4 Remove the access cover at the end of the
inner axle.
or pinched.
Part No. 111165
S-80 • S-85
4 - 85
February 2012
5 Tag, disconnect and plug the axle extend
cylinder.
or spray.
for support.
Non-steer end:
9 Remove the drive motor access covers from
both sides of the axle.
10 Remove the drive motor. Refer to 12-2, How to
Remove a Drive Motor.
11 Remove the drive hub. Refer to 12-3, How to
Remove a Drive Hub.
12 Tag, disconnect and plug the axle extend
cylinder hydraulic hoses from RAE and RAR ports
on the axle select manifold. Cap the fittings on
the manifold.
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
or spray.
8 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
supported when it is removed from
the axle.
for support.
extension cylinder pivot pins. Use a soft metal
drift to remove the pins.
15 Carefully remove the axle extension cylinder
from the machine by pulling it out the end of the
inner axle.
Crushing hazard. The axle
extension cylinder could become
supported when it is removed from
the axle.
4 - 86
S-80 • S-85
Part No. 111165
February 2012
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
operating instructions printed in the
Genie S-80 and Genie S-85 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Read each appropiate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
repair procedure with the machine in the
following configuration:
and other jewelry.
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
squirt or spray.
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Note: Perform all troubleshooting on a firm, level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 111165
S-80 • S-85
5-1
February 2012
FAULT CODES
Fault Codes - Control System
How to Retrieve Control
System Fault Codes
Note: At least one fault code is present when the
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine off,
the key switch turned to platform controls and
both red Emergency Stop button pulled out to the
controls.
1 Open the platform control box lid.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform
control box. Do not touch the circuit board.
3 Determine the error source: The red LED
indidates the error source and will flash two
separate codes. The first code will indicate
the first digit of the two digit code, flashing
once per second. It will then pause for 1.5
seconds and flash the second digit once per
0.5 second.
Note: When the red LED is flashing the code, the
yellow LED will be on solid.
4 Determine the error type: The yellow LED
indidates the error type and will flash two
separate codes. The first code will indicate
the first digit of the two digit code, flashing
once per second. It will then pause for 1.5
seconds and flash the second digit once per
0.5 second.
Note: When the yellow LED is flashing the code,
the red LED will be on solid.
5 Use the fault code table on the following
pages to aid in troubleshooting the machine
by pinpointing the area or component
affected.
Electrostatic discharge (ESD)
can damage printed circuit board
components. If the circuit board
does need to be handled,
maintain firm contact with a
metal part of the machine that is
grounded at all times when
handling the printed circuit board
OR use a grounded wrist strap.
5-2
S-80 • S-85
Part No. 111165
February 2012
FAULT CODES
Error Source
ID
21
22
23
31
32
Name
Boom 1 Joystick
(primary boom up/
down)
Error Type
ID
11
12
15
16
Name
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Value at 5V
Value too high
Value too low
Value at 0V
Boom 1 directional
valves
Boom 1 flow
control valve
Boom 2 Joystick
(secondary boom
up/down or
primary boom
extend/retract)
Boom 2 directional
valves
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1 second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Continued on next page
Part No. 111165
S-80 • S-85
5-3
February 2012
FAULT CODES
Error Source
ID
33
41
42
43
44
5-4
Name
Boom 2 flow
control valve
Turntable rotate
joystick
Error Type
ID
Name
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
Turntable rotate
directional valves
Turntable rotate
flow control valve
Drive enable
override switches
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Solution
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Enable override
direction is frozen at
neutral.
S-80 • S-85
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Part No. 111165
February 2012
FAULT CODES
Error Source
ID
51
53
54
55
61
62
Name
Drive joystick
Drive flow valve
(EDC)
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
21
Fault
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Drive brake valve
High speed drive
motor Valve
Steer joystick
Steer directional
valves
Part No. 111165
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
S-80 • S-85
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
5-5
February 2012
FAULT CODES
Engine Fault Codes GM and Ford Models
How to Retrieve Ford Engine
Fault Codes
How to Retrieve GM Engine
Fault Codes
When an engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the ground controls. Special equipment is
required to retrieve fault codes stored within the
ECM. Contact Genie Service Department for
assistance in retrieving fault codes.
Note: If the check engine light is on and the
engine is stopped, tag the machine and remove
from service. Contact service personnel
immediately.
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest efficiency
while at the same time keeping exhaust
emissions to a minimum. When a sensor fails or
returns signals that are outside of set
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor
and will turn on the Check Engine Light.
Note: Perform this procedure with the key switch
in the off position.
Note: If the check engine light is on and the
engine is still running, contact service personnel
within 24 hours.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of
the ground control box.
controls.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
5-6
S-80 • S-85
Part No. 111165
February 2012
FAULT CODES
4 Move and hold the run/test toggle switch to
the test position.
How to Clear Engine Fault
Codes from the ECM
Result: The check engine light should turn 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: Perform this procedure with the engine off
and the key switch in the off position.
locate the battery.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
times. After the fault codes, the check engine
light will blink a code 123 three times again
indicating the end of the stored codes.
2 Disconnect the negative battery cable from
the battery for a minimum of 5 minutes.
Note: If any fault codes are present, the ECM will
blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive
times, blinks 3 times and then 1 time. That would
indicate code 531.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
Note: Once a fault code has been retrieved and
the repair has been completed, the ECM memory
must be reset to clear the fault code from the
ECM. See How to Clear Engine Fault Codes from
the ECM.
Part No. 111165
S-80 • S-85
5-7
February 2012
FAULT CODES
Code
Problem
111
Closed Loop Multiplier High
(LPG)
112
113
HO2S Open/Inactive
(Bank 1)
HO2S Open/Inactive
S(Bank 2)
114
Post-cat oxygen sensor
open
121
(Gasoline)
122
Closed Loop Multiplier Low
(Gasoline)
124
Closed Loop Multiplier Low
(LPG)
133
Gasoline cat monitor
There are exhaust leaks OR the catalyst system
efficiency is below the acceptable level.
134
LPG cat monitor
135
NG cat monitor
141
Adaptive Lean Fault - High
Limit (Gasoline)
142
Adaptive Rich Fault - Low
Limit (Gasoline)
143
Adaptive Learn High (LPG)
111
(LPG)
112
113
HO2S Open/Inactive
(Bank 1)
HO2S Open/Inactive
S(Bank 2)
114
Post-cat oxygen sensor
open
121
(Gasoline)
5-8
Cause
Solution
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR there are
vacuum leaks or exhaust leaks.
open or shorted OR sensor is faulty.
The post cat Heated Oxygen Sensor wiring
and/or connections are open or shorted OR
sensor is cold, non-responsive or inactive for 60
seconds or longer.
vacuum leaks or exhaust leaks OR fuel pressure
is low OR the fuel injectors need cleaning or
replacing.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
shorted OR sensor is faulty OR one or more fuel
injectors are stuck open OR there is electromagnetic interference from a faulty crankshaft
and/or camshaft position sensor.
open or shorted OR sensor is faulty OR fuel
quality is poor OR fuel system components may
be faulty.
Repair wiring and/or connections OR replace
sensor OR repair vacuum and exhaust
leaks.
sensor.
sensor.
vacuum or exhaust leaks OR one or more fuel
injectors faulty or stuck closed OR fuel quality is
poor OR fuel pressure is too low.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
shorted OR sensor is faulty OR one or more fuel
injectors are stuck closed OR there is electromagnetic interference from a faulty crankshaft
and/or camshaft position sensor.
vacuum leaks or exhaust leaks OR fuel quality is
poor OR fuel system components may be faulty.
vacuum leaks or exhaust leaks.
The post cat Heated Oxygen Sensor wiring
and/or connections are open or shorted OR
sensor is cold, non-responsive or inactive for 60
seconds or longer.
vacuum leaks or exhaust leaks OR fuel pressure
is low OR the fuel injectors need cleaning or
replacing.
S-80 • S-85
the post cat oxygen sensor.
sensor OR repair any vacuum and exhaust
leaks OR test the fuel pressure OR clean or
replace the fuel injectors.
Adjust or replace sensors OR clean or repair
fuel injectors.
sensor OR replace fuel OR test and repair
the fuel system components.
Repair exhaust leaks OR there is an
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair heated oxygen sensor wiring and/or
connections OR replace sensor OR repair
vacuum and exhaust leaks OR test the fuel
pressure OR clean or replace the fuel
injectors.
Adjust or replace sensors OR clean or repair
fuel injectors.
leaks OR replace fuel OR test and repair the
fuel system components.
sensor OR repair vacuum and exhaust
leaks.
sensor.
sensor.
the post cat oxygen sensor.
leaks OR test the fuel pressure OR clean or
replace the fuel injectors.
Part No. 111165
February 2012
FAULT CODES
Code
Problem
144
Adaptive Learn Low (LPG)
161
162
System Voltage Low
211
IAT High Voltage
212
IAT Low Voltage
213
IAT Higher Than Expected
(1)
214
IAT Higher Than Expected
(2)
215
Oil Pressure Low
221
CHT/ECT High Voltage
222
CHT/ECT Low Voltage
223
CHT Higher Than Expected
(1)
224
CHT Higher Than Expected
(2)
231
232
234
235
MAP High Pressure
System Voltage High
MAP Low Voltage
Cause
Engine wire harness may have an intermittent
short to 5V DC or 12V DC OR fuel system
components may be faulty.
Battery is faulty OR alternator is not charging OR
battery supply wiring to ECM is open or shorted.
Alternator is overcharging the battery when
engine RPM is greater than 1500 rpm.
IAT sensor wiring and/or connections are open or
shorted OR sensor is faulty OR engine intake air
temperature is too cold.
IAT sensor wiring and/or connections are open or
shorted OR sensor is faulty OR engine intake air
temperature is too hot.
Air intake temperature is greater than 200° F with
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Air intake temperature is greater than 210° F with
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Faulty oil pressure sensor OR sensor wiring
and/or connections open or shorted OR engine oil
level too low.
Engine cooling system is malfunctioning OR
sensor wires and/or connections open or shorted
OR sensor is faulty.
Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240°
F. Engine cooling system is malfunctioning and
Coolant temperature at the cylinder head is 250°
F. Engine cooling system is malfunctioning and
Open or shorted wiring and/or connections to
MAP sensor OR sensor is faulty.
Open or shorted wiring and/or connections to
MAP sensor OR sensor is faulty.
Solution
Repair short in engine wire harness OR test
and repair the fuel system components.
Replace battery OR repair alternator OR
repair battery supply wiring to ECM.
Repair or replace the alternator.
sensor OR direct warmer air into air intake.
sensor OR direct cooler air into air intake.
Check air intake system for damage and
proper routing of air intake components OR
replace the IAT sensor.
Check air intake system for damage and
proper routing of air intake components OR
replace the IAT sensor.
Replace oil pressure sensor OR repair
sensor wiring and/or connections OR fill
engine oil level to specification.
Repair engine cooling system problems OR
repair open or shorted wiring to sensor OR
replace sensor.
replace sensor OR fill engine coolant level to
specification.
specification.
specification.
Repair wiring and/or connections to sensor
OR replace MAP sensor.
Repair wiring and/or connections to sensor
OR replace MAP sensor.
BP High Pressure
MAP sensor is faulty OR ECM is faulty.
Replace MAP sensor OR replace the ECM.
BP Low Pressure
MAP sensor is faulty OR ECM is faulty.
Replace MAP sensor OR replace the ECM.
Crankshaft position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Crankshaft position sensor wiring and/or
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace sensor.
242
Crank Sync Noise
243
Never Crank Synced At
Start
Part No. 111165
S-80 • S-85
5-9
February 2012
FAULT CODES
Code
Problem
Cause
Camshaft position sensor wiring and/or
Knock sensor wiring and/or connections open or
shorted OR sensor is faulty.
Knock sensor wiring and/or connections open or
shorted OR there is excessive engine vibration
OR sensor is faulty.
Solution
Repair wiring and/or connections to knock
sensor OR replace knock sensor.
Check for excessive engine vibration OR
repair wiring and/or connections to knock
sensor OR replace knock sensor.
Repair wiring and/or connections to fuel
injector #1 OR replace fuel injector #1 OR
replace the ECM.
replace the ECM.
replace the ECM.
replace the ECM.
replace the ECM.
replace the ECM.
replace the ECM.
replace the ECM.
245
Camshaft Sensor Noise
253
Knock Sensor Open
254
Excessive Knock Signal
311
Injector Driver #1 Open
Open wiring and/or connections to fuel injector #1
OR fuel injector #1 is faulty OR ECM is faulty.
312
Injector Driver #1 Shorted
Wiring and/or connections to fuel injector #1
shorted OR fuel injector #1 is faulty OR ECM is
faulty.
313
314
faulty.
315
316
faulty.
321
322
351
Fuel Pump Loop Open or
High Side Short To Ground
352
Fuel Pump High Side
Shorted To Power
353
MegaJector delivery
pressure higher than
expected
354
Megajector delivery
pressure lower than
expected
355
MegaJector communication
lost
The ECM doesn’t get any response from the
MegaJector, or an incorrect response for 500ms
period or longer.
Check CAN circuits for continuity and shorts
to power or ground and for continuity and
repair as necessary OR replace the
MegaJector.
361
MegaJector voltage supply
high
The MegaJector detects voltage greater than 18
volts for 5 seconds anytime the engine is
cranking or running.
Repair charging system OR replace the
MegaJector.
362
MegaJector voltage supply
low
The MegaJector detects voltage less than 9.5
volts for 5 seconds anytime the engine is
cranking or running.
Repair VBAT power or ground circuit to ECM
and MegaJector OR replace battery OR
repair charging system OR replace the
MegaJector.
5 - 10
faulty.
Open wiring and/or connections to fuel pump OR
fuel pump power shorted to ground OR fuel pump
is faulty.
Wiring and/or connections to fuel pump shorted to
power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not
sealing correctly OR the line between the
MegaJector and carburetor is kinked or restricted
or is leaking OR engine cooling system is not
operating properly OR MegaJector is faulty.
Fuel pressure too low OR LPG lockoff not
opening completely OR the line between the
MegaJector and carburetor is kinked or restricted
or is leaking OR engine cooling system is not
operating properly OR MegaJector is faulty.
S-80 • S-85
pump OR replace fuel pump.
pump OR replace fuel pump.
Check fuel pressure OR repair LPG lockoff
OR repair the line between the MegaJector
and carburetor OR repair engine cooling
system OR replace MegaJector.
Check fuel pressure OR repair LPG lockoff
OR repair the line between the MegaJector
and carburetor OR repair engine cooling
system OR replace the MegaJector.
Part No. 111165
February 2012
FAULT CODES
Code
Problem
Cause
363
Megajector internal
actuator fault detection
The MegaJector detects an internal fault. Open or
short in power, ground or CAN circuits.s
364
Megajector internal circuitry
fault detection
The MegaJector detects an internal circuitry
failure. Open or short in power, ground or CAN
circuits.
365
MegaJector internal
communication fault
detection
The MegaJector detects an internal
communications failure. Open or short in power,
ground or CAN circuits.
411
412
413
414
511
512
513
514
521
522
Coil Driver #1 Open
Coil Driver #1 Shorted
Coil Driver #2 Open
Coil Driver #2 Shorted
Open wiring and/or connections to ignition coil #1
OR ignition coil #1 is faulty.
Wiring and/or connections to ignition coil #1
shorted OR ignition coil #1 is faulty.
Open wiring and/or connections to ignition coil #2
OR ignition coil #2 is faulty.
Wiring and/or connections to ignition coil #2
shorted OR ignition coil #2 is faulty.
FPP1 High Voltage
Not used.
FPP1 Low Voltage
Not used.
FPP1 Higher than IVS Limit
Not used.
FPP1 Lower than IVS Limit
Not used.
FPP2 High Voltage
Not used.
FPP2 Low Voltage
531
TPS1 (Signal Voltage) High
532
TPS1 (Signal Voltage) Low
533
TPS2 (Signal Voltage) High
534
TPS2 (Signal Voltage) Low
363
Megajector internal
actuator fault detection
Not used.
The #1 throttle position sensor wiring and/or
system ground connection OR throttle position
sensor #1 is faulty.
The MegaJector detects an internal fault. Open or
short in power, ground or CAN circuits.s
Solution
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair
as necessary OR MegaJector has an
internal fault. Contact Ford Power Products
for assistance.
for assistance.
for assistance.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
If this fault appears on your machine, contact
Genie Industries Service Department.
connections to sensor OR replace throttle
position sensor #1.
position sensor #1.
position sensor #2.
position sensor #2.
for assistance.
Part No. 111165
S-80 • S-85
5 - 11
Code
Problem
February 2012
Cause
The throttle position sensor wiring and/or
connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.
The throttle position sensor wiring and/or
connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.
Governor actuator is stuck closed OR wiring
and/or connections open or shorted OR governor
actuator is faulty.
Governor actuator is stuck open OR wiring and/or
connections open or shorted OR governor
actuator is faulty.
Engine harness wiring and/or connections open
or shorted OR there is a poor system ground
connection OR ECM is faulty.
ECM needs to be re-programmed OR throttle is
sticking open OR there are air leaks between the
throttle body and cylinder head.
535
TPS1 Higher than TPS2
536
TPS1 Lower than TPS2
537
Throttle Unable to Open
538
Throttle Unable to Close
545
Governor Interlock Failure
551
Max Governor Speed
Override
552
Fuel Rev Limit
553
Spark Rev Limit
611
COP Failure
Loose wire connections to ECM OR ECM is
faulty.
612
Invalid Interrupt
faulty.
613
A/D Loss
faulty.
614
RTI 1 Loss
faulty.
615
Flash Checksum Invalid
faulty.
616
RAM Failure
faulty.
631
External 5V DC Ref Lower
than Expected
or shorted to ground OR there is a faulty engine
sensor OR ECM is faulty.
632
External 5V DC Ref Higher
than Expected
or shorted to ground OR there is a faulty engine
sensor OR ECM is faulty.
655
RTI 2 Loss
faulty.
656
RTI 3 Loss
faulty.S
5 - 12
S-80 • S-85
Solution
Be sure engine harness wiring and
connections are in place and secure OR
repair wiring and/or connections to one or
both TPS sensors OR replace one or both
TPS sensors.
Be sure engine harness wiring and
connections are in place and secure OR
repair wiring and/or connections to one or
both TPS sensors OR replace one or both
TPS sensors.
Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Repair wiring and/or connections in engine
harness OR replace the ECM.
Re-program ECM OR repair binding throttle
operation OR repair any air leaks between
the throttle body and cylinder head.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they
are secure OR replace ECM.
damage or shorts OR locate and
troubleshoot or repair faulty engine sensor
OR replace ECM.
damage or shorts OR locate and
troubleshoot or repair faulty engine sensor
OR replace ECM.
Part No. 111165
February 2012
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes the drawings.
Electrical Schematics
and other jewelry.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
or spray.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-80 and Genie S-85 Operator's Manual
on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 111165
S-80 • S-85
problem
solved
Inspect
and test
Perform
repair
6-1
February 2012
Electrical Symbols Legend
FS1
BLK
BLK
P3
WHT
Quick disconnect
terminal
N.O.H.C
Coil
solenoid or relay
N.C.H.O
Limit switch
Horn button
normally open
P1
KS1
TB21
WHT #21
Foot switch
LS3
PLATFORM
OTS2
N.O.
GROUND
T-circuits connect
at terminal
H1
Horn or alarm
T-circuits
connect
Key switch
Oil temperature
switch
normally open
Emergency Stop
button normally
closed
FAN
FB
PR1
CTS1
N.O.
Flashing beacon
Power relay
Coolant temperature
switch
normally open
Connection
no terminal
G1
TS2
START
ENGINE
Gauge
Aux
Pump
Auxiliary pump
OPS1
N.C.
Circuits crossing
no connection
510
HM
Diode
Hydraulic oil
cooling fan
Toggle switch SPDT
Oil pressure switch
normally closed
Resistor with
ohm value
Hour meter
TS6
+
PLATFORM LEVEL
-
LED
25A
AUX MAIN
Fuse
with amperage
Battery separator
Tilt sensor
Toggle switch DPDT
A
CR4
N.O.
Control relay contact
normally open
B
C
HOLD
F1
Gauge sending unit
PULL IN
Battery
UP
DOWN
L3
Fuel or RPM
solenoid
CB1
15A
Circuit breaker
with amperage
6-2
Starting aid:
glow plug or
flame ignitor
Coil
S-80 • S-85
Part No. 111165
February 2012
Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
.035"
(0.89 mm)
Filter with
bypass valve
relief setting
Orifice with size
Solenoid operated
proportional valve
Shut off valve
Pump
fixed displacement
Check valve
Solenoid operated 3 position,
4 way, directional valve
2 position, 3 way, shuttle valve
Priority
flow regulator valve
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump
bi-directional,
variable displacement
Relief valve
with pressure setting
Solenoid operated 2 position,
3 way, directional valve
3000 psi
(206.8 bar)
3:1
o
Brake
Motor
bi-directional
Directional valve
(mechanically activated)
Counterbalance valve
with pressure and pilot ratio
Pilot operated 3 position,
3 way, shuttle valve
Motor
2-speed,
bi-directional
E
Pump prime mover
(engine or motor)
2 position, 2 way
solenoid valve
50%
50%
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Differential
sensing valve
Part No. 111165
S-80 • S-85
6-3
February 2012
6-4
S-80 • S-85
Part No. 111165
February 2012
Ford LRG-425 EFI Engine Wiring Harness
6-6
6-5
February 2012
Ford LRG-425 EFI Engine Wiring Harness
A
B
INJ +
1
INJ 1
INJ 3
INJ 4
INJ 2
INJ 5
INJ 6
AUX OUT 2
EGR
AUX ANA PD1
MAP
2
FPP 1
IAT
ECT
IVS
AUX ANA PU1
FPP 2
EGR PWM
EGR RECIRC
POWER GROUND
POWER GROUND
ANA_RTN
3
5 VOLT REF
VSW
CRANK CRANK +
CAM CAM +
VBAT
VBAT
EGO 2
EGO 1
EGO 3
4
KNK +
KNK -
C
D
E
F
G
H
I
361 R 16
6
361 R 16
7
555 T 16
8
557 BR-Y 16
557 BR-Y 16
9
558 BR-LB 16
558 BR-LB 16
10
556 W 16
361 R 16
743 GY 18
12
359 GY-R 18
21
18 O-Y 18
19
198 DG-O 18
20
358 LG-BK 18
COIL 3
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
6
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
7
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN RS 485 +
RS 485 -
8
RS 232 TX
RS 232 RX
15
151 LB-BK 18
27
743 GY 18
307 BK-Y 18
28
354 LG-R 18
354 LG-R 18
INJECTOR #1
A
B
17
307 BK-Y 18
INJECTOR #4
INJECTOR #2
570 BK-W 16
39 R-W 18
N
FORD
42 PIN
CONNECTOR
16 WATER TEMP
18
150 DG-W 18
16
114 LB-Y 18
22
352 BR-LG 18
23
360 BR-PK 18
1
570 BK-W 16
2
570 BK-W 16
WATER
TEMP
151 LB-BK
307 BK-Y 18
14 FPP1
25 IVS
359 GY-R 18
570 BK-W 16
570 BK-W 16
ECT
570 BK-W 12
F1 30A
570 BK-W 12
34 GROUND
570 BK-W 16
16 R-LG 18
F2
5A
16 R-LG 18
1 VSW
570 BK-W 16
570 BK-W 16
MAP_CONN
F3 20A
13
359 GY-R 18
570 BK-W 16
14
351 BR-W 18
351 BR-W 18
3
16 R-LG 18
33
350 GY 18
358 LG-BK 18
358 LG-BK 18
32
349 DB 18
359 GY-R 18
359 GY-R 18
35
452 GY-R 18
18 O-Y 18
34
282 DB-O 18
198 DG-O 18
198 DG-O 18
4
361 R 16
150 DG-W 18
150 DG-W 18
5
361 R 16
114 LB-Y 18
114 LB-Y 18
25
392 R-LG 18
352 BR-LG 18
352 BR-LG 18
24
74 GY-LB 18
360 BR-PK 18
360 BR-PK 18
361 R 14
CAM
361 R 14
CRANK
O2 SENSOR
26
361 R 14
C
B
A
18 O-Y 18
359 GY-R 18
30
359 GY-R 18
351 BR-W 18
351 BR-W 18
O2
SENSOR
MTRTWR6 MTRSHD6
361A R 16
361A R 16
570 BK-W 16
570 BK-W 16
74 GY-LB 18
392 R-LG 18
151 LB-BK 18
359 GY-R 18
359 GY-R 18
317 GY-O 18
355 GY-W 18
351 BR-W 18
570 BK-W 16
1
850 Y-BK 18
2
851 Y-R 18
3
TWR
361A R 16
1 COIL 1
2 VBAT
1
2
3
A
B
242 DG 18
361A R 16
LOCKOFF SOLENOID
24
25
SHD
TWR
A
A
B
B
C
C
D
D
E
E
F
F
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
4
1
86
32 R-LB 16
86
85
30
87
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
2
32 R-LB 16
32 R-LB 16
85
87
87A
359 GY-R 18
D
351 BR-W 18
C
B
458 O-BK 18
A
RTN
FPP_COMM
787A PK-BK 16
F4 15A
787A PK-BK 16
RX
TWR
86
9
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
151 LB-BK 18
29
317 GY-O 18
6
511 LG-R 18
511 LG-R 18
511 LG-R 18
7
253 DG-W 18
253 DG-W 18
253 DG-W 18
8
11 T-Y 18
11 T-Y 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
658 PK-LG 18
10
238 DG-Y 18
238 DG-Y 18
5
71 O-LG 18
71 O-LG 18
71 O-LG 18
14
72 Y-BK 18
72 Y-BK 18
72 Y-BK 18
15
148 Y-R 18
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
307 BK-Y 18
307 BK-Y 18
11
169 LG-BK 18
169 LG-BK 18
169 LG-BK 18
12
172 LB-R 18
172 LB-R 18
172 LB-R 18
26
33
77 DB-Y 18
349A DB 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
642 DG-O 18
642 DG-O 18
21
461 O 18
461 O 18
461 O 18
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
669 DG-W 18
458 O-BK 18
85
926A LB-O 18
15 R-Y 18
87
87A
361 R 16
OIL PRESSURE
5 FUEL PUMP
POWER
RELAY
30
242 DG 18
F5 15A
361 R 16
253 DG-W 18
570 BK-W 16
361A R 16
459 O-LG 18
662 DG-P 18
MTRTWR4
Part No. 111165
39 STARTER IN (AUTOCRANK)
TX
23
361A R 16
15 STARTER IN (INTERUPT)
5V
342 LG-P 18
361A R 16
31 VREF
342 LG-P 18
669 DG-W 18
77 DB-Y 18
33 ANA RTN
13 STARTER CONTROL
87A
22
S-80 • S-85
38 EGR ANA IN
STARTER
RELAY
30
3
342 LG-P 18
3 COIL 2
13
9 VBATT
361 R 14
361 R 14
29
4
361 R 12
TWR
351 BR-W 18
16 R-LG 18
WPTWR2_GY
6-6
INJECTOR #3
151 LB-BK
TRIM VALVE
TWR
361 R 16
ACT
J2 GREY
COIL 1
M
31
359 GY-R 18
COIL 2
361 R 16
L
556 W 16
11
357 Y-W 18
SPK PWR GROUND
K
555 T 16
J1 BLACK
5
J
TWR
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
18 RS 232-
SHD
PLUG (GROUND)
A
A
B
B
C
C
PLUG (CAN -)
D
D
PLUG (CAN +)
PLUG (RELAY POWER)
MTRSHD4
February 2012
GM 3.0L Engine Wiring Harness
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
#305 GREEN/BLACK
#102 PINK
CAVITY "C"
#104 YELLOW/BLACK
23
8
C B A
OIL PRESSURE SWITCH
MAP SENSOR
#104 YELLOW/BLACK
CAVITY "B"
#205 LT. GREEN
BLACK CONNECTOR
TACHOMETER SIGNAL
FROM ALTERNATOR
CAVITY "B"
CAVITY "A"
#100 BLACK
COOLANT TEMPERATURE SENSOR
ALT. CONNECTOR
(FOR MODEL 7SI)
CAVITY "A"
COIL POWER CONNECTOR
AIR TEMPERATURE SENSOR
#105 GREEN
LOOSE INSIDE CABLE LOOM
CAVITY "A"
#103 ORANGE
#5007 PURPLE COIL WIRE
GRAY
CAVITY "A"
A
#8002 RED
#106 DK. BLUE
#3006 DK. BLUE
AB
1
16
AB
2
CAVITY "B"
ALT. SENSE
WIRE
(+12VDC)
B
CAVITY "B"
3
#2009 WHITE/BLUE
#1006 LT. BLUE
B
A
L.P.G. LOCK-OFF
GROUND CONNECTOR
CAVITY "A"
L.P.G. LOCK-OFF
POSITIVE CONNECTOR
TO STARTER
SOLENOID
L.P.G. INJECTOR CONNECTOR
#2002 RED
ALT. EXCITE WIRE
#2002 RED
PED
CAVITY "B"
1
12
2
11
3
10
4
9
5
8
6
7
4
#1000 BLACK
16
#1002
RED/BLACK
#3002 RED/BLUE
#2002 RED
3 AMP DIODE
1000 PRV MIN.
ENGINE HARNESS
GROUND TERMINAL
#1000 BLACK
#1000 BLACK
GASOLINE
INJECTOR
CONNECTOR
COIL POWER
RELAY
MAIN
POWER
RELAY
FUEL SUPPLY
SELECT RELAY
TO +12V DC BATTERY
STUD ON STARTER
#1 L.P. FUEL REQUEST (+12VDC ENABLES)
#2 HI SPEED REQUEST (+12VDC ENABLES)
#3 +12VDC STARTER INPUT
#4 +12VDC IGN. POWER TO COIL POWER RELAY
#5 AUX. INPUT SHUTDOWN
#6 ENGINE RUN SIGNAL (+12 VDC)
#7 CHECK ENGINE LAMP
#8 AUX. TACH. SIGNAL
#9 MID. SPEED REQUEST (GROUND ENABLES)
#10 EMPTY
#11 +12VDC OUTPUT TO GASOLINE FUEL PUMP
#12 GROUND TO GASOLINE FUEL PUMP
87
87
MOLD #
85
87a
30
86
85
87a
30
87
86
85
87a
87
86
30
85
87a
86
#2000 BLACK/WHITE
A B C D
CAVITY "D"
7
B
30
#5002 RED
#1007 PURPLE
CAVITY "C"
CAVITY "B"
20 AMP FUSE
5
6
DISTRIBUTOR
CONNECTOR
CAVITY "A"
NO.
#1000 BLACK
STARTER
INTERLOCK
RELAY
#2007 PURPLE
12 PIN CONNECTOR CAVITY #'S
#1004 YELLOW
#1007 PURPLE
23
8
#2002 RED
#3007
PURPLE/BLACK
WHITE CONNECTOR
#1000 BLACK
CAVITY "A"
#4007
PURPLE/WHITE
A
#1000 BLACK
B
#1008 GRAY
1
#1006 LT. BLUE
CAVITY "B"
#2001 BROWN
#1005 GREEN/BLACK
GOVERNOR
ACTUATOR
CONNECTOR
#1002 RED/BLACK
#1001 BROWN/WHITE
A
#4002 RED
#1004 YELLOW
#3002 RED/BLUE
#1009 WHITE/BLACK
#2004 YELLOW/BLACK
8
#2006 BLUE/WHITE
#6002 RED/WHITE
#2007 PURPLE
#7012 18 GA. FUSE LINK
#3002 RED/BLUE
#7002 RED
Part No. 111165
S-80 • S-85
6-7
February 2012
GM 3.0L Engine Wiring Harness
6-7
6-8
February 2012
Deutz F4L 913 Models
6 - 10
6-9
GENERATOR
ENGINE RPM
HIGH (FS)
ON
GLOW
PLUG
ENGINE
START
AUXILIARY
POWER
C1-9
C2-7
C1-8
C1-7
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C2P-5
P22BAT BK
C132PLI BL/WH
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD
C2B-5
C3B-10
C1B-2
C7B-2
RD
AUXILIARY
POWER
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
C41RPM OR/BK
GR
GR/BK
RD
BK/RD
C6-28
C6-23
C5-11
C5-7
C5-5
C5-12
WH-21
C5-18
BK/WH
GR/WH
C5-15
MODULE
3
RD
BK
WH
B1 BATTERY
BK
WH
RD
C24TSTP BL/RD
R116HYD OR
R21IGN WH
C43HRN BK
RD
WH
C26TSR GR/BK
C25PSR BL/BK
C27AUX RD
C33STR BK
R33STR BK
C21IGN WH
C5-22
C6-27
C28TTA RD/BK
P134 RD
C6-16
C6-34
C6-33
C107AF WH
C41RPM OR/BK
C6-134 RD
C5-2
C5-3
P20BAT RD
HOLD
PULL IN
BK
HOUR METER
RPM RELAY
RPM SOLENOID
GENERATOR
OPTION
GLOW PLUG RELAY
GLOW PLUG
GLOW PLUG FUEL VALVE
OIL TEMPERATURE AND
OIL PRESSURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
IGNITIOIN/START RELAY
STARTER MOTOR
AUXILIARY PUMP
AUXILIARY POWER RELAY
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
OIL TEMPERATURE
SENDER (OPTION)
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
HYDRAULIC COOLING FAN (OPTION)
FLASHING BEACONS OPTION
ALTERNATOR
-
BATTERY
Part No. 111165
STARTER
AUX
PUMP
H2
2
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
3
ROCKER STEER OPTION ONLY.
ADD D40 ONLY IF UNIT HAS L4 AND L48.
5
+
HOLD
C7P-1
H1
P134PWR GR/BK
RD
IND.
B1
S-80 • S-85
6 - 10
B
REGULATOR
HM
_
2
1
3
S1
NO
S2
NC
FB
AUX
FAN
STA.
TIME DELAY
MOM N.O.
2
NO
WH
+BAT
CR1
1
S-613
PR2
NO
C
B
A
BAT.
BAT.
+
12 V
DC
C21IGN WH
TB21
D42
D14
TB46
D52
CR3
L5
-COM
PR1
EXCT.
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION .
8
BRN
7
ALTERNATOR
TB23
BRN
+AUX
6
G1
RD
C
A
G2
G3
CR1
NO
D22
CR39
NO
CR3
NO
CR5
NO
CR17
NO
D6
P46 RD
TB24
BL/RD
5
P23 RD
D8
TB33A
CB3
20A
FUSE
70A
CR2
NO
CR28
NO
D51
RD
TB20
C21IGN WH
TB24A
TB35
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB28
RD
TB41
C32-8
D13
CB1
15A
C1P-12
C2B-6
BK
7
D7
TB27
WH
TB34
TB33
8
12
D2
OR/BK
RD
RD
RD
6
TS1
C2P-6
GRD
TS4
TS47
TS6
TS2
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
D40
5
TB134
RD
P1
TB23
4
RD
RD
PULL IN
RD
P26ESTP BK
P26ESTP BK
P26ESTP BK
D12
L48
+
P24FS WH
BK
6
P3
HORN
CE Option, See 6 - 98
2
P24FS WH
FS1
P25FS RD
BK
P25FS RD
C9P-1
P2
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB22
KS1
CB2
15A
3
February 2012
C28TTA RD/BK
C27AUX RD
+
1
C28TTA RD/BK
7
WH
OR
RD
BK
RETRACT
AXLE
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C5TRR WH/BK
C6TRF WH/RD
C4TRL WH
TURNTABLE ROTATE
5
R2
BK/RD
BK/WH
BK
PRIMARY BOOM
EXTEND
BOOM
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-5
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
RETRACT
C12DRE BL/WH
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
DOWN
D28
C6-21
C42LS2 GR
C61AXRT BL
C40LS1 OR
C40LS2 BK
C6-22
C6-10
C6-40
C60AX OR/RD
C34-1
S3LED BL/RD
C6-39
C35-1
J3 WH
J1 WH
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C15-1
C14-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
C22-1
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C42AXDP WH
C6-13
7
C6-11
J4 BK
J2 WH
WH
RD
J5 BK
C6-20
C37STC BL/BK
C6-31
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-38
C6-30
C6-14
C6-15
C6-18
GR-17-M.H.
C34-2
C35-2
NC
EXTEND
AXLE
4
1
18
17
15
16
19
20
11
9
10
6
7
8
14
13
12
D34
RIGHT
PLATFORM ROTATE
C6-17
2
2AO
RETRACT
EXTEND
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
YOUT 5
OR
BL
RKOUT 6
4
YOUT 5
BRN
3
PWR
BRN
1
OR
YEL
2
7
6
5
3
4
BRN
1
2
BRN
P24FS WH
P24FS WH
GND
PWR
OUT
GND
XOUT 4
6
7
1
GND 2
PWR 3
BL
CDE1 BL/WH
LEFT
RIGHT
CDE2 BL/BK
LED BL/RD
C29MS RD/WH
DRIVE MODE
H1 RD/BK
D41
P26ESTP BK
C3P-12
C2P-3
C4P-2
C4P-3
C4P-6
TB42
LEFT
H4
C25-2
C24-2
B
C
C26-2
C28-2
C15-2
C14-2
C31-2
C12-2
C13-2
C29-2
C16-2
C17-2
C27-2
C20-2
C21-2
C24-2
C22-2
PLATFORM ROTATE LEFT/JIB UP
PLATFORM ROTATE RIGHT/JIB DOWN
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
DRIVE ENABLE LIMIT SWITCH
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM RETRACT
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRIMARY BOOM UP CUTOUT RELAY
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
LS1RS-BOOM RETRACT SAFETY
DRIVE/ROTATE SPEED
LIMIT SWITCH
LS1RO-BOOM RETRACT OPERATIONAL
DRIVE/ROTATE SPEED LIMIT SWITCH
LS2AS-BOOM ANGLE SAFETY
DRIVE LIMIT SWITCH
LS2AO-BOOM ANGLE OPERATIONAL
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RELAY
AXLE NOT EXTENDED PRESSURE SWITCH
OPEN WHEN AXLE FULLY EXTENDED
GROUND
8
DESCENT ALARM OPTION
6 - 11
S-80 • S-85
Part No. 111165
2
NOHC
2AS
1
1
H3
NC
1RO
4
4
3
C6-19
U4
D57
14
13
TB32
1
2
1
2
3
3
1
4
S3
NC
CR38
CR8
6
2
3
5
TB16
TB40
TB37
1
4
CR38
NC
D41
D29
2
3
3
5
UP
PLATFORM LEVEL
DOWN
D27
C4P-5
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
4
CR8
NC
TB6
TB3
TB9
TB18
TB4
TB1
TB7
TB15
D36
D35
NOHC
1RS
NOHC
LS3
BRN
D38
CR29
NC
TB46
D15
3
D37
4
TS62
TS61
TS63
TB5
TB2
TB8
TB14
TB17
J2
RIGHT
PLATFORM ROTATE
LEFT
TS59
TS57
J1
J1
J1
TS14
TS15
2
CR27 CE
J1
J3
L5
CR26
NC
L1
WH
JOYSTICK CONTROL CARD
CR30
NO
TS16
3
TS9
TS7
+
JC3
JC2
PRIMARY BOOM UP/DOWN
AND TURNTABLE ROTATE
DRIVE & STEERING
JC1
NC
SECONDARY BOOM UP/DOWN
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
February 2012
P26ESTP BK
February 2012
6 - 11
6 - 12
February 2012
6 - 14
6 - 13
February 2012
A
B
C
D
E
F
G
H
I
J
K
L
M
N
NOTE: CE OPTION- LOADSENSE
MODULE CONNECTS TO C32.
1
C32
CONNECTOR
PLUG
1 RD H6
3 BL/WH C1-12
4 BK-22D2
5
6
7
8
12
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM FLOW CONTROL
TURNTABLE ROTATE F.C.
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT FLOW CONTROL
2
P134PWR RD-134B
GR/BK-C3B-10
GR/BK-L45
RD C3B-1
VOLT METER
3
4
L.P.
LIMIT SWITCH #1
ENGINE RPM
LIMIT SWITCH #2
LIMIT SWITCH POWER
KEY SWITCH POWER
KEY SWITCH POWER
B
C
D
RD C6-1
RD/BK C6-19
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
OR C6-14
OR/BK C6-15
D42
OR/RD CR38#87A
GR C6-17
GR/BK C6-18
RD-B1-H1
WH C5-3 & C5-11
OR C4B-2
OR/BK C4B-3
OR/RD C6-11
GR C4B-5
GR/BK C4B-6
RD-B1-H1
WH CR17 #86
BK C23-4
WH C7B-2
RD-CR28#30
RD C6-30
CR39#30
RD-CR39#87&C1B1 RD C5-6
WT/RD C5-23
WH/RD C1B-6
BK C1B-7
BK C5-5
D51
BK/WH C5-22
BK/WH C1B-8
BK/RD C1B-9
BL/BK C1B-11
BL/BK C6-37
WH C2B-2
OR/BK C2B-3
OR/RD C4B-4
RD C6-31
RD C6-23
RD C6-24
OR C6-40
OR/BK C5-2
OR/RD CR29#86
C2-6
G1
C7B
12V DC TO
PLATFORM
1
BK-33AA
OR/BK-41B
BK-33B
RD-27B
BRN GND
BRN-GND STUD
BK-C23-5
WH-23AB
WH-23B
H1
RD-B1-20C
WH-CR2#86
BL/RD L2
RD-B1-20D
RD-B2-S.P.
1
2
3
4
5
6
7
8
9
10
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
G2
G3
RD C4B-12
BRN GND
BK-22A
P1
EMERGENCY
STOP
KS1
KEY SWITCH
TS51
AUXILIARY
PUMP
NC
D2
NC
RD-134A
LABEL
RD-27A
P1
KEY SWITCH
BK-7A
BK/WH-8A
TS51
AUXILIARY TOGGLE SWITCH
TS52
ENGINE START TOGGLE SWITCH
TS56
TS54
GLOW PLUG TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
TS57
PLATFORM ROTATE TOGGLE SWITCH
L2
CHECK ENG. LED
L45
PLATFORM
OVERLOAD
LED
+
-
BL/RD ISM #10
+
-
+
G6
TS61
BOOM
UP/DOWN
-
BRN-CR19#85
U1
TS63
BOOM EXTEND/
RETRACT
RD-1A
BK-33
TS52
ENGINE
START
RD 24B
CB3
OIL COOLER/
OPTION
C4B
TS62
TURNTABLE
ROTATE
RD-24AA
OR/BK-15A
RD-B2-H1
BK-C6-16
BK/RD C5-18
D13
BK/RD-35A
D14
C2B
OR/RD 16B
TS54
HIGH/LOW
RPM
BK 7B
C1B
BL/RD C6-13
D42
BK-33AB
RD-24A
OR C6-33
RD-B1-20A
CB1
ENGINE
CB2
CONTROLS
86
86
C6
CR8
86
CR29
CR28
86
CR17
TS57
PLATFORM
ROTATE
PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
CB1
CIRCUIT BREAKER, ENGINE, 15A
CB2
CIRCUIT BREAKER, CONTROLS, 15A
CB3
CIRCUIT BREAKER, OIL COOLER/OPTION, 15A
VOLT METER GAUGE (OPTIONAL)
G2
OIL PRESSURE GAUGE (OPTIONAL)
G3
OIL TEMPERATURE GAUGE (OPTIONAL)
G6
HOUR METER
L2
CHECK ENGINE LED
L45
PLATFORM OVERLOAD LED
CR2
IGNITION POWER RELAY
CR3
HIGH IDLE CUTOUT RELAY
CR5
HORN RELAY
CR17
HYDRAULIC COOLER FAN RELAY
CR23
DRIVE LIGHT RELAY OPTION
CR25
CR28
AXLE RET L/O RELAY
TROMBETTA PULL IN RELAY
CR29
CR38
AXLE EXTEND LED RELAY
EXTEND FUNCTION CUTOUT RELAY
AUXILIARY PUMP RELAY
R2
5 OHM RESISTOR
U1
IGNITION/START MODULE
GR-17A
WH-C6-34
GR/WH C4B-7
GR/BK-18A
BK C5-7
BL/RD C4B-1
RD-24C
RD-27D
WH/RD-6A
RD C6-27
RD-1B
BK/WH C6-29
BRN
GROUND STUD
WH-4A
WH/BK-5A
RD/BK 2B
ALL BRN WIRES
OR/RD-16C
C5
ENGINE
BRN
6 - 14
TS63
OR-14A
RD-24AD
OR/RD 42C
GROUND STUD
8
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
CR39
TS59
PLATFORM
LEVEL
PLATFORM LEVEL TOGGLE SWITCH
TS61
TS62
WH-21B
FUNCTIONS
7
TS56
GLOW PLUG
BK/WH-34A
BK-22B
TS59
G1
RD-C23-7
86
RED EMERGENCY STOP BUTTON
KS1
BK/RD-9A
IGNITION/
START
MODULE
DESCRIPTION
RD/WH-3A
RD/BK-2A
HOUR METER
CR5
RD C4B-11
RD C23-6
WH-23A
GR/BK-H6
C3B
19/18 CABLES
CR3
86
GR/BK C2B-6
GR/BK C5-14
GR C2B-5
CR2
86
86
BL/BK C5-16
BK/RD-35B
6
TB24AD
30
85
87
WH-21A
5
3
OIL TEMPERATURE
CR23
A
RD CR38#86
RD-S.P.
1
RD/BK CR8#30 RD/BK-S.P.
2 D15
RD/WH-S.P.
3
WH-S.P.
4
WH/BK-S.P.
5
WH/RD-S.P.
6
D57
GND STUD BK-S.P.
7 CR8#86+
BK/WH-S.P.
BK/WH C6-38
8
BK/RD-S.P.
9
10
11
OR-S.P.
14
OR/BK-S.P.
15
D34
16 OR/RD CR8#87A
GR-S.P.
17
GR/BK-S.P.
18
RD-B1-S.P.
20
GND STUD
WH S.P.
21 D52
BK-S.P.
22 BK CR5#30
WH-S.P.-D2
23 WH ISM#7
RD-S.P.-CB1
24 RD CR2#30
RD-S.P.-CB3
24A RD CR17#30
RD-S.P.
27 RD ISM#4
D6
32 WH/RD C6-32
BK-S.P.
33 BK ISM#3
BK ISM#1
33A BK-CR28#86
BK/WH-S.P.
34
BK/RD-S.P.
35 BK/RD CR3#30
37 BL/BK C6-20
38
39
40 OR C6-10
41 OR/BK ISM#2
42 OR/RD C6-22
D7
D8
46
RD-KSI-SP
134 RD-H6
134A
BASE TERMINATION BLOCK
2
OIL PRESSURE
10 AMP FUSE
SBD/DESCENT ALARM
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
AXLE DUMP VALVE
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
12V DC BATTERY SUPPLY
IGNITION POWER
HORN
KEYSWITCH PWR/PWR TO PLAT
FUSED 12V DC
OIL COOLER FAN
AUXILIARY PUMP
BRAKE
ENGINE START
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
DRIVE LIGHT OPTION RELAY
H6
BK C7B-1
RD-TS51
RD-TS52
GR//BK H6
BRN
CR38
CR39
86
86
S-80 • S-85
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
Part No. 111165
R2
CIRCUIT DESCRIPTION
FROM
12 DRIVE ENABLE
BL/WH C6-12
TO
BL/WH C3B-12
19 JIB VALVE
GR/WH C4B-7
GR/WH-S.P.
25 OIL PRESSURE SENDER
BL/BK C5-16
BL/BK-S.P
26 OIL TEMP SENDER
GR/BK C5-14
GR/BK-S.P.
28 TILT ALARM
RD/BK C1-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
30 E.D.C. REV
WH C1B-4
WH C5-21
WH/BK C1B-5
31 E.D.C. FWD
WH/BK C5-20
36 STEER LEFT/AXLE RETRACT
BL CB1-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GEN. OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXT/RET SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
COMPONENT INDEX
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
U13
ALC-500
P2
P3
TS1
TS2
TS4
TS6
3
J3
D12
1
TS7
TS9
GND STUD
J2
J1
11
9
TS14
TS15
TS16
TS47
TS48
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P23SWBAT WH C7P-2
P2-P22BAT BK C7P-1
TS7-C18JD GR/BK C4P-6
TS7-C17JU GR C4P-5
TS9-C15PLD OR/BK C4P-3
TS9-C14PLU OR C4P-2
L40-S3LED BL/RD C4P-1
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
HI-C133PLA GN/BL C3P-10
TS16-C61AX BL/BK C3P11
TS47-C45GEN GR/WH C2P-7
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
TS16-C60AX OR/RD C2P-4
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS4-C35ESPD BK/RD C1P-9
TS6-C34SA BK/WH C1P-8
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
WORK LIGHT TOGGLE SWITCH (OPTION)
DRIVE LIGHT TOGGLE SWITCH (OPTION)
LS18
L1
L4
PLATFORM OVERLOAD LIMIT SWITCH
DRIVE ENABLE LED
AXLE EXTENDED LED
JC3
2
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
AXLE EXTEND/RETRACT TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
TS49
L40
L48
1
EMERGENCY STOP BUTTON
HORN SWITCH
ENGINE START SWITCH
HIGH RPM SWITCH
GLOW PLUG OPTION
3
TILT ALARM LED
DRIVE PROPORTIONAL JOYSTICK, STEER LEFT/RIGHT
JC2
JC1
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
U13 ALC500
CR26 AXLE CUTOUT RELAY
TILT ALARM
H1
C28TTA RD/BK C1P-2
4
BATGND C7P-3
D40
D39
CR13 BRN
BK LS CABLE CIP-12
C4P(BR)
GND STUD
C3P(GR)
BRN
C2P(BK)
C1P(GY)
H1
TILT
ALARM
C2P-9 & 10
C7P
JIB
C9
12V DC
BATTERY
19/18 CONTROL CABLE
LS18
CE LIFT/DRIVE OPTION
OPT.
(OPTION)
REPLACE WIRE WITH THIS WIRING DIAGRAM
RD-H1
RD-P2
RD LS CABLE
FOOT SWITCH
BRN BATGND
GND STUD
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
WH-TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
6
CR30
OR/RD R40LS2
(SPLICE TO R40LS2)
+
3
L48
D12
-
+
CR27
WH-TS7
GN/BK H1 (D39)
TS15
DRIVE
ENABLE
BRN J1-14
4
OR J1-13
WH J1-5
BL J1-4
5
4
2
2
JC3
DRIVE
1
CR26
AXLE CUTOUT
WH J3-2
6
5
1
DETAIL B: GENERATOR OPTION
7
+
DETAIL C: WORKLIGHT/DRIVELIGHT OPTION
+
RD WL1
L4
RD WL2
L1
TS15
NO
TS9
PLATFORM
LEVEL
TS1
AUXILIARY
PUMP
TS14
DRIVE
SPEED
TS6
GLOW PLUG
OPTION
GR/WH C2P-7
TS7
PLATFORM
ROTATE
P3
HORN
RD/BK H1
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
1
BL/WH J1-6
6
-
-
L40
BK/WH C1P-8
7
+
+
2
BL/BK J1-7
7
3
3
RD/WH J1-8
TS16
BRN J1-10
JC1
BOOM
EXTEND/
RETRACT
4
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
OR J1-9
YEL J1-3
D2
RD C1P-1
5
GR/BK C4P-6
6
GR C4P-5
GR/WH JIB CABLE
7
J2-DIODE WH
BRN
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
5
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
BK
NC
TS48/TS49
8
TS2
P2
EMERGENCY
STOP
CE MODELS (SEE DETAIL A)
Part No. 111165
S-80 • S-85
6 - 15
February 2012
6 - 15
6 - 16
February 2012
Deutz BF4L 2011 Models
6 - 18
6 - 17
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 18
S-80 • S-85
Part No. 111165
F
G
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M
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1
C28TTA RD/BK
7
WH
OR
RD
BK
RETRACT
AXLE
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C5TRR WH/BK
C6TRF WH/RD
C4TRL WH
TURNTABLE ROTATE
5
R2
BK/RD
BK/WH
BK
PRIMARY BOOM
EXTEND
BOOM
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-5
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
RETRACT
C12DRE BL/WH
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
DOWN
D28
C6-21
C42LS2 GR
C61AXRT BL
C40LS1 OR
C40LS2 BK
C6-22
C6-10
C6-40
C60AX OR/RD
C34-1
S3LED BL/RD
C6-39
C35-1
J3 WH
J1 WH
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C15-1
C14-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
C22-1
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C42AXDP WH
C6-13
7
C6-11
J4 BK
J2 WH
WH
RD
J5 BK
C6-20
C37STC BL/BK
C6-31
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-38
C6-30
C6-14
C6-15
C6-18
GR-17-M.H.
C34-2
C35-2
NC
EXTEND
AXLE
4
1
18
17
15
16
19
20
11
9
10
6
7
8
14
13
12
D34
RIGHT
PLATFORM ROTATE
C6-17
2
2AO
RETRACT
EXTEND
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
YOUT 5
OR
BL
RKOUT 6
4
YOUT 5
BRN
3
PWR
BRN
1
OR
YEL
2
7
6
5
3
4
BRN
1
2
BRN
P24FS WH
P24FS WH
GND
PWR
OUT
GND
XOUT 4
6
7
1
GND 2
PWR 3
BL
CDE1 BL/WH
LEFT
RIGHT
CDE2 BL/BK
LED BL/RD
C29MS RD/WH
DRIVE MODE
H1 RD/BK
D41
P26ESTP BK
C3P-12
C2P-3
C4P-2
C4P-3
C4P-6
TB42
LEFT
H4
C25-2
C24-2
B
C
C26-2
C28-2
C15-2
C14-2
C31-2
C12-2
C13-2
C29-2
C16-2
C17-2
C27-2
C20-2
C21-2
C24-2
C22-2
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
DRIVE/ROTATE SPEED
LIMIT SWITCH
DRIVE LIMIT SWITCH
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RELAY
GROUND
8
6 - 19
S-80 • S-85
Part No. 111165
2
NOHC
2AS
1
1
H3
NC
1RO
4
4
3
C6-19
U4
D57
14
13
TB32
1
2
1
2
3
3
1
4
S3
NC
CR38
CR8
6
2
3
5
TB16
TB40
TB37
1
4
CR38
NC
D41
D29
2
3
3
5
UP
PLATFORM LEVEL
DOWN
D27
C4P-5
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
4
CR8
NC
TB6
TB3
TB9
TB18
TB4
TB1
TB7
TB15
D36
D35
NOHC
1RS
NOHC
LS3
BRN
D38
CR29
NC
TB46
D15
3
D37
4
TS62
TS61
TS63
TB5
TB2
TB8
TB14
TB17
J2
RIGHT
PLATFORM ROTATE
LEFT
TS59
TS57
J1
J1
J1
TS14
TS15
2
CR27 CE
J1
J3
L5
CR26
NC
L1
WH
CR30
NO
TS16
3
TS9
TS7
+
JC3
JC2
DRIVE & STEERING
JC1
NC
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
February 2012
P26ESTP BK
February 2012
6 - 19
6 - 20
February 2012
6 - 22
6 - 21
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 22
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 23
February 2012
6 - 23
6 - 24
February 2012
GM 3.0L Models
6 - 26
6 - 25
ENGINE SPEED
GENERATOR
C35ESPD BK/RD
C45GEN GR/WH
C1-9
C2-7
C39LP BL/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C2-1
FUEL
SELECT
C25PSR BL/BK
GR/WH
C8-12
C8-9
C8-7
BK
LT BL
DK BL
PU
YE
RD/BL
GR/BK
RD
PU/BK
YE/BK
WH/BL
WH
C8-2
C8-8
C8-4
C8-1
C8-3
C8-5
C8-6
C8-11
BRN
B1 BATTERY
C26TSR GR/BK
C5-12
C38ESL BL/RD
WH-21
C5-13
C35RPM BK/RD
C41RPM OR/BK
P23BATSA RD
C39LP BL/RD
C33STR BK
C27AUX RD
C21IGN WH
C27AUX RD
C28TTA RD/BK
+
C5-18
C5-2
C5-19
C5-10
C5-5
C5-6
C5-11
C6-27
C6-28
C43HRN BK
RD
C6-16
R21IGN WH
P23BAT RD
C6-34
R116HYD OR
C6-23
GR
C6-33
2
1
3
HIGH (FS)
ON
FUEL SELECT
LP
GAS
C33STR BK
ENGINE
START
C27AUX RD
RD
AUXILIARY
POWER
P23BAT WH
WH
C28TTA RD/BK
C46HRN GR
BRN
RD C134-E.H.
HM
BK
OIL PRESSURE
SENDER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
VOLT METER (OPTION)
GENERATOR OPTION
HOUR METER
GM ENGINE
HARNESS
STARTER MOTOR
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
START BATTERY
ALTERNATOR
FLASHING BEACONS (OPTION)
HYDRUALIC OIL TEMPERATURE
SWITCH (OPTION)
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
LP
C1-7
C1-1
C7P-2
C1P-2
C7B-1
C6-24
CE AND LOAD WEIGHT OPTION.
5
GAS
AUXILIARY
POWER
C2P-5
P22BAT BK
RD
4
6
3
ENGINE
START
C7P-1
C1B-12
BK
P20BAT RD
Part No. 111165
BL/WH
G1
BAT.
GM ENGINE HARNESS
M3
B
1
REGULATOR
M4
FUEL
_
AUX
PUMP
AUX
FAN
FB
PR1
2
+
R
NO
12V DC
STARTER
GND.
S-80 • S-85
-
6 - 26
RD
U18
BL
RD
GR/BK
B1
C
G1
G2
A
L5
D52
D42
D14
TB46
D7
OR/BK
RD
RD
RD
D11
G3
WH-E.H.
CR5
NO
CR17
NO
PUMP
6
TB21
CR39
NO
CB3
TB35
TB24
CB1
TB41
TB27
TB39
TB33
D13
TB23
TB23
TB28
NOTES:
8
TB24A
5
H2
7
RD
20A
TB20
C132PLI BL/WH
GRD
D12
H1
TS54
TS53
TS52
TS51
PLAT
D8
CR2
NO
RD
15A
TB22
KS1
3
TB134
TS1
D43
TS4
TS47
TS3
TS2
D10
P134PWR GR/BK
15A
L4
P3
HORN
2
WH
P24FS WH
FS1
RD
P25FS RD
BK
C9P-1
P2
BK
P26ESTP BK
1
N
M
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I
H
G
F
E
D
C
B
A
D2
WH
4
RD
RD
RD
P1
CB2
February 2012
GM 3.0L Models
RD/BK
BRN
+
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
AXLE
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
5
C6-21
C42LS2 GR
C61AXRT BL
C40LS1 OR
C40LS2 BK
C6-22
C6-10
C6-40
C60AX OR/RD
C34-1
S3LED BL/RD
C6-39
C35-1
J3 WH
C42AXDP WH
J4 BK
J2 WH
J1 WH
WH
RD
J5 BK
C6-20
C37STC BL/BK
C6-31
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-38
C6-30
C6-14
C6-15
C6-18
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C15-1
C14-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C6-11
C6-13
7
C22-1
C34-2
C35-2
NC
RETRACT
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C5TRR WH/BK
C6TRF WH/RD
C4TRL WH
TURNTABLE ROTATE
5
R2
BK/RD
BK/WH
BK
PRIMARY BOOM
EXTEND
BOOM
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-5
C3P-6
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
RETRACT
C12DRE BL/WH
C14PLU OR
PLATFORM LEVEL
C15PLD OR/BK
UP
DOWN
D28
GR-17-M.H.
2
2AO
EXTEND
AXLE
4
1
18
17
15
16
19
20
11
9
10
6
7
8
14
13
12
D34
RIGHT
PLATFORM ROTATE
C6-17
H4
1
C28TTA RD/BK
C25-2
C24-2
B
C
C26-2
C28-2
C15-2
C14-2
C31-2
C12-2
C13-2
C29-2
C16-2
C17-2
C27-2
C20-2
C21-2
C24-2
C22-2
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
DRIVE/ROTATE SPEED
LIMIT SWITCH
DRIVE LIMIT SWITCH
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RELAY
GROUND
8
6 - 27
S-80 • S-85
1
2
NOHC
2AS
NC
1RO
4
1
RETRACT
EXTEND
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE2 BL/BK
RIGHT
LEFT
CDE1 BL/WH
7
WH
BL
YOUT 5
OR
BL
RKOUT 6
4
BK
BRN
PWR 3
1
GND 2
7
YOUT 5
OR
RD
6
3
BRN
XOUT 4
PWR
2
OR
YEL
3
4
5
6
7
1
GND
PWR
OUT
BRN
1
2
BRN
P24FS WH
P24FS WH
C3P-12
C2P-3
C4P-6
C4P-3
C4P-2
3
C4P-5
TB42
LEFT
C6-19
U4
D57
14
13
Part No. 111165
S3
NC
CR38
CR8
6
3
3
2
4
3
2
H3
TB16
TB40
TB37
1
2
1
3
5
UP
PLATFORM LEVEL
DOWN
D27
RIGHT
PLATFORM ROTATE
LEFT
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
3
1
4
NOHC
1RS
NOHC
LS3
BRN
D38
CR29
NC
TB46
D15
2
3
4
CR38
NC
D41
D29
D37
D36
D35
1
TB32
TB5
J1
J1
J1
4
CR8
NC
TB6
TB3
TB9
TB18
TB2
TB8
TB14
TB17
TS62
TS61
TS63
TB4
TB1
TB7
TB15
J2
4
TS59
TS57
P26ESTP BK
CR27 CE
J1
J3
D41
GND
WH
CR30
NO
L5
L1
CR26
NC
TS14
TS15
2
TS16
3
TS9
TS7
+
JC3
JC2
DRIVE & STEERING
JC1
NC
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
February 2012
GM 3.0L Models
P26ESTP BK
February 2012
GM 3.0L Models
6 - 27
6 - 28
February 2012
GM 3.0L Models
6 - 30
6 - 29
February 2012
GM 3.0L Models
A
B
C
D
E
F
G
1
H
VOLT METER
2
RD C3B-1
RD/BK C6-19
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
B
C
D
PRIMARY BOOM UP
PRIMARY BOOM DOWN
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
RD C6-1
SBD/DESCENT ALARM
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
AXLE DUMP VALVE
IGNITION POWER
HORN
KEY SWITCH PWR/PWR TO PLAT.
FUSED 12V DC
OIL COOLER FAN
AUXILIARY PUMP
BRAKE
ENGINE START
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
3
L.P.
LIMIT SWITCH #1
ENGINE RPM
LIMIT SWITCH #2
LIMIT SWITCH POWER
KEY SWITCH POWER
KEY SWITCH POWER
4
OR C4B-2
OR/BK C4B-3
OR/RD C6-11
GR C4B-5
GR/BK C4B-6
RD-B1-H1
WH CR17 #86
BK C23-4
WH C7B-2
OR C6-14
OR/BK C6-15
OR/RD CR38#87A
GR C6-17
GR/BK C6-18
RD-B1-H1
WH C5-3 & C5-11
D42
RD C6-30
CR39 #30
RD CR39#86&C1B-1 RD C5-6
WT/RD C5-23
WH/RD C1B-6
BK C1B-7
BK C5-5
BK/WH C5-22
BL/BK C6-37
WH C2B-2
OR/BK C2B-3
OR/RD C4B-4
RD C6-31
RD C6-23
RD C6-24
BK/WH C1B-8
BK/RD C1B-9
BL/BK C1B-11
OR C6-40
OR/BK C5-2
OR/RD CR29#86
C2-6
A
G1
RD-S.P.
1 RD CR38#86
2 D15
RD/WH-S.P.
3
WH-S.P.
4
WH/BK-S.P.
5
WH/RD-S.P.
6
D57
GND STUD BK-S.P.
7 CR8#86+
BK/WH-S.P.
8 BK/WH C6-38
BK/RD-S.P.
9
10
11
OR-S.P.
14
OR/BK-S.P.
15
D34
16 OR/RD CR8#87A
GR-S.P.
17
GR/BK-S.P.
18
RD-B1-S.P.
20
GND STUD
WH S.P.
21 D52
BK-S.P.
22 BK CR5#30
WH-S.P.-D2
23 RD C5-19
RD-S.P.-CB1
24 RD CR2#30
RD-S.P.-CB3
24A RD CR17#30
RD
RD-S.P.
27
32 WH/RD C6-32
BK-S.P.
33
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
33A
34
35 BK/RD CR3#30
37 BL/BK C6-20
38
39
40 OR C6-10
41
42 OR/RD C6-22
D7
46
134 RD-H6
134A
OIL PRESSURE
I
G2
G3
BK-22A
GR/BK C2B-6
RD C4B-11
P1
EMERGENCY
STOP
KSI
KEY SWITCH
RD C4B-12
TS51
AUXILIARY
PUMP
BRN GND
B
NC
D2
3
NC
1
B1
4
RD-134A
2
RD-27A
RD/WH-3A
RD/BK-2A
BL/RD TS53
LABEL
BK-7A
BK/WH-8A
P1
BK/RD-9A
+
D8
RD-KSI-SP
L2
CHECK ENG. LED
BL/RD C5-13
-
BL/RD-39A
+
G6
TS61
BOOM
UP/DOWN
C7B
12V DC TO
PLATFORM
-
BRN-GND STUD
H1
TS53
LP/GAS
BK-C23-5
WH-23AB
TS63
BOOM EXTEND/
RETRACT
RD-1A
WH-C5-11
RD-B1-20D
BK-33
TS52
ENGINE
START
RD-1B
RD-B2-S.P.
RD CR38#30
D11
BK/WH C6-29
C4B
86
CR38
86
CR5
BK-22B
RD-24AA
86
C3B
19/18 CABLES
BK-C6-16
C2B
D14
TS54
HIGH/LOW
RPM
BK 7B
BL/RD C6-13
RD C6-27
RD-27D
RD-24A
FUNCTIONS
86
C6
CR8
86
CR29
86
CR39
RD-24AD
WH-C6-34
CB1
ENGINE
CB2
CONTROLS
TS59
PLATFORM
LEVEL
TS57
PLATFORM
ROTATE
BL/RD C4B-1
C5
ENGINE
TS53
LP/GAS SELECT TOGGLE SWITCH
TS54
TS57
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
TS59
TS61
TS62
TS63
CB1
CB2
CB3
G1
G2
G3
WATER TEMP. GAUGE (OPTIONAL)
G6
L2
HOUR METER
CHECK ENGINE LED
R2
TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS
CR2
CR3
CR5
HORN RELAY
CR8
BOOM FUNCTION CUTOUT
CR17
CR23
DRIVE LIGHT RELAY (OPTIONAL)
CR25
AXLE RET L/O RELAY
CR29
CR38
GR-17A
U1
WH-4A
WH/BK-5A
ALL BRN WIRES
WH/RD-6A
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
GROUND STUD
KEY SWITCH
AUXILIARY POWER TOGGLE SWITCH
TS52
CR39
RD CR2#30
RD/BK 2B
RD-24B
S-80 • S-85
KS1
TS51
GR/WH C4B-7
GR/BK-18A
OR/RD 42C
BRN
6 - 30
86
CR17
D42
DESCRIPTION
OR-14A
RD-B1-20A
WH-21B
GROUND STUD
8
D13
BK/RD-35A
OR/RD 16B
OR C6-33
7
TS62
TURNTABLE
ROTATE
OR/BK-15A
RD-B2-H1
OR/RD 16C
C1B
6
CB3
OIL COOLER/
OPTION
GR C2B-5
CR2
TB24AD
CR23
WH-23A
BK/RD-S.P.
RD-B1-20C
N
10 AMP FUSE
BRN (GND)
2
M
WATER TEMPERATURE
HOUR METER
5
L
GR/BK C5-14
WH-21A
1
K
BL/BK C5-16
3
J
Part No. 111165
R2
TO
CIRCUIT DESCRIPTION
FROM
12 DRIVE ENABLE
BL/WH C6-12
BL/WH C3B-12
19 JIB VALVE
GR/WH C4B-7
GR/WH-S.P.
BL/BK C5-16
BL/BK-S.P
26 WATER TEMP SENDER
GR/BK C5-14
GR/BK-S.P.
28 TILT ALARM
RD/BK C1-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
30 E.D.C. REVERSE
WH C1B-4
WH C5-21
WH/BK C1B-5
31 E.D.C. FORWARD
WH/BK C5-20
BL CB1-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GENERATOR OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
February 2012
GM 3.0L Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
COMPONENT INDEX
HORN SWITCH
FUEL SELECT TOGGLE SWITCH (FORD)
HIGH RPM TOGGLE SWITCH
3
TS7
TS9
1
TS14
TS15
TS16
TS47
TS48
DRIVE SPEED LOW/HIGH TOGGLE SWITCH
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
U13
ALC-500
P2
P3
TS1
TS2
TS3
TS4
J3
D12
GND STUD
J2
J1
11
9
TS49
L1
L4
L40
JC3
JC2
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P22BAT BK C7P-1
TS7-C17JU GR C4P-5
TS9-C14PLU OR C4P-2
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
TS3-C39LP BL/RD C2P-1
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C3PBF RD/WH C3P-3
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
JC1
CR26
U13
H1
LS18
L48
1
GENERATOR TOGGLE SWITCH ( OPTION )
WORK LIGHT RELAY (OPTION)
DRIVE LIGHT RELAY (OPTION)
DRIVE ENABLE LED
AXLE EXTENDED LED
2
BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACT
AXLE CUTOUT RELAY
ALC500
TILT ALARM
TILT ALARM LED
3
C28TTA RD/BK C1P-2
BATGND C7P-3
D40
4
BRN BATGND
CR13 BRN
BK LS CABLE CIP-12
C4P(BR)
19/18 CONTROL CABLE
C7P
JIB
C9
12V DC BATTERY
CR27
WH-TS7
OPT
RD LS CABLE
FOOT
SWITCH
RD-H1
RD-P2
Y
GND STUD
C3P(GR)
BRN
C2P(BK)
C1P(GY)
H1
TILT
ALARM
GND STUD
C2P-9 & 10
Y
D39
WH-TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
5
CR30
+
3
L48
D12
-
+
+
TS15
DRIVE
ENABLE
DETAIL B:
GENERATOR OPTION
GR/WH C2P-7
4
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
BL/RD C2P-1
GN/BK H1 (D39)
BRN J1-14
OR J1-13
WH J1-5
5
4
2
JC3
DRIVE
AND STEER
1
2
1
6
RD WL1
RD WL2
TS15
TS48/TS49
7
+
CR26
AXLE CUTOUT
BL J1-4
WH J3-2
RD/BK H1
1
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
6
5
-
-
L40
7
6
+
+
2
TS7
PLATFORM
ROTATE
+
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
7
3
3
BL/WH J1-6
4
BL/BK J1-7
TS16
BRN J1-10
D2
RD/WH J1-8
JC1
BOOM
EXTEND/
RETRACT
6
5
OR J1-9
YEL J1-3
RD C1P-1
GR/BK C4P-6
GR C4P-5
GR/WH JIB CABLE
BRN
7
J2-DIODE WH
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
OR/RD R40LS2
(SPLICE TO R40LS2)
D12
L4
TS2
L1
D10
NO
P3
HORN
TS1
AUXILIARY PUMP
TS9
PLATFORM
LEVEL
TS14
DRIVE
SPEED
TS2
ENGINE
START
NC
TS4
HIGH/LOW
RPM
TS3
FUEL SELECT
8
P2
EMERGENCY
STOP
Part No. 111165
S-80 • S-85
6 - 31
February 2012
GM 3.0L Models
6 - 31
6 - 32
February 2012
Perkins 804-33 Models
6 - 34
6 - 33
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 34
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
1
C28TTA RD/BK
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
BK
RETRACT
EXTEND
AXLE
AXLE
4
1
18
17
15
16
19
20
11
9
10
6
7
8
14
13
12
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C6TRF WH/RD
C5TRR WH/BK
BOOM
BK/RD
BK/WH
BK
PRIMARY BOOM
R2
5
TURNTABLE ROTATE
C4TRL WH
UP
DOWN
D28
PLATFORM LEVEL
C15PLD OR/BK
C14PLU OR
C12DRE BL/WH
RETRACT
EXTEND
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-6
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
D34
RIGHT
PLATFORM ROTATE
5
C6-21
C42LS2 GR
C61AXRT BL
C40LS1 OR
C40LS2 BK
C6-22
C6-10
C6-40
C34-1
S3LED BL/RD
C60AX OR/RD
C35-1
C6-13
C6-39
C42AXDP WH
J1 WH
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C15-1
C14-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
GR-17-M.H.
C22-1
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C6-11
J4 BK
J3 WH
J2 WH
WH
RD
J5 BK
C6-20
C37STC BL/BK
C6-31
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-38
C6-30
C6-14
C6-15
C6-18
C6-17
C34-2
C35-2
NC
RETRACT
EXTEND
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE2 BL/BK
RIGHT
LEFT
CDE1 BL/WH
7
WH
BL
YOUT 5
OR
BL
RKOUT 6
4
RD
BRN
PWR 3
1
GND 2
7
YOUT 5
6
3
XOUT 4
BRN
1
OR
YEL
2
OR
PWR
GND
7
6
5
BRN
4
3
OUT
2
1
GND
BRN
P24FS WH
P24FS WH
C3P-12
C2P-3
C4P-6
C4P-3
C4P-2
3
C4P-5
TB42
LEFT
C6-19
2
2AO
C25-2
C24-2
B
C
C26-2
C28-2
C15-2
C14-2
C31-2
C12-2
C13-2
C29-2
C16-2
C17-2
C27-2
C20-2
C21-2
C24-2
C22-2
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
DRIVE/ROTATE SPEED
LIMIT SWITCH
DRIVE LIMIT SWITCH
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXT/RET SELECT
AXLE EXTEND RELAY
GROUND
8
6 - 35
S-80 • S-85
Part No. 111165
1
2
NOHC
2AS
4
1
3
NC
1RO
7
CR8
U4
D57
14
13
CR38
S3
NC
H4
6
3
2
4
3
2
H3
TB16
TB40
TB37
1
2
1
3
5
UP
PLATFORM LEVEL
DOWN
D27
RIGHT
PLATFORM ROTATE
LEFT
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
3
1
4
NOHC
1RS
NOHC
LS3
BRN
D38
CR29
NC
TB46
D15
2
3
4
CR38
NC
D41
D29
D37
D36
D35
1
TB32
TB5
J1
J1
J1
4
CR8
NC
TB6
TB3
TB9
TB18
TB2
TB8
TB14
TB17
TS62
TS61
TS63
TB4
TB1
TB7
TB15
J2
4
TS59
TS57
P26ESTP BK
CR27 CE
J1
J3
D41
PWR
WH
CR30
NO
L5
L1
CR26
NC
TS14
TS15
2
TS16
3
TS9
TS7
+
JC3
JC2
DRIVE & STEERING
JC1
NC
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
February 2012
P26ESTP BK
February 2012
6 - 35
6 - 36
February 2012
6 - 38
6 - 37
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 38
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 39
February 2012
6 - 39
6 - 40
February 2012
Ford LRG-425 EFI
6 - 42
6 - 41
February 2012
Ford LRG-425 EFI
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 42
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
Ford LRG-425 EFI
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 43
February 2012
Ford LRG-425 EFI
6 - 43
6 - 44
February 2012
Ford LRG-425 EFI
6 - 46
6 - 45
February 2012
Ford LRG-425 EFI
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 46
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
Ford LRG-425 EFI
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 47
February 2012
Ford LRG-425 EFI
6 - 47
6 - 48
February 2012
6 - 50
6 - 49
GENERATOR
ENGINE RPM
HIGH (FS)
ON
GLOW
PLUG
ENGINE
START
AUXILIARY
POWER
C2P-5
P22BAT BK
C1-9
C2-7
C1-8
C1-7
C1-1
C7P-2
C1P-2
C3P-10
C7B-1
C1B-12
C35ESPD BK/RD
LOW RPM
FUNC. ENABLE
HIGH RPM
C45GEN GR/WH
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD
C2B-5
C3B-10
C1B-2
C7B-2
RD
AUXILIARY
POWER
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL
C46HRN GR
C41RPM OR/BK
GR
GR/BK
BK/RD
C6-28
C6-23
C5-11
C5-7
C5-5
C5-12
WH-21
C5-18
BK/WH
GR/WH
C5-15
MODULE
RD
BK
WH
B1 BATTERY
BK
WH
RD
C24TSTP BL/RD
R116HYD OR
R21IGN WH
C43HRN BK
RD
WH
C26TSR GR/BK
C25PSR BL/BK
C27AUX RD
C33STR BK
R33STR BK
C21IGN WH
C5-22
C6-27
C28TTA RD/BK
P134 RD
C6-16
C6-34
C6-33
C6-134 RD
C41RPM OR/BK
HOLD
PULL IN
BK
HOUR METER
RPM RELAY
RPM SOLENOID
GENERATOR
OPTION
GLOW PLUG RELAY
GLOW PLUG
GLOW PLUG FUEL VALVE
OIL TEMPERATURE AND
OIL PRESSURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
IGNITIOIN/START RELAY
STARTER MOTOR
AUXILIARY PUMP
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
OIL TEMPERATURE
SENDER (OPTION)
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
NOTES:
FLASHING BEACONS OPTION
ALTERNATOR
2
C1B & C1P - GRAY; C2B & C2P - BLACK; C3B & C3P - GREEN; C4B & C4P - BROWN.
3
5
WH
C107AF WH
-
BATTERY
Part No. 111165
HOLD
C7P-1
C132PLI BL/WH
RD
C5-2
C5-3
P20BAT RD
IND.
7
S-80 • S-85
6 - 50
FB
H1
P134PWR GR/BK
RD
8
B
REGULATOR
HM
_
2
1
3
S1
NO
S2
NC
B1
NO
+
STARTER
AUX
PUMP
H2
3
2
1
S-613
PR2
NO
C
B
A
BAT.
BAT.
+
12 V
DC
D42
D14
TB46
TIME DELAY
MOM N.O.
-COM
PR1
EXCT.
TS54
D52
CR3
L5
BRN
+AUX
ALTERNATOR
AUX
FAN
STA.
RD
D22
6
G1
BL/RD
FUSE
70A
+BAT
CR1
CR1
NO
C
A
G2
G3
D6
P46 RD
TB24
CR3
NO
CR5
NO
CR17
NO
TB33A
CR39
NO
C21IGN WH
TB21
5
CR2
NO
CR28
NO
D51
RD
TB20
C21IGN WH
TB24A
P23 RD
D8
CB3
20A
TB23
TB23
TB35
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB28
RD
TB41
C32-8
D13
CB1
15A
D7
TB27
WH
TB34
TB33
8
12
D2
4
C1P-12
C2B-6
BK
7
TS4
TS47
TS6
TS2
OR/BK
RD
RD
RD
6
TS1
C2P-6
GRD
P24FS WH
TS56
TS52
TS51
5
4
PLAT
3
1
D40
5
TB134
RD
P1
PULL IN
RD
D12
L48
+
P25FS RD
BK
6
P3
HORN
2
P25FS RD
FS1
P24FS WH
BK
C9P-1
P2
P26ESTP BK
P26ESTP BK
P26ESTP BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB22
KS1
CB2
15A
3
RD
RD
February 2012
C28TTA RD/BK
C27AUX RD
BRN
+
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
RETRACT
EXTEND
RETRACT
EXTEND
15
8
16
7
6
4
5
13
DRIVE ENABLE
CDE2 BL/BK
RIGHT
LEFT
WH
BL
CDE1 BL/WH
7
YOUT 5
OR
BL
14
1
2
11
12
3
9
10
1
2
AXLE
AXLE
4
1
18
17
15
16
19
20
9
11
10
6
7
8
14
13
12
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C37STC BL/BK
C36STCC BL
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C6TRF WH/RD
C5TRR WH/BK
BOOM
BK/RD
BK/WH
BK
PRIMARY BOOM
R2
5
TURNTABLE ROTATE
C4TRL WH
UP
JIB BOOM
D28
C17JU/PRL GR
C18JD/PRR GR/BK
DOWN
5
C6-21
C61AXRT BL
C40LS1 OR
C40LS2 BK
C42LS2 GR
C6-40
C6-10
C6-22
PLATFORM LEVEL
C15PLD OR/BK
C14PLU OR
C12DRE BL/WH
RETRACT
EXTEND
C7PBBE BK
C8PBR BK/WH
C9PERF BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-6
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C3P-12
C2P-3
C4P-2
D34
PLATFORM
ROTATE
C60AX OR/RD
C34-1
S3LED BL/RD
C6-39
C35-1
J3 WH
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C15-1
C14-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
GR-17-M.H.
C22-1
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C42AXDP WH
C6-13
7
C6-11
J4 BK
J1 WH
RD
J2 WH
WH
J5 BK
C6-31
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-38
C6-30
C6-14
C6-15
C6-18
C6-17
C35-2
C34-2
2
1
C28TTA RD/BK
C20-2
C21-2
C24-2
C22-2
JIB VALVES
PLATFORM ROTATE LEFT/JIB BOOM UP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRIMARY BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE FLOW CONTROL
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
DRIVE LIMIT SWITCH
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
C25-2
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXTEND/RETRACT SELECT
AXLE EXTEND RELAY
GROUND
8
DRIVE/ROTATE SPEED
LIMIT SWITCH
NC
NOHC
2AS
1
2
2AO
NC
1RO
4
1
6 - 51
S-80 • S-85
Part No. 111165
RKOUT 6
4
BRN
PWR 3
1
GND 2
7
RD
BK
6
YOUT 5
OR
XOUT 4
PWR 3
BRN
1
YEL
GND 2
7
6
5
OR
4
3
BRN
OUT
PWR
2
1
GND
BRN
P24FS WH
3
4
3
5
PLATFORM LEVEL
C4P-3
C4P-6
C4P-5
DOWN
UP
RIGHT
LEFT
C6-19
U4
D57
14
13
TB42
C19JSV GR/WH
H4
6
3
3
2
4
3
2
H3
S3
NC
CR38
CR8
NC
1
2
1
P24FS WH
P26ESTP BK
UP
DOWN
D27
DOWN
JIB BOOM
UP
C4P-7
CR8
TB16
TB40
TB37
3
1
4
NOHC
1RS
NOHC
LS3
BRN
D38
RIGHT PLATFORM
ROTATE
LEFT
JIB VALVES
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
CR29
NC
TB46
D15
2
3
4
NC
CR38
D41
D29
3
D36
1
TB32
TB5
D37
D35
4
TB6
TB3
TB9
TB18
TB2
TB8
TB14
TB17
TB4
TB1
TB7
TB15
TS62
TS61
TS63
J1
J1
J1
J1
J3
4
TS59
TS58
TS57
J2
2
TS16
TS9
TS8
TS7
CR27 CE
CR13
CR30
NO
C19JSV GR/WH
WH
WH
3
L5
L1
CR26
NC
TS14
TS15
D41
CR13
NC
+
JC3
JC2
DRIVE & STEERING
JC1
NC
P24FS WH
A
B
C
D
E
F
G
H
I
J
K
L
M
N
February 2012
P26ESTP BK
BRN
February 2012
6 - 51
6 - 52
February 2012
6 - 54
6 - 53
February 2012
A
B
C
D
E
F
G
H
I
J
K
L
M
N
1
C32
CONNECTOR
PLUG
1 RD H6
3 BL/WH C1-12
4 BK-22D2
5
6
7
8
12
PRIMARY BOOM UP
PRIMARY BOOM DOWN
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT FLOW CONTROL
2
P134PWR RD-134B
GR/BK-C3B-10
GR/BK-L45
RD C3B-1
VOLT METER
3
4
L.P.
LIMIT SWITCH #1
ENGINE RPM
LIMIT SWITCH #2
LIMIT SWITCH POWER
KEY SWITCH POWER
KEY SWITCH POWER
B
C
D
RD C6-1
RD/BK C6-19
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
OR C6-14
OR/BK C6-15
D42
OR/RD CR38#87A
GR C6-17
GR/BK C6-18
RD-B1-H1
WH C5-3 & C5-11
OR C4B-2
OR/BK C4B-3
OR/RD C6-11
GR C4B-5
GR/BK C4B-6
RD-B1-H1
WH CR17 #86
BK C23-4
WH C7B-2
RD-CR28#30
RD C6-30
CR39#30
RD-CR39#87&C1B1 RD C5-6
WT/RD C5-23
WH/RD C1B-6
BK C1B-7
BK C5-5
D51
BK/WH C5-22
BK/WH C1B-8
BK/RD C1B-9
BL/BK C1B-11
BL/BK C6-37
WH C2B-2
OR/BK C2B-3
OR/RD C4B-4
RD C6-31
RD C6-23
RD C6-24
OR C6-40
OR/BK C5-2
OR/RD CR29#86
C2-6
G1
C7B
12V DC TO
PLATFORM
3
1
BK-33AA
OR/BK-41B
BK-33B
RD-27B
BRN GND
BRN-GND STUD
BK-C23-5
WH-23AB
WH-23B
H1
RD-B1-20C
WH-CR2#86
BL/RD L2
RD-B1-20D
RD-B2-S.P.
1
2
3
4
5
6
7
8
9
10
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
G2
G3
86
C4B
86
RD C4B-12
BRN GND
BK-22A
P1
EMERGENCY
STOP
NC
B
D2
B1
3
NC
1
2
4
RD-134A
LABEL
RD-27A
P1
RD/WH-3A
RD/BK-2A
BK-7A
BK/WH-8A
BK/RD-9A
L2
CHECK ENG. LED
L45
PLATFORM
OVERLOAD
LED
+
-
BL/RD ISM #10
+
-
+
G6
TS61
BOOM
UP/DOWN
-
BRN-CR19#85
U1
IGNITION/
START
MODULE
TS63
BOOM EXTEND/
RETRACT
RD-1A
BK-33
TS52
ENGINE
START
RD 24B
CB3
OIL COOLER/
OPTION
TS58
JIB
BOOM
TS56
GLOW PLUG
BK/WH-34A
BK-22B
TS62
TURNTABLE
ROTATE
RD-24AA
86
OR/BK-15A
RD-B2-H1
BK-C6-16
BK/RD C5-18
D13
BK/RD-35A
D14
C2B
OR/RD 16B
TS54
HIGH/LOW
RPM
BK 7B
C1B
BL/RD C6-13
D42
BK-33AB
RD-24A
RD-B1-20A
CB1
ENGINE
CB2
CONTROLS
TS59
PLATFORM
LEVEL
TS57
PLATFORM
ROTATE
FUNCTIONS
WH-21B
86
86
C6
CR8
86
CR29
CR28
86
CR17
OR-14A
RD-24AD
BK C5-7
6 - 54
WH-4A
WH/BK-5A
RD/BK 2B
RD-24C
RD-27D
WH/RD-6A
RD C6-27
RD-1B
BK/WH C6-29
BRN
ALL BRN WIRES
OR/RD-16C
C5
ENGINE
GROUND STUD
8
CR38
CR39
86
86
S-80 • S-85
KEY SWITCH
TS52
TS56
TS54
GLOW PLUG TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
TS57
TS58
JIB BOOM UP/DOWN TOGGLE SWITCH
TS59
TS61
TS62
TS63
CB1
CB2
CB3
G2
G3
OIL TEMPERATURE GAUGE (OPTIONAL)
G6
HOUR METER
L2
CHECK ENGINE LED
L45
CR2
CR3
CR5
HORN RELAY
CR8
BOOM FUNCTION CUTOUT RELAY
CR17
CR23
DRIVE LIGHT RELAY OPTION
CR25
CR28
AXLE RET L/O RELAY
TROMBETTA PULL IN RELAY
CR29
CR38
CR39
R2
5 OHM RESISTOR
U1
GR/WH C4B-7
GR/BK-18A
BL/RD C4B-1
BRN
RED EMERGENCY STOP BUTTON
TS51
GR-17A
WH-C6-34
OR/RD 42C
GROUND STUD
DESCRIPTION
KS1
G1
RD-C23-7
OR C6-33
7
TS51
AUXILIARY
PUMP
KS1
KEY SWITCH
HOUR METER
CR5
RD C4B-11
RD C23-6
WH-23A
GR/BK-H6
C3B
19/18 CABLES
CR3
GR/BK C2B-6
BL/BK C5-16
GR C2B-5
CR2
86
GR/BK C5-14
BK/RD-35B
6
TB24AD
30
85
87
WH-21A
2
OIL TEMPERATURE
CR23
A
RD CR38#86
RD-S.P.
1
2 D15
RD/WH-S.P.
3
WH-S.P.
4
WH/BK-S.P.
5
WH/RD-S.P.
6
D57
GND STUD BK-S.P.
7 CR8#86+
BK/WH-S.P.
BK/WH C6-38
8
BK/RD-S.P.
9
10
11
OR-S.P.
14
OR/BK-S.P.
15
D34
16 OR/RD CR8#87A
GR-S.P.
17
GR/BK-S.P.
18
RD-B1-S.P.
20
GND STUD
WH S.P.
21 D52
BK-S.P.
22 BK CR5#30
WH-S.P.-D2
23 WH ISM#7
RD-S.P.-CB1
24 RD CR2#30
RD-S.P.-CB3
24A RD CR17#30
RD-S.P.
27 RD ISM#4
D6
32 WH/RD C6-32
BK-S.P.
33 BK ISM#3
BK ISM#1
33A BK-CR28#86
BK/WH-S.P.
34
BK/RD-S.P.
35 BK/RD CR3#30
37 BL/BK C6-20
38
39
40 OR C6-10
41 OR/BK ISM#2
42 OR/RD C6-22
D7
D8
46
RD-KSI-SP
134 RD-H6
134A
5
OIL PRESSURE
10 AMP FUSE
SBD/DESCENT ALARM
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
AXLE DUMP VALVE
IGNITION POWER
HORN
KEYSWITCH PWR/PWR TO PLAT
FUSED 12V DC
OIL COOLER FAN
AUXILIARY PUMP
BRAKE
ENGINE START
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
H6
BK C7B-1
RD-TS51
RD-TS52
GR//BK H6
BRN
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
Part No. 111165
R2
CIRCUIT DESCRIPTION
FROM
12 DRIVE ENABLE
BL/WH C6-12
BL/WH C3B-12
19 JIB VALVE
TO
GR/WH C4B-7
GR/WH-S.P.
BL/BK C5-16
BL/BK-S.P
26 OIL TEMP SENDER
GR/BK C5-14
GR/BK-S.P.
28 TILT ALARM
RD/BK C1-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
30 E.D.C. REV
WH C1B-4
WH C5-21
31 E.D.C. FWD
WH/BK C5-20
WH/BK C1B-5
BL CB1-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GEN. OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXT/RET SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
February 2012
N
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F
E
D
C
B
A
COMPONENT INDEX
1
11
TS7
TS8
TS9
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
U13
ALC-500
P2
P3
TS1
TS2
TS4
TS6
3
J3
D12
GND STUD
J2
J1
9
TS14
TS15
TS16
TS47
TS48
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C17JU GR C4P-5
TS9-C14PLU OR C4P-2
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
DRIVE LIGHT TOGGLE SWITCH (OPTION)
DRIVE ENABLE LED
AXLE EXTENDED LED
3
TILT ALARM LED
BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN
BOOM PROPORTIONAL JOYSTICK: BOOM UP/DOWN, TURNTABLE ROTATE
U13 ALC500
CR13 JIB BOOM CUTOUT RELAY
CR26 AXLE CUTOUT RELAY
TILT ALARM
H1
BATGND C7P-3
D40
C2P-9 & 10
C7P
LS18
JIB
C9
12V DC
BATTERY
19/18 CONTROL CABLE
OPT.
(OPTION)
RD-H1
RD-P2
RD LS CABLE
FOOT SWITCH
BRN BATGND
5
GND STUD
+
WH-TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
6
OR/RD R40LS2
(SPLICE TO R40LS2)
+
3
L48
D12
-
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
TS15
DRIVE
ENABLE
CR27
WH-TS7
GN/BK H1 (D39)
4
BRN J1-14
5
4
OR J1-13
WH J1-5
BL J1-4
5
2
2
JC3
DRIVE
1
CR26
AXLE CUTOUT
WH J3-2
6
1
DETAIL B: GENERATOR OPTION
7
+
+
RD WL2
L1
TS15
NO
TS9
PLATFORM
LEVEL
RD WL1
L4
TS8
JIB BOOM
TS1
AUXILIARY
PUMP
TS14
DRIVE
SPEED
TS6
GLOW PLUG
OPTION
GR/WH C2P-7
TS7
PLATFORM
ROTATE
P3
HORN
RD/BK H1
1
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
L40
BL/WH J1-6
6
-
-
2
BK/WH C1P-8
7
+
+
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
7
3
3
BL/BK J1-7
TS16
4
RD/WH J1-8
JC1
BOOM
EXTEND/
RETRACT
BRN J1-10
D2
OR J1-9
YEL J1-3
5
JIB
CUTOUT
RD C1P-1
6
GR/BK C4P-6
7
GR C4P-5
GR/WH JIB CABLE
CR13
J2-DIODE WH
BRN
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
4
BK LS CABLE CIP-12
C4P(BR)
C3P(GR)
GND STUD
C2P(BK)
C1P(GY)
BRN
GR/WH C4P-7
GR/WH TS7
RD/BK JIB CABLE
GND
CR13 BRN
H1
TILT
ALARM
WORK LIGHT TOGGLE SWITCH (OPTION)
LS18
L1
L4
JC3
2
JC2
JC1
C28TTA RD/BK C1P-2
D39
LOW/HIGH DRIVE SPEED TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
TS49
L40
L48
1
HORN SWITCH
ENGINE START SWITCH
HIGH RPM SWITCH
GLOW PLUG OPTION
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
BK
NC
TS48/TS49
8
TS2
P2
EMERGENCY
STOP
Part No. 111165
S-80 • S-85
6 - 55
February 2012
6 - 55
6 - 56
February 2012
6 - 58
6 - 57
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 58
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 59
February 2012
6 - 59
6 - 60
February 2012
6 - 62
6 - 61
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 62
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
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J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 63
February 2012
6 - 63
6 - 64
February 2012
GM 3.0L Models
6 - 66
6 - 65
ENGINE SPEED
GENERATOR
C1-9
C35ESPD BK/RD
C45GEN GR/WH
LOW RPM
FUNC. ENABLE
HIGH RPM
C2-7
C39LP BL/RD
3
C2-1
C25PSR BL/BK
GR/WH
B1 BATTERY
C26TSR GR/BK
C5-12
WH-21
C8-9
C8-7
BK
LT BL
DK BL
PU
YE
RD/BL
GR/BK
RD
PU/BK
YE/BK
WH/BL
BRN
C8-2
C8-8
C8-4
C8-1
C8-3
C8-5
C8-6
C8-11
2
1
HIGH (FS)
ON
FUEL SELECT
FUEL
SELECT
C38ESL BL/RD
C8-12
WH
HM
_
LP
LP
C5-13
C35RPM BK/RD
C41RPM OR/BK
P23BATSA RD
C39LP BL/RD
C33STR BK
C27AUX RD
C21IGN WH
+
C27AUX RD
C28TTA RD/BK
+
STARTER
BK
OIL PRESSURE
SENDER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
VOLT METER (OPTION)
GENERATOR OPTION
HOUR METER
GM ENGINE
HARNESS
STARTER MOTOR
START BATTERY
ALTERNATOR
FLASHING BEACONS (OPTION)
HYDRUALIC OIL TEMPERATURE
SWITCH (OPTION)
HORN
HORN RELAY
LEVEL SENSOR
TILT ALARM
AUXILIARY PUMP
ANSI/CSA (DOMESTIC MACHINE) ADD L48.
C5-18
C5-2
C5-19
C5-10
C5-5
C5-6
C5-11
C6-27
C6-28
RD
C43HRN BK
P23BAT RD
C6-16
R21IGN WH
NOTES:
GAS
TB21
C6-23
GR
C6-34
R116HYD OR
CE AND LOAD WEIGHT OPTION.
5
C33STR BK
ENGINE
START
C27AUX RD
RD
AUXILIARY
POWER
P23BAT WH
WH
C28TTA RD/BK
C46HRN GR
C6-33
RD C134-E.H.
4
6
C1-7
C1-1
C7P-2
C1P-2
C7B-1
C6-24
3
GAS
AUXILIARY
POWER
C2P-5
P22BAT BK
RD
B
ENGINE
START
C7P-1
C1B-12
BK
P20BAT RD
Part No. 111165
BL/WH
3
M3
REGULATOR
S-80 • S-85
-
6 - 66
RD
8
TB24A
G1
BAT.
GM ENGINE HARNESS
BL
RD
GR/BK
FB
NO
12V DC
AUX
PUMP
GND.
1
B1
PR1
2
H2
C
A
U18
AUX
FAN
FUEL
M4
PUMP
6
CR5
NO
CR17
NO
BRN
G2
G1
G3
WH-E.H.
L5
D52
CB3
TB35
TB24
CB1
OR/BK
RD
RD
RD
D11
D42
D14
TB46
D7
TB27
TB39
TB33
D13
TB23
TB23
TB28
TB41
WH
CR39
NO
5
R
7
RD
20A
TB20
C132PLI BL/WH
GRD
D12
H1
TS4
TS47
TS3
TS2
TS54
TS53
TS52
TS51
PLAT
D8
CR2
NO
RD
15A
TB22
KS1
TB134
TS1
D43
D10
P134PWR GR/BK
15A
L4
P3
HORN
2
WH
P24FS WH
FS1
RD
P25FS RD
BK
C9P-1
P2
BK
P26ESTP BK
1
N
M
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F
E
D
C
B
A
D2
4
RD
RD
RD
P1
CB2
February 2012
GM 3.0L Models
RD/BK
BRN
+
1
C28TTA RD/BK
H1 RD/BK
DRIVE MODE
C29MS RD/WH
LED BL/RD
BL
WH
RETRACT
EXTEND
RETRACT
EXTEND
15
8
16
7
6
4
5
3
4
2
1
10
9
3
12
11
1
2
14
13
DRIVE ENABLE
CDE2 BL/BK
RIGHT
LEFT
7
CDE1 BL/WH
YOUT 5
OR
BL
RKOUT 6
4
BRN
PWR 3
1
GND 2
7
RD
BK
6
YOUT 5
OR
XOUT 4
PWR 3
BRN
1
YEL
GND 2
7
6
5
OR
OUT
3
BRN
4
PWR
2
1
GND
BRN
P24FS WH
P24FS WH
P26ESTP BK
AXLE
AXLE
4
1
18
17
15
16
19
20
11
9
10
6
7
8
14
13
12
3
5
PLATFORM LEVEL
C3P-11
C4P-1
C7-3
C61AX BL/BK
S3LED BL/RD
BRN
C60AX OR/RD
C40LS OR/RD
C2P-4
C4P-4
C40LS1 OR
C3PBF RD/WH
C9PERF BK/RD
C8PBR BK/WH
BOOM
C7PBBE BK
EXTEND
RETRACT
C12DRE BL/WH
C14PLU OR
C15PLD OR/BK
UP
BK/WH
BK/RD
C6-21
C61AXRT BL
C40LS1 OR
C40LS2 BK
C42LS2 GR
C6-40
C6-10
C6-22
PLATFORM LEVEL
PLATFORM
ROTATE
JIB BOOM
D28
C17JU/PRL GR
C18JD/PRR GR/BK
DOWN
BK
PRIMARY BOOM
R2
5
TURNTABLE ROTATE
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
C36STCC BL
C37STC BL/BK
D34
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C2P-2
C1P-11
C1P-5
C1P-4
C1P-10
C1P-6
C1P-3
C3P-6
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C3P-12
C2P-3
C4P-2
C4P-3
C4P-6
C4P-5
DOWN
UP
RIGHT
LEFT
C34-1
S3LED BL/RD
C60AX OR/RD
C35-1
C6-13
C6-39
C42AXDP WH
J3 WH
C32BRK WH/RD
C29MS RD/WH
C4TRL WH
C5TRR WH/BK
C6TTRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C7PBE BK
C8PBR BK/WH
C9PERF BK/RD
C24-1
A
D
C26-1
C28-1
C14-1
C15-1
C31-1
C12-1
C13-1
C29-1
C16-1
C17-1
C27-1
R16PBR BK/WH
C23BAT RD
OR-14-M.H.
OR/BK-15-M.H.
GR/BK-18-M.H.
GR-17-M.H.
C22-1
C23-1
C21-1
C20-1
C8PBR BK/WH
C12DRE BL/WH
C25-1
C6-11
J4 BK
J1 WH
RD
J2 WH
WH
J5 BK
C6-31
C37STC BL/BK
C6-20
C6-37
C30EDC WH
C36STCC BL
C5-21
C31EDC WH/BK
C6-36
C5-20
C6-32
C5-23
C5-24
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-7
C6-8
C6-9
C6-12
C6-29
C6-30
C6-38
C6-14
C6-15
C6-18
C6-17
C34-2
C35-2
DRIVE LIMIT SWITCH
C20-2
C21-2
C24-2
C22-2
PLATFORM ROTATE LEFT/JIB BOOM UP
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM EXTEND
PRIMARY BOOM EXTEND
CUTOUT RELAY
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRIMARY BOOM UP
CUTOUT RELAY
TURNTABLE ROTATE FLOW CONTROL
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
STEER LEFT
STEER RIGHT
C27-2
C17-2
C16-2
C29-2
C13-2
C12-2
C31-2
C14-2
C15-2
C28-2
C26-2
C
B
C24-2
C25-2
DRIVE/ROTATE SPEED
LIMIT SWITCH
DRIVE LIMIT SWITCH
AXLE DUMP VALVE
AXLE EXTEND/RETRACT SELECT
AXLE EXTEND RELAY
GROUND
8
JIB VALVES
6 - 67
S-80 • S-85
Part No. 111165
2
NC
NOHC
2AS
1
2
2AO
NC
1RO
4
1
3
4
3
C6-19
U4
D57
14
13
CR38
CR8
6
2
H3
S3
NC
H4
7
1
2
1
NC
2
1
4
TB42
C19JSV GR/WH
CR8
3
2
3
TB32
1
4
NC
CR38
D41
D29
3
5
TB16
TB40
TB37
4
TB6
TB3
TB9
TB18
TB4
TB1
TB7
TB15
NOHC
1RS
NOHC
LS3
BRN
UP
DOWN
D27
DOWN
JIB BOOM
UP
C4P-7
C41RPM OR/BK
P46 RD
P23 RD
C27AUX + FE RD
CR29
NC
TB46
D15
3
D37
D36
D35
4
TS62
TS61
TS63
TB5
TB2
TB8
TB14
TB17
D38
RIGHT PLATFORM
ROTATE
LEFT
JIB VALVES
TS59
TS58
TS57
J1
J1
J1
J1
J3
2
CR27 CE
J2
TS16
TS9
TS8
TS7
CR30
NO
C19JSV GR/WH
WH
WH
3
L5
L1
CR26
NC
TS14
TS15
D41
CR13
NC
CR13
+
JC3
JC2
DRIVE & STEERING
JC1
NC
P24FS WH
A
B
C
D
E
F
G
H
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February 2012
GM 3.0L Models
P26ESTP BK
BRN
February 2012
GM 3.0L Models
6 - 67
6 - 68
February 2012
GM 3.0L Models
6 - 70
6 - 69
February 2012
GM 3.0L Models
A
B
C
D
E
F
G
1
H
VOLT METER
2
RD C3B-1
RD/BK C6-19
RD/WH C3B-3
WH C3B-4
WH/BK C3B-5
WH/RD C3B-6
BK C3B-7
BK/WH C3B-8
BK/RD C3B-9
B
C
D
PRIMARY BOOM UP
PRIMARY BOOM DOWN
BOOM EXTEND
BOOM RETRACT
EXTEND/RETRACT F.C.
RD C6-1
RD/BK C3B-2&C6-2
RD/WH C6-3
WH C6-4
WH/BK C6-5
WH/RD C6-6
BK C6-7
BK/WH C6-8
BK/RD C6-9
SBD/DESCENT ALARM
PLATFORM LEVEL UP
PLATFORM LEVEL DOWN
AXLE DUMP VALVE
IGNITION POWER
HORN
KEY SWITCH PWR/PWR TO PLAT.
FUSED 12V DC
OIL COOLER FAN
AUXILIARY PUMP
BRAKE
ENGINE START
START RELAY
GLOW PLUG
ENGINE RPM
STEER RT/AXLE EXT
3
L.P.
LIMIT SWITCH #1
ENGINE RPM
LIMIT SWITCH #2
LIMIT SWITCH POWER
KEY SWITCH POWER
KEY SWITCH POWER
4
OR C4B-2
OR/BK C4B-3
OR/RD C6-11
GR C4B-5
GR/BK C4B-6
RD-B1-H1
WH CR17 #86
BK C23-4
WH C7B-2
OR C6-14
OR/BK C6-15
OR/RD CR38#87A
GR C6-17
GR/BK C6-18
RD-B1-H1
WH C5-3 & C5-11
RD C6-30
CR39 #30
RD CR39#86&C1B-1 RD C5-6
WT/RD C5-23
WH/RD C1B-6
BK C1B-7
BK C5-5
BK/WH C5-22
BL/BK C6-37
WH C2B-2
OR/BK C2B-3
OR/RD C4B-4
RD C6-31
RD C6-23
RD C6-24
BK/WH C1B-8
BK/RD C1B-9
BL/BK C1B-11
OR C6-40
OR/BK C5-2
OR/RD CR29#86
C2-6
D42
A
G1
RD-S.P.
1 RD CR38#86
2 D15
RD/WH-S.P.
3
WH-S.P.
4
WH/BK-S.P.
5
WH/RD-S.P.
6
D57
GND STUD BK-S.P.
7 CR8#86+
BK/WH-S.P.
8 BK/WH C6-38
BK/RD-S.P.
9
10
11
OR-S.P.
14
OR/BK-S.P.
15
D34
16 OR/RD CR8#87A
GR-S.P.
17
GR/BK-S.P.
18
RD-B1-S.P.
20
GND STUD
WH S.P.
21 D52
BK-S.P.
22 BK CR5#30
WH-S.P.-D2
23 RD C5-19
RD-S.P.-CB1
24 RD CR2#30
RD-S.P.-CB3
24A RD CR17#30
RD
RD-S.P.
27
32 WH/RD C6-32
BK-S.P.
33
33A
34
35 BK/RD CR3#30
37 BL/BK C6-20
38
39
40 OR C6-10
41
42 OR/RD C6-22
D7
46
134 RD-H6
134A
OIL PRESSURE
I
G2
G3
BK-22A
GR/BK C2B-6
RD C4B-11
P1
EMERGENCY
STOP
RD C4B-12
TS51
AUXILIARY
PUMP
KSI
KEY SWITCH
BRN GND
B
NC
D2
3
NC
1
B1
4
RD-134A
2
RD-27A
RD/WH-3A
RD/BK-2A
BL/RD TS53
LABEL
P1
BK/RD-9A
KS1
KEY SWITCH
TS51
AUXILIARY POWER TOGGLE SWITCH
TS52
+
D8
L2
CHECK ENG. LED
BL/RD C5-13
-
BL/RD-39A
+
G6
TS61
BOOM
UP/DOWN
C7B
12V DC TO
PLATFORM
-
BRN-GND STUD
H1
TS53
LP/GAS
BK-C23-5
WH-23AB
TS63
BOOM EXTEND/
RETRACT
RD-1A
WH-C5-11
BK-33
TS52
ENGINE
START
RD-1B
RD-B2-S.P.
RD CR38#30
C4B
CR2
CR38
86
CR5
BK-22B
RD-24AA
86
C3B
19/18 CABLES
C2B
BL/RD C6-13
D14
TS54
HIGH/LOW
RPM
BK 7B
RD C6-27
RD-27D
RD-24A
OR C6-33
FUNCTIONS
CR8
C6
7
86
CR29
86
CR39
CR17
RD-24AD
WH-C6-34
D42
CB1
ENGINE
CB2
CONTROLS
TS59
PLATFORM
LEVEL
TS57
PLATFORM
ROTATE
C5
ENGINE
TS58
TS59
TS61
TS62
TS63
CB1
CB3
G1
G2
G3
WATER TEMP. GAUGE (OPTIONAL)
G6
L2
HOUR METER
CHECK ENGINE LED
R2
TURNTABLE ROTATE LIMITING RESISTOR, 5 OHMS
CR2
CR3
CR5
HORN RELAY
CR8
BOOM FUNCTION CUTOUT
CR17
CR23
DRIVE LIGHT RELAY (OPTIONAL)
CR25
AXLE RET L/O RELAY
CR29
CR38
GR-17A
CR39
GR/WH C4B-7
GR/BK-18A
U1
WH-4A
WH/BK-5A
ALL BRN WIRES
WH/RD-6A
WIRING
HARNESS:
TO BASE
CONTROL BOX
CONNECTIONS
GROUND STUD
FUNCTION ENABLE/RPM SELECT TOGGLE SWITCH
CIRCUIT DESCRIPTION
BL/RD C4B-1
RD/BK 2B
RD-24B
S-80 • S-85
LP/GAS SELECT TOGGLE SWITCH
TS54
TS57
OR-14A
RD CR2#30
BRN
6 - 70
86
OR/RD 42C
GROUND STUD
8
RD-B1-20A
WH-21B
86
TS62
TURNTABLE
ROTATE
D13
BK/RD-35A
OR/RD 16C
OR/RD 16B
TS58
JIB
BOOM
OR/BK-15A
RD-B2-H1
BK-C6-16
C1B
6
CB3
OIL COOLER/
OPTION
GR C2B-5
TS53
CB2
D11
BK/WH C6-29
86
DESCRIPTION
BK-7A
BK/WH-8A
RD-KSI-SP
RD-B1-20D
TB24AD
CR23
WH-23A
BK/RD-S.P.
RD-B1-20C
N
10 AMP FUSE
BRN (GND)
2
M
WATER TEMPERATURE
HOUR METER
5
L
GR/BK C5-14
WH-21A
1
K
BL/BK C5-16
3
J
Part No. 111165
R2
FROM
TO
12 DRIVE ENABLE
BL/WH C6-12
BL/WH C3B-12
19 JIB VALVE
GR/WH C4B-7
GR/WH-S.P.
BL/BK C5-16
BL/BK-S.P
26 WATER TEMP SENDER
GR/BK C5-14
GR/BK-S.P.
28 TILT ALARM
RD/BK C1-2
RD/BK C6-28
29 2WD/4WD
RD/WH C5-24
RD/WH C1B-3
30 E.D.C. REVERSE
WH C1B-4
WH C5-21
WH/BK C1B-5
31 E.D.C. FORWARD
WH/BK C5-20
BL CB1-10
BL C6-36
43 HORN
GR C2B-5
GR CR5#86
45 GENERATOR OPTION
GR/WH C2B-7
GR/WH C5-12
60 AXLE EXTEND/RETRACT SELECT
OR/RD C6-39
OR/RD C2B-4
61 AXLE RETRACT
BL/BK C3B-11
BL/BK C6-21
February 2012
GM 3.0L Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
COMPONENT INDEX
BK P2
WH TS4
D12
WH C9-2
WH CR26#85
BL TS16
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 WH
JC3-6 BL
JC3-2 BRN
TS15-DRE A BL/WH
TS15-DRE B BL/BK
L1-C13LED BL/RD
TS14-C29MS RD/WH
GN/BK C3P-10
GN/BK L4
RD C2P-6
RD LS18
U13
ALC-500
P2
P3
TS1
TS2
TS3
TS4
3
TS7
1
TS9
TS8
J3
D12
TS14
TS15
TS16
TS47
TS48
GND STUD
J2
J1
11
9
TS49
L1
L4
L40
JC3
JC2
1
1
P2-P26FS BK C9-1
TS2-P25STR RD C9-3
J3-P24CONT WH C9-2
P2-P22BAT BK C7P-1
JIB CABLE-C19JSV GR/WH C4P-7
TS7-C17JU GR C4P-5
TS9-C14PLU OR C4P-2
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
DLITE GR/BK C2P-6
P3-C43HRN GR C2P-5
TS3-C39LP BL/RD C2P-1
C6TRF WH/RD C3P-6
C40LS1 OR C2P-2
C9PERF BK/RD C3P-9
C7PBE BK C3P-7
C12DRE BL/WH C3P-12
C8PBR BK/WH C3P-8
R40LS2 OR/RD C4P-4
C1PBU RD C3P-1
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3
C2PBD RD/BK C3P-2
C37STC BL/BK C1P-11
C36STCC BL C1P-10
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
TS2-C33STR BK C1P-7
TS1-C27AUX RD C1P-1
RD/BK L48
JC1
CR13
CR26
U13
H1
LS18
L48
1
HORN SWITCH
FUEL SELECT TOGGLE SWITCH (FORD)
HIGH RPM TOGGLE SWITCH
DRIVE SPEED LOW/HIGH TOGGLE SWITCH
GENERATOR TOGGLE SWITCH ( OPTION )
2
WORK LIGHT RELAY (OPTION)
DRIVE LIGHT RELAY (OPTION)
DRIVE ENABLE LED
AXLE EXTENDED LED
BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE
BOOM PROPORTIONAL JOYSTICK: BOOM EXTEND/RETRACT
JIB BOOM CUTOUT RELAY
AXLE CUTOUT RELAY
ALC500
TILT ALARM
TILT ALARM LED
C28TTA RD/BK C1P-2
3
BATGND C7P-3
D40
C7P
JIB
C9
Y
GND STUD
12V DC BATTERY
CR27
WH-TS7
OPT
RD LS CABLE
FOOT
SWITCH
RD-H1
RD-P2
Y
19/18 CONTROL CABLE
4
BRN BATGND
GR/WH C4P-7
GR/WH TS7
BK LS CABLE CIP-12
C4P(BR)
GND STUD
C3P(GR)
BRN
C2P(BK)
C1P(GY)
H1
TILT
ALARM
C2P-9 & 10
Y
CR13 BRN
Y
RD/BK JIB CABLE
GND
D39
WH-TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
5
CR30
+
GR/WH C2P-7
3
L48
D12
-
+
RD LS18
BK C7P-1
WH C7P-2
BK C9-1
BK J3-3
BL/RD C2P-1
DETAIL B:
GENERATOR OPTION
+
TS15
DRIVE
ENABLE
GN/BK H1 (D39)
4
BRN J1-14
5
4
OR J1-13
WH J1-5
5
2
JC3
DRIVE
AND STEER
1
2
1
6
RD WL1
RD WL2
TS15
TS48/TS49
7
TS7
PLATFORM
ROTATE
+
+
CR26
AXLE CUTOUT
BL J1-4
WH J3-2
1
RD/BK H1
6
-
-
L40
BK/RD C1P-9
BK C1P-7
RD C9-3
BL/RD J1-16
7
6
+
+
2
JC2
PRIMARY BOOM
UP/DOWN AND
TURNTABLE
ROTATE
7
3
3
BL/WH J1-6
4
BL/BK J1-7
CR13
JIB BOOM
CUTOUT
BRN J1-10
JC1
BOOM
EXTEND/
RETRACT
RD/WH J1-8
TS16
OR J1-9
YEL J1-3
D2
RD C1P-1
5
GR/BK C4P-6
6
GR C4P-5
GR/WH JIB CABLE
BRN
7
J2-DIODE WH
OR/RD C2P-4
BL C1P-10
BL/BK C3P-11
BL/RD C4P-1
BRN J1-12
OR J1-11
RD J1-1
BK J1-2
OR C4P-2
GR C2P-5
OR/BK C4P-3
AXLE
EX/RET
OR/RD R40LS2
(SPLICE TO R40LS2)
D12
L4
TS8
JIB BOOM
TS2
L1
D10
NO
P3
HORN
TS1
AUXILIARY PUMP
TS9
PLATFORM
LEVEL
TS14
DRIVE
SPEED
TS2
ENGINE
START
NC
TS4
HIGH/LOW
RPM
TS3
FUEL SELECT
8
P2
EMERGENCY
STOP
Part No. 111165
S-80 • S-85
6 - 71
February 2012
GM 3.0L Models
6 - 71
6 - 72
February 2012
6 - 74
6 - 73
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 74
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 75
February 2012
6 - 75
6 - 76
February 2012
6 - 78
6 - 77
February 2012
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 78
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 79
February 2012
6 - 79
6 - 80
February 2012
Ford LRG-425 EFI
6 - 82
6 - 81
February 2012
Ford LRG-425 EFI
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 82
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
Ford LRG-425 EFI
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 83
February 2012
Ford LRG-425 EFI
6 - 83
6 - 84
February 2012
Ford LRG-425 EFI
6 - 86
6 - 85
February 2012
Ford LRG-425 EFI
A
B
C
D
E
1
2
3
4
5
6
7
8
6 - 86
S-80 • S-85
Part No. 111165
F
G
H
I
J
K
L
M
N
February 2012
Ford LRG-425 EFI
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 87
February 2012
Ford LRG-425 EFI
6 - 87
6 - 88
February 2012
Connector Pin Legend - Sheet 1
6 - 90
6 - 89
February 2012
A
B
C
D
E
F
G
H
I
J
K
L
M
1
C7: DTP06-4S
C1 DT06-12SC
2
CKT # PIN #
C27AUX
1
RD/BK
C28TTA
2
BK
P22BAT
1
RD/WH
C29MS
3
WH
P23SWBAT
2
WH
C30EDC+
4
BRN
BATGND
3
WH/BK
C31EDC-
5
N/C
4
WH/RD
C32BRK
6
BK
C33STR
7
BK/WH
C34SA
BK/RD
C35RPM
BL
C36STCC
10
4
BL/BK
C37STC
11
5
BL/WH
C132PLI
12
6
3
C1
6
CKT #
#
C5-ENGINE HARNESS
FORD
DEUTZ
PERKINS
3.0L GM
PIN
ENGINE
ENGINE
ENGINE
ENGINE
#
8
2
C41RPM
OR/BK
OR/BK
OR/BK
9
3
C107AF
WH
WH
WH
1
OR
C40LS1
2
OR/BK
C41RPM
3
OR/RD
C60AX
4
GR
C43HRN
5
GR/BK
C134BAT
6
GR/WH
C45GEN
7
CIRCUIT #
1
C2
BLACK
8
COLOR
C1PBU
RD-3
BK(14)
R33STR
BK(14)
BK(14)
GR
OR/RD
OR/RD
OR/RD
OR/RD
WH(14)
WH(14)
WH
10
11
BL/RD
WH
WH(14)
WH(14)
BL/RD
WH
12
C45GEN
GR/WH
GR/WH
GR/WH
GR/WH
12
C45GEN
GR/WH
GR/WH
GR/WH
13
14
C108ESL
BL/WH
C108ESL
C26TSR OPT.
BL/WH
WH/RD
BL/WH
WH/RD
13
14
15
C24SW
16
C25PSR OPT.
WH
WH/BK
10
11
C4TRL
WH-3
C26TSR OPT.
C5TRR
WH/BK-3
15
C24SW
WH
WH
6
C6TRF
WH/RD-3
16
C25PSR OPT.
WH/BK
WH/BK
C7PBE
BK-3
17
P134BAT
C8PBR
BK/WH-3
18
C35RPM
BK/RD
BK/RD(14)
BK/RD(14)
RD
NC
11
9
C9PERF
BK/RD-3
RD
NC
12
10
C40LS2
OR
19
P23BAT
11
C42LD
WH
20
C31EDC-
WH(14)
WH/BK
WH/BK
12
C12DRE
BL/WH-3
21
C30EDC+
WH
13
S3LED
BL/RD-3
22
C34SA
14
C14PLU
OR-3
23
C32BRK
15
C15PLD
OR/BK-3
24
C29MS
RD/WH
C3PBF
3
17
C17JU
GR-3
WH
C4TRL
4
18
C18JD
GR/BK-3
WH/BK
C5TRR
5
19
C2DA
RD/BK
20
C37STC
BL/BK
21
C61AXRT
BL/BK
22
C42LS2
OR/RD-1
23
P23BATSR
RD
24
P23BAT
RD
25
C46BBR
RD
26
C46BBR
GR
27
C27AUX
RD-1
6
C7PBE
7
C3
BK/WH
C8PBR
8
GREEN
BK/RD
C9PERF
9
BL
C133PLA
10
BL/BK
C61AX
11
BL/WH
C12DRE
12
COLOR
A
C4
28
C28TTA
RD/BK
29
R16PBR
BK/WH
30
C46PWR
RD
31
C46PWR
RD
32
C32TA
WH/RD-1
WH(14)
WH/BK
WH
WH
C31EDC
WH/BK
WH/BK
WH/BK
WH
21
C30EDC
WH
WH
22
C34SA
C32BRK
C29MS
WH
WH
BK/WH
WH/RD
WH/RD
WH/RD
WH/RD
RD/WH
RD/WH
RD/WH
RD/WH
C9 FS DT04-4P
C9
COLOR
R116HYD
OR
34
R21IGN
WH
COLOR
35
GR
C17JU
5
36
C36STCC
BL-1
BK
P22BAT
1
GR/BK
C18JD
6
37
C37STC
BL/BK-1
WH
P24BAT
2
GR/WH
C19JSV
7
38
C8PBR
BK/WH
RD
P25BAT
3
NC
8
39
C60AX
OR/RD
N/C
4
40
C40LS1
OR-1
CKT # PIN #
10
MARK NUMBER ON CABLE 3
BK/RD
BK/WH
AC
33
Part No. 111165
P23BAT
20
24
3
S-80 • S-85
19
23
4
11
WH
WH/BK
RD/WH
C40LS2
12
WH
WH/BK
WH/RD
OR/RD
R2DRVLITE
BK/RD(14)
RD/WH
2
R1DRVLITE
BK/RD(14)
WH/RD
C9 FS DT04-4P
WH
BK/RD
RD/WH
C15PLD
RD
WH/BK
RD
WH/RD
C14PLU
RD
WH/BK
C35RPM
RD/WH
OR/BK
BROWN
WH/RD
WH
P24BAT
WH/RD
OR
9
WH/RD
WH
18
WH
DC
GR/WH
BL/RD
17
BK/WH
1
NC
GR
BK/RD
WH
BL/RD
NC
WH
BK/WH
CKT # PIN #
S3LED (AX)
C4
RD
C127TSW
5
BK
BK(14)
C128RPM(OPT)
C39LP
C21IGN
8
C6TRF
6
9
7
WH/RD
5
8
10
BK
BK(14)
BK(14)
RD
GR
4
R43HRN
BK(14)
R33STR
WH
OR/RD
BL/RD
BL/WH
WH/RD
16
BK(14)
WH
OR/RD
RD/WH-3
2
WH
OR/BK
C107AF
OR/RD
RD/BK-3
C2PBD
OR/BK
WH
C41RPM
3
OR/RD
BL/RD
WH
C2PBD
RD/BK
OR/BK
2
WH
GR
NC
C3
OR/BK
OR/BK
C127TSW
C3PBF
1
ENGINE
P24BAT
C128RPM(OPT)
C39LP
C21IGN
NC
PIN #
3.0L GM
ENGINE
9
BRN
CKT #
PERKINS
ENGINE
8
2
C1PBU
DEUTZ
ENGINE
7
3
COLOR
RD
FORD
4
BRN
9
CKT #
1
7
C6
C2
BL/RD
8
6 - 90
C3
PIN
P24BAT
C4 DT06-12SB
7
C5-GBOX
GRAY
C3 DT06-12SA
5
C7
1
CKT # PIN #
C39LP
NC
CKT # PIN #
COLOR
C2 DT06-12SD
COLOR
4
C1
COLOR
RD
CKT # PIN #
N/C
1
WH
NEUTRAL
2
GRN
CHASSIC
3
BK
LINE
4
XX
N
February 2012
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
ALC500 JOYSTICKS/INPUT
PIN#
CKT#
GM PLUG
WIRE
PIN#
CKT#
2
HARN
GM ENGINE
1
JC2-4
RD
1
C39LP
BL/RD
YL
2
JC2-5
BK
2
C35RPM
BK/RD
LT BL
3
JC1-5
YL
3
C33STR
BK
RD/BL
4
JC3-5
WH
4
P23BATSA
RD
PU
5
JC3-6
BL
5
C27AUX
RD
GR/BK
6
DRE A
BL/WH
6
C21IGN
WH
RD
7
DRE B
BL/BK
7
C38ESL
BL/RD
WH/BL
8
C29MS
RD/WH
8
C41RPM
OR/BK
DK BL
9
JC1-3
OR
9
-----
BRN
YL/BK
10
JC1-2
BRN
10
-----
-----
-----
11
JC2-3
OR
11
PUMP+
BL/WH
PU/BK
12
JC2-2
BRN
12
GND1
BRN
BK
13
JC3-3
OR
14
JC3-2
BRN
15
H1
RD/BK
16
C13LED
BL/RD
J1
16
8
9
1
5
OR/RD
NC
3
C12DRE
BL/WH
4
C40LS1
OR
5
C41RPM
OR/BK
6
C1PBU
RD
7
C2PBD
RD/BK
8
C3PBF
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
C31EDCC36STCC
WH/BK
BL
18
C37STC
BL/BK
19
C32BRK
WH/RD
20
C29MS
RD/WH
J2
6
7
1
R40LS2
2
11
1
20
WIRE
10
CKT#
17
3
4
ALC500 OUTPUT
PIN#
C1
GRAY
8
Part No. 111165
S-80 • S-85
6 - 91
February 2012
6 - 91
6 - 92
February 2012
Dual Battery Option
6 - 94
6 - 93
February 2012
Dual Battery Option
A
B
C
D
CB2
15A
1
E
P1
RD
F
G
CB2
RD
I
P1
15A
RD
KS1
H
RD
RD
RD
KS1
TB22
PLAT
PLAT
GRD
GRD
2
RD
WH
WH
CB1
15A
3
CB1
15A
RD
CB3
20A
RD
CB3
RD
TB20
TB20
20A
RD
RD
4
BAT.
+
C41RPM OR/BK
D22
ALTERNATOR
EXCT.
EXCT.
12V DC
BAT.
-
+
12 V
DC
C5-2
C107AF WH
+
12 V
DC
C5-3
ALTERNATOR
P20BAT RD
D22
C41RPM OR/BK
C107AF WH
5
C5-2
C5-3
P20BAT RD
BATTERY
SEPARATOR
BAT.
+
BAT.
-
STA.
+
STA.
W
6
REGULATOR
IND.
-
-
DUAL BATTERY (OPTION)
S-80 • S-85
ALTERNATOR
START BATTERY
ALTERNATOR
BATTERY SEPARATOR (OPTION)
6 - 94
B1
REGULATOR
IND.
START BATTERY
8
CONTROL BATTERY (OPTION)
7
B1
-
B2
SINGLE BATTERY (STANDARD)
Part No. 111165
J
K
L
M
N
February 2012
Belt Drive Generator Option
M
L
K
J
I
H
G
F
E
D
C
B
A
1
REGULATOR
VOLTAGE
R20BAT RD
NEUTRAL WH
GND BR
LINE BK
2
FIELD BK/WH
GENERATOR
BELT DRIVEN
120VAC / 60HZ
GENERATOR
LINE BK
15A
NEUTRAL WH
LINE
LINE BK
GND GR
FIELD GR
P20BAT
30A
VOLTAGE
REGULATOR
GND
TG4
TG1
CB1
3
CR1
87A
30
86
NEU
NEUTRAL WH
CB2
87
C45GEN
85
TO GBOX
12.5A- 220V
15A- 120V
A
B
C45GEN
B
-
BAT
OUTLET
CB2
TG2
+
TG3
GND BR
Y
BATTERY+
Y
A
BATTERY-
B
4
TG
CR1
120 VAC / 60 HZ with Regulator
1
2
Y
3
Y
4
OUTLET
5
Y
F
REGULATOR
VOLTAGE
R20BAT RD
NEUTRAL WH
GND BR
LINE BK
A
FIELD BK/WH
B
CB1
30A
GENERATOR
PIN# COLOR
1 WH
2 GR
3 BK
4
CKT#
NEUTRAL
FIELD
LINE
PLUG
BELT DRIVEN
6
220VAC / 50HZ
GENERATOR
12.5A
NEUTRAL WH
1
CB1
P20BAT
30A
CR1
87A
30
86
NEU
NEUTRAL WH
87
85
3
4
5
VOLTAGE REGULATOR
PIN# COLOR
1 RD 12GA
2 WH 12GA
3 BR 12GA
4 BK 12GA
5 BK/WH 14GA
GND
TG4
TG1
2
LINE
LINE BK
GND GR
FIELD GR
C45GEN
CKT#
R20BAT
NEUTRAL
GND
LINE
FIELD
7
TO GBOX
-
BAT
OUTLET
CB2
TG2
LINE BK
+
N
TG3
GND BR
220 VAC / 50 HZ with Regulator
8
Part No. 111165
S-80 • S-85
6 - 95
February 2012
Belt Drive Generator Option
6 - 95
6 - 96
February 2012
CE Option
6 - 98
6 - 97
H1
P22BAT BK
C7P-2
WH
C2B-5
C3B-10
C1B-2
C7B-2
P23BAT WH
C133PLA BL
C28TTA RD/BK
TO TS51
C46HRN GR
TB28
C6-28
C6-23
GR/BK
BK
GR/BK
TO SERVICE HORN
H1 RD/BK
DRIVE MODE
C29MS RD/WH
1
4
EXTEND
AXLE
RETRACT
15
8
16
18
17
15
16
19
20
11
9
10
6
7
8
14
12
13
3
5
D37
D36
D35
LED BL/RD
4
5
13
14
1
2
11
12
3
9
10
1
2
J2
D38
D27
DOWN
PLAT LEVEL
UP
3
4
J1
J1
J1
J1
L5
CDE2 BL/BK
7
RIGHT
DRIVE ENABLE
LEFT
6
CDE1 BL/WH
BRN
P24FS WH
P26ESTP BK
NO
+
CR26
NC
TS14
P24FS WH
D41
P24FS WH
CR27 CE
C1P-2
C3P-10
C2P-5
C7B-1
WH
L1
TS15
NC
WH
CR30
C7-3
C4P-1
C3P-11
C2P-4
C4P-4
C2P-2
C1P-11
C1P-10
C1P-4
C1P-5
C1P-3
C1P-6
C3P-6
C3P-4
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C3P-12
C2P-3
C4P-3
C4P-2
C4P-6
RIGHT
PLAT ROTATE C4P-5
LEFT
8
C7P-1
BL/WH
RD
P2
BK
TS16
TS9
TS7
C1B-12
L45
L4
C132PLI BL/WH
TO FB OPT
TO GROUND
P20BAT RD
TO AUX PUMP
C1P-12
BK
WH
RD
H6
C9P-1
LS18
TB23
D2
CB1
D39
C2B-6
U33
P3
HORN
P134BAT GR/BK
4
C40LS OR/RD
C32BRK WH/RD
Part No. 111165
S-80 • S-85
6 - 98
TB24A
RD
20AMP.
TB20
TB24
RD
15AMP.
8
12
LOAD
SENSE
MODULE
4
7
6
GRD
3
5
B
TO TS52, TS54
TB22
PLAT
P28TTA RD/BK
TB134
J3
7
C2P-6
KS1
D43
2
3
1
4
1
RD
2
3
CB3
5
P134BAT RD
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
B1
RD
RD
15AMP.
P1
CB2
February 2012
CE Option
P26ESTP BK
RD
P26ESTP BK
6
February 2012
Platform Level Cutout, CTE Option
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 111165
S-80 • S-85
6 - 99
February 2012
Platform Level Cutout, CTE Option
6 - 99
6 - 100
February 2012
12 kW Hydraulic Generator Wiring Diagram
6 - 102
6 - 101
February 2012
12 kW Hydraulic Generator Wiring Diagram
A
B
C
D
E
F
G
H
I
1
J
K
L
M
N
P25FS-RD
P26FS-BK
P24FS-WH
2
RPM HI
RPM LO
20
15
16
12.5 KW HYDRAULIC GENERATOR
TS47
GENERATOR ON
TS4
FOOTSWITCH
ALC-500
D12
NEUTRAL BUSS BAR
1 N.O.
2 COM
C45GEN GR/WH
8 N.C.
X
C35RPM BK/RD
Y
C2P-7
C1P-9
C29MS RD/WH
L3
C30EDC WH
C31EDC WH/BK
L2
L1
C1P-3
C1P-4
C1P-5
NEMA 4 CONTROL BOX
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
RED
4
2
TB29
124 ohms
1
V151HG GR
V150HG GR/BK
GROUND
STUD ON
PANEL
1
3
5
8
7
6
B1 VALVE 0 FWD COIL
B2 VALVE 1 NC
B3 DIGITAL OUTPUT BYPASS/OMRON
C1 TxD
C2 RxD
C3 /BOOT
8 GA 4 CONDUCTOR
8 GA 5 CONDUCTOR
BRASS
E1 NOT USED
E2 NOT USED
E3 NOT USED
C
B
GREEN 12GA
A
D
120 VAC GFI
CR4PHIGH IDLE
RELAY
D1 ANALOG 0 JOYSTICK
D2 ANALOG 1 NC
D3 DIG IN 3 NC
BLACK 12GA
SILVER
A1 BATTERY +
A2 SENSOR POWER +5 VDC
A3 BATTERY-
MOTOR STROKE
VALVE
5
4
2
APBPC
RS232TxD
RS232RxD
C45GEN GR/WH
2
124 ohms
20 AMP CIRCUIT
BREAKER
F1 DIG IN 0
F2 DIG IN 1 GENERATOR ON
F3 DIG IN 2
U4
SX Controller
12 GA 3 CONDUCTOR
110 VAC
GFI
SILVER
7
BYPASS PCOIL
ENCLOSURE
DRIVE EDC +
DRIVE EDC -
6
BRASS
WHITE
GREEN
GREEN
BLACK
1. Turning on the Generator supplies current
to the high idle relay through the diode
switching the engine to high RPM. In addition
the diode between TB45 and TB29 supplies
power to the motor stroke valve switching
the motors to high speed/low torque mode.
12 GA 3 CONDUCTOR
2. The SX controller is turned ON supplying
power to bypass valve and the change over
relay. The EDC valve is switched over to the
output of the SX controller.
8
6 - 102
S-80 • S-85
C5-12
3
1k ohms
OMRON
RELAY
GREEN
BLACK 12GA
C5-18
C5-24
BLACK
L1
4
GREEN
TB45
WHITE
N
BLACK
TB35
C5-1
5
1
C5-21
L3
Z
RED
TB22
TIME DELAY
MODULE 4S
C5-20
ORANGE
N
6
5 SW INPUT
C2B-7
3
3 GND
C1B-9
L2
TB24
C1B-3
208 VAC
OUTLET
C1B-4
C1B-5
3
Part No. 111165
3. When the AC generator is turned OFF the
SX module will ramp the output to the EDC to
threshold preventing cavitation to the hydraulic
motor powering the generator. When threshold
is reached the bypass valve is turned OFF.
Inside
Enclosure
Harness
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
COLOR
BR
WH
WH/BK
BR
BR
WH
WH/BK
BR
GR/WH
GR/BK
WH
BR
CKT#
GND
C30EDC+
C31EDCGND
GND
C30EDC+(A)
C31EDC-(A)
GND
C45GEN
V150HG
C22PWR
GND
COLOR
WH/RD
WH
WH/BK
BK/RD
BL/RD
RD
RD/BK
OR/RD
GR/WH
GR/BK
RD/WH
GR
February 2012
12 kW Hydraulic Generator Option
H
G
F
E
D
C
B
A
1
B
DRIVE
A
SWV
PUMP
FUNCTION
2
MANIFOLD
CLR
PMP B
OIL
DIVERTER
MANIFOLD
PMP A
3
CW
4
0.031 CV
CX
CU
CY
G2
5
280 psi
G1
MTR A
MTR B
6
3
I
1
J
ROTARY
COUPLER
K
HYDRAULIC
L
3
M
1
N
7
21CC
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.
8
G1
G2
HYDRAULIC GENERATOR
Part No. 111165
S-80 • S-85
6 - 103
February 2012
12 kW Hydraulic Generator Option
6 - 103
6 - 104
February 2012
Hydraulic Schematic, 2WD Models
6 - 106
6 - 105
February 2012
A
B
C
D
E
F
G
H
I
J
TURNTABLE
ROTATE
1
BRAKE/2 SPEED
MANIFOLD
SS
F
MEDIUM
PRESSURE
FILTER
1200 psi
82.7 bar
B
PRIMARY
T2
TT
QQ
RR
C
J2
F
WW
TEST
A
RETRACT
4 GPM
ACCUMULATOR
B
AUXILIARY
PUMP
M
TEST
450 psi
22 bar
V2
ACCUM
PTEST
1.7 gpm
6.4 L/ min
RET
EXT
FUNCTION
MANIFOLD
310 psi
21.4 bar
SW1
T3
G
V1
SW2
30 psi
2 bar
B
C
J
EE
K
T
PR2
JIB SELECT
MANIFOLD
A
R
I
U
D
CC
AA
W
0.6 gpm
2.27 L/min
0.6 gpm
2.27 L/min
BB
GG
KK
NN
PS
3.5 gpm
13.2 L/min
Y
4
DD
S
30 psi
2 bar
0.1 gpm
0.38 L/min
HH
25 psi
1.7 bar
JJ
OIL COOLER
OPTION
Z
AUX
MM
II
T2
ST1
ST2
AXLE EXTEND
PRESSURE SWITCH
0.3 gpm
1.1 L/min
FF
65 psi
4.5 bar
TANK
3 psi
0.2 bar
PLATFORM
ROTATE
DUMP
MANIFOLD
N
O
V
25 psi
1.7 bar
3 psi
0.2 bar
30 psi
2 bar
L
PR1
PR2
PR1
E
D
VV
X
F
RETURN
FILTER
DRIVE PUMP
P
M
H
HIGH 7 bar
PRESSURE
FILTER
FUNCTION
PUMP
Q
E
E
2800 psi
193 bar
102 psi
2
P2
V2
PL2
OO
3625 psi
250 bar
18
P1
2100 psi
145 bar
T1
9
PL1
2500 psi
172 bar
D
E
C
PP
S1 0.030 in
0.076 mm
PRESS
3
J1
XX
C
MASTER
EXTEND
7 GPM (REGEN)
2 SPEED
0.035 in
0.89 mm
V1
C
OC1
OC2
LS TEST
AXLE
LL
CP
LIM SW
RESERVOIR
COUNTERBALANCE VALVE
RATIO
5
6
8
3
1
2
4
5
9
10
7
HYDRAULIC ROTARY COUPLER
TEST
6B
8B
8A
6A
2A
3
1
2D
2B
STEER
CYLINDERS
6
CP
X
A
4
5
10
V1
V2
PILOT
2C
9A
7
9B
RIGHT
B
1000 PSI
B
3:1
2000 PSI
C
3:1
3000 PSI
D
3:1
3300 PSI
E
F
3:1
3500 PSI
5:1
3500 PSI
A
OUT
REAR
FRONT
3:1
B
IN
BA
BD
M3
C
BC
C
C
C
OSCILLATE VALVE
FRB
C
BI
C
C
FLB
BF
M2
LEFT
7
BG
BH
FAE
FLR
50%
280 psi
19.3 bar
FAR
RAE
AXLE SELECT
MANIFOLD
LEFT
0.070 in
1.77 mm
BE
TEST
RAR
TE
M4
TIE ROD
CYLINDER
T
8
REAR
LEFT
C
M1
2WD DRIVE MANIFOLD
T1
6 - 106
S-80 • S-85
Part No. 111165
RIGHT
OSCILLATE CYLINDERS
1000 psi
68.9 bar
BB
50%
AXLE EXTEND
CYLINDERS
C
PRESSURE
A
850 psi
58.6 bar
FRR
REAR
RIGHT
N
JIB BOOM
PRIMARY LIFT
CYLINDER
B
BOOM EXTENSION CYLINDER
UU
BRAKE
A
M
(S-85 Models)
SECONDARY
CP
2
A
L
PLATFORM LEVEL
CYLINDERS
SLAVE
B
51 psi
3.5 bar
K
C
February 2012
N
M
L
K
J
I
H
G
F
E
TURNTABLE
ROTATE
SS
MEDIUM
PRESSURE
FILTER
1200 psi
82.7 bar
B
PRIMARY
T2
A
RR
TT
C
2 SPEED
TEST
A
RETRACT
4 GPM
ACCUMULATOR
B
AUXILIARY
PUMP
TEST
V2
ACCUM
RET
EXT
FUNCTION
MANIFOLD
V1
SW1
T3
G
SW2
M
J
30 psi
2 bar
PR2
JIB SELECT
MANIFOLD
C
A
D
0.6 gpm
2.27 L/min
W
0.6 gpm
2.27 L/min
BB
GG
KK
NN
PS
V
3.5 gpm
13.2 L/min
Y
DD
S
30 psi
2 bar
0.1 gpm
0.38 L/min
25 psi
1.7 bar
AUX
Z
JJ
OIL COOLER
OPTION
ST1
ST2
OC1
OC2
4
4
MM
II
T2
AXLE EXTEND
PRESSURE SWITCH
0.3 gpm
1.1 L/min
HH
FF
65 psi
4.5 bar
TANK
3 psi
0.2 bar
3
3
PLATFORM
ROTATE
DUMP
MANIFOLD
N
O
CC AA
EE
K
T
U
30 psi
2 bar
B
L
PR1
PR2
PR1
E
R
H
25 psi
1.7 bar
3 psi
0.2 bar
P
D
VV
X
I
2800 psi
193 bar
RETURN
FILTER
DRIVE PUMP
Q
E
E
F
102 psi
7 bar
HIGH
PRESSURE
FILTER
P2
V2
PL2
OO
3625 psi
250 bar
FUNCTION
PUMP
P1
2100 psi
145 bar
D
2
2
2
PL1
2500 psi
172 bar
T1
18
C
PP
PRESS
9
J1
XX
C
S1 0.030 in
0.076 mm
450 psi
22 bar
PTEST
1.7 gpm
6.4 L/ min
310 psi
21.4 bar
E
0.035 in
0.89 mm
MASTER
EXTEND
7 GPM (REGEN)
M
1
1
J2
F
WW
C
A
JIB BOOM
V1
B
BOOM EXTENSION CYLINDER
UU
B
(S-85 Models)
SECONDARY
CP
BRAKE
A
QQ
F
PRIMARY LIFT
CYLINDER
C
PLATFORM LEVEL
CYLINDERS
SLAVE
B
51 psi
3.5 bar
BRAKE/2 SPEED
MANIFOLD
D
LS TEST
AXLE
LL
LIM SW
CP
RESERVOIR
COUNTERBALANCE VALVE
RATIO
6
8
3
1
2
4
5
9
10
7
HYDRAULIC ROTARY COUPLER
8B
6B
6A
8A
3
1
2A
2B
4
2D
V1
STEERING
CYLINDERS
TEST
REAR
RIGHT
A
B
V2
PILOT
2C
9A
9B
7
REAR
FRONT
C
BC
C
C
C
AXLE EXTEND
CYLINDERS
B
A
280 psi
19.3 bar
BS
BL
BW
50%
50%
LEFT
FAE
FAR
RAE
RAR
BE
3:1
3500 PSI
5:1
3500 PSI
OSCILLATE VALVE
C
C
OSCILLATE CYLINDERS
TE
TIEROD
CYLINDER
CDL
M2
7
7
1000 psi
69 bar
2 gpm
BT
7.6 L/min
BP
RIGHT
C
BB
TEST
M4
BK
FLR
2 gpm
7.6 L/min
50%
DRIVE MANIFOLD
3300 PSI
E
F
FLB
BQ
50%
M3
M1
3000 PSI
3:1
6
6
LEFT
BN
3:1
D
M6
50%
50%
REAR
LEFT
IN
OUT
C
BJ
BV
C
5
5
BA
FRB
BO
BU
B
2000 PSI
850 psi
58.6 bar
BD
FRONT
RIGHT
M5
2 gpm
7.6 L/min
1000 PSI
3:1
TEST
AXLE SELECT
MANIFOLD
FRR
M8
BR
CDR
10
3:1
RIGHT
M7
BM
5
PRESSURE
A
FRONT
LEFT
8
8
T
C
C
Part No. 111165
S-80 • S-85
6 - 107
February 2012
6 - 107
6 - 108

Checklist A Procedures

Transcription

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