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Service Manual

Part No. 122985

Rev D2

December 2017

Serial Number Range

from S8008-8000 to S8014-11875S-80S-85S-80X from S80X10-8500 to S80X14-11875

from S8508-8001 to S8514-11875

September 2015

S-80 • S-85 • S-80X Part No. 122985

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate operator'smanual on your machine before attempting anymaintenance or repair procedure.

This manual provides detailed scheduled maintenanceinformation for the machine owner and user. It alsoprovides troubleshooting fault codes and repairprocedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However, severalprocedures require specialized skills, tools, liftingequipment and a suitable workshop. In these instances,we strongly recommend that maintenance and repair beperformed at an authorized Genie dealer service center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degree ofaccuracy possible. However, continuous improvement ofour products is a Genie policy. Therefore, productspecifications are subject to change without notice.

Readers are encouraged to notify Genie of errors andsend in suggestions for improvement. Allcommunications will be carefully considered for futureprintings of this and all other manuals.

Contact Us:

http://www.genielift.come-mail: [email protected]

Serial Number Information

Genie offers the following ServiceManuals for these models:

Title 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 3738 to 5380) ... 111165


(from serial number 5381 to 7999) ... 122149

Introduction

Copyright © 2011 Terex Corporation

122985 Rev D February 2012Seventh Edition, Fourth Printing

"Genie" and "S" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.

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Part No. 122985 S-80 • S-85 • S-80X

Revision Date Section Procedure / Schematic Page / Description

D 2/2012 2 - Spec. 2-1

3 - Maint. 3-1, 3-51

4 - Repair 4-3 to 4-6, 4-18

D1 9/2015 3 - Maint. E-4

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 5.6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

Revision History

David.Reichel

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D2

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12/2017

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Front Cover

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Serial Range

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September 2015

S-80 • S-85 • S-80X Part No. 122985

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.3-3_Section 3_Maintenance Procedure Page #.4-48_Section 4_Repair Procedure Page #.Fault Codes_Section 5.6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

September 2015

Part No. 122985 S-80 • S-85 • S-80X iii

Serial Number Legend

S80 08 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Model: S-80

Serial number: S8008-12345

Electrical schematic number: ES503

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 80 ft/ 24.4 m

Maximum platform reach : 71 ft 6 in/ 21.8 m

Sequence number(stamped on chassis)

Serial label(located under cover)

Terex South Dakota500 Oak Wood roadPO Box 1150Watertown, SD 57201USA

September 2015

S-80 • S-85 • S-80X Part No. 122985

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Part No. 122985 S-80 • S-85 • S-80X

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-80 and Genie S-85Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules

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S-80 • S-85 • S-80X Part No. 122985

SAFETY RULES

Section 1 - Safety Rules

vi

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Note: Used to indicate operation or maintenanceinformation.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready for use.Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work area isproperly ventilated and well lit.

September 2015

Part No. 122985 S-80 • S-85 • S-80X

Table of Contents

Introduction

Important Information ................................................................................................... ii

Serial Number Information............................................................................................ ii

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Hydraulic Oil Specifications ................................................................................... 2 - 2

Hydraulic Component Specifications ...................................................................... 2 - 3

Valve Coil Resistance Specifications ..................................................................... 2 - 4

Continental TME27 Engine Specifications ............................................................. 2 - 5

Deutz TD2011L04i Engine Specifications............................................................... 2 - 6

Perkins 804D-33 Engine Specifications ................................................................. 2 - 7

Machine Torque Specifications .............................................................................. 2 - 8

Manifold Component Specifications ....................................................................... 2 - 8

Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 9

SAE and Metric Torque Specifications ................................................................. 2 - 10

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

A-3 Perform Engine Maintenance ....................................................................... 3 - 8

A-4 Perform Function Tests ................................................................................ 3 - 9

A-5 Test the Oscillate Axle ................................................................................. 3 - 9

A-6 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 10

A-7 Perform 30 Day Service ............................................................................. 3 - 10

A-8 Perform Engine Maintenance - Deutz and Continental Models .................... 3 - 11

A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11

A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13

A-11 Perform Engine Maintenance ..................................................................... 3 - 14

A-12 Replace the Drive Hub Oil .......................................................................... 3 - 15

A-13 Perform Engine Maintenance - Perkins Models .......................................... 3 - 17

Checklist B Procedures

B-1 Inspect the Battery(s) ................................................................................. 3 - 18

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19

B-3 Test the Key Switch ................................................................................... 3 - 21

B-4 Check the Exhaust System ....................................................................... 3 - 21

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Section 3 Rev Scheduled Maintenance Procedures, continued

B-5 Inspect the Engine Air Filter ....................................................................... 3 - 22

B-6 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 23

B-7 Confirm the Proper Brake Configuration...................................................... 3 - 24

B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 24

B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 25

B-10 Check and Adjust the Engine RPM ............................................................ 3 - 26

B-11 Perform Engine Maintenance ..................................................................... 3 - 28

B-12 Check the Oscillate Directional Valve Linkage ........................................... 3 - 28

B-13 Test the Ground Control Override ............................................................... 3 - 29

B-14 Test the Platform Self-leveling ................................................................... 3 - 29

B-15 Test the Engine Idle Select Operation ........................................................ 3 - 30

B-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 31

B-17 Test the Drive Enable System ................................................................... 3 - 32

B-18 Test the Drive Brakes ................................................................................ 3 - 33

B-19 Test the Drive Speed - Stowed Position ..................................................... 3 - 33

B-20 Test the Drive Speed - Raised or Extended Position .................................. 3 - 34

B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 35

B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 36

B-23 Perform Hydraulic Oil Analysis ................................................................... 3 - 37

B-24 Inspect the Boom Extend/Retract Cables ................................................... 3 - 37

Checklist C Procedures

C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 39

C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 39

C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 40

C-4 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 43

C-5 Replace the Fuel Filter/ Water Separator Element - Diesel Models ............. 3 - 43

C-6 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X ....... 3 - 45

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S-80 • S-85 • S-80X Part No. 122985

Section 3 Rev Scheduled Maintenance Procedures, continued

Checklist D Procedures

D-1 Check the Boom Wear Pads ...................................................................... 3 - 48

D-2 Check the Free-wheel Configuration ........................................................... 3 - 49

D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 50

D-4 Inspect the Turntable Bearing Wear ........................................................... 3 - 51

D-5 Perform Engine Maintenance ..................................................................... 3 - 53

D-6 Replace the Hydraulic Filter Elements ........................................................ 3 - 53

D-7 Replace the Drive Hub Oil .......................................................................... 3 - 54

D-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 57

E-2 Perform Engine Maintenance - Perkins Models .......................................... 3 - 59

E-3 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 59

E-4 Remove and Replace the Boom Extend/Retract Cables ............................. 3 - 60

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

Platform Controls

1-1 ALC-500 Circuit Board .................................................................................. 4 - 2

1-2 Joysticks ..................................................................................................... 4 - 3

Platform Components

2-1 Platform ....................................................................................................... 4 - 9

2-2 Platform Leveling Slave Cylinder ................................................................ 4 - 10

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TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

2-3 Platform Rotator ......................................................................................... 4 - 11

2-4 Calibrate the Platform Overload System .................................................... 4 - 13

Jib Boom Components, S-85

3-1 Jib Boom.................................................................................................... 4 - 16

3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 17

Boom Components

4-1 Cable Track ................................................................................................ 4 - 18

4-2 Boom ......................................................................................................... 4 - 21

4-3 Boom Lift Cylinder ...................................................................................... 4 - 24

4-4 Boom Extension Cylinders ......................................................................... 4 - 25

4-5 Boom Extend/Retract Cables ..................................................................... 4 - 28

4-6 Platform Leveling Master Cylinder .............................................................. 4 - 32

Engines

5-1 RPM Adjustment ........................................................................................ 4 - 33

5-2 Flex Plate................................................................................................... 4 - 33

Ground Controls

6-1 Control Relays ............................................................................................ 4 - 38

Hydraulic Pumps

7-1 Function Pump ........................................................................................... 4 - 39

7-2 Drive Pump ................................................................................................ 4 - 40

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Manifolds

8-1 Function Manifold Components .................................................................. 4 - 42

8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 44

8-3 Brake/Two-speed Manifold Components .................................................... 4 - 46

8-4 Turntable Rotation Manifold Components ................................................... 4 - 47

8-5 Platform Rotate Manifold Components ....................................................... 4 - 48

8-6 Platform Manifold Components, S-80 ......................................................... 4 - 49

8-7 Platform Manifold Components, S-85 ......................................................... 4 - 50

8-8 2WD Traction Manifold Components .......................................................... 4 - 51

8-9 4WD Traction Manifold Components (before serial number 8581) ............... 4 - 53

8-10 4WD Traction Manifold Components (after serial number 8580) .................. 4 - 55

8-11 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 57

8-12 Valve Adjustments - Traction Manifold ....................................................... 4 - 58

8-13 Valve Coils ................................................................................................. 4 - 59

Fuel and Hydraulic Tanks

9-1 Fuel Tank ................................................................................................... 4 - 61

9-2 Hydraulic Tank ........................................................................................... 4 - 62

Turntable Rotation Components

10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 64

2WD Steer Axle Components

11-1 Yoke and Hub ............................................................................................ 4 - 67

11-2 Steer Cylinder ............................................................................................ 4 - 68

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12-1 Yoke and Drive Hub ................................................................................... 4 - 69

12-2 Drive Motor ................................................................................................ 4 - 70

12-3 Drive Hub ................................................................................................... 4 - 70

12-4 Steer Cylinders........................................................................................... 4 - 71

Non-steer Axle Components

13-1 Drive Motor ................................................................................................ 4 - 72

13-2 Drive Hub ................................................................................................... 4 - 72

Oscillating Axle Components

14-1 Oscillate Axle Cylinders ............................................................................. 4 - 73

14-2 Oscillate Directional Valve ......................................................................... 4 - 74

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

Fault Codes - Control System ................................................................................ 5 - 2

Engine Fault Codes - Continental Models............................................................... 5 - 7

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1

Electrical Symbols Legend .................................................................................... 6 - 2

Hydraulic Symbols Legend .................................................................................... 6 - 3

Connector Pin Legend - View 1 .............................................................................. 6 - 6

Connector Pin Legend - View 2 .............................................................................. 6 - 7

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Section 6 Rev Schematics, continued

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04i Models ......................................................................... 6 - 10

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 14

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 15

Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04i Models ......................................................................... 6 - 18

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04i Models ................... 6 - 19

Electrical Schematic, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 22

Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 26

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 27

Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 30

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111) .............................. 6 - 31

Electrical Schematic, S-80 and S-85 (CE),Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 34

Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 38

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 39

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Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 42

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Deutz TD2011L04i Models (after serial number 8110) ................................. 6 - 43

Electrical Schematic, S-80XDeutz TD2011L04i Models ......................................................................... 6 - 46

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Deutz TD2011L04i Models ......................................................................... 6 - 50

Ground Control Box Switch panel Wiring Diagram, S-80X,Deutz TD2011L04i Models ......................................................................... 6 - 51

Platform Control Box Wiring Diagram, S-80X,Deutz TD2011L04i Models ......................................................................... 6 - 54

Platform Control Box Switch Panel Wiring Diagram, S-80X,Deutz TD2011L04i Models ......................................................................... 6 - 55

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Perkins 804D-33 Models ............................................................................ 6 - 58

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 62

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 63

Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),

Perkins 804D-33 Models ............................................................................ 6 - 66

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models ...................... 6 - 67

Electrical Schematic, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 70

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Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 74

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 75

Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 78

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111) ................................. 6 - 79

Electrical Schematic, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 82

Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 86

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 87

Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 90

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110) .................................... 6 - 91

Electrical Schematic, S-80X,Perkins 804D-33 Models ............................................................................ 6 - 94

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Perkins 804D-33 Models ............................................................................ 6 - 98

Ground Control Box Switch Panel Wiring Diagram, S-80X,Perkins 804D-33 Models ............................................................................ 6 - 99

Platform Control Box Wiring Diagram, S80X,Perkins 804D-33 Models ...........................................................................6 - 102

Platform Control Box Switch Panel Wiring Diagram, S80X,Perkins 804D-33 Models ...........................................................................6 - 103

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Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models .......................................................................6 - 106

Ground Control Box Terminal Strip Wiring DiagramS-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models .................6 - 110

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models .................6 - 111

Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models .......................................................................6 - 114

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models .................6 - 115

Electrical Schematic, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111) ............................6 - 118

Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111) ............................6 - 122

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111) ............................6 - 123

Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111) ............................6 - 126

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111) ............................6 - 127

Electrical Schematic, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110) ...............................6 - 130

Ground Control Box Terminal Strip Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110) ...............................6 - 134

Ground Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110) ...............................6 - 135

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Section 6 Rev Schematics, continued.................................................................................................

Platform Control Box Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110) ...............................6 - 138

Platform Control Box Switch Panel Wiring Diagram, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110) ...............................6 - 139

Electrical Schematic, S-80X,Continental TME27 Models .......................................................................6 - 142

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Continental TME27 Models .......................................................................6 - 146

Ground Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models .......................................................................6 - 147

Platform Control Box Wiring Diagram, S-80X,Continental TME27 Models .......................................................................6 - 150

Platform Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models .......................................................................6 - 151

Continental TME27 Engine Harness....................................................................6 - 154

Platform Level Cutout, CTE Option .....................................................................6 - 155

Continental Options Schematic ...........................................................................6 - 158

Deutz and Perkins Options Schematic ................................................................6 - 159

12 kW Hydraulic Generator Wiring Diagram.........................................................6 - 162

12 kW Hydraulic Generator Electrical Schematic ................................................6 - 163

Belt Driven Generator Option ..............................................................................6 - 166

Relay and Fuse Panel Legend ............................................................................6 - 167

Hydraulic Schematic, 2WD Models .....................................................................6 - 170

Hydraulic Schematic, 4WD Models .....................................................................6 - 171

12 kW Hydraulic Generator Hydraulic Schematic ................................................6 - 173

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2 - 1

Section 2 • SpecificationsSeptember 2015

Part No. 122985 S-80 • S-85 • S-80X

Specifications

Machine Specifications

Rough Terrain and Non Marking Tires and Wheels

Tire size 18-625 FF

Tire ply rating 16

Overall tire diameter 40.7 in

103.3 cm

Tire pressure Foam filled

Wheel diameter 24.5 in

62.2 cm

Wheel width 15 in

38.1 cm

Tire weight, new foam-filled (minimum) 622 lbs

282 kg

High Floatation Tires and Wheels

Tire size 41/18LLx22.5

Tire ply rating 14

Tire pressure 70 psi

4.8 bar

Wheel diameter 22.5 in

57 cm

Wheel width 14 in

35.6 cm

Lugs and Lug Nut Torque

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs

569 Nm

Lug nut torque, lubricated 320 ft-lbs

434 Nm

For operational specifications, refer to theOperator's Manual.

Fluid capacities

Fuel tank, 35 gallons

(Deutz and Perkins models) 132.5 liters

(Continental models) 30 gallons

113.5 liters

LPG tank 33.5 pounds

15.2 kg

Hydraulic tank 40 gallons

151.4 liters

Hydraulic system 50 gallons

(including tank) 189.3 liters

Turntable rotation drive hub 40 fl oz

(single fill port) 1.2 liters

Turntable rotation drive hub 43 fl oz

(Dual fill ports) 1.3 liters

Four wheel drive hubs 30.5 fl oz

0.90 liters

Two wheel drive hubs 23 fl oz

0.68 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oilAPI service classification GL5

2 - 2

Section 2 • Specifications September 2015

S-80 • S-85 • S-80X Part No. 122985

SPECIFICATIONS

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD MV equivalent

Viscosity grade Multi-viscosity

Viscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rando HD MV oil is fully compatible andmixable 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.

Optional fluids

Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Performance Specifications

Drive speed, maximum

Stowed position 40 ft / 7.9-8.5 sec

RT Tires 12.2 m / 7.9-8.5 sec

Stowed position 40 ft / 11-13 sec

Flotation Tires 12.2 m / 11-13 sec

Raised or extended position 40 ft / 40-45 sec

12.2 m / 40-45 sec

Braking distance, maximum

High range on paved surface 3 ft

90 cm

Gradeability Refer to the Operator’s Manual

Boom function speeds, maximumfrom platform controls

Jib boom up (S-85) 25 to 35 seconds

Jib boom down (S-85) 15 to 25 seconds

Boom up (ANSI, CSA, AS models) 57 to 65 seconds

Boom up (CE models) 75 to 83 seconds

Boom down (ANSI, CSA, AS models) 61 to 69 seconds

Boom down (CE models) 75 to 83 seconds

Boom extend 59 to 67 seconds

Boom retract 57 to 65 seconds

Turntable rotate, 360° 95 to 103 seconds

boom fully stowed

Turntable rotate, 360° 210 to 250 seconds

boom raised or extended

Platform rotate, 160° 8 to 12 seconds

Platform level up 50 to 60 seconds

Platform level down 40 to 50 seconds

2 - 3


Part No. 122985 S-80 • S-85 • S-80X

SPECIFICATIONS

Hydraulic ComponentSpecifications

Drive pump

Type: bi-directional variable displacement piston pump

Displacement 0 to 2.8 cu in

0 to 46 cc

Flow rate @ 2300 rpm 0 to 30.3 gpm

0 to 114.7 L/min

Drive pressure, maximum 3750 psi

259 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in

13.9 cc

Flow rate @ 2300 rpm 9 gpm

34.1 L/min

Charge pressure @ 2300 rpm 310 psi

Neutral position 21.4 bar

Function pump

Type: variable displacement piston pump

Displacement 0 to 2.3 cu in

0 to 38 cc

Flow rate @ 2300 rpm 0 to 23 gpm

0 to 87 L/min

Auxiliary pump

Type: fixed displacement gear pump

Displacement - static 0.151 cu in

2.47 cc

Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.

Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

2 - 4


S-80 • S-85 • S-80X Part No. 122985

SPECIFICATIONS

Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve coil resistance specifications

Proportional solenoid valve 3.7 Ω(schematic items SE)

Proportional solenoid valve 4.8 Ω(schematic items SR and SF)

2 position 3 way solenoid valve 4.1 Ω(schematic items SJ)

2 position 3 way solenoid valve 9 Ω(schematic items SK)

3 position 4 way solenoid valve 7.2 Ω(schematic items SI and SL)

Solenoid valve, NO, Poppet 5.6 Ω(schematic items SP and SQ)

Function manifold

System relief pressure 3200 psi

(measured at PTEST port) 221 bar

Boom down relief pressure 2400 psi


Boom extend relief pressure 2400 psi


Steer/axle extend 3.5 gpm

flow regulator 13.2 L/min

Oscillate relief pressure 950 psi

65.5 bar

Drive manifold

Hot oil relief pressure 280 psi

19.3 bar

Brake release pressure

Wheel drive hubs 240 psi

16.5 bar

Drive motors

Displacement per revolution, variable 0.9 to 2.7 cu in

(2 speed motor) 14.7 to 45 cc

Hydraulic filters

High pressure filter Beta 3 ≥ 200

High pressure filter 102 psi

bypass pressure 7 bar

Medium pressure filter Beta 3 ≥ 200

Medium pressure filter 51 psi

bypass pressure 3.5 bar

Hydraulic tank 10 micron with

return filter 25 psi / 1.7 bar bypass

2 - 5


Part No. 122985 S-80 • S-85 • S-80X

SPECIFICATIONS

Continental TME27 Engine

Displacement 164 cu in

2.68 liters

Number of cylinders 4

Bore and stroke 3.58 x 4.06 inches

91 x 103.2 mm

Horsepower 59.03 @ 2500 rpm

44 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Compression ratio 8.2:1

Compression pressurePressure (psi or bar) of the lowest cylinder must be at

least 75% of the highest cylinder.

Low idle - computer controlled 1600 rpm

Frequency 53.33 Hz

High idle - computer controlled 2500 rpm

Frequency 83.33 Hz

Valve clearance, warm

Intake 0.014 in

0.36 mm

Exhaust 0.018 in

0.46 mm

Lubrication system

Oil pressure 40-60 psi

2.8-4.1 bar

Oil capacity 7 quarts

(including filter) 6.65 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures my require the use of

alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Fuel Requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Electronic fuel pump

Fuel pressure, static 55 psi

3.8 bar

Fuel flow rate 0.42 gpm

1.59 L/min

Batteries

Type 12V DC

Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Alternator output 65A @ 13.8V DC

Fan belt deflection 1/2 inch

12 mm

2 - 6


S-80 • S-85 • S-80X Part No. 122985






Oil temperature switch

Oil temperature switch point 284°F

140°C

Oil pressure switch

Oil pressure switch point 22 psi

1.5 bar

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum15,000 psi/1034 bar

Injector opening pressure 3046 psi

210 bar

Fuel Requirement



Batteries

Type 12V DC

Group 31

Quantity 1



Alternator output 80A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch

9 to 12 mm

Deutz TD2011L04i Engine

Displacement 189.6 cu in

3.1 liters



94 x 112 mm

Horsepower

Continuous 69.1 @ 2500 rpm

Net intermittent 72.8 @ 2500 rpm

Continuous 51.5 KW @ 2500 rpm

Net intermittent 54.3 KW @ 2500 rpm


Low idle 1300 rpm

Frequency 331.5 Hz

High idle 2350 rpm

Frequency 599.3 Hz

Compression ratio 17.5:1

Compression pressurePressure (psi or bar) of the lowest cylinder must be at

least 75% of the highest cylinder.

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in

0.3 mm

Exhaust 0.020 in

0.5 mm

Lubrication system

Minimum oil pressure, hot 21.8 psi

(at 1300 rpm) 1.5 bar

Oil capacity 12.8 quarts

(including filter) 12.1 liters

SPECIFICATIONS

2 - 7


Part No. 122985 S-80 • S-85 • S-80X

SPECIFICATIONS

Injection system

Injection pump make Zexel

Injection pump pressure 1707 to 1849 psi

117.7 to 127.5 bar

Injector opening pressure ~2000 psi

~138 bar

Fuel Requirement



Engine coolant

Capacity 12.5 quarts

11.8 liters

Batteries

Type 12V DC

Group 31

Quantity 1



Alternator output 90A, 12V DC

Fan belt deflection 3/8 to 1/2 in

9 to 12 mm

Perkins 804D-33 Engine

Displacement 201 cu in

3.3 liters



94 x 120 mm

Horsepower 63 @ 2600 rpm

47 KW @ 2600 rpm


Compression ratio 22:1

Compression pressure 300 to 500 psi

20.7 to 34.5 bar

Pressure (psi or bar) of lowest cylinder must be

within 50 psi / 3.45 bar of highest cylinder

Low idle 1650 rpm

Frequency 335.5 Hz

High idle 2300 rpm

Frequency 467.7 Hz

Governor mechanical all speed

Valve clearance, cold

Intake 0.0098 in

0.25 mm

Exhaust 0.0098 in

0.25 mm

Lubrication system

Oil pressure @ 2000 rpm 40-60 psi

2.8-4.1 bar

Oil capacity 10.6 quarts

(including filter) 10 liters






2 - 8


S-80 • S-85 • S-80X Part No. 122985

SPECIFICATIONS

Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5, lubricated 480 ft-lbs

651 Nm

3/8 -16 bolts, GR 8 35 ft-lbs*

*(use blue thread locking compound) 47 Nm*

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs

244 Nm

Rotate drive hub mounting bolts, lubricated 80 ft-lbs

108 Nm

Backlash plate mounting bolts, lubricated 280 ft-lbs

379 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 210 ft-lbs

284 Nm

Drive hub mounting bolts, lubricated 160 ft-lbs*

*(use blue thread locking compound) 217 Nm

Drive motor mounting bolts, dry 110 ft-lbs

149 Nm

Drive motor mounting bolts, lubricated 80 ft-lbs*

*(use blue thread locking compound) 108 Nm

Drive hub oil plug, O-ring seal 13 ft-lbs

18 Nm

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 14 ft-lbs / 18.9 Nm




SAE No. 12 84 ft-lbs / 113.9 Nm

2 - 9


Part No. 122985 S-80 • S-85 • S-80X

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

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

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen 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 areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

SPECIFICATIONS

2 - 10


S-80 • S-85 • S-80X Part No. 122985

Size

(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3

6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6

7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6

10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4

12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147

14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234

16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365

18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503

20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SPECIFICATIONS

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

10.9 12.98.84.6

Part No. 122985 S-80 • S-85 • S-80X 3 - 1

Section 3 • Scheduled Maintenance ProceduresSeptember 2015

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed by

a person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall be

completed daily, quarterly, six months, annuallyand every two years as specified on theMaintenance Inspection Report. The frequencyand extent of periodic examinations and testsmay also depend on national regulations.

Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial machine damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for a

period longer than three months must completethe quarterly inspection.

Unless otherwise specified, perform each

procedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steer (yellow arrow) wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.



Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

3 - 2 S-80 • S-85 • S-80X Part No. 122985

Section 3 • Scheduled Maintenance Procedures September 2015

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery PreparationReport to use for each inspection. Store completedforms as required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.To account for repeated procedures, theScheduled Maintenance Procedures Section andthe Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six month or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of four years or in compliancewith employer, jobsite and governmentalregulations and requirements.

SCHEDULED MAINTENANCE PROCEDURES

Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000

Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex SouthDakota, Inc. 133192 Rev D

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before it isput into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirementslisted in the responsibilities manual.

3 - 4 S-80 • S-85 • S-80X Part No. 122985



Part No. 122985 S-80 • S-85 • S-80X 3 - 5


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 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: 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.

• 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.

LegendY = yes, acceptable

N = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Maintenance Inspection Report

Checklist B Y N R

B-1 Battery(s)

B-2 Electrical wiring

B-3 Key switch

B-4 Exhaust system

B-5 Engine air filter

B-6 Oil cooler and fins-

Deutz models

B-7 Brake configuration

B-8 Tires, wheels and

lug nut torque

B-9 Drive hub maintenance

B-10 Engine RPM

B-11 Engine maintenance

B-12 Oscillate directional

Control

B-13 Ground control

override

B-14 Platform self-leveling

B-15 Engine idle select

B-16 Fuel select operation

B-17 Drive enable system

B-18 Drive brakes

B-19 Drive speed-stowed

B-20 Drive speed-raised

or extended

B-21 Alarm package and

descent alarm

B-22 Fuel and hydraulic tank

venting systems

B-23 Hydraulic oil analysis

B-24 Inspect the Boom

Extend/Retract Cables

Checklist A Y N R

A-1 Inspect the manuals

and decals

A-2 Pre-operation

inspection

A-3 Engine maintenance

A-4 Function tests

A-5 Oscillate axle

A-6 Filter condition indicator

Perform after 40 hours:

A-7 30 day service


A-8 Engine maintenance -

Deutz and Continental

models

Perform every 100 hours:

A-9 Inspect filter/separator -

Diesel models

A-10 Grease rotation

bearing

A-11 Engine maintenance


A-12 Replace Drive Hub oil


A-13 Engine maintenance -

Perkins models

Comments

3 - 6 S-80 • S-85 • S-80X Part No. 122985


Checklist C Y N R

C-1 Engine maintenance

C-2 Grease platform

overload (if equipped)

C-3 Test the platform

overload (if equipped)

C-4 Air filter element

C-5 Replace filter/separator

Deutz and Perkins

models

C-6 Safety envelope

S-80X

Checklist D Y N R

D-1 Boom wear pads

D-2 Free-wheel

configuration

D-3 Turntable rotation

bearing bolts

D-4 Turntable bearing wear

D-5 Engine maintenance

D-6 Replace hydraulic filters

D-7 Drive hub oil


D-8 Engine maintenance -

Deutz models

MAINTENANCE INSPECTION REPORT

Checklist E Y N R

E-1 Hydraulic oil

E-2 Engine maintenance -

Perkins models


E-3 Engine maintenance -

Deutz and Perkins

models

Perform every 10 years:

E-4 Replace the Boom

Extend/Retract Cables

Instructions• Make copies of this report to use for

each inspection.

• Select the appropriate checklist(s) for

the type of inspection to be

performed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hourInspection: A+B+C+D

2 Year or 2000 hourInspection: 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.

• 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.

LegendY = yes, acceptable

N = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Part No. 122985 S-80 • S-85 • S-80X 3 - 7


Checklist A Procedures

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate for

the machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with all

required decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

3 - 8 S-80 • S-85 • S-80X Part No. 122985


CHECKLIST A PROCEDURES

A-2Perform Pre-operationInspectionGenie specifications require that this procedure beperformed daily.

Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-3Perform Engine Maintenance

Engine specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in the:

Deutz TD2011 Operation ManualGenie part number 139320

Perkins 804D-33 Operation and Maintenance ManualGenie part number 111332

Continental TME27 Owner's ManualGenie part number 111901

To access the engine:

1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure itfrom moving.

Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.

Part No. 122985 S-80 • S-85 • S-80X 3 - 9



A-4Perform Function TestsGenie specifications require that this procedure beperformed daily.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-5Test the Oscillate Axle

Genie specifications require that this procedure beperformed daily.

Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.

Tip-over hazard. Failure to performthis procedure on a firm, levelsurface will compromise thestability of the machine and couldresult in the machine tipping over.

1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay in

firm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a 6 inch / 15 cmblock or curb.

Result: The three remaining tires should stay in

firm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a6 inch / 15 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

Note: If the chassis does not remain level duringthe test, refer to Repair Procedure 14-2, How to SetUp the Directional Valve Linkage.

3 - 10 S-80 • S-85 • S-80X Part No. 122985



A-6Check the High PressureHydraulic Filter ConditionIndicatorGenie specifications require that this procedure beperformed daily or every 8 hours, whichever comesfirst.

Maintaining the high pressure hydraulic filter ingood condition is essential to good systemperformance and safe machine operation. The filtercondition indicator will show when the hydraulic flowis bypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Open the engine side turntable cover.

2 Start the engine from the ground controls.

3 Change the engine idle to high rpm (rabbitsymbol).

4 Visually inspect the filter condition indicator.

Result: The filter condition indicator should be

operating with the plunger in the green area.

Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-6, Replace the HydraulicFilters.

A-7Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-10 Grease the Turntable Rotation Bearingand Rotate Gear

• B-8 Inspect the Tires, Wheels andLug Nut Torque

• B-9 Check the Drive Hub Oil Level andFastener Torque

• B-24 Inspect the Boom Extend/RetractCables

• D-4 Check the Turnable Rotation BearingBolts

• D-7 Replace the Hydraulic Filter Elements

Part No. 122985 S-80 • S-85 • S-80X 3 - 11



A-8Perform Engine Maintenance -Deutz and Continental Models

Engine specifications require that this one-timeprocedure be performed after the first 50 hours ofoperation.


Required maintenance procedures forcommissioning new and overhauled engines andadditional engine information are available in the:






A-9Inspect the Fuel Filter/WaterSeparator - Diesel Models

Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and/or hard starting, and continueduse may result in component damge. Extremelydirty conditions may require this procedure beperformed more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

Note: Perform this procedure with the engine off.

Perkins Models:

1 Put on protective clothing and eye wear.

2 Open the engine side turntable cover and locatethe fuel filter/water separator next to thehydraulic return filter on the bulkhead.

3 Inspect the filter bowl for water buildup.

Result: If water is present in the filter bowl

continue with steps 4 through 8.

3 - 12 S-80 • S-85 • S-80X Part No. 122985



4 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

5 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

6 Tighten the vent plug.

Note: If the fuel filter/water separator is completelydrained, you must prime the fuel filter/waterseparator before starting the engine. See C-6,Replace The Fuel Filter/Water Separator Element -Perkins Models, for instructions on how to primethe fuel filter/water separator.

7 Clean up any fuel that may have spilled.

8 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

Deutz Models:


2 Remove the engine tray retaining fastenerlocated under the engine tray.Swing the enginetray out and away from the machine.

3 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.


4 Locate the fuel filter/water separator next to theoil filter.

c

b

d

a

Part No. 122985 S-80 • S-85 • S-80X 3 - 13



5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Note: Do not completely drain the filter.

a fuel filter/water separatorb drain valve


7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.


8 Swing the engine back to its original positionand install the engine pivot plate retainingfastener.

A-10Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Locate the grease fitting on the platform end ofthe tank side bulkhead.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in incrementsof 4 to 5 inches / 10 to 13 cm at a time andrepeat this step until the entire bearing has beengreased.

3 Apply grease to each tooth of the drive gear,located under the turntable.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent

a

b

3 - 14 S-80 • S-85 • S-80X Part No. 122985



A-11Perform Engine Maintenance

Engine specifications require that this procedure beperformed every 100 hours.









Part No. 122985 S-80 • S-85 • S-80X 3 - 15



A-12Replace the Drive Hub Oil

Manufacturer specifications require that this one-timeprocedure be performed after the first 150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the initial 150 hours ofuse may cause the machine to perform poorly andcontinued use may cause component damage.

Drive hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at the lowestpoint.

2 Remove both plugs and drain the oil into a suitablecontainer.

3 Drive the machine until one plug is at the top andthe other is at 90 degrees.

a. models with o-ring plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.

5 Install the plugs into the drive hub. Torque toSpecification. Refer to Section 2,Specifications.

6 Repeat steps 1 through 4 for the other drive hub.

7 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.

Turntable rotate drive hub:

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Secure the turntable from rotating with theturntable rotation lock pin.

Note: The turntable rotation lock pin is located nextto the boom rest pad.

2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

a

3 - 16 S-80 • S-85 • S-80X Part No. 122985


4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.

5 Remove the plug the drive hub. Drain the oilfrom the hub into a suitable container.

Single fill port rotatora motorb fill portc drive hub mounting boltsd drive hub

Dual fill port rotatora motorb drive hubc drive hub mounting boltsd fill ports

6 Install the drive hub assembly onto the machine.Torque the drive hub mounting bolts tospecification. Refer to Section 2, Specifications.

7 Fill the drive hub with oil. Refer to Section 2,Specifications. Apply pipe thread sealant to theplug. Install the plug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.

AB

a

c

b

da

AB b

d c


Part No. 122985 S-80 • S-85 • S-80X 3 - 17


A-13Perform Engine Maintenance -Perkins Models




Perkins 804D-33 Operation and Maintenance ManualGenie part number





3 - 18 S-80 • S-85 • S-80X Part No. 122985


Checklist B Procedures

B-1Inspect the Battery(s)

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions. A singlebattery configuraton is standard. A dual batteryoption is available, where one battery is used tostart the engine and the other is used to power thecontrol system and auxiliary power unit. The twobatteries are charged by the alternator through abattery separator.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.


2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Be sure that the battery separator wireconnections are tight (if equipped).

5 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 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 batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge, OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

Part No. 122985 S-80 • S-85 • S-80X 3 - 19


CHECKLIST B PROCEDURES

10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 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 gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled.

a b

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution/ burn hazard.Contact with hot or live circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

1 Open the turntable cover at the engine side ofthe machine.

2 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.

a engine tray anchor holeb engine tray retaining fastener

3 - 20 S-80 • S-85 • S-80X Part No. 122985



3 Locate the engine tray anchor hole on theturntable.

4 Install the bolt that was just removed into theanchor hole to secure the engine tray frommoving.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

• Engine wiring harness

6 Open the turntable cover at the ground controlsside of the machine.


• Battery area wiring

• Inside the ground control box

• Hydraulic manifold wiring

• Hydraulic oil cooler wiring

8 Inspect for a liberal coating of dielectric greasein the following locations:

• All wire harness connectors toground control box

9 Start the engine from the ground controls andraise the boom above the turntable covers.

10 Inspect the turntable area for burnt, chafed andpinched cables.

11 Lower the boom to the stowed position and turnthe engine off.


• Cable track on the boom

• Cables on the boom and jib boom

• Jib, rotate, level manifold

• Inside of the platform control box

13 Inspect for a liberal coating of dielectric greasein the following location:

• All wire harness connectors toplatform control box

14 Remove the engine tray retaining fastener fromthe engine tray anchor hole at the pivot end ofthe engine tray.

15 Swing the engine tray in towards the machine.

16 Install the engine tray retaining fasteners.

Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.

Part No. 122985 S-80 • S-85 • S-80X 3 - 21



B-3Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could cause ahazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and no functions

should operate.

B-4Check the Exhaust System


Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.




3 - 22 S-80 • S-85 • S-80X Part No. 122985



2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

5 Swing the engine pivot plate in towards themachine.

6 Install the bolts that were just removed into theoriginal holes to secure the engine pivot plate.

Crushing hazard. Failure to installthe bolts into the engine pivot plateto secure it from moving couldresult in death or serious injury.

B-5Inspect the Engine Air Filter -Continental, Deutz and PerkinsModels


Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Locate the engine air filter assembly.

2 Release the latches from the air cleaner canisterend cap. Remove the end cap.

3 Remove the filter element.

4 Clean the inside of the canister and the end capwith a damp cloth.

5 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed 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 securethe end cap latches.

Note: Be sure the discharge valve is pointing downwhen the cap is instaled.

Part No. 122985 S-80 • S-85 • S-80X 3 - 23



B-6Check the Oil Cooler andCooling Fins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Oil cooler:

1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.



3 Remove the fasteners from the engine sidecover, then remove the cover.

4 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

5 Clean the oil cooler of debris and foreignmaterial.

Cooling and fan blower fins:

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

9 Clean the cylinder head cooling passages ofdebris and foreign material.

10 Install the engine side cover.


cba

3 - 24 S-80 • S-85 • S-80X Part No. 122985



B-7Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to be sureit is in the engaged position.

B-8Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque, isessential to safe operation and good performance.Tire and/or wheel failure could result in a machinetip-over. Component damage may also result ifproblems are not discovered and repaired in atimely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldresult in death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

Note: The tires on some machines are foam filledand 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 andcracked welds.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

4 Check the pressure in each air-filled tire. Add airas necessary. Refer to Section 2,Specifications.

disengaged position

engaged position

Part No. 122985 S-80 • S-85 • S-80X 3 - 25



B-9Check Drive Hub Oil Level andFastener Torque

Genie specifications require that this procedure beperformed every 250 hours.

Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

Drive hubs:

1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other one isat 90 degrees.

a models with o-ring plugs

2 Remove the plug located at 90 degrees andcheck 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 oiluntil the oil level is even with the bottom of theside plug hole.


5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

6 Repeat steps 1 through 5 for the other drivehubs.


Single fill port rotator:

1 Remove the plug located on the top of the huband check the oil level.

Result: The oil level should be visible below the

bottom of the fill port.


a

AB b

d c

a

3 - 26 S-80 • S-85 • S-80X Part No. 122985



Dual fill port rotator:

2 Remove one of the plugs located on the side ofthe hub and check the oil level.

Result: The oil level should be even with thebottom of the plug hole.


3 If necessary, add oil. Refer to Section 2,Specifications.

4 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.

5 Check the torque of the turntable rotate drivehub mounting fasteners. Refer to Section 2,Specifications.

AB

a

c

b

d

B-10Check and Adjust theEngine RPM

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Continental models:

Note: The engine rpm is controlled by the ECM andcan only be adjusted by re-programming the ECM.If rpm adjustment or service is required, pleasecontact the Genie Industries Service Department.

Deutz TD2011L04i models:

1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.

Part No. 122985 S-80 • S-85 • S-80X 3 - 27


ba

f de

c


Deutz modelsa high idle adjustmentb low idle adjustment

Skip to step 4 if the low idle rpm is correct.

2 Loosen the locknut on the low idle adjustmentscrew.

3 Adjust the low idle adjustment screw until lowidle meets specification. Tighten the locknut.

4 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.Refer to Section 2, Specifications.

If the high idle is correct, disregard adjustmentstep 5.

5 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

Perkins models:

1 Connect a tachometer to the engine. Start theengine from the ground controls and check therpm. Refer to Section 2, Specifications.

Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

Perkins modelsa solenoid bootb yoke lock nutc low idle adjustment screwd low idle lock nute yokef high idle adjustment nut

3 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) position.Refer to Section 2, Specifications.

If high idle rpm is correct, disregard adjustmentstep 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

ba

3 - 28 S-80 • S-85 • S-80X Part No. 122985



B-11Perform Engine Maintenance

Engine specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.









B-12Check the Oscillate DirectionalValve Linkage


Proper axle oscillation is essential to safe machineoperation. If the oscillate directional valve linkage isnot operating correctly, the stability of the machineis compromised and it may tip over.

1 Remove the drive chassis cover from thenon-steer end of the machine.

2 Locate the oscillate directional valve inside ofthe non-steer axle and inspect the linkage forthe following:

• Lock nut is tight against yoke

• Yoke clevis pins are installed

• Cotter pins are installed through clevis pins

• Linkage is properly attached todirectional valve

Part No. 122985 S-80 • S-85 • S-80X 3 - 29



B-13Test the Ground ControlOverrideGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton at the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the red Emergency Stop button at theplatform controls to the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

B-14Test the Platform Self-levelingGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.


2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the boom through a full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

3 - 30 S-80 • S-85 • S-80X Part No. 122985



B-15Test the Engine Idle SelectOperationGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions only.

Functon enable button high idle (rabbit symbol)allows the operator to control multiple boomfunctions simultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This setting activates high idleonly when the foot switch is pressed down.




4 Move and hold the function button in and movethe idle switch to the high idle (rabbit symbol)position.

Result: The engine rpm should change to high

idle.

5 Release the function enable button.

Result: The engine rpm should change to low

idle.

6 Turn the key switch to platform controls.

7 Move the engine idle select toggle switch to lowidle (turtle symbol).

Result: The engine rpm should remain at low

idle.

8 Move the engine idle select toggle switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine rpm should not change to

high idle.

9 Press down the foot switch.

Result: The engine rpm should change to highidle.

high idle.


Result: The engine rpm should change to high

idle.

Part No. 122985 S-80 • S-85 • S-80X 3 - 31



B-16Test the Fuel Select Operation -Gasoline/LPG Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicate fuelsystem problems that could develop into ahazardous situation.

Note: Perform this test after checking the gasolineand LPG fuel levels, and warming the engine tonormal operating temperature.

1 Move the fuel select toggle switch to gasolineand then move the engine idle select switch tofoot switch activated high idle (rabbit and footswitch symbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly and

operate smoothly in low and high idle.

4 Release the foot switch and shut the engine offby pushing the red Emergency Stop button in tothe off position.

5 Move the fuel select toggle switch to LPG.

6 Start the engine and allow it to run at low idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly and

operate smoothly in low and high idle.

Note: The engine may hesitate momentarily andthen continue to run on the selected fuel if the fuelsource is switched while the engine is running.

Blue

Yellow


B-17Test the Drive Enable SystemGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper drive enable system operation isessential to safe machine operation. When theboom is past the non-steering wheels, drivemovement is stopped and theindicator light turns on. The driveenable switch must be held toeither side to reactivate the drivefunction and should alert theoperator that the machine maymove in the opposite direction that the drive andsteer controls are moved. An improperly functioningdrive enable system may allow the machine to bemoved into an unsafe position.

Note: Perform this procedure with the boom in thestowed position.



3 Rotate the turntable until the boom moves pastone of the the non-steer wheels.

Result: The drive enable indicator light should

turn on and remain on while theboom is anywhere in the rangeshown.

4 Slowly move the drive controlhandle off center.

Result: The drive function should not operate.

5 Rotate the turntable until the boom moves pastthe other non-steer wheel.

Result: The drive enable

indicator light should come onand remain on while the boomis anywhere in the range shown.

6 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.

Result: The drive function should operate.

Collision hazard. Always use thecolor-coded direction arrows on theplatform controls and the drivechassis to identify the direction oftravel.

Note: When the drive enable system is in use, themachine may drive in the opposite direction that thedrive and steer control handle is moved.


B-18Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-7, Confirm the Proper BrakeConfiguration.

Note: Select a test area that is firm, level and freeof obstructions.

Note; Perform this procedure with the boom in thestowed position.

1 Mark a test line on the ground for reference.


3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.

4 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.

5 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

B-19Test the Drive Speed -Stowed Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Note: Select a test area that is firm, level and freeof obstructions.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the start and finish lines.

4 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

5 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.

Note: To adjust the speed, refer to Repairprocedure 1-2, How to Adjust the Joystick Max-outSetting.

3 - 34 S-80 • S-85 • S-80X Part No. 122985



B-20Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Select a test area that is firm, level and free ofobstructions.

1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle select toggle switch tofoot switch activated high idle (rabbit and footswitch symbol).

4 Press down the foot switch and raise the boom10° above horizontal.

5 Choose a point on the machine (i.e. contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.


7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.


8 Press down the foot switch and lower the boomto the stowed position.

9 Extend the boom 3 feet / 90 cm.

10 Choose a point on the machine (i.e., contactpatch of a tire), as a visual reference for usewhen crossing the start and finish lines.


12 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, PerformanceSpecifications.


Part No. 122985 S-80 • S-85 • S-80X 3 - 35



B-21Test the Alarm Package(if equipped) and the DescentAlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The alarm package includes:

• Travel alarm

• Flashing beacons

Alarms and beacons are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable rear cover. Beacons are installed on bothturntable covers.

Note: The alarms and beacons will operate with theengine running or not running.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: Both flashing beacons should be on and

flashing.

2 Move and hold the function enable button toeither side and activate the boom toggle switchin the down position, hold for a moment andthen release it.

Result: The descent alarm should sound when

the toggle switch is held down.


Result: The flashing beacons should be on

and flashing.

4 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.

Result: The descent alarm should sound when

the controller is held down.

5 Press down the foot switch. Move the drivecontroller off center, hold for a moment and thenrelease it. Move the drive controller off center inthe opposite direction, hold for a moment andthen release it.

Result: The travel alarm should sound when the

drive controller is moved off center in eitherdirection.

3 - 36 S-80 • S-85 • S-80X Part No. 122985



B-22Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.



Note: This procedure applies to diesel equippedmachines only.

1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.Procced to step 4.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

When checking for positive tank cap venting, airshould pass freely through the cap.

3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

5 Remove the breather cap from the hydraulictank.

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 capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

Part No. 122985 S-80 • S-85 • S-80X 3 - 37



B-23Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more frequently.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

B-24Inspect the BoomExtend/Retract Cables


The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube. Inspecting for foreign objects, damage and/orimproper adjustment of the boom extend/retractcables and related components on a regular basisis essential to good machine performance and safemachine operation. The boom extend and retractfunctions should operate smoothly and be free ofhesitation, jerking and unusual noise.

1 Raise the boom to horizontal and fully extendthe boom.

2 After the boom is fully extended, lower the boomuntil the platform is at chest height. Turn themachine off.

3 Remove the boom end cover retaining fastenersand remove the cover.

4 Remove the retaining fasteners from the accesscovers located on the side of the boom at theplatform end of the machine. Remove thecovers.

3 - 38 S-80 • S-85 • S-80X Part No. 122985



5 Visually inspect the cables and componentsthrough both inspection holes for the following:

• Frayed or broken wire strands

• Kinks in the cables

• Corrosion

• Paint or foreign materials on the cable

• Split or cracked cable ends

• Cables are on all pulleys

• Extend cable break limit switch arm iscentered in the pivot plate

• Cables have equal tension

• Cables at end of adjustment range

• No broken or damaged pulleys

• No unusual or excessive pulley wear

• All fasteners in place and secure

Note: A flashlight and inspection mirror may benecessary to thoroughly inspect the above items.

Note: A pulley groove gauge should be used tocheck the condition of the pulleys.

6 Install the cover at the pivot end of the boom.

7 Install the access panels on the sides of theboom.

8 Start the engine from the ground controls andfully retract and lower the boom to the stowedposition.

9 Turn the key switch to the platform controls.

10 Extend the boom approximately 2 feet / 0.6 m.

11 Retract the boom. While retracting the boom,visually inspect the number 2 and number 3boom tubes.

Result: The number 2 boom tube should not

move more than 1/2 inch / 13 mm before thenumber 3 boom tube begins to retract.

Note: If the number 2 boom tube moves more than1/

2 inch / 13 mm before the number 3 boom tube

begins to retract, the boom extend/retract cablesneed to be adjusted. See Repair Procedure 4-5,How to Adjust the Boom Extend/Retract Cables.

Part No. 122985 S-80 • S-85 • S-80X 3 - 39


Checklist C Procedures

C-1Perform Engine Maintenance


Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.








C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first. Perform this procedure moreoften if dusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent

3 - 40 S-80 • S-85 • S-80X Part No. 122985


CHECKLIST C PROCEDURES

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Note: Perform this procedure with the machine on afirm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

4 Using a suitable lifting device, place a testweight equal to that of the available capacity atone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lights

should be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lights

should be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound and the engine

should shut off. The platform overload indicatorlights should be flashing at both the ground andplatform controls.

Result: The alarm does not sound, the enginedoes not shut off and the platform overloadindicator lights are not flashing. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash, the alarm soundsand the engine shuts off.

Part No. 122985 S-80 • S-85 • S-80X 3 - 41



Timer Relay

OrangeWire

Terminal 5

7 Using a suitable lifting device, remove the testweights, restart the engine and carefully movethe test weights to each remaining location onthe platform. Refer to Illustration 1.

Result: The alarm should sound, the engine

should shut off and the platform overloadindicator lights should be flashing at both theground and platform controls.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a 2 second delay before theoverload indicator lights flash, the alarm soundsand the engine shuts off.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should not

operate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should not

operate.

11 Activate the auxiliary power toggle switch.

12 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions should

operate.

13 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

14 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions should

operate normally.

15 Turn the key switch to platform control.


Result: All platform control functions should

operate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).

17 Push in the red Emergency stop button at theplatform to shut off engine.

18 Using a suitable lifting device, remove all testweights from the platform.

19 Pull out the red Emergency stop button to the onposition at the platform controls.

20 Remove the fasteners securing the lid to theplatform controls. Using Illustration 2 as aguide, locate the timer relay inside the platformcontrol box. Tag and disconnect the red wirefrom terminal 5 on the timer relay.

Illustration 2

3 - 42 S-80 • S-85 • S-80X Part No. 122985


Valve Power LED

ALC 500 Board

21 Using Illustration 3 as a guide, locate D31 ValvePower LED on the ALC500 printed circuit board.

Illustration 3

22 Step on the footswitch at the platform.

Result: The Valve Power LED should not

illuminate.

Result: The Valve Power LED is illuminated.Remove the machine from service and contactthe Genie Service Department.

23 Securely install the red wire, disconnected instep 20, onto terminal 5 of the relay timer.

24 Step on the footswitch at the platform.

Result: The Valve Power LED should illuminate.

Result: The Valve Power LED is not illuminated.Remove the machine from service and contactthe Genie Service Department.

25 Using a suitable lifting device, place a testweight equal to that of the available capacity atthe center location shown in Illustration 1.

26 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound and the Valve

Power LED should not light. The platformoverload indicator lights should be flashing atboth the ground and platform controls.

27 Working from outside the platform and standingnext to the platform rotator, locate the orangewire, which enters into the base of the platformcontrol box from the load sense switch andlocate the wire terminal at the end of the wire.Tag and disconnect the connectors.Refer to Illustration 2.

28 Using a multimeter set to read resistance(ohms), securely install a lead from themultimeter to the connector on the orange wire,and securely connect the other multimeter leadto a ground point in the control box.

Result: The readout on the multimeter should

indicate zero resistance.

Result: The readout on the multimeter showsresistance. Remove the machine from serviceand contact the Genie Service Department.

29 Using a suitable lifting device, remove all weightfrom the platform. Note the result on themultimeter.

Result: The readout on the multimeter should

indicate infinite resistance.

Result: The readout on the multimeter showszero resistance. Remove the machine fromservice and contact the Genie ServiceDepartment.

31 Turn off the multimeter and remove the leadsfrom the machine. Securely connect the wiresdisconnected in step 27.

32 Close the platform control box. Install andsecurely tighten the fasteners. Do notovertighten.


Part No. 122985 S-80 • S-85 • S-80X 3 - 43



C-4Replace the Engine Air FilterElement

Engine specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Release the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

2 Remove the filter element.

3 Use a damp cloth to wipe the filter sealingsurface and the inside of the outlet tube. Makesure that all contaminant is removed before thefilter is inserted.

4 Check new filter element gasket for damagebefore installing.

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.

C-5Replace the Fuel Filter/WaterSeparator Element -Diesel Models

Note: Genie specifications require that thisprocedure be performed every 500 hours or sixmonths, whichever comes first.

Regular replacement of the fuel filter/waterseparator is essential for good engine performance.Failure to perform this procedure can lead to poorengine performance and/or hard starting, andcontinued use may result in component damge.Extremely dirty conditions may require thisprocedure be performed more often.



Perkins Models:


2 Open the engine side turntable cover and locatethe fuel filter/water separator next to thehydraulic return filter on the bulkhead.

3 Inspect the filter bowl for water buildup.

Result: If water is present in the filter bowl

continue with steps 4 through 8.

3 - 44 S-80 • S-85 • S-80X Part No. 122985



c

b

d

a

4 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

5 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

6 Tighten the vent plug.

Note: If the fuel filter/water separator is completelydrained, you must prime the fuel filter/waterseparator before starting the engine. See C-6,Replace The Fuel Filter/Water Separator Element -Perkins Models, for instructions on how to primethe fuel filter/water separator.


8 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.


Deutz Models:


2 Remove the engine tray retaining fastenerlocated under the engine tray.Swing the enginetray out and away from the machine.



4 Locate the fuel filter/water separator next to theoil filter. for leaks.

Part No. 122985 S-80 • S-85 • S-80X 3 - 45



5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Note: Do not completely drain the filter.

a fuel filter/water separatorb drain valve


7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.



C-6Check the Safety Envelope LimitSwitches and Angle Sensor,S-80XNote: Genie specifications require that thisprocedure be performed every 500 hours or sixmonths, whichever comes first.

Testing the safety envelope system regularly isessential to safe machine operation. Continued useof an improperly operating safety envelope couldresult in the system not restricting the range ofmotion. Machine stablity could be compromisedresulting in the machine tipping over.

Note: Perform this procedure with the machine on afirm, level surface with all weight, tools andequipment removed from the platform.

Note: Start this procedure with the boom fullyretracted and in the stowed position.

Ground controls:

1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition.


a

b

3 - 46 S-80 • S-85 • S-80X Part No. 122985


3 Turn and hold the function enable switch to therestricted maximum platform capacity and raisethe primary boom until it is fully elevated.

a restricted maximum platformcapacity

b unrestricted maximum platformcapacity

4 Extend the primary boom until it is fullyextended.

5 Lower the primary boom until it stops.

Result: The boom will automatically stop after

10 degrees.

Result: The primary boom does not stop after 10degrees. Check limit switches LST3O andLST3S.

6 Turn the key switch to the off position and pushin the red Emergency Stop button.

Note: The follwing step can be done using ameasuring tape or a digital protractor (Genie partnumber 58377).

7 Measuring Tape:

Measure the distance between the center of thepivot pins as shown, 201.75 inches / 512 cm± 2.0 inch / 5 cm.

Digital Protractor:

Place the digital protractor on the turntablechassis and reset the protractor to 0°. Place theprotractor on top of the primary boom. Theprotractor should display 58° ± 2°.

Result: The primary boom angle is not withinspecifications.Consult Genie Industries ServiceDepartment.

Measure betweenthe centers of thesepivot pins


1000 lbs /454 kg

500 lbs /227 kg

ba

Part No. 122985 S-80 • S-85 • S-80X 3 - 47


Platform controls:

Note: Start this procedure with the boom fullyretracted and in the stowed position.

1 Pull out the red Emergency Stop button to theon position and start the engine.

2 Select the restricted maximum platform capacitywith the toggle switch.

a restricted maximum platformcapacity

b unrestricted maximum platformcapacity

3 Raise the primary boom until it is fully elevated.

4 Extend the primary boom until it is fullyextended.

5 Lower the primary boom until it stops.

Result: The boom will automatically stop after10 degrees and the unrestricted platformcapacity light will flash.

Result: The primary boom does not stop after 10degrees. Calibrate the boom angle sensor. Referto Repair Procedure 1-2, How to Calibrate theBoom angle Sensor.


500 lbs /227 kg

1000 lbs /454 kg

a b

6 Move the primary boom down joystick off centerand retract the primary boom until theunrestricted platform capacity light stopsflashing.

Result: Primary boom down should return to

normal operation.

7 Lower the primary boom 5 feet / 1.5 m andactivate primary boom extend.

Result: Primary boom extend will stop and the

unrestricated platform capacity light will startflashing.

8 Activate primary boom extend and raise theprimary boom until the unrestricated platformcapacity light stops flashing.

Result: Primary boom extend should return to

normal operation.

9 Return the machine to the fully stowed position.

3 - 48 S-80 • S-85 • S-80X Part No. 122985


Checklist D Procedures

D-1Check the Boom Wear Pads

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

Note: If the wear pads are still within specification,refer to Repair Procedure 4-2, How to Shim theBoom.


2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot / 30 cm.

3 Measure each wear pad. Replace the wear padif it is less than specification. If the wear pad isstill within specification, shim as necessary toobtain zero clearance and zero drag.

a boom 1b boom 2c boom 3

b ca

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Note: Always maintain squareness between theouter and inner boom tubes.

Boom wear pad specifications Minimum

Boom number one

Bottom wear pads 1/2 inch

(extension end of boom) 12.7 mm

Top and side wear pads 5/8 inch


Boom number two

Top, bottom and side wear pads 1/2 inch


Bottom wear pads 1/2 inch

(pivot end of boom) 12.7 mm

Top and side wear pads 5/8 inch


Boom number three

Top, bottom and side wear pads 1/2 inch


Part No. 122985 S-80 • S-85 • S-80X 3 - 49


CHECKLIST D PROCEDURES

disengaged position

engaged position

disengaged position

engaged position

D-2Check the Free-wheelConfiguration

Genie specifications require that this procedure beperformed every 1000 hours or annually, whichevercomes first.

Proper use of the free-wheel configuration isessential to safe machine operation. The free-wheelconfiguration is used primarily for towing. Amachine configured to free-wheel without operatorknowledge could result in death or serious injuryand property damage.

Collision hazard. Select a work sitethat is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer wheels.

3 Lift the wheels off the ground and place blocksunder the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate with

minimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

Steer wheels: 4WD models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer wheels.

9 Lift the wheels off the ground and then placeblocks under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each steer wheelhub.

3 - 50 S-80 • S-85 • S-80X Part No. 122985



11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate with

minimum effort.

12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

All models:

13 Turn the valve in a clockwise direction to besure it is fully closed.

Note: The free-wheel valve is located on the bottomof the drive pump, and should always remainclosed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

D-3Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Start the engine from the platform controls andextend the axles.

2 Turn the key switch to ground controls.

3 Raise the boom and place a safety chock on thelift cylinder rod. Carefully lower the boom ontothe lift cylinder safety chock.

Crushing hazard. Keep handsaway from cylinder and all movingparts when lowering the boom.

Note: The lift cylinder safety chock is availablethrough Genie Service Parts.

4 Remove the center turntable cover retainingfasteners. Remove the cover.

a

d

c

b

Part No. 122985 S-80 • S-85 • S-80X 3 - 51



5 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.

Bolt torque sequence

6 Install the center turntable cover and tighten theretaining 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 underthe drive chassis is torqued in sequence tospecification. Refer to Section 2, Specifications.

D-4Inspect for Turntable BearingWear


Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Note: Perform this procedure with the machine on afirm, level surface and the boom in the stowedposition.

1 Grease the turntable bearing. See A-12, Greasethe Turntable Rotation Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-4, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

3 - 52 S-80 • S-85 • S-80X Part No. 122985


a

b

c

d


4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch /2.5 cm from the turntable rotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Fully extend the boom and lower to a horizontalposition.

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 than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.

Part No. 122985 S-80 • S-85 • S-80X 3 - 53



D-5Perform Engine Maintenance










D-6Replace the Hydraulic Filters

Genie requires that this procedure be performedevery 1000 hours or annually, whichever comesfirst. Perform this procedure more often if dustyconditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.


Hydraulic return filter:

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the cap from the filter housing.

3 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

4 Remove the filter element from the filterhousing.

5 Install the new filter element into the filterhousing.

6 Push the filter element down to be sure theO-ring on the element is fully seated into thehousing.

7 Rotate the filter element clockwise to lock it inplace.

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8 Install the filter housing cap.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.

Medium and high pressure filters:

Note: The medium pressure filter is for the chargepump and the high pressure filter is for all machinefunctions except the drive circuit and oscillatingaxle circuit.

10 Open the engine side turntable cover and locatethe two filters.

Note: The high pressure filter is located toward thebulkhead with a condition indicator. The mediumpressure filter is located nearest the operator.

11 Place a suitable container under the filters.

12 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housings.

13 Remove the filter element from the housings.

14 Inspect the housing seals and replace them ifnecessary.

15 Install the new medium and high pressure filterelements into the housings and tighten themsecurely.

16 Clean up any oil that may have spilled during theinstallation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

D-7Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.

Drive hubs:

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a. models with o-ring plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Install the plugs.


a

Part No. 122985 S-80 • S-85 • S-80X 3 - 55



6 Repeat steps 1 through 4 for the other drive hub.

7 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.


Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.



2 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

3 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

4 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.

5 Remove the plug the drive hub. Drain the oilfrom the hub into a suitable container.


a

AB b

d c

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6 Install the drive hub assembly onto the machine.Torque the drive hub mounting bolts tospecification. Refer to Section 2, Specifications.

7 Fill the drive hub with oil. Refer to Section 2,Specifications. Apply pipe thread sealant to theplug. Install the plug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 10-1, How to Adjust theTurntable Rotation Gear Backlash.

AB

a

c

b

d

D-8Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 1500 hours of operation.





1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out away from the machine and secure.


Part No. 122985 S-80 • S-85 • S-80X 3 - 57


E-1Test or Replace theHydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or every two years,whichever comes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more frequently.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.


Note: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the fuel tank. Refer to RepairProcedure 9-1, How to Remove the Fuel Tank.

open closed

Checklist E Procedures

2 Models without hydraulic tank shutoff valves:Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.

Models with hydraulic tank shutoff valves:Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started with thehydraulic tank shutoff valves in theCLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tank

and completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.

4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.

5 Disconnect and plug the T-fitting located at thereturn filter with the two hoses connected to it.Cap the fitting on the return filter housing.

6 Disconnect and plug the supply hose for theauxiliary power unit. Cap the fitting on thehydraulic tank.

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CHECKLIST E PROCEDURES

7 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.

8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an appropriatelifting device.

9 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank may become unbalanced andfall if it is not properly supportedand secured to the lifting device.

10 Remove the suction strainers from the tank andclean them using a mild solvent.

11 Rinse out the inside of the tank using a mildsolvent.

12 Install the suction strainers using pipe threadsealant on the threads.

13 Install the drain plug using pipe thread sealanton the threads.

14 Install the hydraulic tank onto the machine.

15 Install the two suction hoses and the supplyhose for the auxiliary power unit.

16 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

17 Clean up any oil that may have spilled.

18 Open the hydraulic tank shutoff valves (ifequipped).

Component damage hazard.Be sure to open the two hydraulictank shutoff valves and prime thepump after installing the hydraulictank. Refer to Repair Procedure7-2, How to Prime the Pump.

Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.

19 Operate all machine functions through a fullcycle and check for leaks.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

Part No. 122985 S-80 • S-85 • S-80X 3 - 59



E-2Perform Engine Maintenance -Perkins Models








E-3Perform Engine Maintenance -Deutz and Perkins Models









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E-4Replace the Boom Extend/Retract Cables

Genie specifications require that this procedure beperformed every 10 years.

The boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube. Replacement of the boom extend/retractcables is essential to good machine performanceand safe machine operation. The boom extend/retract functions should operate smoothly and befree of hesitation, jerking and unusual noise.

1 Replace the boom extend/retract cables. SeeRepair Procedure 4-5, How to Replace theBoom Extend/Retract Cables.

Section 4 • Repair Procedures

Part No. 122985 S-80 • S-85 • S-80X 4 - 1

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Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rules andoperating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

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

Use only Genie approved replacement parts.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steering wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine


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The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc primary boom up/down,

extend/retract andturntable rotate right/leftjoystick controller

1-1ALC-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-500Circuit Board1 Push in the Emergency Stop button to the off

position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted tothe inside of the platform control box.

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit board fromthe platform control box.

Platform Controls

bc

a


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PLATFORM CONTROLS

1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.


1 Open the platform control box.


3 Turn the key switch to platform control. Do notstart the engine.

4 Select a joystick to calibrate.

5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.

6 Move the joystick full stroke in either directionand hold for 5 seconds.

7 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds.

Result: The alarm should sound indicatingsuccessful joystick calibration.

Result: The alarm does not sound. Check theelectrical connections or replace the joystick.

8 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

Note: No machine fuction should operate whileperforming the joystick calibration procedure.

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.


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PLATFORM CONTROLS

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

Result: The alarm does not sound. Repeat steps3 through 7.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time with thefunction times listed in Section 2,Specifications. Determine whether the functiontime needs to increase or decrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.

Note: Each time the drive enable toggle switch ismomentarily moved, the function speed will changein 2% increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

13 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Result: The alarm does not sound. Theminimum or maximum adjustment has beenobtained. No changes can be saved.

Note: Do not operate any machine function duringthe 10 second waiting time.

14 Cycle the red Emergency Stop button off, thenback on.

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.




3 Push in the platform controls red EmergencyStop button to the off position.


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September 2015

PLATFORM CONTROLS





Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.



9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 Release the foot switch.

12 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Note: Each time the drive enable toggle switch ismomentarily moved, the time will change in 5%increments.

13 Repeat steps 9 through 11 for each joystickcontrolled machine function.

14 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.




Ramp rate (factory settings)

Turntable rotateaccelerate 3 seconds

decelerate 2 second

Boom up/downaccelerate 3 secondsdecelerate 1 second

Boom extend/retractaccelerate 2.5 seconds

decelerate 1 second

Driveaccelerate 4 seconds

decelerate to neutral 0.5 second

decelerate, change of direction 0.75 second

decelerate, coasting 1 second

decelerate, braking 1 seconddecelerate, shift from low to high speed 1 second

decelerate, shift from high to low speed 4 seconds


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PLATFORM CONTROLS123456789012345678901234567890123456789012345678901234567890

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.




3 Push in the red Emergency Stop button to theoff position at the platform controls.





Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.



9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntable rotate).

13 Return the joystick to the neutral position andwait for approximately 10 seconds.




Function speeds (factory settings)

Boom up 89 to 93 seconds

Boom down 90 to 94 seconds

Boom extend 73 to 79 seconds

Boom retract 79 to 84 seconds

Turntable rotate, 360°

boom fully stowed 95 to 103 seconds

Drive speeds (factory settings)

Stowed- high speed 7.9 to 8.5 seconds

Non-stowed 40 to 45 seconds


Part No. 122985 S-80 • S-85 • S-80X 4 - 7

September 2015

How to Calibrate the BoomAngle SensorThe boom angle sensor controls the maximumangle that the boom can attain.


1 Pull out the red Emergency Stop button to theon position at the ground controls.


3 Move and hold the drive enable toggle switch tothe right and pull out the red Emergency Stopbutton to the on position.


5 Momentarily activate the drive enable toggleswitch to the right 12 times.

Result: There should be a pause and the alarmshould sound 12 times indicating that themachine is in Angle Sensor calibration mode.


7 Momentarily activate the drive enable toggleswitch to the right 1 time to set the stowedposition.

Note: The alarm will not sound indicating thesetting.

8 Raise the primary boom to the fully elevatedposition.

Note: Manually reduce the boom speed as itreaches the fully elevated position.

9 Momentarily activate the drive enable toggleswitch to the right 1 time to set the elevatedposition.

Result: The alarm will sound indicating that theangle sensor has been calibrated.

10 Release the joystick and the foot switch andwait for 10 seconds.

Result: The alarm will sound indicating that thesettings have been saved and is leavingcalibration mode.

11 Cycle the red Emergency Stop button off, thenback on. Start the machine and return to thestowed position.

PLATFORM CONTROLS


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Part No. 122985 S-80 • S-85 • S-80X 4 - 9

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Platform Components

2-1Platform

How to Remove the Platform1 Remove the cable clamp from the top of the

platform mounting weldment.

2 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side. Donot disconnect the wiring.

3 Remove the foot switch mounting fasteners.

4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.

5 Tag and disconnect the foot switch wiring fromthe foot switch. Remove the cable from theback of the platform.


6 Remove the platform control box mountingfasteners. Lower the control box and set itaside.

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

Note: If your machine is equipped with an airline toplatform option, the airline must be disconnectedfrom the platform before removal.

7 Support and secure the platform to anappropriate lifting device.

8 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformcould become unstable and fallwhen it is removed from themachine if not properly supported.


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PLATFORM COMPONENTS

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave CylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is no air in theclosed loop.


1 Extend the primary boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

4 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to drive the rod-end pivot pin out.

Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.

5 Remove the external snap rings from the barrel-end pivot pin.

6 Use a soft metal drift to drive the barrel-endpivot pin out.

7 Carefully pull the cylinder out of the primaryboom to access the hydraulic hoses.

8 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder. Cap the fittings on thecylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

How to Bleed the Slave CylinderNote: Do not start the engine. Use auxiliary powerfor this procedure.

1 Raise the primary boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.


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September 2015

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.


1 Remove the platform. See 2-1,How to Remove the Platform.

PLATFORM COMPONENTS

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the rotator.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

3 S-85: Support the jib boom leveling arms andthe platform mounting weldment with anappropriate lifting device. Do not apply anylifting pressure.

4 Remove the mounting bolts from the platformmounting weldment. Remove the center boltand slide the platform mounting weldment off ofthe platform rotator.

Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if not properlysupported when removed from themachine.

5 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.

S-80:

6 Support the rod end of the platform levelingslave cylinder. Protect the cylinder rod fromdamage.

7 Remove the pivot pin retaining fasteners fromboth the slave cylinder rod-end pivot pin andthe rotator pivot pin.


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PLATFORM COMPONENTS

8 Use a soft metal drift to remove both pivot pins.Remove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.

Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.

S-85:

9 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

10 Support the jib boom leveling arms.

11 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Bodily injury hazard. The jib boomleveling arms may fall if notproperly supported.

12 Lower the jib boom leveling arms.

Crushing hazard. The platformrotator may become unbalancedand fall if not properly supported.

Note: When installing the platform rotatorfasteners, torque the fasteners to specifications.Refer to Section 2, Specifications.

How to Bleed the PlatformRotatorNote: This procedure will require two people. Donot start the engine. Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Place a suitable container underneath theplatform rotator.

3 Open the top bleed screw on the rotator, but donot remove it.



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September 2015

PLATFORM COMPONENTS

4 Move the function enable button to either sideand hold the platform rotate toggle switch to theleft position until the platform is fully rotated tothe left. Continue holding the toggle switch untilair stops coming out of the bleed screw. Closethe bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Open the bottom bleed screw on the rotator, butdo not remove it.


6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Clean up any hydraulic oil that may havespilled.

8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.

2-4Platform Overload System

How to Calibrate the PlatformOverload System (if equipped)

Calibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.


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5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.

PLATFORM COMPONENTS


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.


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PLATFORM COMPONENTS



Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.


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Jib Boom Components, S-85

3-1Jib Boom

How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.


1 Remove the platform. See 2-1, How to Removethe Platform.

Note: Models equipped with platform overoadsystem: If the platform overload components aredisassembled and/or removed from the platformsupport, the platform overload system will need tobe calibrated. See 2-4, How to Calibrate thePlatform Overload System.

2 Models equipped with platform overloadsystem: Tag and disconnect the electricalconnector from the platform load sense module.

3 Remove the hose and cable cover from the sideof the jib boom.

4 Remove the hose and cable clamp from the jibboom pivot pin. Lay all hoses and cables to theside.

Component damage hazard.Hoses and cables can becomedamaged if they are kinked orpinched.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Attach a lifting strap from an overhead crane tothe jib boom assembly.

7 Place blocks under the platform levelingcylinder for support. Protect the cylinder rodfrom damage.

8 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The jib boomcould fall when the slave cylinderrod-end pivot pin is removed if notproperly attached to the overheadcrane.

9 Remove the pin retaining fastener from the jibboom bellcrank to primary boom pivot pin.

10 Use a soft metal drift to remove the pin andcarefully remove the jib boom assembly fromthe primary boom.

Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.


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JIB BOOM COMPONENTS, S-85

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.


1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Attach a lifting strap from an overhead crane tothe lug at the rod end of the jib boom liftcylinder.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.


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4-1Cable Track

The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable track isnecessary when performing major repairs thatinvolve removing the boom.

How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Open the platform control box.

2 Tag and disconnect the foot switch wiring fromthe terminal strip inside the platform controlbox.

3 Loosen the squeeze connector and remove thefoot switch cable from the control box.

4 Disconnect the wire connectors from the bottomof the platform control box.

Note: When installing the wire connectors to thebottom of the platform control box, match the colorof the connectors to those on the control box to besure they are installed in the correct location.

5 Remove the mounting fasteners from the powerto platform outlet box bracket. Lay the outletbox and bracket assembly off to the side.

Boom Components

6 S-80: Tag, disconnect and plug the hydraulichoses from the counterbalance valve manifoldlocated on the platform rotator. Cap the fittingson the manifold.


7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling slave cylinder at theplatform manifold and cap the fittings.


8 Remove the timing link/timing link cam pin andgently rest the timing link against thecounterweight.

9 S-85:Remove the hose and cable cover from theside of the jib boom.

10 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate selectmanifold. Cap the fittings on the manifold.


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BOOM COMPONENTS

11 Tag, disconnect and plug the wiring from the jibboom/platform rotate select manifold.

12 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.


All models:

13 From the ground controls, raise the boom to ahorizontal position.

14 Remove the fasteners from the drive speed limitswitch bracket (LS1RS) mounted on the side ofthe boom at the platform end of the boom. Donot remove the limit switch from the bracket.

15 Remove the cotter pin from the upper cabletrack at the platform end of the boom.

Note: Always replace the cotter pin with a new one.

16 Remove the cable track guide fasteners fromthe cable track guides at the platform end of theboom. Remove the cable track guides from theboom.

17 Remove the cable clamp from the pivot end ofthe boom.

18 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

19 Attach a lifting strap from an overhead crane tothe cable track.

20 Remove the mounting fasteners that attach thelower cable track to the boom.

21 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

Component damage hazard. Thecable track can be damaged if it istwisted.


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BOOM COMPONENTS

How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.

Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 77896. The kit includes a 4-link section ofcable track.

1 Visually inspect the cable track and determinewhich 4 link section needs to be replaced.

2 Carefully remove the snap rings from each endof the damaged section of cable track.

3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.

4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

5 Remove the upper rollers from the replacementsection of cable track.

6 Lift up the hoses and cables and carefully insertthe new 4 link section of cable track.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.

8 Install the rollers onto the new section of cabletrack.

9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.


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4-2Boom

How to Shim the Boom1 Measure each wear pad.

Note: Replace the pad if thickness is less thanminimum specification. If thickness is more thanminimum specification, perform the followingprocedure. Refer to Section 3, D-1, Check theBoom Wear Pads.

2 Extend the boom until the wear pads areaccessible.

3 Loosen the wear pad mounting fasteners.

4 Install the new shims under the wear pad toobtain zero clearance and zero drag.

5 Tighten the mounting fasteners.

6 Extend and retract the boom through an entirecycle. Check for tight spots that could causebinding or scraping.

Note: Always maintain squareness between theouter and inner boom tubes.

BOOM COMPONENTS

How to Remove the BoomTIp-over hazard. This procedurerequires the removal of theturntable counterweight. Failure toremove the counterweight beforeremoving the boom assembly willresult in the machine tipping over.Do not remove the boom withoutfirst removing the counterweight.

TIp-over hazard. When installingthe boom onto the machine, theboom assembly must be firstinstalled prior to the installation ofthe counterweight. If thecounterweight is installed beforethe boom assembly, the machinewill tip over resulting in death orserious injury.

TIp-over hazard. The turntablecounterweight is essential formachine stability. Failure to installthe counterweight after installingthe boom assembly willcompromise machine stabilityresulting in the machine tippingover. Death or serious injury willresult.

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

1 Remove the jib boom. See 3-1, How to Removethe Jib Boom.

2 Remove the cable track. See 4-1, How toRemove the Cable Track.


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BOOM COMPONENTS

3 Raise the boom until the short and long link armto boom pivot pins are above the turntablecovers.

4 Place a block of wood measuring4 x 4 x 60 inches / 10 x 10 x 152 cm under thelong link arm, across the turntable covers.

5 Slowly lower the boom until the long link armcontacts the wood block. Do not rest the entireweight of the boom on the block. Turn themachine off.

Component damage hazard. Theturntable covers can becomedamaged if the weight of the boomis allowed to rest on the block.

6 Place wood blocks between the short link armand the turntable weldment for support.

7 Insert a 1.125 x 12 inches / 32 x 300 mmeye-bolt through each hole located on the topsurface of the counterweight. Secure the eye-bolts in position with flat washers and nuts.

8 Securely attach lifting straps or chains with aminimum rating of 5 tons / 5000 kg to the liftingpoints on the top of the turntable counterweight.Attach the lifting straps or chains to a5 ton / 5000 kg overhead crane.

Note: A spreader bar and other hardware may beneeded to safely remove the counterweight.

9 Slowly operate the overhead crane to applytension to the lifting straps. Do not attempt to liftthe machine with the overhead crane.

10 Locate and remove the counterweight retainingfastener at the center of the counterweight.Carefully lift the counterweight upwards andremove the counterweight from the machine.Set the counterweight on the ground. Do notleave the counterweight suspended above theground.

Crushing hazard. The turntablecounterweight will fall if notproperly supported by theoverhead crane resulting in deathor serious injury. Keep personnelaway from the area whenremoving the counterweight.

11 Attach lifting straps from a 5 ton / 5000 kgoverhead crane to each end of the boom.Support the boom. Do not apply any liftingpressure.

12 Support and secure the rod end of the boom liftcylinder to a second overhead crane or similarlifting device.

13 Remove the lift cylinder rod-end pivot pinretaining fasteners. Use a soft metal drift toremove the pin.

Crushing hazard. The boom couldfall if not properly supported whenthe lift cylinder rod-end pivot pin isremoved.


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BOOM COMPONENTS

14 Using auxiliary power, activate the boom downfunction so the cylinder will retract. Retract thecylinder just enough until the rod end of thecylinder will clear the mounting bracket on theboom. Turn the machine off.

Crushing hazard. The boom liftcylinder could fall if not properlysupported and secured to thelifting device.

15 Using the overhead crane, carefully lower theboom lift cylinder and allow it to rest on theboom rest pad. Protect the cylinder rod fromdamage.

16 Remove the boom end cover retainingfasteners and remove the cover.

17 Tag, disconnect and plug the boom extensioncylinder hydraulic hoses. Cap the fittings on thecylinder.


18 Tag and disconnect the electrical connector forthe cable break limit switch.

19 Tag and disconnect all boom wire harnesselectrical connectors located at the pivot end ofthe boom.

20 Support the platform leveling master cylinder.Remove the master cylinder rod-end pivot pinretaining fasteners. Place a rod through the pinand twist to remove. Carefully lower the mastercylinder down.

21 Tag, disconnect and plug the hydraulic hosesfrom the bulkhead fittings at the pivot end of theboom. Cap the bulkhead fittings.


22 Remove the external snap rings from both boompivot pins at the short and long link arms. Donot remove the pins.


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BOOM COMPONENTS

23 Using the overhead crane, adjust the boom asnecessary to relieve pressure from the pivotpins.

24 Use a soft metal drift to remove each boompivot pin. Carefully remove the boom assemblyfrom the machine and place it on a structurecapable of supporting it.

Crushing hazard. The boom couldfall if not properly supported by theoverhead crane when each boompivot pin is removed.

Crushing hazard. The long andshort link arms may fall if notproperly supported when theboom pivot pins are removed.

4-3Boom Lift Cylinder

The boom lift cylinder raises and lowers the boom.The boom lift cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the BoomLift Cylinder



1 Raise the boom to a horizontal position.

2 Attach a 5 ton / 5000 kg overhead crane to theboom at the platform end for support. Do not liftthe boom.

3 Support and secure both ends of the boom liftcylinder to a second overhead crane or similarlifting device.

4 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The boom willfall if not properly supported whenthe primary boom rod-end pivotpin is removed.


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BOOM COMPONENTS

5 Using auxiliary power, activate the boom downfunction so the cylinder will retract. Retract thecylinder just enough until the rod end of thecylinder will clear the mounting bracket on theboom. Turn the machine off.

6 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Remove the pin retaining fasteners from theboom lift cylinder barrel-end pivot pins. Do notremove the pins.

8 Use a slide hammer to remove the barrel-endpivot pins.

Crushing hazard. The boom liftcylinder could become unbalancedand fall if not properly supportedand secured to the lifting device.

9 Move the boom lift cylinder towards thecounterweight end of the machine. Rotate theboom lift cylinder until the barrel-end pivot pinbores will clear the boom linkage.

10 Carefully remove the boom lift cylinder from themachine.

Crushing hazard. The boom liftcylinder could become unbalancedand fall if not properly supportedand secured to the lifting device.

4-4Boom Extension Cylinder

The boom extension cylinder is located inside theboom assembly and incorporates cables andpulleys that are responsible for extending thenumber 3 boom tube. The primary boom extensioncylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove the BoomExtension Cylinder



Note: Perform this procedure with the boom fullyretracted.

1 Raise the boom to a horizontal position.


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BOOM COMPONENTS


3 Remove the access covers from both sides ofthe boom at the pivot end.

4 Fully loosen the lock nuts on the extend cables.Do not remove the nuts.

5 Loosen the retract cable nut at the platform endof the boom. Pull the cable rod from the supportand let it hang down.

6 Remove the cable guard fasteners and removethe cable guard.

7 Locate the retaining plates that secure theretract cables to the inside of the number 3boom tube.

8 Remove the cable retaining plates and pull theretract cables off of the pulleys. Lay the cablesflat and out of the way.

9 Remove the fasteners from the retaining blocksfrom the extension cylinder saddle. Remove theblocks.

Note: Access the fasteners through the accesshole in the outer boom tube at the pivot end.

10 Disconnect the wire connector to the extendcable break limit switch.

11 Remove the retaining fasteners that secure theextend cable mounting plates to the inside ofthe number 1 boom tube.

ba

a cable guardb retaining block


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BOOM COMPONENTS

a extend cable lock nutsb extend cable mounting platec extend cable mounting plate fastenerd extend cable bracket

12 Pull back on the extend cable mounting plateuntil it clears the blocks welded to the inside ofthe number 1 boom tube.

dcba

13 Lift up the extend cable mounting plate and pushthe extend cables towards the platform to createslack in the cables. Rest the cable and bracketassembly on top of the extend cylinder.

14 Locate the lower extend cable bracket on thebottom of the number 3 boom tube.

15 Remove the lower extend cable bracketmounting fasteners and pull back on thebracket to release it from the number 3 boomtube.

16 While pushing the lower extend cable brackettowards the platform, pull the extend cablemounting plate towards the pivot end of theboom.

17 Secure the extend cable bracket and cables tothe cylinder to prevent them from falling offwhen removing the cylinder.

18 Remove the external snap rings from theextension cylinder pin at the pivot end of theboom.

19 Use a soft metal drift to remove the pin.

20 Tag, disconnect and plug the boom extensioncylinder hydraulic hoses. Cap the fittings on thecylinder.



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21 Attach a lifting strap from a 5 ton / 5000 kgoverhead crane to the lug at the rod end of theboom extension cylinder.

22 Lift the boom extension cylinder with the craneuntil it clears the cylinder saddle inside thenumber 2 boom tube.

23 Carefully support and slide the extensioncylinder out of the boom.

Crushing hazard. The extensioncylinder could fall when removedfrom the boom if not properlysupported.

Component damage hazard. Becareful not to damage the cablebreak limit switch.

Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe boom.

Note: During removal of the extension cylinder, theoverhead crane strap will need to be carefullyadjusted for proper balancing.

4-5Boom Extend/Retract Cables

How to Adjust the Boom Extend/Retract CablesThe boom extend/retract cables are responsible forthe extension and retraction of the number 3 boomtube. Proper adjustment of the boom extend/retractcables and related components on a regular basisis essential to good machine performance and safemachine operation. The boom extend and retractfunctions should operate smoothly and be free ofhesitation, jerking and unusual noise.

Note: Perform this procedure with the boom in ahorizontal position.

1 Start the engine from the Ground Controls.

2 Raise the boom to a horizontal position

3 Fully retract the boom.

4 Stop the engine.


6 Inspect the threaded ends of the boom extendcables. The threads must be clean and in goodcondition with no damaged threads.

BOOM COMPONENTS


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Illustration 1

6.375 inches / 16.2 cm

BOOM COMPONENTS

7 Locate the retract cable adjustment nut on thebottom of the number 1 boom tube at theplatform end of the boom. Loosen the nut, butdo not remove the nut.

8 Locate the extend cable adjustment nuts on thecounterweight end of boom tube #1. Refer toIllustration 2. Loosen the nylock nuts and jamnuts on the cable tension equalizer bracket. Donot remove the nuts.

9 Adjust the extend cable adjustment nut to obtain6 3/8 inches/16.2 cm to 6 1/2 inches/16.5 cmbetween the platform end of boom tube #2 andboom tube #3. Refer to illustration 1. Thereshould be approximately 1/2 inch of exposedthreads on the adjustment bolts. Refer toIllustration 2.

Note: If the cables have been replaced, be sure theadjustment nuts have been replaced. Do not re-use the existing nuts.

10 Extend the boom until there is approximately 3feet / 1 m of travel left. Do not fully extend theboom.

11 Locate the retract cable adjustment nut on thebottom of the number 1 boom tube at theplatform end of the boom.

12 Using a dial type torque wrench, torque theretract cable adjustment nut to 32-36 ft lbs /43-49 Nm using gentle and steady torque.

13 Retract and extend the boom approximately3 feet / 1 m two times and stop during theextension cycle. This will create slack in theretract cables.

Note: Be sure to not fully extend the boom. Stopwhen there is approximately 3 feet / 1 m oftravel left.

14 Repeat steps 12 and 13 two to three times.

15 Fully extend the boom then retract the boomapproximately 12 inches / 30 cm.

16 At the pivot end of the boom, visually inspectthe boom extend cables for even cable droop orsag.

Note: If the boom extend cables are uneven,tighten the boom extend cable adjustment nut atthe pivot end of the boom for the appropriate cable.


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17 Visually inspect the cable break limit switch armto be sure the wheel of the limit switch arm iscentered in the notch of the pivot plate.

Note: If the boom extend cables are adjustedevenly, the wheel of the limit switch arm should becentered in the notch of the pivot plate.

Illustration 2

a cable break limit switchb extend cable adjustment nutc extend cable pivot plate

18 Install the boom end cover at the pivot end ofthe boom.

19 Fully retract and lower the boom to the stowedposition.

How to Replace the BoomExtend/Retract CablesNote: The cable pulleys must also be replacedwhen replacing the cables.

1 Remove the boom extension cylinder. SeeSection 4-4, How to Remove the BoomExtension Cylinder.

Boom extend cables:

2 Remove the cables from the lower boom extendcable bracket that attaches to the number 3boom tube.

3 Remove the rue rings and clevis pins from theboom extend cables located near the extendcable break limit switch.

4 Remove the external snap rings from the boomextend cable pulley pivot pin. Use a soft metaldrift to remove the pin.

Note: When driving the pivot pin out, be sure todrive it from the shaped end of the pin.

5 Remove the pulley and boom extend cablesfrom the extension cylinder assembly. Discardthe old cables and pulleys.

6 Route the new boom extend cables through theboom extend pulley bracket.

7 Install the new boom extend cable pulley, pivotpin and snap rings.

Note: Be sure the boom extend cables are routedthrough the grooves of the pulley and the upperwear pad on the extension cylinder.

a

cb

BOOM COMPONENTS


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8 Install the boom extend cable clevis pins andrue rings to the pivot plate near the cable breaklimit switch.

9 Install the boom extend cables to the lowerextend cable bracket that mounts to the number3 boom tube.

Boom retract cables:

10 Remove the rue rings and clevis pins from theboom retract cables at the platform end of theboom.

11 Attach the cable pulling tool or a rope to one ofthe boom retract cables at the pivot end of theboom.

Note: A cable pulling tool is available throughGenie Service Parts Department (Genie part no.94510)

12 At the platform end of the boom, pull on theboom retract cable that has the rope attachedto it.

13 Pull the old cable completely out of the boomtube. Remove the rope. Discard the old boomretract cable.

14 Securely attach the rope to the same end of thenew boom retract cable.

15 At the pivot end of the boom, carefully pull therope with the new retract cable attached.

16 Pull the new cable towards the pivot end of theboom until the end of the cable is at the end ofthe boom tube. Remove the rope.

17 Repeat steps 14 through 19 for the other boomretract cable.

18 At the platform end of the boom, install theretract cables, clevis pins and rue rings to theadjustment plate.

19 Remove and discard the old boom retractpulleys from the pivot end of the boomextension cylinder.

20 Install the new boom retract pulleys to the pivotend of the boom extension cylinder.

21 Install the boom extension cylinder assemblyinto the boom.

Note: Before lowering the extension cylinder intothe saddles of the number 1 boom tube, wrap theboom retract cables around the pulleys.

22 Adjust the boom extend/retract cables.See Section 4-5, How to Adjust the BoomExtend/Retract Cables.

BOOM COMPONENTS


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BOOM COMPONENTS

4-6Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed loop hydrauliccircuit that keeps the platform level through theentire range of boom motion. The master cylinderis located inside the pivot end of the boom.

How to Remove the PlatformLeveling Master CylinderNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Raise the boom until the master cylinderrod-end pivot pin is accessible.

2 Remove the turntable end cover to access themaster cylinder.

3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


4 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin.

5 Place a rod through the barel-end pivot pin andtwist to remove the pin.

6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

7 Remove the pin retaining fastener from therod-end pivot pin.

8 Place a rod through the rod-end pivot pin andtwist to remove the pin.

9 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properlysupported by the lifting devicewhen removed from the machine.


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5-1RPM Adjustment

Refer to Maintenance Procedure B-10,Check and Adjust the Engine RPM.

Engines

5-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drive thepump.

Type "B" flex plates combines the pump coupler,as part of the flex plate, which is installed onto theengine flywheel.

Type "B"(flexplate with

coupler combined)


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ENGINES

How to Remove the Flex PlateNote: Perform this procedure with the engine offand cool to the touch.

1 Open the engine side turntable cover.

2 Tag and disconnect the battery cables from thebattery(s).


3 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.

a engine tray anchor holeb engine tray retaining fastener

4 Tag and disconnect the wiring plug at theelectronic displacement controller (EDC),located on the drive pump.

a b

Deutz model:

5 Tag and disconnect the wiring from the bellhousing.

6 Remove the U-bolt from the exhaust flex pipe atthe muffler.

Burn hazard. Hot engine parts cancause severe burns.

7 Remove the muffler bracket retaining fastenersfrom bell housing. Remove the muffler andbracket assembly from the engine.

8 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing engine fasteners.

9 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched

10 Remove the flex plate mounting fasteners,and remove the flex plate from the engineflywheel.


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ENGINES

Perkins model:

11 Tag and disconnect the wiring from the bellhousing.

12 Remove the exhaust pipe clamp at the muffler.

Burn hazard. Hot engine parts cancause severe burns.

13 Remove the muffler mounting bracket fasteners.Remove the muffler and bracket assembly fromthe engine.

14 Remove the hose clamps from the air cleanerelbow and the engine intake manifold.

15 Remove the air cleaner mounting bracketfasteners. Remove the air cleaner and bracketassembly from the engine.

16 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing to engine fasteners.

Continental model:

17 Tag and disconnect the wire harness from theoxygen sensor.

18 Remove the exhaust pipe heat shield fastenersfrom the top of the muffler.

Burn Hazard. Hot engine parts cancause severe burns.

19 Remove the muffler retainer bracket fasteners.

20 Remove the muffler fasteners securing themuffler to the exhaust manifold. Remove themuffler from the bracket.

21 Remove the relay housing from the mufflermount. Do not disconnect the relays.

22 Disconnect and remove the ECM from themuffler mount.

23 Close the shutoff valve on the Liquid PetroleumGas (LPG) tank by turning it clockwise(if equipped).

24 Unbolt the EPR valve from the muffler mount.Leave the hoses attached to the EPR valve.

25 Remove the muffler mount.

26 Support the drive pump with an appropriatelifting device. Remove all of pump platemounting fasteners.

27 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

28 Remove the flex plate mounting fasteners.Remove the flex plate from the engine flywheel.


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ENGINES

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump. ApplyLoctite® removable thread sealant to themounting screws.

Note: Torque the flex plate mounting bolts in twostages.

Continental model: Torque the flex platemounting bolts in sequence to20.8 ft-lbs / 28 Nm.Deutz model: Torque the flex plate mountingbolts in sequence to 28 ft-lbs / 38 Nm.Perkins model:Torque the flex plate mounting bolts insequence to 46.7 ft-lbs / 63.3 Nm.

2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

3 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

4 Install the pump onto the pump mounting plate.

Apply Loctite® removable thread sealant to thepump retaining fasteners. Torque the pumpretaining fasteners to 57 ft-lbs / 77 Nm.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

5 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

6 Install the pump and pump mounting plateassembly onto the engine. Apply Loctite®

removable thread sealant to the mountingscrews.Perkins model:Torque the pump mounting plate fasteners insequence to 28 ft-lbs / 38 Nm.Deutz model:Torque the pump mounting plate fasteners insequence to 46.7 ft-lbs / 63.3 Nm.Continental model:Torque the pump mounting plate fasteners insequence to 23 ft-lbs / 31.2 Nm.

Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.


Part No. 122985 S-80 • S-85 • S-80X 4 - 37

September 2015

ENGINES

1

2

3

4 5

6

Perkins, Deutz and ContinentalFlex Plate

10

6 1

8

4

11

7 5

92

12

3

10

6 1

8

4

11

7 5

92

12

3

Deutz BF4L-2011Pump Mounting Plate

Perkins 804C-33Pump Mounting Plate

1

8

6

10

11 12

3

5

92

7

4

Continental Pump Mounting Plate


4 - 38 S-80 • S-85 • S-80X Part No. 122985

September 2015

Ground Controls

6-1Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay


1 Tag and disconnect all the wiring from the relayto be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.

Test Desired result

terminal 85 to 86 with resistor 75 to 85Ω

terminal 87 to 87a and 30 no continuity

(infinite Ω)

terminal 87a to 30 continuity

(zero Ω)

3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87 to 87a and 30 no continuity(infinite Ω)

terminal 87 to 30 continuity

(zero Ω)

terminal no. 87a - N.C.terminal no. 85 - coil negative (-)terminal no. 30 - commonterminal no. 86 - coil positive (+)terminal no. 87 - N.O.

Control Relay Schematic


Part No. 122985 S-80 • S-85 • S-80X 4 - 39

September 2015

2 Tag, disconnect and plug the hydraulic hosesfrom the function pump. Cap the fittings on thepump.


3 Remove the pump mounting fasteners.Carefully remove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves (if equipped) andprime the pump after installing thepump. See 7-2, How to Prime thePump.

Hydraulic Pumps

7-1Function Pump

How to Remove the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

open closed


4 - 40 S-80 • S-85 • S-80X Part No. 122985

September 2015

HYDRAULIC PUMPS

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the wire harness at the electronicdisplacement controller (EDC), located on thedrive pump.

2 Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

open closed


Part No. 122985 S-80 • S-85 • S-80X 4 - 41

September 2015

3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.


4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump assembly from themachine.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

Note: Before installing the pump, verify properpump coupler spacing. See 5-2, Flex Plate.

How to Prime the PumpComponent damage hazard. Besure that the hydraulic tank shutoffvalves (if equipped) are in theopen position before priming thepump. The engine must not bestarted with the hydraulic tankshutoff valves in the closedposition or component damage willoccur.

1 Connect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Continental models: If equipped, close thevalve on the LPG tank, then disconnect thehose from the tank. Move the fuel select toggleswitch to the LPG position.Deutz and Perkins models: Disconnect theengine wiring harness from the fuel solenoid atthe injector pump.

3 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 300 psi / 20.7 bar.

4 Continental models: If equipped, connect theLPG hose to the LPG tank and open the valveon the tank.Deutz and Perkins models: Connect theengine wiring harness to the fuel solenoid.

5 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS


4 - 42 S-80 • S-85 • S-80X Part No. 122985

September 2015

Manifolds

8-1Function Manifold Components

The function manifold assembly is located on the tank side tray, behind the ground control box.

Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 2 position 3 way ...... SJ ......... Boom up ........................................... 50-55 ft-lbs / 68-75 Nm

2 Solenoid valve, 2 position 3 way ...... SK ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm

3 Solenoid valve, NO, Poppet .............. SP ......... Extend ............................................... 33-37 ft-lbs / 45-50 Nm

4 Solenoid valve, NO, Poppet .............. SQ ........ Retract .............................................. 33-37 ft-lbs / 45-50 Nm

5 Proportional valve ............................. SR ........ Extend proportional .......................... 20-25 ft-lbs / 27-34 Nm

6 Differential sensing valve .................. SS ......... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm

7 Proportional valve ............................. SF ......... Boom up/down proportional ............. 33-37 ft-lbs / 45-50 Nm

8 Solenoid valve, 3 position, 4 way ..... SL ......... Steering directional .......................... 20-25 ft-lbs / 27-34 Nm

9 Proportional valve ............................. SE ......... Swing proportional ........................... 20-25 ft-lbs / 27-34 Nm

10 Solenoid valve, 3 position, 4 way ..... SI .......... Swing directional .............................. 26-30 ft-lbs / 35-41 Nm

11 Flow regulator valve .......................... SD ........ Oscillate flow control ........................ 20-25 ft-lbs / 27-34 Nm

12 Relief valve, 2400 psi / 165 bar ........ SN ........ Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm

13 Relief valve, 2400 psi / 165 bar ........ SO ........ Boom extend relief ........................... 20-25 ft-lbs / 27-34 Nm

14 Check valve, 30 psi / 2.1 bar ............. ST ......... Return check valve ........................... 30-35 ft-lbs / 41-47 Nm

15 Differential sensing valve .................. SH ........ Primary lift ......................................... 30-35 ft-lbs / 41-47 Nm

16 Check valve ....................................... SA ......... Back flow / check function pump ...... 30-35 ft-lbs / 41-47 Nm

17 Relief valve, 3200 psi / 221 bar ........ SB ......... System relief ..................................... 20-25 ft-lbs / 27-34 Nm

18 Pressure reducing valve ................... SC ........ Oscillate pressure control ................. 30-35 ft-lbs / 41-47 Nm

19 Differential sensing valve .................. SG ........ Differential sensing/turntable rotate . 30-35 ft-lbs / 41-47 Nm

20 Flow regulator valve .......................... SM ........ Steering flow control ......................... 20-25 ft-lbs / 27-34 Nm


Part No. 122985 S-80 • S-85 • S-80X 4 - 43

September 2015

MANIFOLDS

SK

SP

SQ

SR

SS

SF

SL

SE

SI

SD

SO

ST

SM

SG

SC

SB

SA

SH

SJ

SN

1

14

1

2

3

4

8

9

10

11

13

12

16

17

18

19

20

15

7

6

5


4 - 44 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

8-2Valve Adjustments -Function Manifold

How to Adjust the SystemRelief ValveNote: Perform this procedure with the boom in thestowed position.

Note: Auxiliary power will be used to perform thisprocedure. Do not start the engine.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple (PTEST) locatednext to the auxiliary pump.

2 Simultaneously activate and hold the auxiliarypower toggle switch and the primary boomretract toggle switch with the primary boom fullyretracted. Observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

3 Locate the system relief valve on the functionmanifold (item SB). Use a wrench to hold therelief valve and remove the cap using an allenwrench.

4 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counter clockwise toreduce the pressure. Install the relief valve cap.

Component damage hazard. Donot adjust the relief valve higherthan specified.

5 Repeat step 2 to confirm relief valve pressure.

6 Remove the pressure gauge.

How to Adjust the Boom DownRelief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the diagnostic nipple located next tothe auxiliary pump.


3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom down toggle switch with theboom fully lowered. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item SN) onthe function manifold.

5 Adjust the internal hex socket. Turn it clockwiseto increase pressure or counterclockwise todecrease pressure. Install the relief valve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 and confirm reliefvalve pressure.


Part No. 122985 S-80 • S-85 • S-80X 4 - 45

September 2015

How to Adjust the Boom ExtendRelief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 3000 psi / 0 to 200 bar pressuregauge to the diagnostic nipple (PTEST port) on thefunction manifold.


3 Hold the function enable/rpm select toggleswitch to the high idle position and activate andhold the boom extend toggle switch with theboom fully extended. Observe the pressurereading on the pressure gauge. Refer toSection 2, Hydraulic Specifications.

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item SO) onthe function manifold.

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

6 Repeat steps 2 through 5 to confirm relief valvepressure.

MANIFOLDS


4 - 46 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

8-3Brake/Two-Speed Manifold Components

The brake/two speed manifold is mounted inside the drive chassis.Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 2 position 3 way .... BA ........... Brake release .................................... 20-25 ft-lbs / 27-34 Nm

2 Solenoid valve, 2 position 3 way .... BC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm

3 Check valve .................................... BB ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm

4 Orifice, 0.025 inch / 0.63 mm ......... BD ........... Turntable rotation brake release

BD

BA BC

BB3

4

1 2


Part No. 122985 S-80 • S-85 • S-80X 4 - 47

September 2015

8-4Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor at the ground control sideof the machine.


1 Counterbalance valve, 1000 psi ....... RA ........ Turntable rotate left ........................... 25-30 ft-lbs / 34-41 Nm

2 Counterbalance valve, 1000 psi ....... RB ........ Turntable rotate right ........................ 25-30 ft-lbs / 34-41 Nm

3 Shuttle valve, 2 position 3 way ......... RD ........ Turntable rotation brake release ........ 8-10 ft-lbs / 10-15 Nm

4 Orifice, 0.030 inch / 0.8 mm ............... RC ........ Brake release circuit

MANIFOLDS

1 2

RA

RD

RB

4RC

3


4 - 48 S-80 • S-85 • S-80X Part No. 122985

September 2015

8-5Platform Rotate Manifold Components

The platform rotate manifold is mounted on the platform rotator.


1 Counterbalance valve, 3300 psi ........ PA ......... Platform rotate right .......................... 37-44 ft-lbs / 50-60 Nm

2 Counterbalance valve, 3300 psi ........ PB ......... Platform rotate left ............................. 37-44 ft-lbs / 50-60 Nm

2

1

PB

PA

MANIFOLDS


Part No. 122985 S-80 • S-85 • S-80X 4 - 49

September 2015

MANIFOLDS

8-6Platform Manifold Components, S-80

The jib boom/platform rotate manifold is mounted on the platform end of the boom.


1 Solenoid valve, 3 position 4 way ...... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm

2 Solenoid valve, 3 position 4 way ...... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm

3 Counterbalance valve, 3500 psi ....... EC ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm

4 Counterbalance valve, 3500 psi ....... ED ........ Platform level CB valve .................... 26-30 ft-lbs / 35-41 Nm

5 Needle valve ..................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm

6 Pressure comp., flow control valve ... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm

EF

EB

EC

ED

EA

EE

3

5

6

1

2

4


4 - 50 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

EF

EB

EC

ED

EA

EE

EH

EG

1

2

3

4

5

6

8

7

8-7Platform Manifold Components, S-85

The jib boom/platform rotate manifold is mounted on the platform end of the boom.


1 Solenoid valve, 3 position 4 way ....... EF ......... Platform rotate CW/CCW .................. 30-35 ft-lbs / 41-47 Nm

2 Solenoid valve, 3 position 4 way ....... EB ......... Platform level up/down ..................... 30-35 ft-lbs / 41-47 Nm

3 Solenoid valve, 3 position 4 way ....... EH ........ Jib Up/Down...................................... 30-35 ft-lbs / 41-47 Nm

4 Counterbalance valve, 3500 psi ........ EC ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm

5 Counterbalance valve, 3500 psi ........ ED ........ Platform level CB valve ..................... 26-30 ft-lbs / 35-41 Nm

6 Needle valve ...................................... EA ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm

7 Pressure comp., flow control valve.... EE ......... Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm

8 Pressure comp., flow control valve.... EG ........ Platform rotate flow control ............... 33-37 ft-lbs / 45-50 Nm


Part No. 122985 S-80 • S-85 • S-80X 4 - 51

September 2015

8-82WD Traction Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.


1 Relief Valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm

2 Flow Divider / Combiner Valve ......... DB ........ Controls flow to drive motors in.......................................................................... forward and reverse .................... 90-100 ft-lbs / 120-133 Nm

3 Check Valve ...................................... DC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

4 Check Valve ...................................... DD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

5 Shuttle Valve, 3 position 3 way ......... DF ......... Controls flow to drive motors in.......................................................................... forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm

6 Orifice Plug, 0.070 inch / 1.8 mm ...... DA ........ Equalizes flow across flow divider/.......................................................................... combiner valve BY

MANIFOLDS


4 - 52 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

DE

DB

DC

DD

DF

DA6

2

5

3

4

1


Part No. 122985 S-80 • S-85 • S-80X 4 - 53

September 2015

8-94WD Traction Manifold Components (before serial number 8581)



1 Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm

2 Flow divider/combiner valve ............. DB ........ Controls flow to non-steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

3 Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm

4 Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm

5 Flow divider/combiner valve ............. CK ........ Controls flow to flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm

6 Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm

7 Orifice, 0.040 inch / 1 mm.................. DL ......... Equalizes pressure on both sidesof flow divider/combiner valve 5

8 Orifice, 0.040 inch / 1 mm.................. DA ........ Equalizes pressure on both sidesof flow divider/combiner valve 2

9 Orifice, 0.040 inch / 1 mm.................. DN ........ Equalizes pressure on both sidesof flow divider/combiner valve 13

10 Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm

11 Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm

12 Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ........................ 80-90 ft-lbs / 108-122 Nm

13 Flow divider/combiner valve ............. DM ........ Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

14 Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm

MANIFOLDS


4 - 54 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

DE

DB

DF

DC

DK

DD

DLDADN

DG

DH

DJ

DM

DP

9 8 7

10

11

13

6

5

3

2

4

1

14

12


Part No. 122985 S-80 • S-85 • S-80X 4 - 55

September 2015

8-104WD Traction Manifold Components (after serial number 8580)



1 Relief valve, 280 psi / 19.3 bar ......... DE ........ Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm

2 Flow divider/combiner valve ............. DB ........ Controls flow to non-steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

3 Check valve ....................................... DF ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm

4 Check valve ....................................... DC ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm

5 Flow divider/combiner valve ............. CK ........ Controls flow to flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm

6 Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm

7 Orifice, 0.040 inch / 1 mm.................. DL ......... Equalizes pressure on both sidesof flow divider/combiner valve 5

8 Orifice, 0.040 inch / 1 mm.................. DA ........ Equalizes pressure on both sidesof flow divider/combiner valve 2

9 Orifice, 0.040 inch / 1 mm.................. DN ........ Equalizes pressure on both sidesof flow divider/combiner valve 13

10 Check valve ....................................... DG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm

11 Check valve ....................................... DH ........ Steer end drive motor circuit ............ 35-40 ft-lbs / 48-54 Nm

12 Shuttle valve, 3 position 3 way ......... DJ ......... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ........................ 80-90 ft-lbs / 108-122 Nm

13 Flow divider/combiner valve ............. DM ........ Controls flow to steer enddrive motors in forwardand reverse ................................... 80-90 ft-lbs / 108-122 Nm

14 Check valve ....................................... DP ........ Non-steer end drive motor circuit ..... 35-40 ft-lbs / 48-54 Nm

MANIFOLDS


4 - 56 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

DE

DB

DF

DC

DD

DK

DLDADN

DG

DH

DJ

DM

DP

9 8 7

10

11

13

6

5

3

2

4

1

14

12


Part No. 122985 S-80 • S-85 • S-80X 4 - 57

September 2015

MANIFOLDS

8-11Drive Oil Diverter Manifold Components (welder option)

The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.


1 Directional Valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm

2 Orifice disc, 0.031 inch / 0.8 mm .... CV ........... Delays shift to drive

3 Solenoid valve ............................... CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm

4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm

5 Pressure switch .............................. CZ ........... Power to relay .............................................. 16 ft-lbs / 22 Nm

6 Connector ........................................ --- ............ For pressure switch ..................................... 11 ft-lbs / 15 Nm

7 Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm

CY

CX

CU

CV

CW

1

3

4

7

2

6

5CZ


4 - 58 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

8-12Valve Adjustments -Traction Manifold

How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in thetraction manifold) is necessary to return hot oilfrom the closed loop drive circuit to the hydraulictank for cooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.

Note: The following procedure will require twopeople.

1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 40 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Start the engine from the platform controls andallow the engine to run at low idle. Note thepressure reading on the pressure gauge.

3 Turn the engine off and connect a0 to 600 psi / 0 to 40 bar pressure gauge to thediagnostic nipple located on the tractionmanifold.

4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item BJ). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.

6 Repeat steps 4 and 5 until a pressuredifferential (between the charge pump readingand the hot oil shuttle relief valve) of40 psi / 14.5 bar is obtained.


Part No. 122985 S-80 • S-85 • S-80X 4 - 59

September 2015

Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.8°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Proportional solenoid valve 4.8 Ω(schematic items K and W)

2 position 3 way solenoid valve 6.3 Ω(schematic items D, R, X, TT and UU)

2 position 3 way solenoid valve 3.3 Ω(schematic items G)

3 position 4 way solenoid valve 6.3 Ω(schematic items A, E, N and S)

2 position 3 way solenoid valve 6.3 Ω(schematic items AK, AM, VV and WW)

2 position 3 way solenoid valve 3.3 Ω(schematic item G)

8-13Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infinite resistanceindicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification canproduce erratic operation. When coil resistancedecreases below specification, amperageincreases. As resistance rises above specification,voltage increases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.


Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil tobe tested.

2 Test the coil resistance using a multimeter setto resistance (Ω). Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.

MANIFOLDS


4 - 60 S-80 • S-85 • S-80X Part No. 122985

September 2015

MANIFOLDS

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.


1 Test the coil for resistance. Refer to, How toTest a Coil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Note: The battery should read 9V DC or morewhen measured across the terminals.

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DCcurrent, should be capable of reading up to 800mA.

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate a reversedconnection as specified in step 6.

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

9VBATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

d

a

b

b

c

c


Part No. 122985 S-80 • S-85 • S-80X 4 - 61

September 2015

Fuel and Hydraulic Tanks

9-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

1 Turn the manual fuel shutoff valve to theclosed position (if equipped).

2 Remove the fuel filler cap from the tank.

3 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer tocapacity specifications.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Note: Be sure to only use a hand operated pumpsuitable for use with gasoline and diesel fuel.

4 Tag, disconnect, drain and plug the supply andreturn fuel hoses. Cap the fittings on the fueltank.

5 Remove the fuel tank retaining fasteners.

6 Remove the fuel tank from the machine.

Component damage hazard.The fuel tank is plastic and maybecome damaged if allowed to fall.

Component damage hazard.When installing the plastic fueltank, do not overtighten theretaining fasteners.

Note: Clean the fuel tank and inspect for damagebefore installing it onto the machine.


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FUEL AND HYDRAULIC TANKS

9-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and de-aerate the hydraulic fluid duringoperation. The tank utilizes internal suctionstrainers for the pump supply hoses and has anexternal return filter equipped with a filter conditionindicator.

How to Remove theHydraulic Tank

Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.


1 Remove the fuel tank. See 9-1, How to Removethe Fuel Tank.

2 Close the two hydraulic tank valves located atthe hydraulic tank (if equipped).

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe CLOSED position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.

4 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tank.

5 Tag and disconnect and plug the hose from thereturn filter. Cap the fitting on the return filterhousing.

6 Tag and disconnect and plug the supply hosefor the auxiliary power unit. Cap the fitting onthe hydraulic tank.

open closed


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7 Remove the retaining fasteners from thehydraulic tank hold down straps. Remove thehold down straps from the hydraulic tank.

8 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an overheadcrane.

9 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedand secured to the overheadcrane.

10 Remove the suction strainers from the tank andclean them using a mild solvent.

11 Rinse out the inside of the tank using a mildsolvent.

12 Install the suction strainers using pipe threadsealant on the threads.

13 Install the drain plug using pipe thread sealanton the threads.

14 Install the hydraulic tank onto the machine.

15 Install the two suction hoses and the supplyhose for the auxiliary power unit.

16 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

FUEL AND HYDRAULIC TANKS


18 Open the hydraulic tank shutoff valves(if equipped).

Component damage hazard.Be sure to open the two hydraulictank shutoff valves (if equipped)and prime the pump after installingthe hydraulic tank.

Note: Always use pipe thread sealant wheninstalling the drain plug and strainers.


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a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts

5 Remove the backlash pivot plate mountingbolts. Carefully remove the drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotation drive hub assembly couldbecome unbalanced and fall whenit is removed from the machine ifnot properly supported.

When installing the drive hub assembly:

6 Install the drive hub. Apply removable threadlocking compound to fastener threads.Torquethe backlash pivot plate mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.

7 Install the brake and then the motor onto thedrive hub. Apply removable thread lockingcompound to fastener threads.Torque themotor/brake mounting fasteners tospecification. Refer to Section 2, MachineTorque Specifications.

8 Adjust turntable rotation gear backlash.See 10-1, How to Adjust the Turntable RotationGear Backlash.

10-1Turntable Rotation Drive HubAssembly

How to Remove the TurntableRotation Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.


2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.


3 Loosen the backlash pivot plate and adjustmentbolts.

4 Attach a suitable lifting device to the lifting eyeson the drive hub assembly.

Turntable Rotation Components

unlocked locked

AB a

c

b


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TURNTABLE ROTATION COMPONENTS

How to Remove the TurntableRotation Hydraulic MotorNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.



2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on themotor.


3 Remove the hydraulic tube that connects fromthe counterbalance manifold to the brake. Capthe fittings on the brake and manifold.


4 Remove the motor/brake mounting fasteners.Carefully remove the motor from the brake.


a motorb drive hub mounting boltsc drive hub with brake

a

AB

c b


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How to Adjust the TurntableRotation Gear BacklashThe turntable rotation drive hub is mounted on anadjustable plate that controls the gap between therotation motor pinion gear and the turntable bearingring gear.

Note: Perform this procedure with the boombetween the non-steer end tires and with themachine on a firm and level surface.



2 Loosen the backlash pivot plate mountingfasteners.

a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts

3 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation gear into the turntable bearing ringgear).

4 Loosen the lock nut on the adjustment bolt.

5 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.

6 Turn the adjustment bolt one half turncounterclockwise. Tighten the lock nut on theadjustment bolt.

7 Rotate the backlash pivot plate away from theturntable until it contacts the adjustment bolt.Then torque the mounting fasteners on thebacklash 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.

TURNTABLE ROTATION COMPONENTS

AB a

c

b


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11-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the pin retaining fasteners from both

the steering cylinder and the tie rod cylinderpivot pins. Use a soft metal drift to remove thepins.

2 Loosen the wheel lug nuts. Do not removethem.

3 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.

4 Raise the machine approximately6 inches / 15 cm and place blocks under thechassis for support.

5 Remove the lug nuts. Remove the tire andwheel assembly.

6 Remove the pin retaining fasteners from theyoke pivot pins.

7 Support and secure the yoke and hub assemblyto a lifting jack.

8 Use a slide hammer to remove the upper yokepivot pin, then use a soft metal drift to drive thelower yoke pivot pin down and out.

9 Remove the yoke and hub assembly from themachine.

Crushing hazard. The yoke andhub assembly may becomeunbalanced and fall if not properlysupported and secured to thelifting jack when it is removed fromthe machine.

How to Remove the Huband Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.



5 Remove the dust cap, cotter pin and castle nut.

Note: Always replace the cotter pin with a new onewhen installing the castle nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.


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2WD STEER AXLE COMPONENTS

How to Install the Hub andBearings, 2WD ModelsNote: When replacing a wheel bearing, both theinner and outer bearings including the pressed-inraces must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearing.

Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.

8 Loosen the castle nut one turn, and then torqueto 35 ft-lbs / 47 Nm.

9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.

Note: Always use a new cotter pin when installinga castle nut.

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

11-2Steer Cylinder

How to Remove aSteer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.


2 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.

3 Remove the steer cylinder from the machine.


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7 Remove the hydraulic hose clamp retainingfastener from the top of the yoke pivot pin.

8 Remove the drive motor mounting fasteners.

9 Slide the drive motor shaft out of the drive huband remove the drive motor from the machine.

10 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

11 Support and secure the yoke and drive hubassembly to a lifting jack.

12 Use a slide hammer to remove the upper yokepivot pin. Use a soft metal drift to drive thelower yoke pivot pin down and out.

Crushing hazard. The yoke anddrive hub assembly could becomeunbalanced and fall when the yokepivot pins are removed if notproperly supported and secured tothe lifting jack.

13 Place the yoke and drive hub assembly on a flatsurface with the drive hub facing down.

14 Remove the drive hub mounting fasteners thatattach the drive hub to the yoke. Remove theyoke from the drive hub. Refer toSection 2, Specifications.

Note: Replace the thrust washer when installingthe yoke and drive hub assembly onto the axle.


12-1Yoke and Drive Hub

How to Remove the Yokeand Drive Hub AssemblyNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the pin retaining fasteners from boththe steer cylinder and the tie rod cylinder pivotpins. Remove the pins.

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.



4 Block the non-steer wheels, and center a liftingjack of ample capacity under the steer axle.



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12-2Drive Motor

How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSauer dealer.

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Extend the axles.

2 Remove the drive motor access covers fromboth sides of the inner axle.

3 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


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.Refer to Section 2, Specifications.


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12-4Steer Cylinders

How to Remove a Steer CylinderThere are two identical steer cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod cylinder maintains equal movement ofthe tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.


2 Remove the hose bracket mounting fastener onthe steer cylinder barrel-end pivot pin.

3 Remove the pin retaining fasteners from thesteer cylinder pivot pins. Remove the pivot pinfrom each end of the steer cylinder.

4 Remove the steer cylinder from the machine.

12-3Drive Hub

How to Remove a Drive HubNote: When removing a hose assembly or fitting,the O-ring (if equipped) on the fitting and/or thehose end must be replaced. All connections mustbe torqued to specification during installation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the drive motor. See 12-2, How toRemove a Drive Motor.


3 Center a lifting jack of ample capacity under thenon-steer axle.


5 Remove the wheel lug nuts, then the tire andwheel assembly.

6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.

7 Remove the drive hub mounting fasteners thatattach the drive hub to the axle. Remove thedrive hub.

Crushing hazard. The drivehub could become unbalancedand fall if not properly supportedand secured to the lifting jackwhen removed from the machine.

Note: Do not re-use the drive hub mountingfasteners. Genie specifications require the use ofnew fasteners.



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Non-steer Axle Components

13-1Drive Motor

How to Remove a Drive MotorThis procedure is the same as the steer axleprocedure. See 12-2, How to Remove a DriveMotor.

13-2Drive Hub

How to Remove a Drive HubThis procedure is the same as the steer axleprocedure. See 12-3, How to Remove a Drive Hub.


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September 2015

Oscillating Axle Components

14-1Oscillate Axle Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the axle to maintaina level chassis while driving over uneven terrain.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic hose failure.

How to Remove an Oscillate AxleCylinderNote: Perform this procedure on firm, level surfacewith the boom in the stowed position.


1 Rotate the turntable until the boom is betweenthe steer tires.

2 Remove the fasteners from the drive chassiscover at the steer end. Remove the cover.

3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on thecylinder.


4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

7 Remove the cylinder from the machine.

Crushing hazard. The oscillatecylinder could become unbalancedand fall if not properly attached tothe overhead crane whenremoved from the machine.


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OSCILLATING AXLE COMPONENTS

14-2Oscillate Directional Valve

How to Adjust the OscillateRelief Valve Pressure1 Connect a 0 to 2000 psi / 0 to 150 bar pressure

gauge to the diagnostic nipple located on thefunction manifold.

2 Remove the drive chassis cover from the non-steer end of the machine.

3 Disconnect the directional valve linkage, byremoving the clevis yoke from the drivechassis. Refer to illustration 1.

a oscillate valveb clevis yokec drive chassis

4 Start the engine from the ground control.

5 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

6 Turn the engine off.

7 Locate the relief valve on the function manifold(item SC).

8 Loosen the jam nut on the relief valve.

9 Turn the valve clockwise to increase thepressure or counterclockwise to decrease thepressure.

Tip-over hazard. Do not adjust therelief valve higher than specified.

10 Tighten the jam nut.

11 Repeat steps 4 through 10 to confirm theoscillate relief valve pressure.

Note: The oscillate pressure required is while theoscillate cylinders are in motion. Do not dead headthe cylinders to either side.

12 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.

13 Install the cover on the non-steer end of thedrive chassis.

a

b

c


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How to Set Up the DirectionalValve LinkageNote: Perform this procedure on a firm, levelsurface.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the surfacethe machine is on is completely level.

Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldresult in the machine tipping over.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

4 Remove the drive chassis cover from thenon-steer end of the machine.

5 Disconnect the linkage clevis yoke from theaxle.

6 Place a "bubble type" level on the turntablerotate bearing plate at the non-steer end.Confirm whether the drive chassis is completelylevel.

7 If the drive chassis is not level, start the engineand push up or pull down on the linkageadjustment rod until the machine is completelylevel.

8 Verify that the ground and drive chassis arecompletely level.

9 Loosen the jamb nuts and adjust the length ofthe rod by turning the clevis yoke until theclevis yoke can be pinned to the axle.

10 Install the cotter pin and tighten the jamb nuts.

11 Measure the gap between the drive chassis andthe non-steer axle on both sides (from the insideof the drive chassis).

Result: The measurements should be equal.

Note: The gap on both sides should be between0.150 inch / 0.381 cm and 0.170 inch / 0.432 cm.

12 Add or remove shims between the oscillationstop bar and the drive chassis to achieve theproper gap.

OSCILLATING AXLE COMPONENTS


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Part No. 122985 S-80 • S-85 • S-80X 5 - 1

September 2015 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules and

operating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

Be sure that all necessary tools and test

equipment are available and ready for use.

Read each appropiate fault code thoroughly.

Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and follow

generally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified onthe repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Unless otherwise specified, perform each

repair procedure with the machine in thefollowing configuration:


• Boom in stowed position

• Turntable rotated with the boom between the non-steer wheels

• Turntable secured with the turntable rotation lock

• Key switch in the off position with the key removed

• Wheels chocked

• All external AC power disconnectedfrom the machine

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September 2015Section 5 • Fault Codes

FAULT CODES

Fault Codes - Control System

How to Retrieve ControlSystem Fault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.

Note: Perform this procedure with the engineoff, the key switch turned to platform controlsand both red Emergency Stop button pulled outto the on position at both the ground andplatform controls.

1 Open the platform control box lid.

Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platformcontrol box. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD)can damage printed circuitboard components. If the circuitboard does need to be handled,maintain firm contact with ametal part of the machine that isgrounded at all times whenhandling the printed circuit boardOR use a grounded wrist strap.

3 Determine the error source: The red LEDindidates the error source and will flash twoseparate codes. The first code will indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 second.

Note: When the red LED is flashing the code, theyellow LED will be on solid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicatethe first digit of the two digit code, flashingonce per second. It will then pause for 1.5seconds and flash the second digit once per0.5 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 followingpages to aid in troubleshooting the machineby pinpointing the area or componentaffected.

Part No. 122985 S-80 • S-85 • S-80X 5 - 3


FAULT CODES

Error Source Error Type Condition Solution

ID Name ID Name

21 Primary 11 Value at 5V Function is Cycle power off,Up / Down 12 Value too high inoperative. then on afterJoystick 15 Value too low Alarm sounds problem has been

16 Value at 0V indicating a fault. corrected.17 Not calibrated Calibrate joystick.

22 Primary 21 Fault Valve is operating Cycle power off,Up / Down outside of limits. then on afterDirectional Alarm sounds problem has beenValves indicating a fault. correted.

23 Primary 12 Value too high Valve is operating Cycle power off,Up / Down 15 Value too low outside of limits. then on afterFlow Valve Alarm sounds problem has been

indicating a fault. corrected.17 Not calibrated Normal function Calibrate valve

except threshold threshold.for one or bothdirections is zero.

24 Angle sensor 11 Value at 5V Reduced speed Cycle power off,12 Value too high function. then on after15 Value too low Alarm sounds problem has been16 Value at 0V indicating a fault. corrected.17 Not calibrated Calibrate angle sensor.31 Invalid setup

26 Angle sensor 19 Out of rangecross check(S-80X)

Continued on next page

5 - 4 S-80 • S-85 • S-80X Part No. 122985


FAULT CODES


ID Name ID Name

31 Primary 11 Value at 5V Function is Cycle power off,Ext. / Ret. 12 Value too high inoperative. then on afterJoystick 15 Value too low Alarm sounds problem has been

16 Value at 0V indicating a fault. corrected.17 Not calibrated Calibrate joystick.

32 Primary 21 Fault Valve is operating Cycle power off,Ext. / Ret. outside of limits. then on afterDirectional Alarm sounds problem has beenValves indicating a fault. correted.

33 Primary 12 Value too high Valve is operating Cycle power off,Ext. / Ret. 15 Value too low outside of limits. then on afterFlow Alarm sounds problem has beenValve indicating a fault. corrected.

17 Not calibrated Normal function Calibrate valveexcept threshold threshold.for one or bothdirections is zero.

34 Ext. Ret. 31 Invalid setupLimit SwitchCross Check

41 Turntable 11 Value at 5V Limited speed Cycle power off,Rotate 12 Value too high and direction then on afterJoystick 15 Value too low frozen at zero problem has been

16 Value at 0V and neutral. corrected.Alarm soundsindicating a fault.

17 Not calibrated Calibrate joystick.

Part No. 122985 S-80 • S-85 • S-80X 5 - 5


FAULT CODES


ID Name ID Name

42 Turntable 21 Fault Limited direction. Cycle power off,Rotate Frozen at zero then on afterDirectional and neutral. problem has beenValves Alarm sounds corrected.

indicating a fault.

43 Turntable 12 Value too high Limited speed Cycle power off,Rotate 15 Value too low and direction. then on afterFlow Valve Frozen at zero problem has been

and neutral. correted.Alarm soundsindicating a fault.


44 Drive Enable 21 Fault Drive enable Cycle power off,Override override direction then on afterSwitch is frozen at problem has been

neutral. corrected.

51 Drive Joystick 11 Value at 5V Limited speed Cylcle power off,12 Value too high and direction. then on after15 Value too low Frozen at zero problem has been16 Value at 0V and neutral. corrected.

Alarm soundsindicating a fault.



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ID Name ID Name

53 Drive Flow 12 Value too high Limited speed Cycle power off,Valve (EDC) 15 Value too low and direction. then on after

Frozen at zero problem has beenand neutral. corrected.



54 Drive Brake 21 Fault Drive frozen Cycle power off,Valve at zero and then on after

neutral. problem has beenAlarm sounds correted.indicating a fault.

55 High Drive 21 Fault Motor speed Cycle power off,Motor Speed in the low state. then on afterValve Alarm sounds problem has been

indicating a fault. corrected.

61 Steer Joystick 11 Value at 5V Limited speed Cylcle power off,12 Value too high and direction. then on after15 Value too low Frozen at zero problem has been16 Value at 0V and neutral. corrected.



62 Steer 21 Fault Limited speed Cycle power off,Directional and direction. then on afterValve Frozen at zero problem has been

and neutral. corrected.Alarm soundsindicating a fault.

FAULT CODES

Part No. 122985 S-80 • S-85 • S-80X 5 - 7


FAULT CODES

Continental Engine Models

How to Retrieve ContinentalEngine Fault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highestefficiency while at the same time keepingexhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault codein memory that relates to the appropriate sensorand will turn on the Check Engine Light.

Note: Perform this procedure with the key switchin the off position.

1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch tothe test position.

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 inthe test position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 1654 threetimes. After the fault codes, the check enginelight will blink a code 1654 three times againindicating the end of the stored codes.

Note: If any fault codes are present, the ECM willblink a three or four digit code three times foreach code stored in memory. It will blink the firstdigit of a three digit code, pause, blink thesecond digit, pause, blink the third digit, thenpause and possibly a fourth digit. For example:the check engine light blinks 5 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.

Note: Once a fault code has been retrieved andthe repair has been completed, the ECMmemory must be reset to clear the fault codefrom the ECM. See How to Clear Engine FaultCodes from the ECM.

How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.

1 Open the engine side turntable cover andlocate the battery.

2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.

Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

3 Connect the negative battery cable to thebattery.

5 - 8 S-80 • S-85 • S-80X Part No. 122985


System Code Fault Name Fault Conditions

MAP 108 MAP Pressure High Y Y MAP pressure > 16 psi and TPS < 10%

and RPM > 1800

To Unlatch, MAP pressure must be < 10 psi

107 MAP Voltage Low Y Y MAP voltage < 0.05 vdc and TPS > 2%

and RPM < 7000

To Unlatch, MAP voltage must be > 0.5 vdc

ECT/ 118 ECT Voltage High Y ECT voltage > 4.95 vdc

CHT 117 ECT Voltage Low Y ECT voltage < 0.05 vdc

116 ECT higher than expected 1 Y Y Y ECT > 210° F and RPM > 600

217 ECT higher than expected 2 Y ECT > 230° F and RPM > 600

IAT 113 IAT Voltage High Y IAT voltage > 4.95 vdc

112 IAT Voltage Low Y IAT voltage < 0.05 vdc

111 IAT higher than expected 1 Y Y IAT > 200° F and RPM > 1000

127 IAT higher than expected 2 Y IAT > 210° F and RPM > 1000

BP 2229 BP Pressure High Y Y BP pressure > 16 psi

129 BP Pressure Low Y Y BP pressure < 8.3 psi

Battery 563 Voltage High Y Y Voltage > 18 vdc

Voltage 562 Voltage Low Y Y Voltage < 9.5 vdc and RPM > 1500

5V 643 5VE1 High Voltage Y 5VE1 > 5.4 vdc

External 642 5VE1 Low Voltage Y 5VE1 < 4.6 vdc

TPS 123 TPS1 High Voltage Y TPS1 voltage > 4.8 vdc

122 TPS1 Low Voltage Y TPS1 voltage < 0.2 vdc

223 TPS2 High Voltage Y TPS2 voltage > 4.8 vdc

222 TPS2 Low Voltage Y TPS2 voltage < 0.2 vdc

221 TPS1 > than TPS2 Y (TPS1 percent - TPS2 percent) > 20%

121 TPS1 < than TPS2 Y (TPS1 percent - TPS2 percent) < -20%

2112 Unable to reach > TPS Y (target TPS - actual TPS) > 20%

2111 Unable to reach < TPS Y (target TPS - actual TPS) < -20%

2135 TPS1/2 simultaneous Y Uses same parameters as individual

voltages out of range TPS1/2 voltage fault detection above

FAULT CODES

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* Adaptive Learn Key Cycle

Part No. 122985 S-80 • S-85 • S-80X 5 - 9



FPP 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc

2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc

Engine 219 Max Govern Speed Override RPM > 3400

Speed 1111 Rev Fuel Limit RPM > 3600

1112 Spark Rev Limit Y RPM > 3800

Oil 524 Oil Pressure Low Y Oil pressure pulled-up input with a

Pressure threshold voltage of 2.5 vdc and

RPM > 500 and run-time > 30 s

Adaptive 171 AL High Gasoline Bank 1 AL_BM > 30% and RPM between 0-9999

Learn and MAP between 0-99 psi

172 AL Low Gasoline Bank 1 AL_BM < -30% and RPM between 0-9999

and MAP between 0-99 psi

1161 AL High LPG AL_BM > 30% and RPM between 0-9999


1162 AL Low LPG AL_BM < -30% and RPM between 0-9999


Closed 1155 CL High Gasoline Bank 1 CL_BM > 40% and RPM between 0-9999

Loop and MAP between 0-99 psi

1156 CL Low Gasoline Bank 1 CL_BM <-40% and RPM between 0-9999


1151 CL High LPG CL_BM > 35% and RPM between 0-9999


1152 CL Low LPG CL_BM < -35% and RPM between 0-9999


Catalyst 420 Gasoline Cat Monitor Y Y EGO2 RMS > 0.005 phi and EGO2

Monitor RMS > EGO1 RMS* 50% and

EGO2 RMS > CL waveform RMS* 50%

1165 LPG Cat Monitor Y Y EGO2 RMS > 0.005 phi and EGO2

RMS > EGO1 RMS* 50% and

EGO2 RMS > CL waveform RMS* 50%

FAULT CODES

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te 2

Lo

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5 - 10 S-80 • S-85 • S-80X Part No. 122985


FAULT CODES

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*

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te 1

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te 2

Lo

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imit


EGO 134 EGO Open/Lazy Pre-cat 1 Y Y EGO cold persistently > 120 seconds

Sensors 154 EGO Open/Lazy Post-cat 1 Y Y EGO cold persistently > 120 seconds

Injectors 261 Injector Loop Open or Injector off-state low-side < 4 vdc

Low-Side Short to Ground Y Y Y and battery voltage > 9 vdc

262 Injector Coil Shorted Y Y Y Injector on-state low-side > 4 vdc

and battery voltage < 16 vdc

Power 686 Relay Control Ground Short

Relay 685 Relay Coil Short

Control 687 Relay Coil Short to Pwr

Coil

Tach 2618 Tach Output Ground Short Does not turn on MIL

Output 2619 Tach Output Short to Pwr Does not turn on MIL

EPR 1171 EPR Delivery Pressure Y Y MJ actual-commanded press > 4 in. H20

Diagnostics > than expected

LPG 1172 EPR Delivery Pressure Y Y MJ actual-commanded press < 4 in. H20

< than expected

1173 EPR Comm Lost Y Y No MJ packets received within 500 ms

1174 EPR Voltage Supply High Y Y

1175 EPR Voltage Supply Low Y Y

1176 EPR Internal Actuator Y Y

fault detection

1177 EPR Internal Circuitry Y Y

fault detection

1178 EPR Internal Comm Y Y

fault detection


Part No. 122985 S-80 • S-85 • S-80X 5 - 11



Cam 342 Cam Loss Y Y No cam pulse in 4 cycles and RPM > 1000

Crank 337 Crank Loss Cam pulses without crank activity

Sensors > 6 cam pulses

341 Cam Sync Noise Y Y Number of invalid cam re-syncs = 1

within a time window of <= 700 ms

336 Crank Sync Noise Y Y Number of invalid crank re-syncs = 1

within a time window of <= 800 ms

16 Never Crank Synced Cranking revs without sync < 4 revs

at Start and RPM > 90 rpm

Internal 606 COP Failure Y Y

Processor 1612 RTI 1 Loss Y Y

Diagnostics 1613 RTI 2 Loss Y Y

1614 RTI 3 Loss Y Y

1615 A/D Loss Y Y

1616 Invalid Interrupt Y Y

601 Flash Checksum Invalid Y Y

604 RAM Failure Y Y

J1939 1625 Shutdown Request Number of shutdown requests >= 1

Network 1626 CAN Tx Failure TX error counter > 100

1627 CAN Rx Failure Rx error counter > 100

1628 CAN Address Conflict Failure Address conflict counter > 5

FAULT CODES

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5 - 12 S-80 • S-85 • S-80X Part No. 122985



September 2015 Section 6 • Schematics

Part No. 122985 S-80 • S-85 • S-80X 6 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

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

About This SectionThere are two groups of schematics in this section.

Electrical Schematics


Hydraulic Schematics


September 2015Section 6 • Schematics

6 - 2 S-80 • S-85 • S-80X Part No. 122985

Electrical Symbols Legend

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Battery separator

MA

INA

UX

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B


Part No. 122985 S-80 • S-85 • S-80X 6 - 3

Hydraulic Symbols Legend

Pumpfixed displacement

Motorbi-directional

Accumulator

Shut off valve

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve


6 - 4 S-80 • S-85 • S-80X Part No. 122985


Section 6 • Schematics September 2015

6 - 5 6 - 6

Connector Pin Legend - View 1


1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

6 - 6 S-80 • S-85 • S-80X Part No. 122985


C1 DT06-12SA

RDRD/BKRD/WH

C28TTAC29MS

C27AUX

COLOR

C35RPM BK/RD

12V POWER TO PLAT

RDP134PWR(C)

C132PLI1

C9

BRSNSR GNDRD/BKC123PBS

GR/WHC45GEN403938373635343332

ORC118LSR313029

2625

RDP134PWR(A)23OR/RD22

21C42LS

2019

16

1312

1234567891011

1415

18

24

2728

17

21P26ESTP

CKT # PIN #

P24FS

4PLUGP25FS 3

COLOR

BKWHRD

C9 FS DT04-4P

CIRCUIT #

V155PCE OR/RD

CONTINENTALTME27

C33STR BK

C41RPM OR/BK

2011L04iDEUTZ

804PERKINS

R21IGN WH(14)

C127TSW GR

P24PWR RD

C31EDC- WH/BKC30EDC+ WH

C29MS RD/WH

C32BRK WH/RD

C39LP BL/RD

C108ESL BL/WH

PIN# CIRCUIT # COLOR

1

32

4

65

7

9

8

1112

13

10

14

15

17

18

16

19

2120

23

24

22 C34SA BK/WHOR/WHLT BR--

--

1

32

45

C1PBU

C4TRLC5TRR

C3PBFC2PBD

C3 DT06-12SC

COLOR

WHRD/WH

WH/BK

RD/BKRD

789

C8PBRC9PERF

C7PBE

C59CNKC133PLA

10

1211

C4 DT06-12SD

12

543

67

910

8

V155PCEC17PRL

C15PLDC14PLUC13DRE

C49DLITE

C43JUC44JD

C18PRR

OR

GR

BK/WH

BLBK/RD

BK

BL/BKBL/WH

BL/RD

OR/BK

COLOR

OR/RD

GR/WHGR/BK

WH/RD C6TRF 6

12PLUGPLUG 11

C6

C59CNK

C28TTA

P134PWR(B) RD

RD/BK

BL/BK

C36STCC37STCC BL/BK

BL

C3PBF

C1PBUC2PBD

COLOR

RD/WH

RDRD/BK

C5TRR

C9PERF

C4TRL

C6TRFC7PBEC8PBR BK/WH

BK

WH

BK/RD

WH/BK

C40LS OR

WH/RD

1

32

4

C7 DTP06-4S

P22PWR

PLUGBATGNDP23PWR

CIRCUIT # PIN #COLOR

BRWHBK

C7

C1GRAY

C3GREEN

PLUGPLUGSNSR GNDP109ANG

C2 DT06-12SB

C2BLACK

1

32

45

BL/RDOROR/BK

GR

C39LP

C42LSC46HRN

C41RPMC40LS

COLOR

OR/RD

78

11

9

GR/WHC123PBSC45GEN

10

12

GR/BK P134PWR 6

BL/WHC37STCCBL/BK

12

543

WH/BK C31EDC-C30EDC+WH

67

98

C4BROWN

BK

BK/RDBL

BK/WH

C32BRKC33STR

C36STCC35RPMC34SA

1112

10

WH/RD

GR/RD

OR/GRRD/OR

LT BR

P109ANG GR/WH

P23PWR WH

C46HRN GRC27AUX RD

R24PWR RD

C35RPM BK/RD

C27AUX RDC46HRN GR

P24PWR RD

C32BRK WH/RD

C29MS RD/WH

C30EDC+ WHC31EDC- WH/BK

C24TSPS WH

R21IGN WH(14)

C41RPM OR/BK

C33STR BK

V155PCE OR/RD

C21IGN WHC21IGN WH

V155PCE OR/RD

C33STR BK

C41RPM OR/BK

R21IGN WH(14)

C24TSPS WH

C31EDC- WH/BKC30EDC+ WH

C29MS RD/WH

C32BRK WH/RD

P24PWR RD

C46HRN GRC27AUX RD

C35RPM BK/RD

C34SA BK/WH

FOOTSWITCH

FUNCTION MANIFOLD

ENGINE

C5

PIN#

C13DRE BL/RD

C177LSBL/WH 12(CE MODEL)(S-80X MODEL)

CIRCUIT # PIN #

CIRCUIT # PIN #

CIRCUIT # PIN #

CIRCUIT # PIN #

C132PLI2 (CE MODEL)

P109LS 12BL/WH

(CE MODEL)

(S-80X MODEL)

SPARE

ES0507C

GR/WHC109LS (S-80X MODEL)

BL/RDC177LS (S-80X MODEL)

CIRCUIT # COLOR CIRCUIT # COLOR

P210PWR BK (S-80X MODEL)

C211LO BL/BK (S-80X MODEL)

C212LO GR/BK (S-80X MODEL)

Section 6 • SchematicsSeptember 2015

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 122985 S-80 • S-85 • S-80X 6 - 7


11

0

20

11

J2

J1

C108ESL

CONTINENTAL TME27

ALC500OUTPUT

ALC500INPUT 9

10

1112

345

7

8

6

21

PIN# CIRCUIT #

BL/WHGNBL/RDWH/RD

BLBL/WHBK(14)

WH

BK/RD

OR/BK

COLOR

WHWH

RD/WHWH/RD

COLOR

BL/WH

RD/WH

BL/BK

BL/WHWH/RDWH/BK

BRORBRORBR

BL/RDRD/BK

GR/WH

CIRCUIT #PIN#

12

C29MS

6

8

7

543

P162JPW1JSGND114

13121110

C13DRE(A)1615

P109ANG9

C28TTA

JSGND2P162JPW2SNSR GND

C163PLS

C144DERC143DEL

C159STCC160JPL

C165TRSC164PES

1816

9

C123PBSC40LS

C42LSC41RPM

C2PBDC1PBU

C13DRE

C5TRRC6TRFC7PBE

C30EDC+

9 C4TRL

151617

C31EDC-

C37STCC

10

11121314 C9PERF

C8PBR

345

7

8

6

C3PBF

21

PIN# CIRCUIT #

WH

WHWH/BK

BL/BK

WH/BK

WH/RDBKBK/WHBK/RD

BL/RDOR/RDOR/BK

RD/BK

RD/WH

RD

COLOR

OR

181920 C29MS

C32BRK

C36STC BL

WH/RDRD/WH

R23PWR

C38RETC21RET

R21IGNC41RPMR33STRC38FP

C127TSWC39LPC26TSR

C35RPM

C14GRAY

J22

OR/BK

6 C44JD GR/BK

10

C14PLUC15PLD

OR

9

11

87

GR

COLOR

GNDC18PRR

C43JUC17PRL

GND

GR

GR/BKBRBR

54

23

1

J22 DT04-12PA

GNDGNDGNDGND BR

BRBRBR

ENGINE PLUG ENGINE PLUG

GND

C24TSC25PSRC24PSR21IGN

C107AFC26TSR

C41RPMWHOR/BK

COLOR

WH

BR

WH(14)

WH/BKWHWH/RD

CIRCUIT #PIN#

12

6

8

7

543

109

DEUTZ 2011LO4i

RD/BK

PLATFORM MANIFOLD

P24FSGND

P24FSP26ESTP3

4

21

PIN# CIRCUIT #

BKWH

COLOR

BRWH

ALC500POWER/VALVE INPUT

J3

124

3

J144

(GAUGE OPTION)

12

PIN # CIRCUIT #

C184PL

P109LS

NCC169LED2

C177LS

P109LS

NC

C169LED19 NC

10

3

4

5

7

8

6

SNSR GND

2

1

PIN# CIRCUIT #

-GR

-

-

BL

BL/RD

BR

GR/WH

WIRE

GR/WHWH

S-80X MODEL

J8

16

510

--

--

ES0507C


6 - 8


6 - 7


6 - 9

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04i Models

6 - 10


1

2

3

4

5

6

7

8


6 - 10 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

TIMER 30

U16NO

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER

IGN / FUEL ONENGINE FAULT

KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/

STA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NOO

ILP

RE

SS

UR

ES

WIT

CH

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MC

ON

TR

OL

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

HM

+

P25FS RD

P26ESTP BK

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C1

-9C

35

RP

MB

K/R

D

+

12 VDC

B1B2

D22

CR17NO

D6

HO

LD

PU

LL

IN

-COM

+AUX

S-613

+BAT

MOM N.O.

BR

WH

RD

RP

MS

OL

EN

OID

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RR

D

CB215AMP

C2

8T

TA

RD

/BK

7

WH

GR

/BK

TB2812 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1

P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

P24FS WH

P26ESTP BK

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

OIL

CO

LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D40

+

C1

33

PL

SG

R/B

K

L48

CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

RP

MM

OD

UL

E

J1

44

-8J1

44

-7

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67 D68

C4

-4V

15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C1

-2

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

C28TTA RD/BK

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD

C21ING WHC24TSPS WH

-

F2020A

AU

XIL

IAR

YP

UM

P

C32

ES0504D

LO

W

RD

C33STR BK

-

CB715A

M3

FB

M1

P1

34

FB

RD

12 VDC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

GL

OW

PL

UG

TIM

ED

EL

AY

30

SE

CO

ND

S

HO

UR

ME

TE

R

M2

CH

EC

KE

NG

INE

LE

D


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 11

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04I Models

C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

7.5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5

C4

TR

LW

H

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58

TS8JIB BOOM(S-85 OPTION)

H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D

LIFT / DRIVE(OPTION)

1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H

JC7PRIMARY BOOMUP / DOWNEXTEND / RETRACTTURNTABLE ROTATE

U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y

ROCKER / STEER OPTION

C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)

CR34

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

C6

-31

TB118

24

14

23

13NO

NO

WH

BK

BR

RD

4 3 2 1

C11

8L

SO

R

P1

34

PW

RR

D


6 - 12


6 - 11


6 - 13

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04I Models

6 - 14


1

2

3

4

5

6

7

8


6 - 14 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

HM

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

C3

2-8

WH

/RD

-TR

AV

EL

AL

AR

M

RD

U1

6-2

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-T

B1

34

C

BK

-C7

B-1

GR

/BK

-T

B1

33

C

WH

-TS

51

-5R

D-T

S5

3-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

WS

TE

ER

CC

W

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

DH

OR

N

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

OR

&W

H-B

EA

CO

NS

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

RD

KS

1-2

1 2

U16

3 5

BK

/WH

C5

-22

RD

TB

23

A

BR

GN

D

BK

/WH

TB

34

C

OR

/BK

ISM

#2

BK

/WH

TS

56

-3

BK

ISM

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.F

AU

LT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-C5

-39

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.O

N

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

WH

ISM

#7

GL

OW

PL

UG

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

S-8

5(O

PT

ION

)

HARNESS TOSWITCH PANEL

CONTROLS CIRCUIT BREAKER, 15A

LABEL

CB2

DESCRIPTION

PRIMARY BOOM SPEED REDUCTION RELAYCR34

HOUR METERG6

KEY SWITCHKS1

LED - CHECK ENGINEL2

LED - CABLE TENSIONL46

EMERGENCY STOP BUTTONP1

FUNCTION ENABLE TOGGLE SWITCHP4

RESISTOR, 10 PRIMARY BOOM UP / DOWN SPEED��R14

RESISTOR, 5 TURNTABLE ROTATE SPEED��R14(A)

RESISTOR, 7.5 PRIMARY BOOM UP / DOWN SPEED��R16

AUXILIARY PUMPTS51

ENGINE START TOGGLE SWITCHTS52

GLOW PLUG TOGGLE SWITCHTS56

PLATFORM ROTATE TOGGLE SWITCHTS57

PLATFORM LEVEL UP / DOWN TOGGLE SWITCHTS59

PRIMARY BOOM UP / DOWN TOGGLE SWITCHTS61

TURNTABLE ROTATE TOGGLE SWITCHTS62

PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCHTS63

DRIVE LIGHT RELAY (OPTION)CR23

RPM SELECT TOGGLE SWITCHTS54

JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)TS58

IGNITION START MODULEU1

GLOW PLUG TIME DELAY RELAYU16

WH/BK C4B-9

WH DL1

RD DL2

BK GND1

TB21C

CR23

10 AMP FUSE

DRIVE LIGHT OPTION RELAY

BR GND2

RD

C3

2-1

(UN

US

ED

)

(UN

US

ED

)

BK

/WH

U1

6-5

NOTE: DASHED LINES INDICATE OPTIONS

ES504D

F19


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 15

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

E-S

TO

P

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-TB

13

4D

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

- GN

DS

TU

D

BR

-L4

6(-

)

BR

-HM

( -)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/ BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

BK

/WH

-TB

34

D

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

11

8D

BR

-HM

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 3

0

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TI O

NS

ES0504D

TS

56

32

1

WH

-IS

M#

10

87


6 - 16

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),

Deutz TD2011L04I Models

6 - 15


6 - 17 6 - 18

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Deutz TD2011L04I Models


1

2

3

4

5

6

7

8


6 - 18 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

LS

18

-C1

77

LS

BL

/RD

C1

P-1

2

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW

U13ALC-500

OPTION OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY

J8

-P1

09

LS

GR

/WH

C3

P-1

2

ES0505D

WH TS7

WH/RD C32BRK

(SPLICE TOC32BRK, C1P-6)

OR/RD C40LS

(SPLICE TOC40LS, C2P-2)

LIFT / DRIVE SELECT (OPTION)

CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

CONTROL HARNESSTO PLATFORMSWITCH PANEL

TS

8-C

43

JU

GR

J2

2-5

TS

8-C

44

JD

GR

/BK

J2

2-6


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 19

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L47

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

RD

RDRD

ES0504D

CONTROL HARNESSTO PLATFORM BOX

H1

COMPONENT INDEX

TILT ALARM

JC3 JOYSTICK - DRIVE / STEER

JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE

L1 LED - DRIVE ENABLE

L47 LED - CABLE TENSION

L48 LED - TILT ALARM

P2 EMERGENCY STOP BUTTON

P3 HORN BUTTON

TS1 AUXILIARY TOGGLE SWITCH

TS2 ENGINE START TOGGLE SWITCH

TS4 RPM SELECT TOGGLE SWITCH

TS6 GLOW PLUG TOGGLE SWITCH

TS7 PLATFORM ROTATE TOGGLE SWITCH

TS9 PLATFORM LEVEL UP/DOWN TOGGLE SWITCH

TS14 DRIVE SPEED TOGGLE SWITCH

TS15 DRIVE ENABLE TOGGLE SWITCH

U13 ALC500 JOYSTICK CONTROLLER CARD

1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1

1 ROCKER / STEER OPTION


TS8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6

TS8 JIB BOOM UP/DOWN TOGGLE SWITCH

BK


6 - 20

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Deutz TD2011L04I Models

6 - 19


6 - 21

Electrical Schematic, S-80 and S-85 (CE),Deutz TD2011L04i Models (before serial number 8111)

6 - 22


1

2

3

4

5

6

7

8


6 - 22 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

30 SEC

U16NO

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/

STA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NOO

ILP

RE

SS

UR

ES

WIT

CH

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MC

ON

TR

OL

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

G6

+

P25FS RD

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C1

-9C

35

RP

MB

K/R

D

+

12V DC

B1B2

D22

CR17NO

D6

HO

LD

PU

LL

IN

-COM

+AUX

S-613

+BAT

MOM N.O.

BR

WH

RD

RP

MS

OL

EN

OID

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RR

D

CB215AMP

7

WH

GR

/BK

TB28

12 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1

P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

OIL

CO

LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D39

+

C1

33

PL

SG

R/B

K

L4

CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

RP

MM

OD

UL

E

J1

44

-8J1

44

-7

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67D68

C4

-4V

15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD

C21ING(A) WHC24TSPS WH

-

F2020A

AU

XIL

IAR

YP

UM

P

U33

ES0504A

LO

W

RD

C33STR BK

-

CB715A

M3

FB

M1

P1

34

FB

RD

12V DC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

GL

OW

PL

UG

TIM

ED

EL

AY

30

SE

CO

ND

S

HO

UR

ME

TE

R

M2

CH

EC

KE

NG

INE

LE

D

H6

+

- L45

C1

-2C

28

TTA

RD

/BK

D40

D88PBOX

GROUND

2 SEC.

U35

PBOXGROUND

R14

4.7K�

P26ESTP BK

R26ESTP BK

2 SEC.

U34

C4

-10

LS18

LS18A

NO30A

5 9

8

3

2

NO10A

2

5

9

83

C132PLI BK

PBOXGROUND

C4

-10


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 23


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

CR34

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5

C4

TR

LW

H

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

22NCHO

21

C6

-31

TB118

C11

8L

SO

R

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)


6 - 24


6 - 23


6 - 25

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Deutz TD2011L04I Models (before serial number 8111)

6 - 26


1

2

3

4

5

6

7

8


6 - 26 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

G6

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

RD

U1

6-2

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

W

ST

EE

RC

CW

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

OR

-BE

AC

ON

(RIG

HT

)

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/24 CABLE

1 2

U1

6 3 5

BK

/WH

C5

-22

RD

TB

23

A

BR

GN

D

BK

/WH

TB

34

C

GL

OW

PL

UG

BK

/WH

TS

56

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.F

AU

LT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

( -)

10

WH

-C4

-10

9

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.O

N

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

PL

AT

FO

RM

LO

AD

INP

UT

PL

AT

FO

RM

LO

AD

AL

AR

M

OR

/BK

ISM

#2

BK

/WH

U1

6-5

BK

ISM

#3

WH

ISM

#7

WH

-BE

AC

ON

(LE

FT

)

S-8

5(O

PT

ION

)


ES0504A

WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

2310

AM

P

DR

IVE

LIG

HT

RE

LA

Y(O

PT

ION

)

BR

GN

D2

F1

9


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51






TIME DELAY, GLOW PLUG, 30 SECONDSU16


LED - PLATFORM OVERLOADL45






PLATFORM OVERLOAD ALARMH6

UN

US

ED

UN

US

ED

LOAD SENSE MODULEU33


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 27

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

-G6

(-)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/ BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

WH

-IS

M#

10

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

1 18

D

BR

-G6

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 30

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

ES0504A

+

L4

5G

R/B

K-H

6(-

)

RD

-KS

1-2

RD

-TB

13

4D

87

TS

56

12

3

BK

/WH

-TB

34

D


6 - 28

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE),

Deutz TD2011L04I Models (before serial number 8111)

6 - 27


6 - 29

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Deutz TD2011L04I Models (before serial number 8111)

6 - 30


1

2

3

4

5

6

7

8


6 - 30 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)

J1

-SN

SR

GN

DB

RC

2P

-10

J1

-P1

09

AN

GG

R/W

HC

2P

-9

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

14

PL

UO

RC

4P

-2

TS

8-C

43

JU

GR

C4

P-7

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

7-C

17

PR

LG

RC

4P

-5

TS

8-C

44

JD

GR

/BK

C4

P-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

7-C

17

PR

LG

RJ2

2-4

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

8-C

43

JU

GR

J2

2-5

J22

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

44

DE

RB

L/W

H

TS

14

-C2

9M

SR

D/W

H

L1

-C1

3D

RE

(A)

BL

/RD

TS

15

-C1

43

DE

LB

L/B

K

D39

D40

J1

C2

8T

TA

RD

/BK

C1P-2 C28TTA RD/BK

L4

8-C

28

TTA

RD

/BK

H1

J1

9

1

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

GR

/BK

C3

P-1

2

JC

7-1

JS

GN

D2

BR

JC

7-2

P1

62

JP

W2

OR

JC

7-5

C1

63

PE

SW

H/B

K

JC

3-4

C1

60

JP

LW

H/R

D

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-1

JS

GN

D1

BR

JC

3-2

P1

62

JP

W1

OR

JC

3-5

C1

59

ST

CB

L/W

H

C2

P-1

0S

NS

RG

ND

BR

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-9

P1

09

AN

GG

R/W

H

C4

P(B

R)

C3

P(G

N)

C2

P(B

K)

C1

P(G

Y)

C2

PB

DR

D/B

KC

3P

-2

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

BL

C1

P-1

0

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

TS

2-C

33

ST

RB

KC

1P

-7

C3

2B

RK

WH

/RD

C1

P-6

C2

9M

SR

D/W

HC

1P

-3

TS

1-C

27

AU

XR

DC

1P

-1

TS

6-C

34

SA

BK

/WH

C1

P-8

C3

7S

TC

CB

L/B

KC

1P

-11

J2

C4

0L

SO

RC

2P

-2

C7

PB

EB

KC

3P

-7

C1

PB

UR

DC

3P

-1

C1

3D

RE

BL

/RD

C4

P-1

C8

PB

RB

K/W

HC

3P

-8

C6

TR

FW

H/R

DC

3P

-6

C9

PE

RF

BK

/RD

C3

P-9

C4

2L

SO

R/R

DC

2P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

0E

DC

+W

HC

1P

-4

C4

1R

PM

OR

/BK

C2

P-3

1

11

P2

-P2

6E

ST

PB

KC

9P

-1

P2

-P2

3P

WR

WH

C7

P-2

J3

-P2

4F

SW

HC

9P

-2

TS

2-P

25

FS

RD

C9

P-3

P3

-C4

6H

RN

GR

C2

P-5

L4

7-C

59

CN

KB

L/B

KC

3P

-11

P2

-P2

2P

WR

BK

C7

P-1

WH

C9

P-2

WH

L1

BK

P2

J3

1

3

H1

+ -BRN

GND STUD

BATGND J3-1

BATGND C7P-3

J22-1, 2, 9, 10, 11 & 12

C7P C9

12V BATT F.S.

LS18 OPT.

U13ALC-500

RD

LS

18

LS

18

-C1

32

PL

I1B

KC

1P

-12

H1

-C1

33

PL

AG

R/B

KC

3P

-12

GR

/BK

L4

D88

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

3

2

NO

5R

26

ES

TP

BK

C9

P-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

R2

0

C132PLI BK C3P-12

LS

18

-C1

32

PL

I2B

KC

3P

-10

COM

3

2

NO

5

U34

C3-10

C4-10

WH TS7

WH/RD C32BRK


OR/RD C40LS(SPLICE TOC40LS, C2P-2)


CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0504A


TS

47

C4

5G

EN

GR

/WH

C2

P-7


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 31

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (before serial number 8111)

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/WH

C1

P-8

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

C4

P-5

/J2

2-4

GR

/BK

C4

P-6

/J2

2-3

WH

C9

P-2

TS15

OR

J1

-11

RD

/WH

J1

-2

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

JC7

6

1

GR

C2

P-5

TS4

L1

+

L47

P3

NO

OR

C4

P-2

/J2

2-7

OR

/BK

C4

P-3

/J2

2-8

+

TS2

NC

WH

C7

P-2

BK

C7

P-1

RD

LS

18

BK

C9

-1

BK

J3

-3

TS7

TS8

TS14

TS1TS9

L48

P2RD

RD

BK

RD

ES0504A

+

L4

GR

/BK

H1

(D3

9)

TS6

BK

C1

P-7

BK

/RD

C1

P-9

JC3

61

WH

/RD

J1

-4

BR

J1

-14

BL

/WH

J1

-5

OR

J1

-13

1

CONTROL HARNESSTO PLATFROM BOX

H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON









TS8 JIB BOOM UP/DOWN TOGGLE SWITCH (S-85 OPTION)

CR27 LIFT / DRIVE SELECT - BRAKE CIRCUIT (OPTION)

CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION)

J22 PLATFORM MANIFOLD

L4 LED - PLATFORM OVERLOAD

LS18 PLATFORM OVERLOAD LIMIT SWITCH

R20 RESISTOR - 4700�


U35 TIME DELAY RELAY - 2 SECONDS, 30A




RD


6 - 32

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE),

Deutz TD2011L04I Models (before serial number 8111)

6 - 31


6 - 33

Electrical Schematic, S-80 and S-85 (CE),Deutz TD2011L04I Models (after serial number 8110)

6 - 34


1

2

3

4

5

6

7

8


6 - 34 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

TIMER 30

U16NO

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/

STA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NO

OIL

PR

ES

SU

RE

SW

ITC

H

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MC

ON

TR

OL

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

G6

+

P25FS RD

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C1

-9C

35

RP

MB

K/R

D

+

12V DC

B1B2

D22

CR17NO

D6

HO

LD

PU

LL

IN

-COM

+AUX

S-613

+BAT

MOM N.O.

BR

WH

RD

RP

MS

OL

EN

OID

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RR

D

CB215AMP

7

WH

GR

/BK

TB28

12 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1

P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

P24FS WH

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

OIL

CO

LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D39

+

C1

33

PL

AG

R/B

K

L4

CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

RP

MM

OD

UL

E

J1

44

-8J1

44

-7

J1

44

-4

J1

44

-6

J1

44

-2

J1

44

-1

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67D68

C4

-4V

15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD


-

F2020A

AU

XIL

IAR

YP

UM

P

U33

ES0504D

LO

W

RD

C33STR BK

-

CB715A

M3

FB

M1

P1

34

FB

RD

12V DC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

GL

OW

PL

UG

TIM

ED

EL

AY

30

SE

CO

ND

S

HO

UR

ME

TE

R

M2

CH

EC

KE

NG

INE

LE

D

H6

+

- L45

C1

-2C

28

TTA

RD

/BK

D40

D88

D89

PBOXGROUND

2 SEC.

U3530A

PBOXGROUND

R14

4.7K�

P26ESTP BK

R26ESTP BK

2 SEC.

U3410A

C3

-10

C1

32

PL

I2B

K

LS18

LS18A

NO

2 9

8

3

5

NO

5

2

9

83


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 35


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

7.5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5C

4T

RL

WH

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)

CR34

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

C6

-31

TB118

24

14

23

13NO

NO

WH

BK

BR

RD

4 3 2 1

C11

8L

SO

R

P1

34

PW

RR

D


6 - 36


6 - 35


6 - 37

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Deutz TD2011L04I Models (after serial number 8110)

6 - 38


1

2

3

4

5

6

7

8


6 - 38 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

G6

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

WH

C5

-1

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

W

ST

EE

RC

CW

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

RD

U3

4-2

OR

&W

H-B

EA

CO

NS

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

1 2

U16

3 5

BK

/WH

C5

-22

RD

TB

23

A

BR

GN

D

BK

/WH

TB

34

C

GL

OW

PL

UG

BK

/WH

TS

56

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.

FA

ULT

IGN

. /F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-U3

4#

99

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.

ON

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

PL

AT

FO

RM

LO

AD

INP

UT

PL

AT

FO

RM

LO

AD

AL

AR

M

OR

/BK

ISM

#2

BK

/WH

U1

6-5

BK

ISM

#3

WH

ISM

#7

S-8

5(O

PT

ION

)


WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

23

10

AM

PF

US

E

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

BR

GN

D2

F1

98 9

U34

3 5

WH

C5

-3

WH

ISM

-#9

BR

GN

D

BK

C3

B-1

0

2R

DT

B1

34

C(A

)


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51






GLOW PLUG TIME DELAYU16

LOAD SENSE MODULE









(UN

US

ED

)

ES0504D

U33

LOAD SENSE TIME DELAYU34


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 39

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

- G6

(-)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

WH

-IS

M#

10

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

118

D

BR

-G6

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 3

0

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

ES0504D

+

L4

5G

R/B

K-H

6(-

)

RD

-KS

1-2

RD

-TB

13

4D

87

TS

56

12

3

BK

/WH

-TB

34

D


6 - 40


Deutz TD2011L04I Models (after serial number 8110)

6 - 39


6 - 41

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Deutz TD2011L04I Models (after serial number 8110)

6 - 42


1

2

3

4

5

6

7

8


6 - 42 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

6-C

34

SA

BK

/WH

C1

P-8

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

H1

-C1

33

PL

AG

R/B

KC

3P

-12

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW

U13 - JOYSTICKCONTROL CARD

LS18 OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0504D

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

32

NO

5

R2

6E

ST

PB

KC

9P

-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

47

00

�

R2

0

D88

D89

C132PLI1 BL/WH C1P-12

C132PLI2 BK C3P-10

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

8-C

43

JU

GR

J2

2-5

TS

8-C

43

JU

GR

C4

P-7

TS

8-C

44

JD

GR

/BK

C4

P-8

GR

/BK

L4

GR

/BK

C3

P-1

2

D39


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 43

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Deutz TD2011L04I Models (after serial number 8110)

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

GR

/BK

H1

(D3

9)

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L4

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

RDBK

RDRD

ES0504D


1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1


H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON
















U35 TIME DELAY RELAY


TS8

GR

/BK

C4

P-8

/J2

2-6

GR

C4

P-7

/J2

2-5

+

L47

BR

GN

DS

TU

D


6 - 44


Deutz TD2011L04I Models (after serial number 8110)

6 - 43


6 - 45

Electrical Schematic, S-80X,Deutz TD2011L04I Models

6 - 46


1

2

3

4

5

6

7

8


6 - 46 S-80 • S-85 • S-80X Part No. 122985


MA

INA

UX

.

+

3

1

4

2

B

B1

-

CB2

15 AMP

TB20

P1

KS1

PLAT

GRD

TB22

TB134

TB132

GROUND

4

1 3

5

6

12

7

8C32

TB133

H1

D40L48

P2

P3HORN

C2

-6

C7

-1

P1

34

PW

RR

D

P2

2P

WR

BK

C2

-5

TB28

TB46

TB23D2

C1

-2

C7

-2

C9P-1

FS1C9P-3

C9P-2

P26ESTP BK

P25FS RD

P24FS WH

P25FS RD

P24FS WH

TS1AUXILIARYPUMP

TS2ENGINESTART

TS6GLOWPLUG

TS4ENGINERPM

P26ESTP BK

C28TTA RD/BK C28TTA RD/BK

P26ESTP BK

P24FS WH

C1

-1

C1

-7

C1

-8

C1

-9

V1

55

PC

EO

R/R

D

D12

HIG

HR

PM

(FS

)

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

D67 D68

D4

TB41

TB155

C3

5R

PM

BK

/RD

D13

TB35

TS54ENGINERPM

LO

WR

PM

HIG

HR

PM

LO

WR

PM

TB34

D64

TB33

D6

TB27

P4FUNCTION

ENABLE

TS56GLOWPLUG

TS52ENGINESTART

AU

XIL

IAR

YP

UM

P

TS51

C3

4S

AB

K/W

H

C3

3S

TR

BK

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3P

WR

WH

C4

6H

RN

GR

GR

/BK

B1

BA

TR

D

B1

BA

TR

D

F17

20A

C5

-2

C5

-7

C6

-24

C6

-28

C5

-5

P24PWR RD

R21IGN WH

B1BAT RD

BAT2 APU RD

C5

-6

C5

-1

C5

-3

C5

-15

C5

-22

C5

-18

C5

-19

C5-11TB21

12

3

4

5

6

7

8

9

10

START RELAYTACHOMETER

START INPUT

AUXILIARY

GROUND

BATTERY

KEY POWER

KEY BYPASS

IGN / FUEL ON

ENGINE FAULT

IGN / STARTMODULE

L2

BL/RD

HM

+

-

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C33STR BKC27AUX RD

P24PWR RD

C21IGN WHC24TSPS WH

F7

20A

D22

12V DC 12V DC

B2 B1

+ +

- -

BAT+

BAT-

STA

INDREGULATOR

EXCT

ALTERNATOR

FB FB

C4

1R

PM

OR

/BK

P1

34

FB

RD

P1

34

FB

RD

CR17NO

30

87

86

85R11

6H

YD

OR

C11

6H

YD

WH

CR5NO

R4

6H

RN

GR

86

85

30

87

HYDFAN

SW4NO

H2

A C

B

RD

WH

D51

P1

34

PW

RR

D

C2

8T

TA

RD

/BK

BK

PR2

M3

R3

3S

TR

BK

CR1 CR39A CR2NO

86

85

30

87

NO

86

85

30

87

NO

R2

7A

UX

RD

PR1NO

M2

R2

1IG

NW

H

F2260A

CR15NO

86

85

30

87

S2 S1

NC NOC

24

TS

PS

WH

V1

55

PC

EO

R/R

D

CR3NO

86

85

30

87

CB2010A

Y74

R3

4S

AB

K/W

H

CO

NT

RO

LB

AT

TE

RY

STA

RT

BA

TT

ER

Y

BA

TT

ER

YS

EP

ER

AT

OR

ALT

ER

NA

TO

R

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

OIL

CO

OL

ER

FA

N(O

PT

ION

)

OIL

CO

OL

ER

TE

MP

ER

AT

UR

ES

WIT

CH

(OP

TIO

N)

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

STA

RT

ER

MO

TO

R

PO

WE

RR

EL

AY

IGN

ITIO

N/

STA

RT

RE

LA

Y

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PR

EL

AY

FU

EL

SO

LE

NO

ID

IGN

ITIO

NP

OW

ER

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

RT

EM

PE

RA

TU

RE

SW

ITC

H

GL

OW

PL

UG

GL

OW

PL

UG

RE

LA

Y

FU

EL

PU

MP

RP

MR

EL

AY

PO

WE

RR

EL

AY

PR

ES

SU

RE

CO

MP

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

HO

UR

ME

TE

R

ES504D

CR4

RP

MS

OL

EN

OID

M4

P210PWR BK

ZONE A

ZONE B

OFF

1000 LB (A)

500 LB (A & B)

D101


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 47


P134PWR RD

D23

D24

17

10 56 82

1

4

2

3

5

6

P162JPW1-OR

JSGND1-BR

C159STC-BL/WH

C160JPL-WH/RD

C159STC-BL/WH

J25

910

JC3DRIVE / STEER


1

4

2

3

5

6

P162JPW2-OR

JSGND2-BR

C164PES-RD/WH

C165TRS-WH/RD

C163PLS-WH/BK

J127

31 2 654

J114

BK

RD

YL

OR

BR

BL

RIG

HT

LE

FT

1

2 12

11

14

13

5

7 158166 452 1 314

15

16

19

18

17

20 411910678 14

13

12

3

JOYSTICK CONTROL CARD

TB134A

3 2

SN

SR

-GN

DB

R

P1

09

AN

GG

R/W

H

C1

23

PB

SR

D/B

K

J3

J2

CR30

NO


NC

CR27L47

TS9PLATFORMLEVEL

TS7PLATFORMROTATE

CW

CC

W

DO

WN

UP

C5

9C

NK

BL

/BK

J2

2-7

J2

2-8

J2

2-5

J2

2-6

J2

2-4

J2

2-3

J2

2-2

J2

2-1

J2

2-1

0

J2

2-9

J2

2-1

2

J2

2-11

Y71 Y70 Y19 Y20

GND BR

C28TTA RD/BK

P26ESTP BK

P24FS WH

P2

6E

ST

PB

K

P2

4F

SW

H

P2

4F

SW

H

GN

DB

R

C1

84

PL

WH

P1

09

TS

GR

/WH

ZO

NE

SE

LE

CT

SN

SR

BR

L51 L50

ZONE A ZONE B

C2

08

LE

DG

R

C2

09

LE

DB

L

C1

43

DE

LB

L/B

K

TS15DRIVEENABLE

TS75ZONE SELECT

C1

44

DE

RB

L/W

H

L1

LE

DB

L/R

D

C2

9M

SR

D/W

H

TS14DRIVESELECT

H1

RD

/BK

J1 J8 J8 J1 J1 J1

J2

P210PWR BK

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

C4

-6

C4

-5

C4

-8

C4

-7

C4

-3

C4

-2

C3

-11

C1

-3

C1

-6

C1

-10

C1

-11

C1

-5

C1

-4

C3

-3

C3

-2

C3

-1

C1

-12

BL

/RD

GR

/WH

C3

-12

C2

-3

C3

-7

C3

-8

C3

-9

C3

-4

C3

-5

C3

-6

C4

-1

C2

-2

C2

-4

C2

-8

C2

-9

C2

-10

C7

-3

CC

W

TS57PLATFORMROTATE

CW

TB18

TB17

TB44

TB43D30

D29

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C4

4JD

GR

/BK

C4

3JU

GR

TS59

TB15

TB14

DO

WN

UP

PL

AT

FO

RM

LE

VE

L

TB59

L46

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

TB29 TB32

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

TB36 TB37

TB31 TB30

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

R16

7.5�TS61PRI. BOOMUP / DOWN

R14

10�

CR34 CR68

CR53

UP

DO

WN C1

77

LS

BL

/RD

TB1

TB2

TB3

P1

09

LS

GR

/WH

CR52

CR69

TS63PRI. BOOMEXT. / RET.

C7

PB

EB

K

EX

TE

ND

RE

TR

AC

T

C8

PB

RB

K/W

H

C9

PE

RB

K/R

D

R14(A)

5�

TS62TURNTABLEROTATE

C4

TR

LW

H

CW

CC

W

TB13

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

3D

RE

BL

/RD

TB42

P1

34

PW

RR

D

C4

0L

SO

R

C4

2L

SO

R/R

D

P1

09

AN

GG

R/W

H

SN

SR

-GN

DB

R

C1

23

PB

SR

D/B

K

GN

DB

R

C6

-24

C6

-11

C5

-24

C5

-23

C6

-36

C6

-37

C5

-20

C5

-21

C11

8L

SO

R

TB118 C6

-31

C6

-3

C6

-2

C6

-1

C6

-12

P2

10

PW

RB

K

P1

34

PW

RR

D

C6

-21

C6

-30

C6

-38

C6

-16

BL

/RD

C2

11P

LO

BL

/BK

S2

12

PL

OG

R/B

K

GR

/WH

J133

J133B

K

RD

OR

WH

1 4 5 2

BL

3 6

BR

BL

BK

GR

J134

C1

29

DA

RD

/BK

C2

9M

SR

D/W

H

H4

C3

2B

RK

WH

/RD

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C9

PE

RF

BK

/RD

C8

PB

RB

K/W

H

C7

PB

EB

K

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C6

-9

C6

-8

C6

-7

C6

-6

C6

-5

C6

-4

TB9

TB8

TB7

TB5

TB4

NO14

13

WH

BK

Y27 Y2 Y4 Y3 Y5 Y6

U4

Y12 Y21 Y22 Y15 Y25 Y26 Y13 Y24 Y23

21

22

NC

BR

RD

4 3 2 1

24 23

14 13

NO

NO

22 21

14 13

NO

NC22 21

14 13NO

NC22 21

14 13NO

NC

WH

BK

/WH

BK

BR

RD

4 3 2 1 4 3

2 1

BR

BL

BK

BK

/WH

BR

BL

BK

WH

BK

BR

RD

2 1

2 1 4 3 2 1 2 1BR

RD

WH

BK

BR

RD

WH

BK

BR

RD

WH

BK

2324

NO

1314

NO

2324

NO

1314

NO

2122

NC

1314

NO

C6

-13

C6

-25

C6

-23

C6

-40

C6

-22

C6

-35

C6

-34

C6

-33

C4

2L

SO

R/R

D

C4

0L

SO

R

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

PL

AT

FO

RM

RO

TA

TE

CW

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

DE

SC

EN

TA

LA

RM

LO

OS

EC

AB

LE

LE

D’S

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

ST

EE

RC

W

ST

EE

RC

CW

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

CR

34

-P

RIM

AR

YB

OO

MS

PE

ED

RE

DU

CT

ION

RE

LA

Y

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

LS

T3

O-

BO

OM

UP

/DO

WN

GR

OU

ND

BO

X-

ZO

NE

AO

PE

RA

TIO

NA

ND

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

LS

B1

EO

-B

OO

ME

XT

EN

DC

AP

AC

ITY

OP

ER

AT

ION

AL

LIM

ITS

WIT

CH

LS

B1

ES

-B

OO

ME

XT

EN

DC

AP

AC

ITY

SA

FE

TY

LIM

ITS

WIT

CH

LS

T3

S-

BO

OM

AN

GL

ES

TO

WE

DG

RO

UN

DB

OX

-Z

ON

EA

SA

FE

TY

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

TF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

CW

TU

RN

TA

BL

ER

OTA

TE

CC

W

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

LS

B1

RO

BO

OM

RE

TR

AC

TD

RIV

E/

RO

TA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T2

OA

NG

LE

ST

OW

ED

DR

IVE

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

S1

7P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-O

PE

RA

TIO

NA

L

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


6 - 48


6 - 47


6 - 49 6 - 50

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Deutz TD2011L04I Models


1

2

3

4

5

6

7

8


6 - 50 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Deutz TD2011L04I Models

BK

C5

-5

RD

-TB

20

B

RD

-TB

20

A

BR

-GN

DS

TU

D

WH

-TB

23

B

BK

-C3

2-5


BK

C3

2-4

BL

/WH

C3

2-3

OR

/BK

ISM

#2

RD

U1

6-2

BK

/WH

U1

6-5

RD

/12

BA

TT

+R

D/1

2B

AT

T+

WH

KS

1-1

(D2

)W

H/1

2C

7B

-2

RD

C6

-25

BK

/RD

C5

-18

WH

/RD

C5

-23

WH

/BK

C5

-20

WH

C5

-21

BK

/RD

C6

-9

BK

/WH

C6

-8

BK

C6

-7

WH

/RD

C6

-6

WH

/BK

C6

-5

WH

C6

-4

RD

/WH

C6

-3

RD

C2

B-6

BL

/BK

C3

B-1

1

GR

C2

B-5

GR

/WH

C2

B-7

OR

/RD

C2

B-4

OR

/BK

C2

B-3

OR

C2

B-2

BL

C1

B-1

0

BK

/RD

C1

B-9

BK

/WH

C1

B-8

RD

C1

B-1

RD

/BK

C1

B-2

WH

/BK

C1

B-5

RD

/WH

C1

B-3

WH

C1

B-4

WH

/RD

C1

B-6

BK

C1

B-7

GR

/BK

C4

B-6

GR

C4

B-5

OR

/BK

C4

B-3

OR

C4

B-2

BL

/RD

C4

B-1

BK

/RD

C3

B-9

BK

/WH

C3

B-8

BK

C3

B-7

WH

/RD

C3

B-6

WH

/BK

C3

B-5

WH

C3

B-4

RD

/WH

C3

B-3

RD

/BK

C3

B-2

RD

C3

B-1

OR

/RD

TS

62

-5(D

68

)

OR

CR

34

#8

6

BL

/BK

L4

6(+

)

BK

/RD

TS

54

-1(D

13

)

BK

/WH

TS

56

-3

RD

TS

51

-4

BK

/12

KS

1-3

WH

HM

(+)

OR

/BK

TS

59

-3

OR

TS

59

-1

BK

/WH

TS

63

-3

BK

CR

69

-87

A

RD

C6

-1

13

4

118

13

3

13

2

59

13

4A

15

5

46

OR

/RD

C4

B-4

(D6

7)

RD

C6

-24

BL

/BK

C6

-11

OR

C6

-31

RD

C6

-23

OR

/RD

C5

-19

GR

C5

-7

BL

/BK

C6

-37

37

BL

/BK

C1

B-1

1

24

14

15

23

20

18

17

22 21

33

29

30

32 31

28

13 9 8 7

35 134 26

34

RD

/12

CB

2-2

GR

/BK

TS

57

-1

GR

TS

57

-3

BK

TS

52

-3

BK

/RD

R1

4(A

)

27

36

RD

TS

61

-4

WH

/BK

TS

62

-1

WH

TS

62

-3

RD

/WH

CR

34

#3

0

RD

/BK

CR

68

-87

A

5

WH

/RD

R1

4(A

)

WH

C5

-11

BL

C6

-36

RD

/WH

C5

-24

RD

C5

-6

RD

/BK

C6

-28

BL

/RD

C6

-13

RD

/BK

C6

-2

45

44

3941

42

40

43

GR

/WH

C6

-39

OR

C6

-40

OR

/RD

C6

-22

OR

/BK

C5

-2

RD

ISM

#4

BK

ISM

#3

WH

ISM

#7

PR

IB

OO

ME

XT

12

VP

OW

ER

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

(UN

US

ED

)

LIM

ITS

WIT

CH

-L

SB

1R

O

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

ER

EL

EA

SE

RE

VE

RS

E/E

DC

-

PL

AT

FO

RM

LE

VE

LA

LA

RM

EN

GIN

ES

TA

RT

12

VIG

NIT

ION

SU

PP

LY

(UN

US

ED

)

AC

GE

NE

RA

TO

R(O

PT

ION

)

ST

EE

RC

W

ST

EE

RC

CW

(UN

US

ED

)

RP

M/TA

CH

SIG

NA

L

LIM

ITS

WIT

CH

-L

ST

20

DR

IVE

EN

AB

LE

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

TF

OR

M

PL

AT

FO

RM

LE

VE

LU

P

(UN

US

ED

)

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ER

PM

GL

OW

PL

UG

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.F

AU

LT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-C5

-39

U1

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.O

N

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

RD

TB

23

A

BK

/WH

C5

-22

BK

/WH

TB

34

C

BR

GN

DS

TU

D

1 2 3

U16

5

BK

-C5

-5

18/22 CABLE

C5

BC

DA

12V TO PLAT

3

ENGINE16/22 CABLE

C6

FUNCTIONS

C1BC7B C2BC3BC4B

1 2

BA

SE

TE

RM

INA

TIO

NB

LO

CK

D6

RD

-T

B1

34

C1 4 7

C3

28

BL

/WH

-TB

13

2C

BK

-C7

B-1

WH

-TS

51

-5

RD

-TS

56

-2

GN

/BK

-TB

13

3C

BR

-GN

D

3 5 6

12

BK

-TB

22

C

OR

-134

A(D

)

RD

-44

C

CABLERESTRAINT

WH

/BK

-32C

BK

-GN

D

WH

-134

A(C

)

BL-

GN

DG

R-G

ND

D3

0R

D/B

KT

B4

4C

D2

9

WH

-BE

AC

ON

(LE

FT

)O

R-B

EA

CO

N(R

IGH

T)

TB

2C

-DE

SC

.A

LA

RM

(UN

US

ED

)

CABLERESTRAINT

GROUND STUD

CR

52

CR

53

CR

68

CR

69

GN

DB

R

TS

61

-6C

2P

BD

RD

/BK

TS

63

-1C

7P

BE

BK

TB

2D

R2

PB

DR

D/B

K

TB

7D

R7

PB

EB

K

RD

/BK

BK

C6

-30

C2

11L

OB

L/B

K

C6

-38

C2

12

LO

GR

/BK

ES0504D

PRIMARY BOOM EXTEND CUTOUT RELAY, OPERATIONALCR53

PRIMARY BOOM EXTEND CUTOUT RELAY, SAFETYCR69

HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51









PRIMARY BOOM DOWN CUTOUT RELAY, SAFETYCR68


LABEL

CB2

DESCRIPTION



PRIMARY BOOM DOWN CUTOUT RELAY, OPERATIONALCR52

GR

/BK

C3

2-8

RD

C3

2-1

GR

/BK

C4

B-8

GR

C4

B-7


GLOW PLUG TIME DELAY RELAYU16

WH/BK C4B-9

WH DL1

RD DL2

BK GND1

TB21C

CR23

10 AMP FUSE


BR GND2

KS

1-2

F19


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 51

Ground Control Box Switch Panel Wiring Diagram, S-80X,Deutz TD2011L04I Models

BL

/RD

-C5

-15

D2

NC

WH

/RD

-TS

62

-4

BR

-HM

(-)

OR

-TB

118

D

RD

-TS

63

-2

23

WH

/RD

-TB

6D

RD

/WH

-TB

3D

RD

/WH

-TS

61

-1

D4RD

-TS

61

-2

12

D6

8

D1

3

BK

/RD

-TB

35

D

BK

-TB

33

D

RD

- TB

20

D

OR

/RD

-TB

15

5D

WH

-TB

21

D

BK

-TB

22

D

BL

/BK

-TB

59

D

RD

-TB

1D

RD

/BK

-CR

52

-30

RD

/WH

-R1

4

WH

-TB

4D

WH

/BK

-TB

5D

WH

/RD

-R1

4(A

)

BK

-CR

53

-30

BK

/WH

-TB

8D

BK

/RD

-TB

9D

GN

/BK

- TB

18

D

GN

-TB

17

D

OR

/BK

-TB

15

D

OR

-TB

14

D

WH

-TB

23

D

RD

-R1

6

RD

-R1

6

RD

-TS

61

-2

RD

-TS

51

-1

BR

-CR

34

#8

5

BR

- HM

(-)

BR

-L4

6(-

)

BR

- GN

DS

TU

D

64

5

32

1

WH

-IS

M#

10

RD

-CB

2-1

RD

-P1

- 2

WH

-C3

2-6

WH

-TS

51

-2

WH

-KS

1-1

RD

-L4

5(+

)

4

3

2B

1B

2A

1A

641

3

3 2 1456

1236 5 4

123

3 2 1

12

31

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

L4

6

L2

TS

52

CB

2

TS

54

3

42

B

KS

1

B1

1N

C

P1

TS

51

NO

P4

TS

61

TS

63

TS

59

TS

57

TS

62

R1

6

R1

4

R1

4(A

)

CR

34

TS

56

12

3

RD

-C3

2-7

BL

/WH

-TB

34

D

G6

86

85 3

0

87

A

87

+ -

D6

4

4

3

NO

BK

C6

-12

RD

-TB

27

D

D1

01

ES0504D


6 - 52

Ground Control Box Switch Panel Wiring Diagram, S-80X,Deutz TD2011L04I Models

6 - 51


6 - 53

Platform Control Box Wiring Diagram, S-80X,Deutz TD2011L04I Models

6 - 54


1

2

3

4

5

6

7

8


6 - 54 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram, S-80X,Deutz TD2011L04I Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

LS

18

-C1

77

LS

BL

/RD

C1

P-1

2

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

6-C

34

SA

BK

/WH

C1

P-8

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

TS

75

-2C

18

4P

LW

H

C3

P-1

2P

10

9L

SB

L/W

H

L5

0(-)

C1

69

LE

D2

GR

L5

1(-)

C1

69

LE

D1

GR

TS

75

-3S

NS

RB

R

C1

P-1

2C

17

7L

SB

L/W

H

TS

75

-1P

10

9T

SG

R/W

H

CA

NH

I

CA

NL

OW

U13ALC-500

OPTION OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY

J8

-P1

09

LS

GR

/WH

C3

P-1

2


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0504D


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 55

Platform Control Box Switch Panel Wiring Diagram, S-80X,Deutz TD2011L04I Models

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L47

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

+

L51 L50

+

TS75

GR

J8

-10

GR

/WH

J8

-6

WH

J8

-2

GR

J8

-5

BR

J8

-8

RDBKBKBK

RDRD

ES0504D


H1

COMPONENT INDEX

TILT ALARM






L50 LED - ZONE B, 500 LB CAPACITY

L51 LED - ZONE A, 1000 LB CAPACITY


P3 HORN BUTTON









TS75 ZONE SELECT TOGGLE SWITCH (OPTION)


1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1




6 - 56

Platform Control Box Switch Panel Wiring Diagram, S-80X,Deutz TD2011L04I Models

6 - 55


6 - 57

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Perkins 804D-33 Models

6 - 58


1

2

3

4

5

6

7

8


6 - 58 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/S

TA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NOO

ILP

RE

SS

UR

ES

WIT

CH

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MP

OW

ER

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

G6

+

P25FS RD

P26ESTP BK

C1

-1C

27

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XR

D

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C1

-8

C1

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35

RP

MB

K/R

D

+

12V DC

B1B2

D22

CR17NO

D6

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

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OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

77

LS

BL

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P1

34

PW

RR

D

CB215AMP

C2

8T

TA

RD

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7

WH

GR

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TB2812 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1

P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

P24FS WH

P26ESTP BK

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CO

OL

ER

TE

MP.S

WIT

CH

(OP

TIO

N)

OIL

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LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

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ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D40

+

P1

09

LS

GR

/WH

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CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

RP

MS

OL

EN

OID

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67 D68

C4

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15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C1

-2

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.V

ALV

E(F

UN

CT

ION

EN

AB

LE

)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

C28TTA RD/BK

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD

C21ING WHC24TSPS WH

-

AU

XIL

IAR

YP

UM

P

C32

ES0503D

LO

W

RD

C33STR BK

-

CB2010A

M3

FB

M1

P1

34

FB

RD

12V DC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

HO

UR

ME

TE

R

M2

CH

EC

KE

NG

INE

LE

D

CR4NO

RP

MC

ON

TR

OL

RE

LA

Y

M4

FU

EL

PU

MP

R3

5R

PM

BK

/RD


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 59


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

7.5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5

C4

TR

LW

H

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)

CR34

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

C6

-31

TB118

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

24

14

23

13NO

NO

WH

BK

BR

RD

4 3 2 1

C11

8L

SO

R

P1

34

PW

RR

D


6 - 60


6 - 59


6 - 61

Ground Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Perkins 804D-33 Models

6 - 62


1

2

3

4

5

6

7

8


6 - 62 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

HM

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

C3

2-8

WH

/RD

-TR

AV

EL

AL

AR

M

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-T

B1

34

C

BK

-C7

B-1

GR

/BK

-T

B1

33

C

WH

-TS

51

-5R

D-T

S5

3-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

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20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

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CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

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RE

TR

AC

TE

DL

S

PR

IB

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ME

XT

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TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

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RE

VE

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E/E

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LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

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ION

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PP

LY

JIB

BO

OM

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AC

GE

NE

RA

TO

R

ST

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RC

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CC

W

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AL

BO

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AN

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TO

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DL

S

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EN

AB

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LS

AU

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OW

ER

FO

RW

AR

D/E

DC

+

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IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

DH

OR

N

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

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MR

ET

RA

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EN

GIN

ES

PE

ED

D2

9

OR

&W

H-B

EA

CO

NS

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

RD

KS

1-2

OR

/BK

ISM

#2

BK

/WH

TS

56

-3

BK

ISM

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.

FA

ULT

IGN

. /F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-C5

-39

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.

ON

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

WH

ISM

#7

GL

OW

PL

UG

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

S-8

5(O

PT

ION

)



LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51












WH/BK C4B-9

WH DL1

RD DL2

BK GND1

TB21C

CR23

10 AMP FUSE


BR GND2

RD

C3

2-1

(UN

US

ED

)

(UN

US

ED

)


ES503D

F19


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 63

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

E-S

TO

P

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-TB

13

4D

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

- HM

(-)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

BK

/WH

-TB

34

D

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

118

D

BR

-HM

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 3

0

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

ES0503D

TS

56

32

1

WH

-IS

M#

10

87


6 - 64

Ground Control Switch Panel Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),

Perkins 804D-33 Models

6 - 63


6 - 65 6 - 66

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Perkins 804D-33 Models


1

2

3

4

5

6

7

8


6 - 66 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

6-C

34

SA

BK

/WH

C1

P-8

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW U13

ALC-500

OPTION OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0503D

TS

8-C

43

JU

GR

C4

P-7

TS

8-C

44

JD

GR

/BK

C4

P-8

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

8-C

43

JU

GR

J2

2-5

J8

-P1

09

LS

GR

/WH

C3

P-1

2

LS

18

-C1

77

LS

BL

/RD

C1

P-1

2


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 67

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Perkins 804D-33 Models

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

RD

RDRD

ES0503D


H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON










1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1



TS8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6


BK

+

L47


6 - 68

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),

Perkins 804D-33 Models

6 - 67


6 - 69

Electrical Schematic, S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111)

6 - 70


1

2

3

4

5

6

7

8


6 - 70 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/

STA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NOO

ILP

RE

SS

UR

ES

WIT

CH

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MP

OW

ER

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

G6

+

P25FS RD

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C1

-9C

35

RP

MB

K/R

D

+

12V DC

B1B2

D22

CR17NO

D6

RP

MS

OL

EN

OID

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RR

D

CB215AMP

7

WH

GR

/BK

TB28

12 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1

P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

OIL

CO

LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D39

+

C1

33

PL

SG

R/B

K

L4

CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67D68

C4

-4V

15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD


-

AU

XIL

IAR

YP

UM

P

U33

ES0503A

LO

W

RD

C33STR BK

-

CB2010A

M3

FB

M1

P1

34

FB

RD

12V DC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

FU

EL

PU

MP

HO

UR

ME

TE

R

M2

CH

EC

KE

NG

INE

LE

D

H6

+

- L45

C1

-2C

28

TTA

RD

/BK

D40

D88PBOX

GROUND

2 SEC.

U35

PBOXGROUND

R14

4.7K�

P26ESTP BK

R26ESTP BK

2 SEC.

U34

C4

-10

LS18

LS18A

NO30A

5 9

8

3

2

NO10A

2

5

9

83

C132PLI BK

PBOXGROUND

C4

-10

CR4NO

M4

R3

5R

PM

BK

/RD

RP

MC

ON

TR

OL

RE

LA

Y


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 71


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

CR34

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5C

4T

RL

WH

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

22NCHO

21

C6

-31

TB118

C11

8L

SO

R

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)


6 - 72


6 - 71


6 - 73

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111)

6 - 74


1

2

3

4

5

6

7

8


6 - 74 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

G6

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

W

ST

EE

RC

CW

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

OR

-BE

AC

ON

(RIG

HT

)

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/24 CABLE

GL

OW

PL

UG

BK

/WH

TS

56

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.

FA

ULT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-C4

-10

9

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.

ON

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

PL

AT

FO

RM

LO

AD

INP

UT

PL

AT

FO

RM

LO

AD

AL

AR

M

OR

/BK

ISM

#2

BK

ISM

#3

WH

ISM

#7

WH

-BE

AC

ON

(LE

FT

)

S-8

5(O

PT

ION

)


ES0503A

WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

2310

AM

P

DR

IVE

LIG

HT

RE

LA

Y(O

PT

ION

)

BR

GN

D2

F1

9


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51














UN

US

ED

UN

US

ED



1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 75

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

- GN

DS

TU

D

BR

-L4

6(-

)

BR

- G6

(-)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

WH

-IS

M#

10

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

11

8D

BR

-G6

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 30

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

ES0503A

+

L4

5G

R/B

K-H

6(-

)

RD

-KS

1-2

RD

-TB

13

4D

87

TS

56

12

3

BK

/WH

-TB

34

D


6 - 76


Perkins 804D-33 Models (before serial number 8111)

6 - 75


6 - 77

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Perkins 804D-33 Models (before serial number 8111)

6 - 78


1

2

3

4

5

6

7

8


6 - 78 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)

J1

-SN

SR

GN

DB

RC

2P

-10

J1

-P1

09

AN

GG

R/W

HC

2P

-9

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

14

PL

UO

RC

4P

-2

TS

8-C

43

JU

GR

C4

P-7

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

7-C

17

PR

LG

RC

4P

-5

TS

8-C

44

JD

GR

/BK

C4

P-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

7-C

17

PR

LG

RJ2

2-4

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

8-C

43

JU

GR

J2

2-5

J22

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

44

DE

RB

L/W

H

TS

14

-C2

9M

SR

D/W

H

L1

-C1

3D

RE

(A)

BL

/RD

TS

15

-C1

43

DE

LB

L/B

K

D39

D40

J1

C2

8T

TA

RD

/BK

C1P-2 C28TTA RD/BK

L4

8-C

28

TTA

RD

/BK

H1

J1

9

1

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

GR

/BK

C3

P-1

2

JC

7-1

JS

GN

D2

BR

JC

7-2

P1

62

JP

W2

OR

JC

7-5

C1

63

PE

SW

H/B

K

JC

3-4

C1

60

JP

LW

H/R

D

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-1

JS

GN

D1

BR

JC

3-2

P1

62

JP

W1

OR

JC

3-5

C1

59

ST

CB

L/W

H

C2

P-1

0S

NS

RG

ND

BR

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-9

P1

09

AN

GG

R/W

H

C4

P(B

R)

C3

P(G

N)

C2

P(B

K)

C1

P(G

Y)

C2

PB

DR

D/B

KC

3P

-2

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

BL

C1

P-1

0

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

TS

2-C

33

ST

RB

KC

1P

-7

C3

2B

RK

WH

/RD

C1

P-6

C2

9M

SR

D/W

HC

1P

-3

TS

1-C

27

AU

XR

DC

1P

-1

TS

6-C

34

SA

BK

/WH

C1

P-8

C3

7S

TC

CB

L/B

KC

1P

-11

J2

C4

0L

SO

RC

2P

-2

C7

PB

EB

KC

3P

-7

C1

PB

UR

DC

3P

-1

C1

3D

RE

BL

/RD

C4

P-1

C8

PB

RB

K/W

HC

3P

-8

C6

TR

FW

H/R

DC

3P

-6

C9

PE

RF

BK

/RD

C3

P-9

C4

2L

SO

R/R

DC

2P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

0E

DC

+W

HC

1P

-4

C4

1R

PM

OR

/BK

C2

P-3

1

11

P2

-P2

6E

ST

PB

KC

9P

-1

P2

-P2

3P

WR

WH

C7

P-2

J3

-P2

4F

SW

HC

9P

-2

TS

2-P

25

FS

RD

C9

P-3

P3

-C4

6H

RN

GR

C2

P-5

L4

7-C

59

CN

KB

L/B

KC

3P

-11

P2

-P2

2P

WR

BK

C7

P-1

WH

C9

P-2

WH

L1

BK

P2

J3

1

3

H1

+ -BRN

GND STUD

BATGND J3-1

BATGND C7P-3

J22-1, 2, 9, 10, 11 & 12

C7P C9

12V BATT F.S.

LS18 OPT.

U13ALC-500

RD

LS

18

LS

18

-C1

32

PL

I1B

KC

1P

-12

H1

-C1

33

PL

AG

R/B

KC

3P

-12

GR

/BK

L4

D88

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

3

2

NO

5R

26

ES

TP

BK

C9

P-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

R2

0

C132PLI BK C3P-12

LS

18

-C1

32

PL

I2B

KC

3P

-10

COM

3

2

NO

5

U34

C3-10

C4-10

WH TS7

WH/RD C32BRK


OR/RD C40LS(SPLICE TOC40LS, C2P-2)


CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0503A


TS

47

C4

5G

EN

GR

/WH

C2

P-7


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 79

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (before serial number 8111)

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/WH

C1

P-8

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

C4

P-5

/J2

2-4

GR

/BK

C4

P-6

/J2

2-3

WH

C9

P-2

TS15

OR

J1

-11

RD

/WH

J1

-2

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

JC7

6

1

GR

C2

P-5

TS4

L1

+

L47

P3

NO

OR

C4

P-2

/J2

2-7

OR

/BK

C4

P-3

/J2

2-8

+

TS2

NC

WH

C7

P-2

BK

C7

P-1

RD

LS

18

BK

C9

-1

BK

J3

-3

TS7

TS8

TS14

TS1TS9

L48

P2RD

RD

BK

RD

ES0503A

+

L4

GR

/BK

H1

(D3

9)

TS6

BK

C1

P-7

BK

/RD

C1

P-9

JC3

61

WH

/RD

J1

-4

BR

J1

-14

BL

/WH

J1

-5

OR

J1

-13

1

CONTROL HARNESSTO PLATFROM BOX

H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON





















RD


6 - 80


Perkins 804D-33 Models (before serial number 8111)

6 - 79


6 - 81 6 - 82

Electrical Schematic, S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110)


1

2

3

4

5

6

7

8


6 - 82 S-80 • S-85 • S-80X Part No. 122985


SW4NO

MA

INA

UX

GROUNDAUXILIARY ON

KEY POWERBATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

8765

109

123

IGN / STARTMODULE

P1

34

PW

RR

DL

EV

EL

SE

NS

OR

SE

RV

ICE

HO

RN

B1

BA

TR

D

R4

6H

RN

GR

C4

1R

PM

OR

/BK

CR5NO

RD

TB41

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

IGN

ITIO

N/S

TA

RT

ER

RE

LA

Y

STA

RT

ER

AU

XIL

IAR

YP

UM

P

TB35

TS2ENGINESTART

R2

7A

UX

RD

PR1NO

C2

8T

TA

RD

/BK

CR1NO NO

CR2

TS51

TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33RD

C3

3S

TR

BK

P24FS WH

TS54ENG.RPM

HIG

H

TS4ENGINERPM

REGULATORIND

BAT+

STA

BAT-

EXCT

FU

EL

SO

LE

NO

ID

L2

C2

4T

SP

SW

H

S2NC

S1NO

OIL

PR

ES

SU

RE

SW

ITC

H

OL

IT

EM

PE

RA

TU

RE

SW

ITC

H

TB34

TS56GLOWPLUG

C3

4S

AB

K/W

H

TS6GLOWPLUG

CR3NO

RP

MP

OW

ER

RE

LA

Y

HIG

H

LO

W

TILT

AL

AR

M

RD

WH

BK

BK

H2

G6

+

P25FS RD

C1

-1C

27

AU

XR

D

C1

-7

C1

-8

C1

-9C

35

RP

MB

K/R

D

+

12V DC

B1B2

D22

CR17NO

D6

RP

MS

OL

EN

OID

C5

-7

C5

-2

C6

-28

C5

-6

C5

-15

R2

1IN

GW

H

C5

-22

C5

-18

D13

D12

C11

6H

YD

WH

R11

6H

YD

OR

A C

B

R3

3S

TR

BK

BL/RD

P2

2P

WR

BK

C1

32

PL

IB

L/W

H

P1

34

PW

RR

D

CB215AMP

7

WH

GR

/BK

TB28

12 8

TB134

RD

PLAT

GND

KS1TB22

P1 RD

6

1

4

3

5

C4

6H

RN

GR

H1P3HORN

RD

P2

3P

WR

WH

WH

TB23D2

FS1

BKC9P-1

P2

CR39ANO

C5

-5

D51

R21ING WH

P25FS RD

P24FS WH

OIL

CO

OL

ER

TE

MP.S

WIT

CH

(OP

TIO

N)

OIL

CO

LL

ER

FA

N(O

PT

ION

)

ALT

ER

NA

TO

R

BA

TT

ER

YS

EP

ER

AT

OR

STA

RT

BA

TT

ER

Y

CO

NT

RO

LB

AT

TE

RY

D39

+

C1

33

PL

SG

R/B

K

L4

CR15NO

GL

OW

PL

UG

GL

OW

PL

UG

CO

NT

RO

LR

EL

AY

RD

C6

-24

R3

4S

AB

K/W

H

C5

-3

F1720A

F2260A

F720A

C9P-3

C9P-2

GBOXGROUND

FB

P1

34

FB

RD

D64

P4FUNC. ENABLE

TB133

TB132

TB46

D67D68

C4

-4V

15

5P

CE

OR

/RD

TB155

V1

55

PC

EO

R/R

D

C3

-12

C2

-5

C2

-6

C1

-12

C7

-1

3

1

4

2

C5

-1

P24PWR RD

PR

ES

SU

RE

CO

MP.V

ALV

E(F

UN

CT

ION

EN

AB

LE

)

Y74

TB20

B

B1

PR2

BAT2 APU

B1BAT RD

D4

P24FS WH

P26ESTP BK

C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C5

-19

C7

-2

C5

-11

TB21

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C27AUX RD

P24PWR RD


-

AU

XIL

IAR

YP

UM

P

U33

ES0503D

LO

W

RD

C33STR BK

-

CB2010A

M3

FB

M1

P1

34

FB

RD

12V DC

-

+

-

SE

RV

ICE

HO

RN

RE

LA

Y

STA

RT

ER

PO

WE

RR

EL

AY

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PC

ON

TR

OL

RE

LA

Y

FU

EL

SO

LE

NO

IDC

ON

TR

OL

RE

LA

Y

FU

EL

PU

MP

HO

UR

ME

TE

R

M4

CH

EC

KE

NG

INE

LE

D

H6

+

- L45

C1

-2C

28

TTA

RD

/BK

D40

D88

D89

PBOXGROUND

2 SEC.

U3530A

PBOXGROUND

R14

4.7K�

P26ESTP BK

R26ESTP BK

2 SEC.

U3410A

C3

-10

C1

32

PL

I2B

K

LS18

LS18A

NO

2 9

8

3

5

NO

5

2

9

83

CR4NO

M2

RP

MC

ON

TR

OL

RE

LA

Y

R3

5R

PM

BK

/RD


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 83


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

7.5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5C

4T

RL

WH

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)

CR34

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

C6

-31

TB118

24

14

23

13NO

NO

WH

BK

BR

RD

4 3 2 1

C11

8L

SO

R

P1

34

PW

RR

D


6 - 84

Electrical Schematic, S-80 and S-85 (CE)Perkins 804D-33 Models (after serial number 8110)

6 - 83


6 - 85 6 - 86

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110)


1

2

3

4

5

6

7

8


6 - 86 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

G6

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

W

ST

EE

RC

CW

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

RD

U3

4-2

OR

&W

H-B

EA

CO

NS

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

GL

OW

PL

UG

BK

/WH

TS

56

-3

U1

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.

FA

ULT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

( -)

10

WH

-U3

4#

99

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.

ON

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

RD

ISM

#4

D6

PL

AT

FO

RM

LO

AD

INP

UT

PL

AT

FO

RM

LO

AD

AL

AR

M

OR

/BK

ISM

#2

BK

ISM

#3

WH

ISM

#7

S-8

5(O

PT

ION

)


WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

23

10

AM

PF

US

E

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

BR

GN

D2

F1

98 9

U34

3 5

WH

C5

-3

WH

ISM

-#9

BR

GN

D

BK

C3

B-1

0

2R

DT

B1

34

C(A

)


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51






LOAD SENSE MODULE









(UN

US

ED

)

ES0503D

U33



1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 87

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

51

P1

NC

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

13

21

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

- G6

(-)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

-TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/ BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

WH

-IS

M#

10

BK

/RD

-TB

35

D

D6

4D

13

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

RD

-TS

63

-2

OR

-TB

118

D

BR

-G6

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/RD

-C5

-15

87

A

85 3

0

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TI O

NS

ES0503D

+

L4

5G

R/B

K-H

6(-

)

RD

-KS

1-2

RD

-TB

13

4D

87

TS

56

12

3

BK

/WH

-TB

34

D


6 - 88


Perkins 804D-33 Models (after serial number 8110)

6 - 87


6 - 89

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Perkins 804D-33 Models (after serial number 8110)

6 - 90


1

2

3

4

5

6

7

8


6 - 90 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

6-C

34

SA

BK

/WH

C1

P-8

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

H1

-C1

33

PL

AG

R/B

KC

3P

-12

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW


LS18 OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0503D

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

32

NO

5

R2

6E

ST

PB

KC

9P

-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

47

00

�

R2

0

D88

D89


C132PLI2 BK C3P-10

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

8-C

43

JU

GR

J2

2-5

TS

8-C

43

JU

GR

C4

P-7

TS

8-C

44

JD

GR

/BK

C4

P-8

GR

/BK

L4

GR

/BK

C3

P-1

2

D39


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 91

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Perkins 804D-33 Models (after serial number 8110)

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

GR

/BK

H1

(D3

9)

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L4

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

RDBK

RDRD

ES0503D


1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1


H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON
















U35 TIME DELAY RELAY


TS8

GR

/BK

C4

P-8

/J2

2-6

GR

C4

P-7

/J2

2-5

+

L47

BR

GN

DS

TU

D


6 - 92


Perkins 804D-33 Models (after serial number 8110)

6 - 91


6 - 93

Electrical Schematic, S-80X,Perkins 804D-33 Models

6 - 94


1

2

3

4

5

6

7

8


6 - 94 S-80 • S-85 • S-80X Part No. 122985


MA

INA

UX

.

+

3

1

4

2

B

B1

-

CB2

15 AMP

TB20

P1

KS1

PLAT

GRD

TB22

TB134

TB132

GROUND

4

1 3

5

6

12

7

8C32

TB133

H1

D40L48

P2

P3HORN

C2

-6

C7

-1

P1

34

PW

RR

D

P2

2P

WR

BK

C2

-5

TB28

TB46

TB23D2

C1

-2

C7

-2

C9P-1

FS1C9P-3

C9P-2

P26ESTP BK

P25FS RD

P24FS WH

P25FS RD

P24FS WH

TS1AUXILIARYPUMP

TS2ENGINESTART

TS6GLOWPLUG

TS4ENGINERPM

P26ESTP BK

C28TTA RD/BK C28TTA RD/BK

P26ESTP BK

P24FS WH

C1

-1

C1

-7

C1

-8

C1

-9

V1

55

PC

EO

R/R

D

D12

HIG

HR

PM

(FS

)

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

D67 D68

D4

TB41

TB155

C3

5R

PM

BK

/RD

D13

TB35

TS54ENGINERPM

LO

WR

PM

HIG

HR

PM

LO

WR

PM

TB34

D64

TB33

D6

TB27

P4FUNCTION

ENABLE

TS56GLOWPLUG

TS52ENGINESTART

AU

XIL

IAR

YP

UM

P

TS51

C3

4S

AB

K/W

H

C3

3S

TR

BK

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3P

WR

WH

C4

6H

RN

GR

B1

BA

TR

D

B1

BA

TR

D

F17

20A

C5

-2

C5

-7

C6

-24

C6

-28

C5

-5

P24PWR RD

R21IGN WH

B1BAT RD

BAT2 APU RD

C5

-6

C5

-1

C5

-3

C5

-15

C5

-22

C5

-18

C5

-19

C5-11TB21

12

3

4

5

6

7

8

9

10

START RELAYTACHOMETER

START INPUT

AUXILIARY

GROUND

BATTERY

KEY POWER

KEY BYPASS

IGN / FUEL ON

ENGINE FAULT

IGN / STARTMODULE

L2

BL/RD

HM

+

-

C27AUX RD

C41RPM OR/BK

P23PWR WH

C33STR BK

C33STR BKC27AUX RD

P24PWR RD

C21IGN WHC24TSPS WH

F7

20A

D22

12V DC 12V DC

B2 B1

+ +

- -

BAT+

BAT-

STA

INDREGULATOR

EXCT

ALTERNATOR

FB FB

C4

1R

PM

OR

/BK

P1

34

FB

RD

P1

34

FB

RD

CR17NO

30

87

86

85R11

6H

YD

OR

C11

6H

YD

WH

CR5NO

R4

6H

RN

GR

86

85

30

87

HYDFAN

SW4NO

H2

A C

B

RD

WH

D51

P1

34

PW

RR

D

C2

8T

TA

RD

/BK

BK

PR2

M3

R3

3S

TR

BK

CR1 CR39A CR2NO

86

85

30

87

NO

86

85

30

87

NO

R2

7A

UX

RD

PR1NO

M2

R2

1IG

NW

H

F2260A

CR15NO

86

85

30

87

S2 S1

NC NOC

24

TS

PS

WH

V1

55

PC

EO

R/R

D

CR3NO

86

85

30

87

CB2010A

Y74

R3

4S

AB

K/W

H

CO

NT

RO

LB

AT

TE

RY

STA

RT

BA

TT

ER

Y

BA

TT

ER

YS

EP

ER

AT

OR

ALT

ER

NA

TO

R

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

OIL

CO

OL

ER

FA

N(O

PT

ION

)

OIL

CO

OL

ER

TE

MP

ER

AT

UR

ES

WIT

CH

(OP

TIO

N)

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

STA

RT

ER

MO

TO

R

PO

WE

RR

EL

AY

IGN

ITIO

N/

STA

RT

RE

LA

Y

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

PP

OW

ER

RE

LA

Y

AU

XIL

IAR

YP

UM

PR

EL

AY

FU

EL

SO

LE

NO

ID

IGN

ITIO

NP

OW

ER

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

RT

EM

PE

RA

TU

RE

SW

ITC

H

GL

OW

PL

UG

GL

OW

PL

UG

RE

LA

Y

FU

EL

PU

MP

RP

MR

EL

AY

PO

WE

RR

EL

AY

PR

ES

SU

RE

CO

MP

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

HO

UR

ME

TE

R

ES0503D

CR4

RP

MS

OL

EN

OID

M4

P210PWR BK

ZONE A

ZONE B

OFF

1000 LB (A)

500 LB (A & B)

D101


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 95


P134PWR RD

D23

D24

17

10 56 82

1

4

2

3

5

6

P162JPW1-OR

JSGND1-BR

C159STC-BL/WH

C160JPL-WH/RD

C159STC-BL/WH

J25

910

JC3DRIVE / STEER


1

4

2

3

5

6

P162JPW2-OR

JSGND2-BR

C164PES-RD/WH

C165TRS-WH/RD

C163PLS-WH/BK

J127

31 2 654

J114

BK

RD

YL

OR

BR

BL

RIG

HT

LE

FT

1

2 12

11

14

13

5

7 158166 452 1 314

15

16

19

18

17

20 411910678 14

13

12

3


TB134A

3 2

SN

SR

-GN

DB

R

P1

09

AN

GG

R/W

H

C1

23

PB

SR

D/B

K

J3

J2

CR30

NO


NC

CR27L47

TS9PLATFORMLEVEL

TS7PLATFORMROTATE

CW

CC

W

DO

WN

UP

C5

9C

NK

BL

/BK

J2

2-7

J2

2-8

J2

2-5

J2

2-6

J2

2-4

J2

2-3

J2

2-2

J2

2-1

J2

2-1

0

J2

2-9

J2

2-1

2

J2

2-11

Y71 Y70 Y19 Y20

GND BR

C28TTA RD/BK

P26ESTP BK

P24FS WH

P2

6E

ST

PB

K

P2

4F

SW

H

P2

4F

SW

H

GN

DB

R

C1

84

PL

WH

P1

09

TS

GR

/WH

ZO

NE

SE

LE

CT

SN

SR

BR

L51 L50

ZONE A ZONE B

C2

08

LE

DG

R

C2

09

LE

DB

L

C1

43

DE

LB

L/B

K

TS15DRIVEENABLE

TS75ZONE SELECT

C1

44

DE

RB

L/W

H

L1

LE

DB

L/R

D

C2

9M

SR

D/W

H

TS14DRIVESELECT

H1

RD

/BK

J1 J8 J8 J1 J1 J1

J2

P210PWR BK

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

C4

-6

C4

-5

C4

-8

C4

-7

C4

-3

C4

-2

C3

-11

C1

-3

C1

-6

C1

-10

C1

-11

C1

-5

C1

-4

C3

-3

C3

-2

C3

-1

C1

-12

BL

/RD

GR

/WH

C3

-12

C2

-3

C3

-7

C3

-8

C3

-9

C3

-4

C3

-5

C3

-6

C4

-1

C2

-2

C2

-4

C2

-8

C2

-9

C2

-10

C7

-3

CC

W

TS57PLATFORMROTATE

CW

TB18

TB17

TB44

TB43D30

D29

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C4

4JD

GR

/BK

C4

3JU

GR

TS59

TB15

TB14

DO

WN

UP

PL

AT

FO

RM

LE

VE

L

TB59

L46

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

TB29 TB32

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

TB36 TB37

TB31 TB30

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

R16


R16

10�

CR34 CR68

CR53

UP

DO

WN C1

77

LS

BL

/RD

TB1

TB2

TB3

P1

09

LS

GR

/WH

CR52

CR69


C7

PB

EB

K

EX

TE

ND

RE

TR

AC

T

C8

PB

RB

K/W

H

C9

PE

RB

K/R

D

R14(A)

5�

TS62TURNTABLEROTATE

C4

TR

LW

H

CW

CC

W

TB13

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

3D

RE

BL

/RD

TB42

P1

34

PW

RR

D

C4

0L

SO

R

C4

2L

SO

R/R

D

P1

09

AN

GG

R/W

H

SN

SR

-GN

DB

R

C1

23

PB

SR

D/B

K

GN

DB

R

C6

-24

C6

-11

C5

-24

C5

-23

C6

-36

C6

-37

C5

-20

C5

-21

C11

8L

SO

R

TB118 C6

-31

C6

-3

C6

-2

C6

-1

C6

-12

P2

10

PW

RB

K

P1

34

PW

RR

D

C6

-21

C6

-30

C6

-38

C6

-16

BL

/RD

C2

11P

LO

BL

/BK

S2

12

PL

OG

R/B

K

GR

/WH

J133

J133B

K

RD

OR

WH

1 4 5 2

BL

3 6

BR

BL

BK

GR

J134

C1

29

DA

RD

/BK

C2

9M

SR

D/W

H

H4

C3

2B

RK

WH

/RD

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C9

PE

RF

BK

/RD

C8

PB

RB

K/W

H

C7

PB

EB

K

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C6

-9

C6

-8

C6

-7

C6

-6

C6

-5

C6

-4

TB9

TB8

TB7

TB5

TB4

NO14

13

WH

BK

Y27 Y2 Y4 Y3 Y5 Y6

U4

Y12 Y21 Y22 Y15 Y25 Y26 Y13 Y24 Y23

21

22

NC

BR

RD

4 3 2 1

24 23

14 13

NO

NO

22 21

14 13

NO

NC22 21

14 13NO

NC22 21

14 13NO

NC

WH

BK

/WH

BK

BR

RD

4 3 2 1 4 3

2 1

BR

BL

BK

BK

/WH

BR

BL

BK

WH

BK

BR

RD

2 1

2 1 4 3 2 1 2 1BR

RD

WH

BK

BR

RD

WH

BK

BR

RD

WH

BK

2324

NO

1314

NO

2324

NO

1314

NO

2122

NC

1314

NO

C6

-13

C6

-25

C6

-23

C6

-40

C6

-22

C6

-35

C6

-34

C6

-33

C4

2L

SO

R/R

D

C4

0L

SO

R

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

PL

AT

FO

RM

RO

TA

TE

CW

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

DE

SC

EN

TA

LA

RM

LO

OS

EC

AB

LE

LE

D’S

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

ST

EE

RC

W

ST

EE

RC

CW

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

CR

34

-P

RIM

AR

YB

OO

MS

PE

ED

RE

DU

CT

ION

RE

LA

Y

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

LS

T3

O-

BO

OM

UP

/DO

WN

GR

OU

ND

BO

X-

ZO

NE

AO

PE

RA

TIO

NA

ND

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

LS

B1

EO

-B

OO

ME

XT

EN

DC

AP

AC

ITY

OP

ER

AT

ION

AL

LIM

ITS

WIT

CH

LS

B1

ES

-B

OO

ME

XT

EN

DC

AP

AC

ITY

SA

FE

TY

LIM

ITS

WIT

CH

LS

T3

S-

BO

OM

AN

GL

ES

TO

WE

DG

RO

UN

DB

OX

-Z

ON

EA

SA

FE

TY

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

TF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

CW

TU

RN

TA

BL

ER

OTA

TE

CC

W

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

LS

B1

RO

BO

OM

RE

TR

AC

TD

RIV

E/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T2

OA

NG

LE

ST

OW

ED

DR

IVE

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

S1

7P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-O

PE

RA

TIO

NA

L

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


6 - 96


6 - 95


6 - 97 6 - 98

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Perkins 804D-33 Models


1

2

3

4

5

6

7

8


6 - 98 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Perkins 804D-33 Models

BK

C5

-5

RD

-TB

20

B

RD

-TB

20

A

BR

-GN

DS

TU

D

WH

-TB

23

B

BK

-C3

2-5


BK

C3

2-4

BL

/WH

C3

2-3

OR

/BK

ISM

#2

RD

/12

BA

TT

+R

D/1

2B

AT

T+

WH

KS

1-1

(D2

)W

H/1

2C

7B

-2

RD

C6

-25

BK

/RD

C5

-18

WH

/RD

C5

-23

WH

/BK

C5

-20

WH

C5

-21

BK

/RD

C6

-9

BK

/WH

C6

-8

BK

C6

-7

WH

/RD

C6

-6

WH

/BK

C6

-5

WH

C6

-4

RD

/WH

C6

-3

RD

C2

B-6

BL

/BK

C3

B-1

1

GR

C2

B-5

GR

/WH

C2

B-7

OR

/RD

C2

B-4

OR

/BK

C2

B-3

OR

C2

B-2

BL

C1

B-1

0

BK

/RD

C1

B-9

BK

/WH

C1

B-8

RD

C1

B-1

RD

/BK

C1

B-2

WH

/BK

C1

B-5

RD

/WH

C1

B-3

WH

C1

B-4

WH

/RD

C1

B-6

BK

C1

B-7

GR

/BK

C4

B-6

GR

C4

B-5

OR

/BK

C4

B-3

OR

C4

B-2

BL

/RD

C4

B-1

BK

/RD

C3

B-9

BK

/WH

C3

B-8

BK

C3

B-7

WH

/RD

C3

B-6

WH

/BK

C3

B-5

WH

C3

B-4

RD

/WH

C3

B-3

RD

/BK

C3

B-2

RD

C3

B-1

OR

/RD

TS

62

-5(D

68

)

OR

CR

34

#8

6

BL

/BK

L4

6(+

)

BK

/RD

TS

54

-1(D

13

)

BK

/WH

TS

56

-3

RD

TS

51

-4

BK

/12

KS

1-3

WH

HM

(+)

OR

/BK

TS

59

-3

OR

TS

59

-1

BK

/WH

TS

63

-3

BK

CR

69

-87

A

RD

C6

-1

13

4

118

13

3

13

2

59

13

4A

15

5

46

OR

/RD

C4

B-4

(D6

7)

RD

C6

-24

BL

/BK

C6

-11

OR

C6

-31

RD

C6

-23

OR

/RD

C5

-19

GR

C5

-7

BL

/BK

C6

-37

37

BL

/BK

C1

B-1

1

24

14

15

23

20

18

17

22 21

33

29

30

32 31

28

13 9 8 7

35 134 26

34

RD

/12

CB

2-2

GR

/BK

TS

57

-1

GR

TS

57

-3

BK

TS

52

-3

BK

/RD

R1

4(A

)

27

36

RD

TS

61

-4

WH

/BK

TS

62

-1

WH

TS

62

-3

RD

/WH

CR

34

#3

0

RD

/BK

CR

68

-87

A

5

WH

/RD

R1

4(A

)

WH

C5

-11

BL

C6

-36

RD

/WH

C5

-24

RD

C5

-6

RD

/BK

C6

-28

BL

/RD

C6

-13

RD

/BK

C6

-2

45

44

3941

42

40

43

GR

/WH

C6

-39

OR

C6

-40

OR

/RD

C6

-22

OR

/BK

C5

-2

RD

ISM

#4

BK

ISM

#3

WH

ISM

#7

PR

IB

OO

ME

XT

12

VP

OW

ER

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

(UN

US

ED

)

LIM

ITS

WIT

CH

-L

SB

1R

O

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

ER

EL

EA

SE

RE

VE

RS

E/E

DC

-

PL

AT

FO

RM

LE

VE

LA

LA

RM

EN

GIN

ES

TA

RT

12

VIG

NIT

ION

SU

PP

LY

(UN

US

ED

)

AC

GE

NE

RA

TO

R(O

PT

ION

)

ST

EE

RC

W

ST

EE

RC

CW

(UN

US

ED

)

RP

M/TA

CH

SIG

NA

L

LIM

ITS

WIT

CH

-L

ST

20

DR

IVE

EN

AB

LE

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

TF

OR

M

PL

AT

FO

RM

LE

VE

LU

P

(UN

US

ED

)

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ER

PM

GL

OW

PL

UG

RD

-C5

-1

KE

YB

YP

AS

S

BA

TT

ER

Y

KE

YP

WR

.

EN

G.F

AU

LT

IGN

./F

UE

LO

N

WH

-TB

23

C6 87

WH

L2

(-)

10

WH

-C5

-39

U1

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

X.O

N

GR

OU

ND

STA

RT

RE

LA

YO

R/B

K-T

B4

1C

BK

-TB

33

C

RD

-TB

27

C

BR

GN

D

1 2 3 4 5

BK

-C5

-5

18/22 CABLE

C5

BC

DA

12V TO PLAT

3

ENGINE16/22 CABLE

C6

FUNCTIONS

C1BC7B C2BC3BC4B

1 2

BA

SE

TE

RM

INA

TIO

NB

LO

CK

D6

RD

-T

B1

34

C1 4 7

C3

28

BL

/WH

-TB

13

2C

BK

-C7

B-1

WH

-TS

51

-5

RD

-TS

56

-2

GN

/BK

-TB

13

3C

BR

-GN

D

3 5 6

12

BK

-TB

22

C

OR

-134

A(D

)

RD

-44

C

CABLERESTRAINT

WH

/BK

-32C

BK

-GN

D

WH

-134

A(C

)

BL-

GN

DG

R-G

ND

D3

0R

D/B

KT

B4

4C

D2

9

WH

-BE

AC

ON

(LE

FT

)O

R-B

EA

CO

N(R

IGH

T)

TB

2C

-DE

SC

.A

LA

RM

(UN

US

ED

)

CABLERESTRAINT

GROUND STUD

CR

52

CR

53

CR

68

CR

69

GN

DB

R

TS

61

-6C

2P

BD

RD

/BK

TS

63

-1C

7P

BE

BK

TB

2D

R2

PB

DR

D/B

K

TB

7D

R7

PB

EB

K

RD

/BK

BK

C6

-30

C2

11L

OB

L/B

K

C6

-38

C2

12

LO

GR

/BK

ES0503D



HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51











LABEL

CB2

DESCRIPTION




GR

/BK

C3

2-8

RD

C3

2-1

GR

/BK

C4

B-8

GR

C4

B-7


WH/BK C4B-9

WH DL1

RD DL2

BK GND1

TB21C

CR23

10 AMP FUSE


BR GND2

KS

1-2

F19


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 99

Ground Control Box Switch Panel Wiring Diagram, S-80X,Perkins 804D-33 Models

BL

/RD

-C5

-15

D2

NC

WH

/RD

-TS

62

-4

BR

-HM

(-)

OR

-TB

118

D

RD

-TS

63

-2

23

WH

/RD

-TB

6D

RD

/WH

-TB

3D

RD

/WH

-TS

61

-1

D4RD

-TS

61

-2

12

D6

8

D1

3

BK

/RD

-TB

35

D

BK

-TB

33

D

RD

-TB

20

D

OR

/RD

-TB

15

5D

WH

-TB

21

D

BK

-TB

22

D

BL

/BK

- TB

59

D

RD

-TB

1D

RD

/BK

-CR

52

-30

RD

/WH

-R1

4

WH

-TB

4D

WH

/BK

-TB

5D

WH

/RD

-R1

4(A

)

BK

-CR

53

-30

BK

/WH

-TB

8D

BK

/RD

-TB

9D

GN

/BK

-TB

18

D

GN

-TB

17

D

OR

/BK

-TB

15

D

OR

-TB

14

D

WH

-TB

23

D

RD

-R1

6

RD

-R1

6

RD

-TS

61

-2

RD

-TS

51

-1

BR

-CR

34

#8

5

BR

-HM

(-)

BR

-L4

6(-

)

BR

-GN

DS

TU

D

64

5

32

1

WH

-IS

M#

10

RD

-CB

2-1

RD

-P1

- 2

WH

-C3

2-6

WH

-TS

51

-2

WH

-KS

1-1

RD

-L4

5(+

)

4

3

2B

1B

2A

1A

641

3

3 2 1456

1236 5 4

123

3 2 1

12

31

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TI O

NS

L4

6

L2

TS

52

CB

2

TS

54

3

42

B

KS

1

B1

1N

C

P1

TS

51

NO

P4

TS

61

TS

63

TS

59

TS

57

TS

62

R1

6

R1

4

R1

4(A

)

CR

34

TS

56

12

3

RD

-C3

2-7

BL

/WH

-TB

34

D

G6

86

85 3

0

87

A

87

+ -

D6

4

4

3

NO

BK

C6

-12

RD

-TB

27

D

D1

01

ES0503D


6 - 100

Ground Control Box Switch Panel Wiring Diagram, S-80X,Perkins 804D-33 Models

6 - 99


6 - 101

Platform Control Box Wiring Diagram, S-80X,Perkins 804D-33 Models

6 - 102


1

2

3

4

5

6

7

8


6 - 102 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram, S-80X,Perkins 804D-33 Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

LS

18

-C1

77

LS

BL

/RD

C1

P-1

2

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

6-C

34

SA

BK

/WH

C1

P-8

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

TS

75

-2C

18

4P

LW

H

C3

P-1

2P

10

9L

SB

L/W

H

L5

0(-)

C1

69

LE

D2

GR

L5

1(-)

C1

69

LE

D1

GR

TS

75

-3S

NS

RB

R

C1

P-1

2C

17

7L

SB

L/W

H

TS

75

-1P

10

9T

SG

R/W

H

CA

NH

I

CA

NL

OW

U13ALC-500

OPTION OPTION

H1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY

J8

-P1

09

LS

GR

/WH

C3

P-1

2


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0503D


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 103

Platform Control Box Switch Panel Wiring Diagram, S-80X,Perkins 804D-33 Models

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

/WH

C1

P-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7

P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2 TS6

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

+

L51 L50

+

TS75

GR

J8

-10

GR

/WH

J8

-6

WH

J8

-2

GR

J8

-5

BR

J8

-8

RDBKBKBK

RDRD

ES0503D


H1

COMPONENT INDEX

TILT ALARM









P3 HORN BUTTON









TS75 ZONE SELECT TOGGLE SWITCH (OPTION)


1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1



+

L47


6 - 104

Platform Control Box Switch Panel Wiring Diagram, S-80X,Perkins 804D-33 Models

6 - 103


6 - 105

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS)Continental TME27 Models

6 - 106


1

2

3

4

5

6

7

8


6 - 106 S-80 • S-85 • S-80X Part No. 122985

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models

C3

3S

TR

BK

C3

5R

PM

BK

/RD

P2

2P

WR

BK

C1

77

LS

BL

/RD

P1

34

PW

RR

D

12

6

4

+

3

1

4

2

B

B1

-

PU

MP

AU

XIL

IAR

Y

C32

RD RD

RD

KS1

PLAT

GND

TB22

RD

TB20

CB215 AMP P1

GBOX GND

1 3

5

7

8TB133

TB134TB132

WH

RD

TB46

GN

/WH

TB28

P3HORN

C7

-1

C1

-12

C2

-6

RD

BK

P2C9P-1

BK

FS1 C9P-3

C9P-2

P26ESTP BK

P25FS RD

P24FS WH

P25FS RD

P24FS WH

D40

H1

L48

TS1AUXILIARYPUMP

TS2ENGINESTART

C28TTA RD/BK

V1

55

PC

EO

R/R

D

TS4ENGINERPM

TS3FUELSELECT

HIG

H

D10

D12

LO

W

LP

GA

S

C28TTA RD/BK

P26ESTP BK

P24FS WH

C2

-1

C1

-9

C4

-4

C1

-7

C1

-1

C7

-2

C1

-2

C3

-12

C2

-5C

46

HR

NG

R

C1

09

LS

GR

/WH

C2

8T

TA

RD

/BK

WH

P2

3P

WR

WH

D2TB23

TB27

RD

TB33

TS51

C2

7A

UX

RD

TS52ENGINESTART

P4FUNCTION

ENABLE

TB155 TB21

D67D68

G6

+

-

TS64ENGINEFAULT

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ES0505D

D43


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 107

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS)Continental TME27 Models

C5

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S-85(OPTION)


6 - 108

Electrical Schematic, S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models

6 - 107


6 - 109 6 - 110

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models


1

2

3

4

5

6

7

8


6 - 110 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

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C5

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C5

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C6

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43

40

42 41

39

44

45

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C6

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C6

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C5

-6

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C6

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C5

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4(A

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5

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61

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62

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61

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27

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63

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57

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57

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32

30

29

33 21

22

17

18

20

23

15

14

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C6

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46

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CABLERESTRAINT


ES0505D

S-8

5(O

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AY

BR

GN

D2


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51


FUEL SELECT TOGGLE SWITCHTS53









F1

9

ENGINE FAULT CODE TEST TOGGLE SWITCHTS64


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 111

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

53

TS

51

P1

NC

E-S

TO

P

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

12

31

32

1

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

-HM

( -)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

- TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/ BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

BL

/RD

-TB

39

D

BK

/RD

-TB

35

D

D1 1

D1

3

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

OR

/BK

-TB

15

D

RD

-TS

63

-2

OR

-TB

118

D

BR

-HM

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/WH

-C5

-13

87

A

85 3

0

TO GROUNDCONTROL BOXCONNECTIONS

ES0505D

87


6 - 112

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

6 - 111


6 - 113

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS),Continental TME27 Models

6 - 114


1

2

3

4

5

6

7

8


6 - 114 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

LS

18

-C1

32

PL

IR

DC

1P

-12

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW

U13ALC-500

OPTION OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY

J8

-P1

09

LS

BL

/WH

C3

P-1

2

ES0505D

WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)


TS

8-C

43

JU

GR

J2

2-5

TS

8-C

44

JD

GR

/BK

J2

2-6


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 115

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

C4

P-5

/J2

2-4

GR

/BK

C4

P-6

/J2

2-3

WH

C9

P-2

TS15

JC3

61

WH

/RD

J1

-4

BR

J1

-14

BL

/WH

J1

-5

OR

J1

-13

OR

J1

-11

RD

/WH

J1

-2

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

JC7

6

1

GR

C2

P-5

TS4

L1

+

L47

P3

NO

OR

C4

P-2

/J2

2-7

OR

/BK

C4

P-3

/J2

2-8

+

TS3

TS2

NC

WH

C7

P-2

BK

C7

P-1

RD

LS

18

BK

C9

-1

BK

J3

-3

TS7

TS8

TS14

TS1TS9

L48

P2

BL

/RD

C2

P-1

D10

RD

RD

BK

RD

D43

ES0505D

1


H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON



TS3 FUEL SELECT TOGGLE SWITCH









CR30 LIFT / DRIVE SELECT - LIMIT SWITCH CIRCUIT (OPTION) 1 ROCKER STEER OPTION



6 - 116

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (ANSI / CSA / AS), Continental TME27 Models

6 - 115


6 - 117 6 - 118

Electrical Schematic, S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111)


1

2

3

4

5

6

7

8


6 - 118 S-80 • S-85 • S-80X Part No. 122985


C3

3S

TR

BK

C3

5R

PM

BK

/RD

12

6

4

+

3

1

4

2

B

B1

-

PU

MP

AU

XIL

IAR

Y

U33

RD RD

RD

KS1

PLAT

GND

TB22

RD

TB20

CB215 AMP P1

GBOX GND

1 3

5

7

8TB133

TB134TB132

WH

RD

TB46

GN

/BK

TB28

P3HORN

C7

-1

C1

-12

C2

-6

RD

BK

P2C9P-1

FS1 C9P-3

C9P-2

P26ESTP BK

P25FS RD

P24FS WH

P25FS RD

P24FS WH

D39

H1

TS1AUXILIARYPUMP

TS2ENGINESTART

V1

55

PC

EO

R/R

D

TS4ENGINERPM

TS3FUELSELECT

HIG

H

D10

D12

LO

W

LP

GA

S

C28TTA RD/BK

P26ESTP BK

P24FS WH

C2

-1

C1

-9

C4

-4

C1

-7

C1

-1

C7

-2

C1

-2

C3

-12

C2

-5C

46

HR

NG

R

C1

33

PL

AG

R/B

K

C2

8T

TA

RD

/BK

WH

P2

3P

WR

WH

D2TB23

TB27

RD

TB33

TS51

C2

7A

UX

RD

TS52ENGINESTART

P4FUNCTION

ENABLE

TB155 TB21

D67D68

G6

+

-

TS64ENGINEFAULT

L2

TS54ENGINERPM

TS53FUELSELECT

HIG

H

LO

WD13

D11

LP

GA

S

TB35 TB39

D4

C3

9L

PB

L/R

D

P134PWR RD

C41RPM OR/BK

C27AUX+FE RD

C27AUX RD

TB41

C27AUX RD

P134PWR RD

P23PWR WH

C5

-7

C6

-24

C6

-28

C5

-6

C5

-1

C5

-5

C5

-19

C5

-11C5-2

C5-10

C5-9

C5-13

C5-8

C41RPM OR/BK

C39LP BL/RD

C35RPM BK/RD

C108ESL BL/WH

C127TSW GR

6

11

8

9

10

7

2

5

1

4

3

R21IGN WH

C21RET WH

R33STR BK

R23PWR WH

C38FP BL/WH

C38RET BL

BK

-1

2G

A

CO

NT

INE

NTA

LT

ME

27

EN

GIN

EV

EH

ICL

EIN

TE

RF

AC

E1

HARNESS

F1720 A

B1

BA

TR

D

P24PWR RD

R21IGN WH

P20BAT RD

BAT2 APU

F720 A

R6

510�

12V DC 12V DC

+ +

- -B2 B1

BAT+

BAT-

EXCT

STA

INDREGULATOR

M1 SW4NO

H2

CR17NO

CR5NO

R11

6H

YD

OR

R2

1IG

NW

H

R4

6H

RN

GR

P1

34

FB

RD

P1

34

FB

RD

FB FB

P1

34

PW

RR

D

C2

8T

TA

RD

/BK

A C

BBK

WHRD

PR1NO

M2

R2

7A

UX

RD

CR39ANO

CR39BNC

CR1NO

CR2NO

V1

55

PC

EO

R/R

D

Y74M3

M4

+

-

RD - 12GA

WH - 14GA

CO

NT

RO

LB

AT

TE

RY

STA

RT

BA

TT

ER

Y

BA

TT

ER

YS

EP

ER

AT

OR

ALT

ER

NA

TO

R

HY

D.

OIL

CO

OL

ER

FA

N(O

PT

ION

)

HY

D.

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

HO

RN

HO

RN

RE

LA

Y

FL

AS

HIN

GB

EA

CO

N(O

PT

ION

)

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

PR

EL

AY

VO

LTA

GE

DR

OP

RE

LA

Y

AP

UC

UT

-OU

TR

EL

AY

STA

RT

RE

LA

Y

IGN

ITIO

NR

EL

AY

PR

ES

SU

RE

CO

MP

VA

LVE

FU

NC

TIO

NE

NA

BL

E

STA

RT

ER

HO

UR

ME

TE

R

EN

GIN

EF

AU

LTC

OD

ET

ES

TS

WIT

CH

FU

EL

PU

MP

CH

EC

KE

NG

INE

LIG

HT

ES0505A

+

-H6

L45

D40

L4

PBOX GND

D88

R20

4.7K�

LS18A

LS18

2 SEC.

PBOX GND

2 SEC.

NO30A

NO10A

C5

-17

C5

-15

P1

34

PW

RR

D

C1

32

PL

IB

L/W

H

P2

2P

WR

BK

U34

PBOX GND

C4

-10

5

2

9

83

U35

2

5 9

83

C3

-10

C132PLI BK

D43


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 119


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

CR34

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5

C4

TR

LW

H

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

22NCHO

21

C6

-31

TB118

C11

8L

SO

R

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)


6 - 1206 - 119



6 - 121 6 - 122

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111)


1

2

3

4

5

6

7

8


6 - 122 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

HM

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

WH

C5

-1

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

321

TS64

BL

/RD

C5

-10

BL

/RD

TS

53

-1(D

11)

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

DS

TU

D

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

GR

-C5

-8

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R

ST

EE

RC

W

ST

EE

RC

CW

GA

S/L

PF

UE

LS

EL

EC

T

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

WH

-BE

AC

ON

(LE

FT

)W

H-B

EA

CO

N(R

IGH

T)

D3

0

RD

/BK

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT


U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(C)

WH

-13

4A

(C)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

S-8

5(O

PT

ION

)

ES0505A


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51













WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

23

10

AM

PF

US

E

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

BR

GN

D2

F1

9


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 123

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)

86

G6

+ -

+

+

CR

34

R1

4(A

)

R1

4

R1

6

TS

62

TS

57

TS

58

TS

59

TS

63

TS

61

P4

NO

TS

53

TS

51

P1

NC

E-S

TO

P

1B

1

KS

1 B

24

3

TS

54

CB

2

TS

52

L2

L4

6

12

31

32

1

1233 2 1

3 2 1

4563 2 1

6 5 4123

31 4

6

1A 2A

1B 2B

3

4

RD

-L4

5(+

)

WH

-KS

1-1

WH

-TS

51

-2

WH

-C3

2-6

RD

-P1

-2

RD

-CB

2-1

RD

-C3

2-7

12

3

54

6

BR

-GN

DS

TU

D

BR

-L4

6(-

)

BR

-HM

( -)

BR

-CR

34

#8

5

RD

-TS

51

-1

RD

-TS

61

-2

RD

-R1

6

RD

-R1

6

WH

-TB

23

D

OR

-TB

14

D

OR

/BK

-TB

15

D

GR

-TB

17

D

GR

/BK

- TB

18

D

RD

-TB

27

D

BK

/RD

-TB

9D

BK

/WH

-TB

8D

BK

-TB

7D

WH

/RD

-R1

4(A

)

WH

/BK

-TB

5D

WH

-TB

4D

RD

/WH

-R1

4

RD

/BK

-TB

2D

RD

-TB

1D

BL

/ BK

-TB

59

D

BK

-TB

22

D

WH

-TB

21

D

OR

/RD

-TB

15

5D

RD

-TB

20

D

BK

-TB

33

D

BL

/RD

-TB

39

D

BK

/RD

-TB

35

D

D1 1

D1

3

D6

8

GR

-TB

43

D

GR

/BK

-TB

44

D

21

RD

-TS

61

-2

D4

RD

/WH

-TS

61

-1

RD

/WH

-TB

3D

WH

/RD

-TB

6D

32

OR

/BK

-TB

15

D

RD

-TS

63

-2

OR

-TB

118

D

BR

-HM

(-)

WH

/RD

-TS

62

-4

NC

D2

BL

/WH

-C5

-13

87

A

85 3

0

ES0505A

+

L4

5G

R/B

K-H

6(-

)

RD

-KS

1-2

RD

-TB

13

4D

87

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS


6 - 124


Continental TME27 Models (before serial number 8111)

6 - 123


6 - 125

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Continental TME27 Models (before serial number 8111)

6 - 126


1

2

3

4

5

6

7

8


6 - 126 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)

J1

-SN

SR

GN

DB

RC

2P

-10

J1

-P1

09

AN

GG

R/W

HC

2P

-9

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

14

PL

UO

RC

4P

-2

TS

8-C

43

JU

GR

C4

P-7

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

7-C

17

PR

LG

RC

4P

-5

TS

8-C

44

JD

GR

/BK

C4

P-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

7-C

17

PR

LG

RJ2

2-4

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

8-C

43

JU

GR

J2

2-5

J22

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

44

DE

RB

L/W

H

TS

14

-C2

9M

SR

D/W

H

L1

-C1

3D

RE

(A)

BL

/RD

TS

15

-C1

43

DE

LB

L/B

K

D39

D40

J1

C2

8T

TA

RD

/BK

C1P-2 C28TTA RD/BK

L4

8-C

28

TTA

RD

/BK

H1

J1

9

1

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

GR

/BK

C3

P-1

2

JC

7-1

JS

GN

D2

BR

JC

7-2

P1

62

JP

W2

OR

JC

7-5

C1

63

PE

SW

H/B

K

JC

3-4

C1

60

JP

LW

H/R

D

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-1

JS

GN

D1

BR

JC

3-2

P1

62

JP

W1

OR

JC

3-5

C1

59

ST

CB

L/W

H

C2

P-1

0S

NS

RG

ND

BR

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-9

P1

09

AN

GG

R/W

H

C4

P(B

R)

C3

P(G

N)

C2

P(B

K)

C1

P(G

Y)

C2

PB

DR

D/B

KC

3P

-2

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

BL

C1

P-1

0

C5

TR

RW

H/B

KC

3P

-5

C4

TR

LW

HC

3P

-4

TS

2-C

33

ST

RB

KC

1P

-7

C3

2B

RK

WH

/RD

C1

P-6

C2

9M

SR

D/W

HC

1P

-3

TS

1-C

27

AU

XR

DC

1P

-1

C3

7S

TC

CB

L/B

KC

1P

-11

J2

C4

0L

SO

RC

2P

-2

C7

PB

EB

KC

3P

-7

C1

PB

UR

DC

3P

-1

C1

3D

RE

BL

/RD

C4

P-1

C8

PB

RB

K/W

HC

3P

-8

C6

TR

FW

H/R

DC

3P

-6

C9

PE

RF

BK

/RD

C3

P-9

C4

2L

SO

R/R

DC

2P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C3

0E

DC

+W

HC

1P

-4

C4

1R

PM

OR

/BK

C2

P-3

1

11

P2

-P2

6E

ST

PB

KC

9P

-1

P2

-P2

3P

WR

WH

C7

P-2

J3

-P2

4F

SW

HC

9P

-2

TS

2-P

25

FS

RD

C9

P-3

TS

3-C

39

LP

BL

/RD

C2

P-1

P3

-C4

6H

RN

GR

C2

P-5

L4

7-C

59

CN

KB

L/B

KC

3P

-11

P2

-P2

2P

WR

BK

C7

P-1

WH

C9

P-2

WH

L1

BK

P2

J3

1

3

H1

+ -BRN

GND STUD

BATGND J3-1

BATGND C7P-3

J22-1, 2, 9, 10, 11 & 12

C7P C9

12V BATT F.S.

LS18 OPT.

U13ALC-500

RD

LS

18

LS

18

-C1

32

PL

IR

DC

1P

-12

H1

-C1

33

PL

AG

R/B

KC

3P

-12

GR

/BK

L4

D88

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

32

NO

5R

26

ES

TP

BK

C9

P-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

R2

0

C132PLI BK C1P-12

COM

32

NO

5

U34

C3-10

C4-10


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)ES0505A


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 127

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (before serial number 8111)

+

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

GR

C4

P-7

/J2

2-5

GR

/BK

C4

P-8

/J2

2-6

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

C4

P-5

/J2

2-4

GR

/BK

C4

P-6

/J2

2-3

WH

C9

P-2

TS15

OR

J1

-11

RD

/WH

J1

-2

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

JC7

6

1

GR

C2

P-5

TS4

L1

+

L47

P3

NO

OR

C4

P-2

/J2

2-7

OR

/BK

C4

P-3

/J2

2-8

+

TS3

TS2

NC

WH

C7

P-2

BK

C7

P-1

RD

LS

18

BK

C9

-1

BK

J3

-3

TS7

TS8

TS14

TS1TS9

L48

P2

BL

/RD

C2

P-1

D10

RD

RD

BK

RD

D43

ES0505A

+

L4

GR

/BK

H1

(D3

9)

JC3

61

WH

/RD

J1

-4

BR

J1

-14

BL

/WH

J1

-5

OR

J1

-13

1

H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON













C1P 18/22 CONTROL CABLE (GREY)

C2P 18/22 CONTROL CABLE (BLACK)

C3P 16/22 CONTROL CABLE (GREEN)

C4P 16/22 CONTROL CABLE (BROWN)

C7P 12VDC POWER TO PLATFORM

C9 FOOT SWITCH







ROCKER STEER OPTION1




6 - 128


Continental TME27 Models (before serial number 8111)

6 - 127


6 - 129 6 - 130

Electrical Schematic, S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110)


1

2

3

4

5

6

7

8


6 - 130 S-80 • S-85 • S-80X Part No. 122985


6

4

+

3

1

4

2

B

B1

-

KS1

P1

CB215 AMP

TB20

GROUNDGROUND BOX

PLAT

GRND

TB22

TB134

1 3

5

7

812

C32

TB132

TB133

TB46

GR

/BK

C4

6H

RN

GR

C2

-5

C2

-6

C7

-1

P1

34

PW

RR

D

P2

2P

WR

BK

P3HORN

D40L48

P2C9P-1

FS1 C9P-3

C9P-2

P24FS WH

P25FS RD

P26ESTP BK

P25FS RD

TS1TS2ENGINESTART

P24FS WH

C28TTA RD/BK

P26ESTP BK

C1

-2

C7

-2

C1

-1

C1

-7

C4

-4V

15

5P

CE

OR

/RD

TS4ENGINERPM

TS3FUELSELECT

C1

-9

C2

-1

D12

HIG

H

LO

W

LP

GA

S

D10

C28TTA RD/BK

P26ESTP BK

P24FS WH

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

D4

D11

TB41

TB39TB35

C3

9L

PB

L/R

D

C3

5R

PM

BK

/RD

TS53

D13

L2FUELSELECT

LP

GA

STS54

HIG

H

LO

W

ENGINERPM

TS64

ENGINEFAULTCODE

RU

N

TE

ST

G6

+

-

TB21

D67D68

P4FUNCTION

ENABLE

TB155

TS52ENGINESTART

TB33TB27

TB23D2TB28

C3

3S

TR

BK

C2

7A

UX

RD

TS51AUX.PUMP

P2

3P

WR

WH

C2

8T

TA

RD

/BK

C5

-7

B1

BA

TR

D

B1

BA

TR

D

F1720A

F720A

C6

-24

C6

-28

C5

-6

C5

-1

C5

-5

C5

-15

C5

-17

C5

-19

C5

-11

C41RPM OR/BK

C5-10

C5-9

C5-13

C5-8

C5-2

C39LP BL/RD

C35RPM BK/RD

C108ESL BL/WH

C127TSW GR

R21ING WH

R21RET WH

R33STR BK

R23PWR WH

C38FP BL/WH

C38RET BL

6

11

8

9

10

7

2

5

1

4

3

BK

12

GA

VE

HIC

LE

INT

ER

FA

CE

1H

AR

NE

SS

CO

NT

INE

NTA

LT

ME

27

EN

GIN

E

C27AUX RD

P134PWR RD

P23PWR WH

M4

+

-

RD

12

GA

WH

14

GA

M3Y74

V1

55

PC

EO

R/R

D

CR1NO

CR39BNCNO

CR39A

R2

7A

UX

RD

PR1NO

M2

C2

8T

TA

RD

/BK

P1

34

PW

RR

D

A C

B

BK

WH

RD

FBFB

CR5

P1

34

FB

RD

P1

34

FB

RD

NONO

CR17

R4

6H

RN

GR

C11

6H

YD

WH

R11

6H

YD

OR

H2SW4NO

M1

R6

510�

ALT

ER

NA

TO

R

EXCT

BAT -

IND

BAT +

VOLT REG.

STA

12V DC12V DC

+

-

+

-

AU

XM

AIN

P24PWR RD

R21ING WH

B1BAT RD

BAT 2 APU RD

CO

NT

RO

LB

AT

TE

RY

STA

RT

BA

TT

ER

Y

BA

TT

ER

YS

EP

ER

AT

OR

HY

D.

OIL

CO

OL

ER

(OP

TIO

N)

HY

D.

OIL

CO

OL

ER

TE

MP.

SW

ITC

H(O

PT

ION

)

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

(OP

TIO

N)

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

PR

EL

AY

VO

LTA

GE

DR

OP

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

CU

TO

UT

RE

LA

Y

STA

RT

RE

LA

Y

CR2NO

EN

GIN

EIG

NIT

ION

RE

LA

Y

PR

ES

SU

RE

CO

MP

VA

LVE

(FU

NC

TIO

NE

NA

BL

E)

STA

RT

ER

MO

TO

R

HO

UR

ME

TE

R

EN

GIN

EF

AU

LTC

OD

ET

ES

TS

WIT

CH

FU

EL

PU

MP

CH

EC

KE

NG

INE

LIG

HT

H1

ES0505D

D43

B1B2


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 131


C5

-24

C5

-23

C5

-20

C5

-21

SN

SR

-GN

DB

R

P1

09

AN

GG

N/W

H

C1

23

PB

SR

D/B

K

C28TTA RD/BK

P26ESTP BK

P24FS WH

GR

OU

ND

C2

-10

C4

2L

SO

R/R

D

WH

BK

BR

RD

14

24

13

23 13NC

2122

14

C6

-25

J2

TB42

C27AUX RD

Y4 Y3Y12 Y21 Y22 Y13 Y24 Y23

C2

-9S

17

PR

IMA

RY

BO

OM

AN

GL

ES

EN

SO

R-

OP

ER

AT

ION

AL

Y15 Y25 Y26Y27 Y5 Y6

2C

2-8

3C

4-1

C1

3D

RE

BL

/RD

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

C6

-13

TB13

TU

RN

TA

BL

ER

OTA

TE

CW

CR34

R16

7.5�

TB134A

C6

-33

C6

-34

C6

-35

P134PWR RD

PR

IMA

RY

BO

OM

RE

TR

AC

T

C41RPM OR/BK

C1

5P

LD

OR

/BK

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

DO

WN

UP

JIB

BO

OM

(S-8

5O

PT

ION

)

TB43

TB44

UP

DO

WN

PL

AT.

LE

VE

L

TS59

TS9

TB15

TB14

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

FL

OW

CO

NT

RO

L

EX

TE

ND

RE

TR

AC

TP

RIM

AR

YB

OO

M

C9

PE

RF

BK

/RD

TB9

TS63

C8

PB

RB

K/W

H

TB8

C1

4P

LU

OR

TB7

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C9

PE

RB

K/R

D

C7

PB

EB

K

C4

TR

LW

H

PR

IMA

RY

BO

OM

UP

/D

OW

NF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

DO

WN

UP

DO

WN

PR

IMA

RY

BO

OM

TB2

TS61

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

TB3

C1

PB

UR

D

C2

PB

DR

D/B

K

TS62

CW

CC

WT

UR

NTA

BL

ER

OTA

TE

TB4

TB6

TB1

C5

TR

RW

H/B

K

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

PU

BR

D

TB5

C4

TR

LW

H

C4

0L

SO

R

2S

PE

ED

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M(O

PT

ION

)

C2

9M

SR

D/W

H

C3

6S

TC

BL

C3

7S

TC

CB

L/B

KC

37

ST

CC

BL

/BK

C3

6S

TC

BL

ST

EE

RC

W

TS15DRIVE ENABLE

ED

C-

DR

IVE

RE

VE

RS

E

L1

C3

2B

RK

WH

/RD

BR

WH

TS58


H3 H4

3

12

13

14 8 7 6 10 9 11 420

17

18

19

16

15

4 1 312 5 4

TS14DRIVE MODE

6 16 8 157

5

CR27NC

13

14

11122

C3

-2

C3

-1

C2

-3

GN

DB

R

C3

-3

C3

-9

C2

-4

C3

-7

C3

-8

P2

6E

ST

PB

K

P2

4F

SW

H

C3

-4

C3

-5

C3

-6

C1

-10

C1

-11

C1

-3

C1

-6

C1

-5

C1

-4

C1

44

DE

RB

L/W

H

LE

DB

L/R

D

C4

-3

C4

-2

C4

-7

C4

-8

J1J1J1J3

H1

RD

/BK

C2

9M

SR

D/W

H

C1

43

DE

LB

L/B

K

C2

-2

C7

-3

1

C3

0E

DC

WH

C3

1E

DC

WH

/BK

D29

U4

C6

-9

C6

-8

C6

-7

C27AUX + FE RD

RIG

HT

LE

FT

BK

RD

YL

OR

BR

BL

J114

C1

23

PB

SR

D/B

K

P1

09

AN

GG

N/W

H

SN

SR

-GN

DB

R

65431 2

1

4

2

3

5

6J127

10 9

J1

TB40

C6

TR

FW

H/R

D

C4

4JD

GR

/BK

C4

3JU

GR

L4

6/

L4

7L

OO

SE

CA

BL

EL

ED

D30

13NO

14

TB59

L46

L47

C3

-11

C4

2L

SO

R/R

D

C6

-11

LSB2SNC

21

P1

34

PW

RR

D


1

4

2

3

5

6

JC3DRIVE / STEER

C1

29

DA

RD

/BK

C6

-3

C6

-6

C6

-4

C6

-5

C6

-1

C6

-2

C6

-40

C6

-37

C6

-36

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

DE

SC

EN

TA

LA

RM

C6

-22

C4

0L

SO

R

C1

30

TA

WH

/RD

TB37TB36

RD

BR

NO

NO NO

C1

7P

RL

GR

C1

8P

RR

GR

/BK

TS57

TB18

TB17

CC

W

CW

PL

AT.

RO

TA

TE

C4

-6

C4

-5

TS7PLATFORMROTATE

CC

W

CW

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

RO

TA

TE

CC

W

JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

CW

JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LD

OW

N

J2

2-7

J2

2-8

J2

2-6

J2

2-5

J2

2-3

J2

2-4

GND BR

J2

2-1

J2

2-2

J2

2-9

J2

2-1

2

J2

2-11

J2

2-1

0

Y20Y19Y73Y72Y70 Y71

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

LS

T2

O-

ST

OW

ED

AN

GL

ED

RIV

ES

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

LS

B1

RO

-B

OO

MR

ET

RA

CT

DR

IVE

/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

CR30NO

P2

4F

SW

H


U13ALC-500 JOYSTICK

CONTROL CARD J2J2

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

CR

34

-S

PE

ED

RE

DU

CT

ION

RE

LA

Y

TB29 TB31

TB32

TB30

R14

10�

R14(A)

5�

WH

BK

BR

RD

WH

BK

BR

RD

4 3 2 1 4 3 2 1 4 3 2 1

14

24

13

23NO

NO

22

Y2

ED

C-

DR

IVE

FO

RW

AR

D

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

UP

TU

RN

TA

BL

ER

OTA

TE

CC

W

ST

EE

RC

CW

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


C159STC-BL/WH

JSGND1-BR

C160JPL-WH/RD

C159STC-BL/WH

P162JPW1-OR

J25

JSGND2-BR

C163PES-WH/BK

C165TRS-WH/RD

C164PLS-RD/WH

P162JPW2-OR

S-85(OPTION)

CR34

LS

T3

O-

BO

OM

UP

/D

OW

NS

PE

ED

RE

DU

CT

ION

LIM

ITS

WIT

CH

C6

-31

TB118

24

14

23

13NO

NO

WH

BK

BR

RD

4 3 2 1

C11

8L

SO

R

P1

34

PW

RR

D


6 - 132


6 - 131


6 - 133 6 - 134

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110)


1

2

3

4

5

6

7

8


6 - 134 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)

1 3 5 7 86 124

BA

SE

TE

RM

INA

TIO

NB

LO

CK

21

C4B C3B C2BC7B C1B

FUNCTIONS

C6

18/22 CABLE ENGINE

3

12V TO PLAT

AD

CB

C5

GROUND STUD

OR

/BK

C5

-2

OR

/RD

C6

-22

OR

C6

-40

GR

/WH

C6

-39

43

40

42 41

39

44

45

RD

/BK

C6

-2

BL

/RD

C6

-13

RD

/BK

C6

-28

RD

C5

-6

RD

/WH

C5

-24

BL

C6

-36

WH

C5

-11

WH

/RD

R1

4(A

)

5

RD

/BK

TS

61

-6

RD

/WH

CR

34

#3

0

WH

TS

62

-3

WH

/BK

TS

62

-1

RD

TS

61

-4

36

27

BK

/RD

TS

63

-6

BK

TS

52

-3

GR

TS

57

-3

GR

/BK

TS

57

-1

RD

/12

CB

2-2

34 6 24 3 135 78913

2831

32

30

29

33 21

22

17

18

20

23

15

14

24

BL

/BK

C1

B-1

13

7B

L/B

KC

6-3

7

GR

C5

-7

OR

/RD

C5

-19

RD

C6

-23

OR

C6

-31

BL

/BK

C6

-11

RD

C6

-24

OR

/RD

C4

B-4

(D6

7)

46

15

5

13

4A

59

13

2

13

3

118

13

4

RD

C6

-1

BK

TS

63

-1

BK

/WH

TS

63

-3

OR

TS

59

-1

OR

/BK

TS

59

-3

WH

G6

(+)

BK

/12

KS

1-3

RD

TS

51

-4

BK

/RD

TS

54

-1(D

13

)

GR

/BK

TS

58

-3

GR

TS

58

-1

BL

/BK

L4

6(+

)

OR

CR

34

#8

6

OR

/RD

TS

62

-5(D

68

)

RD

C3

B-1

RD

/BK

C3

B-2

RD

/WH

C3

B-3

WH

C3

B-4

WH

/BK

C3

B-5

WH

/RD

C3

B-6

BK

C3

B-7

BK

/WH

C3

B-8

BK

/RD

C3

B-9

BL

/RD

C4

B-1

OR

C4

B-2

OR

/BK

C4

B-3

GR

C4

B-5

GR

/BK

C4

B-6

BK

C1

B-7

WH

/RD

C1

B-6

WH

C1

B-4

RD

/WH

C1

B-3

WH

/BK

C1

B-5

RD

/BK

C1

B-2

RD

C1

B-1

BK

/WH

C1

B-8

BK

/RD

C1

B-9

BL

C1

B-1

0

BL

/RD

C2

B-1

OR

C2

B-2

OR

/BK

C2

B-3

OR

/RD

C2

B-4

GR

C4

B-7

GR

/BK

C4

B-8

GR

/WH

C2

B-7

GR

C2

B-5

BL

/BK

C3

B-1

1

BL

/WH

C1

B-1

2

GR

/BK

C3

B-1

2

RD

C2

B-6

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

WH

C5

-21

WH

/BK

C5

-20

WH

/RD

C5

-23

BK

/RD

C5

-9

RD

C6

-25

WH

/12

C7

B-2

WH

KS

1-1

(D2

)

RD

/12

BA

TT

+R

D/1

2B

AT

T+

GR

/BK

H6

(-)

WH

/RD

-TR

AV

EL

AL

AR

M

WH

C5

-1

BL

/WH

C3

2-3

BK

C3

2-4

BK

-C3

2-5

WH

-TB

23

B

BR

-GN

DS

TU

D

RD

-H6

(+)

BK

-C7

B-1

GR

/BK

-H6

(-)

WH

-TS

51

-5

RD

-TS

53

-2

BR

-GN

D

BL

/WH

-TB

13

2C

BK

-TB

22

C

RD

-TB

20

A

RD

-TB

20

B

BK

C5

-5

PR

IB

OO

ME

XT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

JIB

BO

OM

DO

WN

BO

OM

RE

TR

AC

TE

DL

S

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

E

RE

VE

RS

E/E

DC

-

LE

VE

LS

EN

SO

RA

LA

RM

STA

RT

12

VIG

NIT

ION

SU

PP

LY

JIB

BO

OM

UP

AC

GE

NE

RA

TO

R(O

PT

ION

)

ST

EE

RC

W

ST

EE

RC

CW

RP

MS

IGN

AL

BO

OM

AN

GL

ES

TO

WE

DL

S

DR

IVE

EN

AB

LE

LS

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/E

DC

+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

T

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

LIF

TS

PE

ED

RE

DU

CT

ION

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ES

PE

ED

D2

9

RD

U3

4-2

OR

&W

H-B

EA

CO

NS

D3

0

TB

44

C

2C/R

D-DE

SCEN

T ALA

RM

C3

2

CABLERESTRAINT

U3

3

H6

RD

-P1

34

PW

RT

B1

34

C

GR

/BK

-TB

13

3C

GR

/BK

-L4

5(-

)

RD

L4

5(+

)R

DH

6(+

)

CABLERESTRAINT

RD

-44

C

WH

/BK

-32

C

OR

-13

4A

(D)

WH

-13

4A

(D)

BK

-GN

D

BL

-GN

D

GR

-GN

D

16/22 CABLE

(UN

US

ED

)

PL

AT

FO

RM

LO

AD

INP

UT

PL

AT

FO

RM

LO

AD

AL

AR

M

S-8

5(O

PT

ION

)


WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

23

10

AM

PF

US

E

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

BR

GN

D2

F1

98 9

U34

3 5

WH

C5

-17

WH

C5

-15

BR

GN

D

BK

C3

B-1

0

2R

DT

B1

34

C(A

)


LABEL

CB2

DESCRIPTION


HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51





LOAD SENSE MODULE








FU

EL

SE

LE

CT

ES0505D

U33


321

TS64

BR

-GN

DS

TU

D

GR

-C5

-8


BL

/RD

C5

-10

BL

/RD

TS

53

-1(D

11)



1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 135

Ground Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)

BL

/RD

-C5

-13

D2

NC

WH

/RD

-TS

62

-4

BR

-HM

(-)

OR

-TB

118

D

RD

-TS

63

-2

23

WH

/RD

-TB

6D

RD

/WH

-TB

3D

RD

/WH

-TS

61

-1

D4RD

-TS

61

-2

12

D6

8

D1

3

BK

/RD

-TB

35

D

BK

-TB

33

D

RD

-TB

20

D

OR

/RD

-TB

15

5D

WH

-TB

21

D

BK

-TB

22

D

BL

/BK

- TB

59

D

RD

-TB

1D

RD

/BK

-CR

52

-30

RD

/WH

-R1

4

WH

-TB

4D

WH

/BK

-TB

5D

WH

/RD

-R1

4(A

)

BK

-CR

53

-30

BK

/WH

-TB

8D

BK

/RD

-TB

9D

GN

/BK

- TB

18

D

GN

-TB

17

D

OR

/BK

-TB

15

D

OR

-TB

14

D

WH

-TB

23

D

RD

-R1

6

RD

-R1

6

RD

-TS

61

-2

RD

-TS

51

-1

BR

-CR

34

#8

5

BR

-HM

(-)

BR

-L4

6(-

)

BR

-GN

DS

TU

D

64

5

32

1

RD

-C3

2-7

RD

-CB

2-1

RD

-P1

-2

WH

-C3

2-6

WH

-TS

51

-2

WH

-KS

1-1

RD

-L4

5(+

)

4

3

2B

1B

2A

1A

641

3

3 2 1456

1236 5 4

123

3 2 1

12

31

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TI O

NS

L4

6

L2

TS

52

CB

2

TS

54

3

42

B

KS

1

B1

1N

C

P1

TS

51

NO

P4

TS

61

TS

63

TS

59

TS

57

TS

62

R1

6

R1

4

R1

4(A

)

CR

34

TS

53

12

3

BL

/RD

-TB

39

D

G6

86

85 3

0

87

A

87

+ -

D11

4

3

NO

BK

C6

-12

RD

-TB

27

D

D1

01

ES0505D3 2 1T

S5

8

GR

/BK

-TB

44

D

GR

-TB

43

D

L4

5

RD

-KS

1-2

GR

/BK

-H6

(-)

RD

-TB

13

4D


6 - 136


Continental TME27 Models (after serial number 8110)

6 - 135


6 - 137

Platform Control Box Wiring Diagram,S-80 and S-85 (CE),Continental TME27 Models (after serial number 8110)

6 - 138


1

2

3

4

5

6

7

8


6 - 138 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

H1

-C1

33

PL

AG

R/B

KC

3P

-12

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

CA

NH

I

CA

NL

OW


LS18 OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY


WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)

ES0505D

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+

P1

34

PW

RR

D

COM

32

NO

5

R2

6E

ST

PB

KC

9P

-1

U35

RD

-E-S

TO

P

P1

34

PW

RR

D

RD

LS

18

CA

BL

E

47

00

�

R2

0

D88

D89


C132PLI2 BK C3P-10

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

8-C

44

JD

GR

/BK

J2

2-6

TS

8-C

43

JU

GR

J2

2-5

TS

8-C

43

JU

GR

C4

P-7

TS

8-C

44

JD

GR

/BK

C4

P-8

GR

/BK

L4

GR

/BK

C3

P-1

2

D39

TS

3-C

39

LP

BL

/RD

C2

P-1


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 139

Platform Control Box Switch Panel Wiring Diagram,S-80 and S-85 (CE), Continental TME27 Models (after serial number 8110)

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

L1

TS4

TS7P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

RD

RDRD

ES0505D


H1

COMPONENT INDEX

TILT ALARM







P3 HORN BUTTON










1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

1



+

L47

D43

BK


TS8 JIB BOOM UP / DOWN TOGGLE SWITCH

+

L4

TS8

GR

/BK

C4

P-8

/J2

2-6

GR

C4

P-7

/J2

2-5

GR

/BK

H1

(D3

9)

TS3

D10

BL

/RD

C2

P-1


6 - 140


Continental TME27 Models (after serial number 8110)

6 - 139


6 - 141 6 - 142

Electrical Schematic, S-80X,Continental TME27 Models


1

2

3

4

5

6

7

8


6 - 142 S-80 • S-85 • S-80X Part No. 122985


STA

RT

ER

HO

UR

ME

TE

R

EN

GIN

EF

AU

LTC

OD

ET

ES

TS

WIT

CH

CH

EC

KE

NG

INE

LIG

HT

FU

EL

PU

MP

IGN

ITIO

NR

EL

AY

STA

RT

RE

LA

Y

AP

UC

UT

-OU

TR

EL

AY

VO

LTA

GE

DR

OP

RE

LA

Y

GA

S

D10

C2

-1L

P

TS3FUELSELECT

D11

C3

9L

PB

L/R

D

GA

S

LP

TS53FUELSELECT

TB39

C5

-11

TB21

-

+

C5

-19

TS64ENGINEFAULT

P23PWR WH

WH

-1

4G

A

RD

-1

2G

A

M3

CR2NO

C5

-6

C5

-5

NOCR1

C5

-1

CR39BNC

P134PWR RD

B1BAT RD

BAT2 APU RD

P24PWR RD

R21IGN WH

CO

NT

INE

NTA

LT

ME

27

EN

GIN

EV

EH

ICL

EIN

TE

RF

AC

E1

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

+

B1

BA

TR

D

R4

6H

RN

GR

CR5NO

TB41

FL

AS

HIN

GB

EA

CO

N(O

PT

ION

)

AU

XIL

IAR

YP

UM

P

AU

XIL

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YP

UM

PR

EL

AY

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TS2ENGINESTART

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7A

UX

RD

PR1NO

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TB27

TS1AUXILIARYPUMP

TS52ENGINESTART

TB33

FBC

33

ST

R/B

K

P24FS WH

TS54ENGINERPM H

IGH

RP

M

TS4ENGINERPM

REGULATORIND

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PM

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RP

M

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AL

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M

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D

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C1

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-

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C6

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D12

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WR

BK

P1

34

PW

RR

D

15 AMP

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C2

8T

TA

RD

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GR

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TB134

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1

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TE

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SW

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FA

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ALT

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NA

TO

R

BA

TT

ER

YS

EP

ER

AT

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RT

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GROUND

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34

FB

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TB132

TB46

D67D68

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OR

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3

1

4

2

PR

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SU

RE

CO

MP.V

ALV

EF

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CT

ION

EN

AB

LE

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B

B1

C28TTA RD/BK

D4

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C28TTA RD/BK

C27AUX RD

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C7

-2

C27AUX RD

-

R6

510�

C5

-15

C5

-17

B1

BA

TR

D

B

A

BK

WHRD

C2

8T

TA

RD

/BK

P1

34

PW

RR

D

R11

6H

YD

OR

C11

6H

YD

WH

NOCR17

SW4NO

MA

INA

UX

D101

ZONE B

ZONE A

OFF

500 LB (A & B)

1000 LB (A)

P4FUNCTION

ENABLE

G6

M1 M2

M4

P210PWR BK

D43

3

6

12

5

7

8

AU

XIL

IAR

YP

UM

P

L2

C5-2

C5-10

C5-9

C5-13

C5-8

C41RPM OR/BK

C39LP BL/RD

C35RPM BK/RD

C108ESL BL/WH

C127TSW GR

R21IGN WH

C21RET WH

R33STR BK

R23PWR WH

C38FP BL/WH

C38RET BLHARNESS

6

11

8

9

10

7

2

5

1

4

3+

-

BK

-1

2G

A

86

85

30

87

86

85

30

8786

85

30

87A

CR39A86

85

30

87

C

FB

P1

34

FB

RD

86

85

30

87

86

85

30

87

-

-

12V DC

ES0505D


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 143


P134PWR RD

D23

D24

17

10 56 82

1

4

2

3

5

6

P162JPW1-OR

JSGND1-BR

C159STC-BL/WH

C160JPL-WH/RD

C159STC-BL/WH

J25

910

JC3DRIVE / STEER


1

4

2

3

5

6

P162JPW2-OR

JSGND2-BR

C164PES-RD/WH

C165TRS-WH/RD

C163PLS-WH/BK

J127

31 2 654

J114

BK

RD

YL

OR

BR

BL

RIG

HT

LE

FT

1

2 12

11

14

13

5

7 158166 452 1 314

15

16

19

18

17

20 411910678 14

13

12

3


TB134A

3 2

SN

SR

-GN

DB

R

P1

09

AN

GG

R/W

H

C1

23

PB

SR

D/B

K

J3

J2

CR30

NO


NC

CR27L47

TS9PLATFORMLEVEL

TS7PLATFORMROTATE

CW

CC

W

DO

WN

UP

C5

9C

NK

BL

/BK

J2

2-7

J2

2-8

J2

2-5

J2

2-6

J2

2-4

J2

2-3

J2

2-2

J2

2-1

J2

2-1

0

J2

2-9

J2

2-1

2

J2

2-11

Y71 Y70 Y19 Y20

GND BR

C28TTA RD/BK

P26ESTP BK

P24FS WH

P2

6E

ST

PB

K

P2

4F

SW

H

P2

4F

SW

H

GN

DB

R

C1

84

PL

WH

P1

09

TS

GR

/WH

ZO

NE

SE

LE

CT

SN

SR

BR

L51 L50

ZONE A ZONE B

C2

08

LE

DG

R

C2

09

LE

DB

L

C1

43

DE

LB

L/B

K

TS15DRIVEENABLE

TS75ZONE SELECT

C1

44

DE

RB

L/W

H

L1

LE

DB

L/R

D

C2

9M

SR

D/W

H

TS14DRIVESELECT

H1

RD

/BK

J1 J8 J8 J1 J1 J1

J2

P210PWR BK

P134PWR RD

C41RPM OR/BK

C27AUX + FE RD

C27AUX RD

C4

-6

C4

-5

C4

-8

C4

-7

C4

-3

C4

-2

C3

-11

C1

-3

C1

-6

C1

-10

C1

-11

C1

-5

C1

-4

C3

-3

C3

-2

C3

-1

C1

-12

BL

/RD

GR

/WH

C3

-12

C2

-3

C3

-7

C3

-8

C3

-9

C3

-4

C3

-5

C3

-6

C4

-1

C2

-2

C2

-4

C2

-8

C2

-9

C2

-10

C7

-3

CC

W

TS57PLATFORMROTATE

CW

TB18

TB17

TB44

TB43D30

D29

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C4

4JD

GR

/BK

C4

3JU

GR

TS59

TB15

TB14

DO

WN

UP

PL

AT

FO

RM

LE

VE

L

TB59

L46

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C5

9C

NK

BL

/BK

P1

34

PW

RR

D

TB29 TB32

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

TB36 TB37

TB31 TB30

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

R16


R14

10�

CR34 CR68

CR53

UP

DO

WN C1

77

LS

BL

/RD

TB1

TB2

TB3

P1

09

LS

GR

/WH

CR52

CR69


C7

PB

EB

K

EX

TE

ND

RE

TR

AC

T

C8

PB

RB

K/W

H

C9

PE

RB

K/R

D

R14(A)

5�

TS62TURNTABLEROTATE

C4

TR

LW

H

CW

CC

W

TB13

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C1

3D

RE

BL

/RD

TB42

P1

34

PW

RR

D

C4

0L

SO

R

C4

2L

SO

R/R

D

P1

09

AN

GG

R/W

H

SN

SR

-GN

DB

R

C1

23

PB

SR

D/B

K

GN

DB

R

C6

-24

C6

-11

C5

-24

C5

-23

C6

-36

C6

-37

C5

-20

C5

-21

C11

8L

SO

R

TB118 C6

-31

C6

-3

C6

-2

C6

-1

C6

-12

P2

10

PW

RB

K

P1

34

PW

RR

D

C6

-21

C6

-30

C6

-38

C6

-16

BL

/RD

C2

11P

LO

BL

/BK

S2

12

PL

OG

R/B

K

GR

/WH

J133

J133B

K

RD

OR

WH

1 4 5 2

BL

3 6

BR

BL

BK

GR

J134

C1

29

DA

RD

/BK

C2

9M

SR

D/W

H

H4

C3

2B

RK

WH

/RD

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C9

PE

RF

BK

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PB

RB

K/W

H

C7

PB

EB

K

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C6

-9

C6

-8

C6

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C6

-6

C6

-5

C6

-4

TB9

TB8

TB7

TB5

TB4

NO14

13

WH

BK

Y27 Y2 Y4 Y3 Y5 Y6

U4

Y12 Y21 Y22 Y15 Y25 Y26 Y13 Y24 Y23

21

22

NC

BR

RD

4 3 2 1

24 23

14 13

NO

NO

22 21

14 13

NO

NC22 21

14 13NO

NC22 21

14 13NO

NC

WH

BK

/WH

BK

BR

RD

4 3 2 1 4 3

2 1

BR

BL

BK

BK

/WH

BR

BL

BK

WH

BK

BR

RD

2 1

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RD

WH

BK

BR

RD

WH

BK

BR

RD

WH

BK

2324

NO

1314

NO

2324

NO

1314

NO

2122

NC

1314

NO

C6

-13

C6

-25

C6

-23

C6

-40

C6

-22

C6

-35

C6

-34

C6

-33

C4

2L

SO

R/R

D

C4

0L

SO

R

P1

34

PW

RR

D

C1

3D

RE

BL

/RD

PL

AT

FO

RM

RO

TA

TE

CW

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

DE

SC

EN

TA

LA

RM

LO

OS

EC

AB

LE

LE

D’S

LS

B2

SL

OO

SE

CA

BL

EL

IMIT

SW

ITC

H

MO

TO

RS

TR

OK

E

BR

AK

ER

EL

EA

SE

ST

EE

RC

W

ST

EE

RC

CW

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

CR

34

-P

RIM

AR

YB

OO

MS

PE

ED

RE

DU

CT

ION

RE

LA

Y

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

LS

T3

O-

BO

OM

UP

/DO

WN

GR

OU

ND

BO

X-

ZO

NE

AO

PE

RA

TIO

NA

ND

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

LS

B1

EO

-B

OO

ME

XT

EN

DC

AP

AC

ITY

OP

ER

AT

ION

AL

LIM

ITS

WIT

CH

LS

B1

ES

-B

OO

ME

XT

EN

DC

AP

AC

ITY

SA

FE

TY

LIM

ITS

WIT

CH

LS

T3

S-

BO

OM

AN

GL

ES

TO

WE

DG

RO

UN

DB

OX

-Z

ON

EA

SA

FE

TY

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

TF

LO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

CW

TU

RN

TA

BL

ER

OTA

TE

CC

W

LS

T1

OD

RIV

EE

NA

BL

EL

IMIT

SW

ITC

H

LS

B1

RO

BO

OM

RE

TR

AC

TD

RIV

E/R

OTA

TE

SP

EE

DL

IMIT

SW

ITC

H

LS

T2

OA

NG

LE

ST

OW

ED

DR

IVE

SP

EE

DR

ED

UC

TIO

NL

IMIT

SW

ITC

H

S1

7P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-O

PE

RA

TIO

NA

L

S1

8P

RIM

AR

YB

OO

MA

NG

LE

SE

NS

OR

-S

AF

ET

Y


6 - 144


6 - 143


6 - 145 6 - 146

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Continental TME27 Models


1

2

3

4

5

6

7

8


6 - 146 S-80 • S-85 • S-80X Part No. 122985

Ground Control Box Terminal Strip Wiring Diagram, S-80X,Continental TME27 Models

BK

C5

-5

RD

-TB

20

B

RD

-TB

20

A

BL

/RD

TS

53

-1(D

11)

BL

/RD

C5

-10

BR

-GN

DS

TU

D

WH

-TB

23

B

BK

-C3

2-5


BK

C3

2-4

BL

/WH

C3

2-3

RD

U1

6-2

RD

/12

BA

TT

+R

D/1

2B

AT

T+

WH

KS

1-1

(D2

)W

H/1

2C

7B

-2

RD

C6

-25

BK

/RD

C5

-18

WH

/RD

C5

-23

WH

/BK

C5

-20

WH

C5

-21

BK

/RD

C6

-9

BK

/WH

C6

-8

BK

C6

-7

WH

/RD

C6

-6

WH

/BK

C6

-5

WH

C6

-4

RD

/WH

C6

-3

RD

C2

B-6

BL

/BK

C3

B-1

1

GR

C2

B-5

GR

/WH

C2

B-7

GR

/BK

C4

B-8

GR

C4

B-7

OR

/RD

C2

B-4

OR

/BK

C2

B-3

OR

C2

B-2

BL

/RD

C2

B-1

BL

C1

B-1

0

BK

/RD

C1

B-9

RD

C1

B-1

RD

/BK

C1

B-2

WH

/BK

C1

B-5

RD

/WH

C1

B-3

WH

C1

B-4

WH

/RD

C1

B-6

BK

C1

B-7

GR

/BK

C4

B-6

GR

C4

B-5

OR

/BK

C4

B-3

OR

C4

B-2

BL

/RD

C4

B-1

BK

/RD

C3

B-9

BK

/WH

C3

B-8

BK

C3

B-7

WH

/RD

C3

B-6

WH

/BK

C3

B-5

WH

C3

B-4

RD

/WH

C3

B-3

RD

/BK

C3

B-2

RD

C3

B-1

OR

/RD

TS

62

-5(D

68

)

OR

CR

34

#8

6

BL

/BK

L4

6(+

)

BK

/RD

TS

54

-1(D

13

)

RD

TS

51

-4

BK

/12

KS

1-3

WH

HM

(+)

OR

/BK

TS

59

-3

OR

TS

59

-1

BK

/WH

TS

63

-3

BK

CR

69

-87

A

RD

C6

-1

13

4

118

13

3

13

2

59

13

4A

15

5

46

OR

/RD

C4

B-4

(D6

7)

RD

C6

-24

BL

/BK

C6

-11

OR

C6

-31

RD

C6

-23

OR

/RD

C5

-19

GR

C5

-7

BL

/BK

C6

-37

37

BL

/BK

C1

B-1

1

24

14

15

23

20

18

17

22 21

33

29

30

32 31

28

13 9 8 7

35 134 26

34

RD

/12

CB

2-2

GR

/BK

TS

57

-1

GR

TS

57

-3

BK

TS

52

-3

BK

/RD

R1

4(A

)

27

36

RD

TS

61

-4

WH

/BK

TS

62

-1

WH

TS

62

-3

RD

/WH

CR

34

#3

0

RD

/BK

CR

68

-87

A

5

WH

/RD

R1

4(A

)

WH

C5

-11

BL

C6

-36

RD

/WH

C5

-24

RD

C5

-6

RD

/BK

C6

-28

BL

/RD

C6

-13

RD

/BK

C6

-2

45

44

3941

42

40

43

GR

/WH

C6

-39

OR

C6

-40

OR

/RD

C6

-22

OR

/BK

C5

-2

PR

IB

OO

ME

XT

12

VP

OW

ER

TU

RN

TA

BL

ER

OTA

TE

FL

OW

TU

RN

TA

BL

ER

OTA

TE

CC

W

PR

IB

OO

MF

LO

W

PR

IB

OO

MD

OW

N

TU

RN

TA

BL

ER

OTA

TE

CW

PR

IB

OO

MU

P

LIM

ITS

WIT

CH

-L

SB

1R

O

PR

IB

OO

ME

XT

/RE

TF

LO

W

PO

WE

RT

OP

LA

TF

OR

M

BR

AK

ER

EL

EA

SE

RE

VE

RS

E/

ED

C-

PL

AT

FO

RM

LE

VE

LA

LA

RM

EN

GIN

ES

TA

RT

12

VIG

NIT

ION

SU

PP

LY

AC

GE

NE

RA

TO

R(O

PT

ION

)

ST

EE

RC

W

ST

EE

RC

CW

GA

S/L

PF

UE

LS

EL

EC

T

RP

M/

TA

CH

SIG

NA

L

LIM

ITS

WIT

CH

-L

ST

20

DR

IVE

EN

AB

LE

AU

XIL

IAR

YP

OW

ER

FO

RW

AR

D/

ED

C+

DR

IVE

SP

EE

D

PL

AT

FO

RM

RO

TA

TE

CC

W

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

RO

TA

TE

CW

12

VB

AT

TS

UP

PLY

KE

YS

WIT

CH

PW

RT

OP

LA

TF

OR

M

PL

AT

FO

RM

LE

VE

LU

P

LO

OS

EC

AB

LE

LE

D

HO

RN

PR

ES

SU

RE

CO

MP

EN

AB

LE

KE

YS

WIT

CH

PO

WE

R

BO

OM

SP

EE

DR

ED

UC

TIO

N

KE

YS

WIT

CH

PO

WE

R(A

)

PR

IB

OO

MR

ET

RA

CT

EN

GIN

ER

PM

16/22CABLE

C5

BC

DA

12V TOPLATFORM

3

ENGINEHARNESS

18/22CABLE

C6

FUNCTIONMANIFOLD

C1BC7B C2BC3BC4B

1 2

BA

SE

TE

RM

INA

TIO

NB

LO

CK

RD

-T

B1

34

C1 4 7

C3

2

8

BL

/WH

-TB

13

2C

BK

-C7

B-1

WH

-TS

51

-5

RD

-TS

53

-2

GN

/BK

-TB

13

3C

BR

-GN

D

3 5 6

12

BK

-TB

22

C

OR

-134

A(D

)

RD

-44

C

CABLERESTRAINT

WH

/BK

-32C

BK

-GN

D

WH

-134

A(C

)

BL-

GN

DG

R-G

ND

D3

0R

D/B

KT

B4

4C

D2

9

WH

-BE

AC

ON

(LE

FT

)O

R-B

EA

CO

N(R

IGH

T)

TB

2C

-DE

SC

.A

LA

RM

CABLERESTRAINT

GROUNDSTUD

ES0505D

CR

52

CR

53

CR

68

CR

69

GN

DB

R

TS

61

C2

PB

DR

D/B

K

TS

63

C7

PB

EB

K

TB

2D

R2

PB

DR

D/B

K

TB

7D

R7

PB

EB

K

C6

-30

C2

11L

OB

L/B

K

C6

-38

C2

12

LO

GR

/BK

RD

/BK

BK



HOUR METERG6

KEY SWITCHKS1








AUXILIARY PUMPTS51











LABEL

CB2

DESCRIPTION




(UN

US

ED

)

GR

/BK

C3

2-8

(UN

US

ED

)

(UN

US

ED

)

(UN

US

ED

)

(UN

US

ED

)

RD

C3

2-1

KS

1-2

WH

/BK

C4

B-9

WH

DL

1

RD

DL

2

BK

GN

D1

TB

21

C

CR

23

10

AM

PF

US

E

DR

IVE

LIG

HT

OP

TIO

NR

EL

AY

BR

GN

D2

F1

9

321

TS64

BR

-GN

DS

TU

D

GR

-C5

-8



1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 147

Ground Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models

BL

/RD

-C5

-15

D2

NC

WH

/RD

-TS

62

-4

BR

-HM

(-)

OR

-TB

118

D

RD

-TS

63

-2

23

WH

/RD

-TB

6D

RD

/WH

-TB

3D

RD

/WH

-TS

61

-1

D4RD

-TS

61

-2

12

D6

8

D1

3

BK

/RD

-TB

35

D

BK

-TB

33

D

RD

- TB

20

D

OR

/RD

-TB

15

5D

WH

-TB

21

D

BK

-TB

22

D

BL

/BK

-TB

59

D

RD

-TB

1D

RD

/BK

-CR

52

-30

RD

/WH

-R1

4

WH

-TB

4D

WH

/BK

-TB

5D

WH

/RD

-R1

4(A

)

BK

-CR

53

-30

BK

/WH

-TB

8D

BK

/RD

-TB

9D

GN

/BK

- TB

18

D

GN

-TB

17

D

OR

/BK

-TB

15

D

OR

-TB

14

D

WH

-TB

23

D

RD

-R1

6

RD

-R1

6

RD

-TS

61

-2

RD

-TS

51

-1

BR

-CR

34

#8

5

BR

-HM

(-)

BR

-L4

6(-

)

BR

- GN

DS

TU

D

64

5

32

1

WH

-IS

M#

10

RD

-CB

2-1

RD

-P1

-2

WH

-C3

2-6

WH

-TS

51

-2

WH

-KS

1-1

RD

-L4

5(+

)

4

3

2B

1B

2A

1A

641

3

3 2 1456

1236 5 4

123

3 2 1

12

31

TO

GR

OU

ND

CO

NT

RO

LB

OX

CO

NN

EC

TIO

NS

L4

6

L2

TS

52

CB

2

TS

54

3

42

B

KS

1

B1

1N

C

P1

TS

51

NO

P4

TS

61

TS

63

TS

59

TS

57

TS

62

R1

6

R1

4

R1

4(A

)

CR

34

TS

53

12

3

RD

-C3

2-7

BL

/RD

-TB

39

D

G6

86

85 3

0

87

A

87

+ -

D11

4

3

NO

BK

C6

-12

RD

-TB

27

D

D1

01

ES0505D


6 - 148

Ground Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models

6 - 147


6 - 149

Platform Control Box Wiring Diagram, S-80X,Continental TME27 Models

6 - 150


1

2

3

4

5

6

7

8


6 - 150 S-80 • S-85 • S-80X Part No. 122985

Platform Control Box Wiring Diagram, S-80X,Continental TME27 Models

J1

-P1

09

AN

GG

R/W

HC

2P

-9

J1

-SN

SR

GN

DB

RC

1P

-10

C1

23

PB

SR

D/B

KC

2P

-8

LS

18

-C1

77

LS

BL

/RD

C1

P-1

2

TS

1-V

15

5P

CE

OR

/RD

C4

P-4

TS

48

-C4

9D

LIT

EW

H/B

KC

4P

-9

TS

7-C

17

PR

LG

RC

4P

-5

TS

7-C

18

PR

RG

R/B

KC

4P

-6

TS

9-C

14

PL

UO

RC

4P

-2

TS

9-C

15

PL

DO

R/B

KC

4P

-3

TS

9-C

15

PL

DO

R/B

KJ2

2-8

TS

9-C

14

PL

UO

RJ2

2-7

TS

7-C

18

PR

RG

R/B

KJ2

2-3

TS

7-C

17

PR

LG

RJ2

2-4

J2

2

TS

4-C

35

RP

MB

K/R

DC

1P

-9

TS

15

-C1

43

DE

LB

L/B

KL

1-C

13

DR

E(A

)B

L/R

D

TS

14

-C2

9M

SR

D/W

H

TS

15

-C1

44

DE

RB

L/W

H

D40

J1

C2

8T

TA

RD

/BK

L4

8-C

28

TTA

RD

/BK

H1

C1P-2 C28TTA RD/BK

9

J1

1

RD

LS

18

RD

C2

P-6

JC

7-3

C1

64

PE

SR

D/W

H

JC

3-2

P1

62

JP

W1

OR

JC

3-1

JS

GN

D1

BR

JC

3-3

C1

59

ST

CB

L/W

H

JC

3-4

C1

60

JP

LW

H/R

D

JC

7-5

C1

63

PE

SW

H/B

K

JC

7-2

P1

62

JP

W2

OR

JC

7-1

JS

GN

D2

BR

C2

P-9

P1

09

AN

GG

R/W

H

JC

7-4

C1

65

TR

SW

H/R

D

C2

P-1

0S

NS

RG

ND

BR

JC

3-5

C1

59

ST

CB

L/W

H

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-11

TS

1-C

27

AU

XR

DC

1P

-1

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

TS

2-C

33

ST

RB

KC

1P

-7

C4

TR

LW

HC

3P

-4

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

BL

C1

P-1

0

C3

PB

FR

D/W

HC

3P

-3

J2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C3

1E

DC

-W

H/B

KC

1P

-5

C4

2L

SO

R/R

DC

2P

-4

C9

PE

RF

BK

/RD

C3

P-9

C6

TR

FW

H/R

DC

3P

-6

C8

PB

RB

K/W

HC

3P

-8

C1

3D

RE

BL

/RD

C4

P-1

C1

PB

UR

DC

3P

-1

C7

PB

EB

KC

3P

-7

C4

0L

SO

RC

2P

-2

1

11

P2

-P2

2P

WR

BK

C7

P-1

L4

7-C

59

CN

KB

L/B

KC

3P

-11

TS

47

-C4

5G

EN

GR

/WH

C2

P-7

P3

-C4

6H

RN

GR

C2

P-5

TS

3-C

39

LP

BL

/RD

C2

P-1

TS

2-P

25

FS

RD

C9

P-3

J3

-P2

4F

SW

HC

9P

-2

P2

-P2

3P

WR

WH

C7

P-2

P2

-P2

6E

ST

PB

KC

9P

-1

WH

L1

WH

C9

P-2

BK

P2

J31

3

2

1

J7 J8

1

6

TS

75

-2C

18

4P

LW

H

C3

P-1

2P

10

9L

SB

L/W

H

L5

0(-)

C1

69

LE

D2

GR

L5

1(-)

C1

69

LE

D1

GR

TS

75

-3S

NS

RB

R

C1

P-1

2C

17

7L

SB

L/W

H

TS

75

-1P

10

9T

SG

R/W

H

CA

NH

I

CA

NL

OW

U13ALC-500

OPTION OPTIONH1

+ -

GROUND

J22-1,2,9,10,11 AND 12

BATGND C7P-3

BATGND J3-1

C7P C9

FOOTSWITCH

12VBATTERY

J8

-P1

09

LS

GR

/WH

C3

P-1

2

ES0505D

WH TS7

WH/RD C32BRK


OR/RD C40LS



CR30

CR27

WH TS14

BR BATGND

(GROUND STUD)



1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 151

Platform Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models

RD

C1

P-1

RD

/BK

H1

(D4

0)

BL

/RD

J1

-16

D12

BK

/RD

C1

P-9

BR

GN

DS

TU

D

OR

/RD

C4

P-4

RD

/WH

J1

-8

BK

C1

P-7

RD

C9

P-3

BL

/BK

J1

-7

BL

/WH

J1

-6

BL

/BK

C3

P-11

GR

/BK

C4

P-6

/J2

2-3

GR

C4

P-5

/J2

2-4

WH

C9

P-2

TS15

1 6

JC3

WH

/RD

J1

-4

BL

/WH

J1

-5

BR

J1

-14

OR

J1

-13

RD

/WH

J1

-2

OR

J1

-11

BR

J1

-12

WH

/BK

J1

-3

WH

/RD

J1

-1

1

6

GR

C2

P-5

+

1TS4

TS7P3

NO

TS9

JC7

OR

/BK

C4

P-3

/J2

2-8

OR

C4

P-2

/J2

2-7

TS1

TS14

TS2

L48

+

NC

P2

BK

J3

-3

BK

C9

-1

RD

LS

18

BK

C7

P-1

WH

C7

P-2

+

L51 L50

+

TS75

GR

J8

-10

GR

/WH

J8

-6

WH

J8

-2

GR

J8

-5

BR

J8

-8

RDBK

BKBK

RDRD

TS3

BL

/RD

C2

P-1

D10

ES0505D

H1

COMPONENT INDEX

TILT ALARM









P3 HORN BUTTON








1

NOTE: DASHED LINES INDICATE OPTIONS.


+

L47

TS75 ZONE SELECT TOGGLE SWITCH




CR27 BRAKE CIRCUIT (LIFT / DRIVE OPTION)

CR30 LIMIT SWITCH (LIFT / DRIVE OPTION)


6 - 1526 - 151

Platform Control Box Switch Panel Wiring Diagram, S-80X,Continental TME27 Models


6 - 153 6 - 154

Continental TME27 Engine Harness


1

2

3

4

5

6

7

8


6 - 154 S-80 • S-85 • S-80X Part No. 122985

Continental TME27 Engine Harness

WHITE/LT GREEN 1854

TAN/BLACK 18

PINK/TAN 18

RED/TAN 14

WHITE/BLUE 18

RED 14

85

30

86

86

85

AUX PWM4 RECIRC

AUX PWM3 RECIRC

AUX PWM5 RECIRC

BLACK/RED 1686

PINK/BLACK 18AUX PWM4AUX PWM2AUX PWM1AUX PWM3

87888990

RED/BLACK 18GRAY/RED 18

RED/TAN 14

PINK/TAN 18

PINK/BLACK 18

WHITE/BLUE 18

RED 14 30

86

85

WHITE 14 30

85

PINK/YELLOW 16

86

30

70

TAN/ORANGE 18

77AUX PWM5

FPUMP

V BAT

GROUNDDBW+/STEP +

DBW-/STEP -8485

78

80

8281

79

83

MIL

EGOH 2EGOH 3

FUEL LOCKOFF

BUZZ

RELAYEGOH 1

STARTER

76

71

73

7574

72

TAN/BLACK 18

LT BLUE/BLK 18

PINK/WHITE 18

PINK/YELL 16

BLACK 16

RED/TAN 16

BLACK/YELLOW 16BLACK/WHITE 16

WHITE/BLACK 18

WHITE/BLUE 18

YELLOW/LT GREEN 18

ORANGE 18

61INJ1 LS

INJ8 LSINJ7 LSINJ6 LSINJ5 LSINJ4 LSINJ3 LSINJ2 LS

GROUND

68

62

6463

6667

65

69

TACHPULSE IN

V BATV BAT PROT

PC RXPC TX

AUX ANA PUD1

57

5958

60

5655

BROWN/BLUE 16

BROWN/WHITE 16

BROWN/GREEN 16BROWN/YELLOW 16

BLACK 16

PINK/YELLOW 16

DK GREEN 18

RED/TAN 16

F4

BAT +

PINK/TAN 18

RED/TAN 14

5A

F2

F1

20A

FUEL PUMP RELAY

PINK/DK GREEN 16

POWER RELAY

87

PINK/YELLOW 1687

F3

15A

15A

RED 12

RED 14

PINK 18

RED 14

PINK/DK GREEN 16

PINK/YELLOW 16

PINK/DK GREEN 16

PIN

K/D

KG

RE

EN

16

BL

AC

K1

6

PINK/TAN 18

WHITE/BLACK 18

STARTER RELAY

LT BLUE/PINK 14

BLUE/GREEN 14

EPR RELAY

87A

87

PINK/YELLOW 1687

15A

F5

FUEL LOCKOFF

PINK/YELLOW 16

WHITE 14

A

B

STARTER RELAY

BLACK 16BLACK 16 BLACK 12

GROUND

SPLICE WITHIN 6" FROM CONNECTOR

WHITE/PURPLE 18

TAN/BROWN 18

GRAY/WHITE 18GRAY/DK BLUE 18

TAN/BROWN 18

LT GREEN/BLACK 18

GRAY/DK BLUE 18GRAY/WHITE 18

YELLOW/GRAY 18

5V EXTAUX ANA PU3AUX ANA PU2AUX ANA PU1

OIL PGOV 2GOV 1

5V RTN

4748

46

49

5253

5150

SPK COIL 4B

ECT

V SWITCHAUX DIG 3AUX DIG 2AUX DIG 1

EGT

38

4039

41

IAT

45

4344

42

DK BLUE/YELLOW 18

LT GREEN/WHITE 18

DK BLUE/YELLOW 18

TAN 18

PINK/TAN 18

YELLOW/BLACK 18

30KNK 2 -

SPK COIL 4ASPK COIL 3BSPK COIL 3ASPK COIL 2BSPK COIL 2ASPK COIL 1BSPK COIL 1A 31

32

3637

353433

CAM POSCRK NEG

SPD NEGSPD POSCAM NEG

KNK 1 -KNK 2 +

KNK 1 +

2223

2928

2627

2524

YELLOW/RED 18

YELLOW/LT GREEN 18

YELLOW 18

PURPLE/ORANGE 18GRAY/BROWN 18

LT BLUE/DK BLUE 186TPS1/STEP2 +

PURPLE/YELLOW 18DK BLUE 18

WHITE/RED 18

DK BLUE 18

LT GREEN 18

14CAN 1 +

5V RTN5V EXT

CAN 2 TERM +CAN 2 +

CRK POS

CAN 2 -

CAN 1 - 15

21

17

1920

18

16

TPS2/STEP2 -MAP

AUX ANA PD2FPP2-IVS

AUX ANA PD1FPP1

AUX ANA PD3CAN 1 TERM + 13

10

1211

987

PURPLE/WHITE 18

LT GREEN/RED 18BLACK/LT GREEN 18

TAN/DK GREEN 18

PURPLE/LT BLUE 18

DK GREEN/ORANGE 18

EGO 2

EGO 4EGO 3

EGO 1

3

54

12

LT GREEN/BLACK 18

TXDK GREEN 18

BLK/LT GREEN 18

LT GREEN/RED 18

B

C5V

DRTN

COMM

ORANGE 18 ARX

OIL PRESSURE SWITCH

DK BLUE/YELLOW 18

PIN

K/D

KG

RE

EN

16

PIN

K/D

KG

RE

EN

16

YE

LL

OW

/BL

AC

K1

8

BL

AC

K/L

TG

RE

EN

18

PIN

K/D

KG

RE

EN

16

YE

LL

OW

/RE

D1

8

BL

AC

K/L

TG

RE

EN

18

PIN

K/D

KG

RE

EN

16

BL

AC

K/L

TG

RE

EN

18

BL

AC

K/L

TG

RE

EN

18

YE

LL

OW

/LT

GR

EE

N1

8

NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B

NOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER

INJECTOR 2

BROWN/GREEN 16

BROWN/YELLOW 16

INJECTOR 4 INJECTOR 3

BROWN/WHITE 16

COIL 4

BAB

LA

CK

16

C D

COIL 3

A B

BL

AC

K1

6

C D

BROWN/BLUE 16

INJECTOR 1

COIL 2

A

BL

AC

K1

6

DCB

COIL 1

A

BL

AC

K1

6

DB C

YE

LL

OW

18

TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH

BLUE/WHITE 18

WHITE/ORANGE 18

LT BLUE/BLACK 18

TAN/BROWN 18

ORANGE 18

GRAY/RED 18

ESL/TEST SWITCH

FUEL SELECTTEMP SENDER12

11

109 MIL

BLACK 16BLUE/GREEN 14

PURPLE/YELLOW 18

WHITE/ORANGE 18

BLUE/WHITE 18

RED/BLACK 18

LT BLUE/PINK 14

BLACK/RED 16

GRAY/WHITE 18GRAY/DK BLUE 18

YELLOW/LT GREEN 18

PINK/YELLOW 16

PINK 18

VEHICLE INTERFACE 1

DEUTSCH DT04 RECEPTACLE

FUEL PUMP -FUEL PUMP +

GOV SELECT 2GOV SELECT 1

START COMMAND

2

4

678

3

5TACH

IGN OUT1 VSW

NOT USED (PLUGGED)NOT USED (PLUGGED)

START IN (AUTOCRANK)

NOT USED (PLUGGED)CAN LOW11

12

FPP2 IVS

GROUND

CAN HIGH

AUX ANA PU14

765

8910

POST CAT HEGO

DBW THROTTLE CONNECTOR

A

C

A

C

PRE CAT HEGO

TAN/ORANGE 18BLK/LT GREEN 18LT GREEN/RED 18

PURPLE/LT BLUE 18LT BLUE/DK BLUE 18

PINK/WHITE 18


PURPLE/ORANGE 18

GRAY/BROWN 18

2

6

345

1

BLK/LT GREEN 18

PURPLE/ORANGE 18

GRAY/BROWN 18 B


WHITE/PURPLE 18

PURPLE/WHITE 18


LT GREEN/RED 18

BLK/LT GREEN 18

PURPLE/WHITE 18

WHITE/PURPLE 18

B

LT GREEN/RED 18

LT GREEN 18

BLACK/LT GREEN 18TAN/DK GREEN 18PINK/DK GREEN 16BLACK/YELLOW 16

BLACK/LT GREEN 18DK GREEN/ORANGE 18

PINK/DK GREEN 16BLACK/WHITE 16

A

B

DC

4

A

B

DC

LT GREEN/RED 18TAN 18

BLACK/LT GREEN 18

BLACK/LT GREEN 18

YELLOW/GRAY 18 ECT

32

1

B

TMAP

A

SPLICE WITHIN 6" OF CONNECTOR

BLACK/LT GREEN 18

LT GREEN/RED 18

DK BLUE 18

GASOLINE SENSOR INTERFACE

WHITE/LT GREEN 18 4

LT GREEN/WHITE 18LT GREEN/RED 18

BLACK/LT GREEN 18

CAM SENSOR

3

1

2

VEHICLE INTERFACE 2

DEUTSCH DT06 PLUG

VREF

ANA RETURNFPP1

1

32

PINK/YELLOW 16

CRANK SENSOR

BLACK/LT GREEN 18

WHITE/RED 18 A

BLPG TEMP

WHITE/ORANGE 18WHITE/ORANGE 18

BLUE/WHITE 18

JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR

JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR

BLUE/WHITE 18

WHITE/ORANGE 18

WHITE/ORANGE 18

BLUE/WHITE 18

WHITE/ORANGE 18

COBRA EPR

3

6

7

BLACK 16 GROUND

CAN +

VBAT

WHITE/ORANGE 18

BLUE/WHITE 18

CAN + TERM2

1 CAN -


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 155

Platform Level Cutout, CTE Option

Y19

MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED

PL

AT

FO

RM

LE

VE

LD

OW

N

GROUND

CR21NO

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C42LS OR/RD

TS

9-3

TS

9-1

C2P-4J2-4

J2

2-8

C4

-2T

B1

4

TB

15

C4

-3

GROUND BOX

PLATFORM BOX

CR20NO

C1

5P

LD

OR

/BK

C1

4P

LU

OR

J2

2-7

Y20

PL

AT

FO

RM

LE

VE

LU

P


6 - 156

Platform Level Cutout, CTE Option

6 - 155


6 - 157

Continental Options Schematic

6 - 158


1

2

3

4

5

6

7

8


6 - 158 S-80 • S-85 • S-80X Part No. 122985

Continental Options Schematic

R21IGN WH

P22BAT BK

P134PWR RD

P2C9P-1

BK

FS1

P25FS RD

P24FS WH

C9P-3

C9P-2

P25FS RD

P24FS WH

P26ESTP BK

P25FS RD

P24FS WH

P26ESTP BK

F1810 A

TS49WORK LIGHT

WH

WH

BK

BK

L30L30

PLATFORM BOXGROUND

TS48DRIVE LIGHT

F1910A

C4

-9C

49

LIT

EW

H/B

K

L29 L29

CR23

TB21

CO

NT

INE

NTA

LT

ME

27

EN

GIN

EV

EH

ICL

EIN

TE

RF

AC

E1

HARNESS

C26TSR GR/BK 12

G2G3G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

EC

25

PS

RB

L/B

K

CO

OL

AN

TT

EM

P.

GA

UG

E

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S

ES0505C

TS43CONTROL BOXHEATER

R22

10�

R21

10�

THS1NC

PL

AT

FO

RM

CO

NT

RO

LB

OX

HE

AT

ER


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 159

Deutz and Perkins Options Schematic

R21IGN WH

P22BAT BK

P134PWR RD

P2C9P-1

BK

FS1

P25FS RD

P24FS WH

C9P-3

C9P-2

P25FS RD

P24FS WH

P26ESTP BK

P25FS RD

P24FS WH

P26ESTP BK

F1810 A

TS49WORK LIGHT

WH

WH

BK

BK

L30L30

PLATFORM BOXGROUND

TS48DRIVE LIGHT

TS47GENERATOR

TB45

C2

-7C

6-3

9

C4

5G

EN

GR

/WH

Y29

HY

DR

AU

LIC

GE

NE

RA

TO

RO

PT

ION

CR46

BE

LTD

RIV

EN

GE

NE

RA

TO

RO

PT

ION

F1910A

C4

-9C

49

LIT

EW

H/B

K

L29 L29

CR23

TB21

G2

G1

G3

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

C2

6T

SR

WH

/RD

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S

ES0503DES0504D

C2

5P

SR

WH

/BK

C10-2

C10-3C10-1C10-4

CO

OL

AN

TT

EM

P.

GA

UG

E

TS43CONTROL BOXHEATER

R22

10�

R21

10�

THS1NC

PL

AT

FO

RM

CO

NT

RO

LB

OX

HE

AT

ER


6 - 160

Deutz and Perkins Options Schematic

6 - 159


6 - 161 6 -162

12 kW Hydraulic Generator Wiring Diagram


1

2

3

4

5

6

7

8


6 - 162 S-80 • S-85 • S-80X Part No. 122985

12 kW Hydraulic Generator Wiring Diagram

L1

L2

L3N

RED

ORANGE

BLACK

GREEN

GREEN

BLACK

WHITE

RED

8 GA 4 CONDUCTOR

208 VACOUTLET

SILVER

GREEN

L1 L2 L3

NEUTRAL BUSS BAR

12.5 KW HYDRAULIC GENERATOR

NEMA 4 CONTROL BOX

50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI

BRASS

SILVER

120 VAC GFI

GREEN 12GA

BLACK 12GA

110 VACGFI

BRASS

BLACK

GREEN

WHITE

XY

Z

8 GA 5 CONDUCTOR

20 AMP CIRCUITBREAKER

GROUNDSTUD ONPANEL

12 GA 3 CONDUCTOR

1 2

3

N

5 4

6

BLACK 12GA

12 GA 3 CONDUCTOR

ENCLOSURE

ES0506B


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 163

12 kW Hydraulic Generator Electrical Schematic

TB24

TIME DELAY

MODULE 4S

5 SW INPUT3 GND

1 N.O.

2 COM

8 N.C.

C1P-4C1P-5

C3

0E

DC

WH

C3

1E

DC

WH

/BK

C1

B-4

C1

B-5

C5

-20

C5

-21

C32BRK WH/RD C2

P-7

P25FS-RD

P24FS-WH

TS4

C1

P-9

RP

MH

I

GENERATOR

D12

RP

MLO

FOOTSWITCH

P26ESTP-BK

TS47

P22PWR-BK

ON

C1

P-3

CR66

753

18

642

C2

B-7

C4

5G

EN

GR

/WH

TB45TB35

C3

5R

PM

BK

/RD

C1

B-9

CR

4

HIG

HID

LE

RE

LA

Y

TB29

C1

B-3

C2

9M

SR

D/W

HM

OT

OR

ST

RO

KE

VA

LVE

C5

-18

C5

-24

D98

D99

C57

BK

-2Y75

Y75

C57

RD

-1

PR

ES

SU

RE

SW

ITC

H

20

0P

SI

OMRON

RELAY

SX Controller

BY

PA

SS

CO

IL

3

1

2

A

B

C

124 ohms

124 ohms1k ohms

V150HG GR/BK

V151HG GR

RS232TxD

A1BATTERY +

A2SENSOR POWER +5 VDC

A3BATTERY-

B1VALVE 0 FWD COIL

B2VALVE 1 NC

B3DIGITAL OUTPUT BYPASS

C1TxD

C2RxD

C3/BOOT

D1ANALOG 0 JOYSTICK

D2ANALOG 1 NC

D3C41 RPM

E1NOT USED

E2NOT USED

E3NOT USED

F1DIG IN 0

F2DIG IN 1 GENERATOR ON

F3DIG IN 2

RS232RxD

75

31 8

6

42

C1

B-4

C1

B-5

C5

-20

C5

-21

D A

U4

CB

DR

IVE

ED

C+

DR

IVE

ED

C-

PILOT PRESSURE SIGNAL

FROM GENERATOR MANIFOLD

DIVERTER MANIFOLD

N.O.

NC

CR50

PS4

C4

5G

EN

GR

/WH

C6

-39

C5

-12

BK 16-2

C5

-23

BR

AK

E

RE

LE

AS

E

TB32

C1

P-6

C3

2B

RK

WH

/RD

D65

BR-2

(16-2)

TB21

TB41

C5

-4W

H

C5

-12

OR

/BK

C4

1R

PM

OR

/BK

P2

OMRON

RELAY

20

ALC-500

15

16

19


6 - 1646 - 163

12 kW Hydraulic Generator Electrical Schematic


6 - 165

Belt Driven Generator Option

6 - 166


1

2

3

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6 - 166 S-80 • S-85 • S-80X Part No. 122985

Belt Driven Generator Option

120VAC / 60HZGFI OUTLETLINE BK

NEUTRAL WH

GND GR

GND BR

P20BAT

TG3

TG1TG4

TG2

CR46

CB4

15A

LINE BK

FIELD BK/WH

GND BR

NEUTRAL WH

R20BAT RD

C45GEN TO GBOX

FIELD GR

NEUTRAL WH

NEU

LINE

GND

LINE BK

BA

TT

ER

Y

30A

CB6

BELT DRIVENGENERATOR

VO

LTA

GE

RE

GU

LA

TO

R

220VAC / 50HZGFI OUTLETLINE BK

NEUTRAL WH

GND GR

GND BR

P20BAT

TG3

TG1TG4

TG2

CR46

CB2

12.5A

LINE BK

FIELD BK/WH

GND BR

NEUTRAL WH

R20BAT RD

C45GEN TO GBOX

FIELD GR

NEUTRAL WH

NEU

LINE

GND

LINE BK

30A

CB6 87A

87

8586

30

87A

87

8586

30

VO

LTA

GE

RE

GU

LA

TO

R

BELT DRIVENGENERATOR

BA

TT

ER

Y

-

+

LINE

FIELD

CB630A

CB4

VOLTAGEREGULATOR

BK/WH 14GA

BK 12GA

5

54321

VOLTAGE REGULATOR

3

4

1

PIN#

2 WH 12GA

COLOR

NEUTRAL

CIRCUIT#

RD 12GA

BR 12GA

R20BAT

GND

LINE

NEUTRAL

BK

WH

CIRCUIT #COLORPIN#

1

4

3

GENERATOR

C45GEN

GENERATOR

BATTERY-

OUTLET4

3

2

1

12.5A- 220V15A- 120V

A B

BATTERY+

PLUG

CR46

BA

BA FIELDGR2

TG120 VAC / 60 HZ with Regulator

220 VAC / 50 HZ with Regulator

-

+


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 167

Relay and Fuse Panel Legend

Deutz TD2011L04i

1 2

5 6

3 4

7 8

F22

F7

F17

F20

CR1 CR39 CR3

1 2

5 6

3 4

7 8

F7

F17 B1PBAT

B3PBAT

CR17

CR5 CR2CR5

CR17

R21IGN

02GND

B1BAT

P24PWR

CR15

CR2

NOT USED

LABEL DESCRIPTION

CR1 START RELAY

CR2 IGNITION / FUEL RELAY

CR3 HIGH IDLE RELAY

CR5 HORN RELAY

CR15 GLOW PLUG RELAY

CR17 HYDRAULIC OIL COOLER RELAY

CR39 AUXILIARY PUMP RELAY


F7 FUSE, 30A, OIL COOLER FAN / HORN

F17 FUSE, 30A, ENGINE / AUXILIARY PUMP

F20 FUSE, 20A, ENGINE RPM SOLENOID

F22 FUSE, 60A, GLOW PLUGS

1 2

5 6

3 4

7 8

F22

F7

F17

CB20

CR1 CR39 CR3CR5

CR17

R21IGN

02GND

B1BAT

P24PWR

CR15

CR2 CR4

Perkins 804D-33LABEL DESCRIPTION

CR1 START RELAY


CR3 HIGH IDLE RELAY

CR5 HORN RELAY

CR15 GLOW PLUG RELAY





CR4 ENGINE RPM SOLENOID RELAY

CB20 CIRCUIT BREAKER, 10A, ENGINE RPM SOLENOID

F22 FUSE, 60A, GLOW PLUGS

Continental TME27LABEL DESCRIPTION

CR1 START RELAY


CR5 HORN RELAY


CR39A AUXILIARY PUMP RELAY



02PGND

R21PIGN

CR1 CR39A

CR39B

CR39B AUXILIARY PUMP ENGINE CUTOUT RELAY


6 - 168

Relay and Fuse Panel Legend

6 - 167


6 - 169 6 - 170

Hydraulic Schematic, 2WD Models


1

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3

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7

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6 - 170 S-80 • S-85 • S-80X Part No. 122985


TRACTION MANIFOLD

HYDRAULIC ROTARY COUPLER

X X X X

RIGHTREAR

LEFTREAR

M3

CDL

M1

50%

50%

M4

M2

CDR

280 psi19 bar

TESTBA

A

B

B

A

T

8B 6B8C 6C 6A 8A 3 1

1386 2 54

E

3750 psi256 bar

A

B

310 psi21 bar

51 psi3.5 bar

T2

CP

2SPEED

25 psi2 bar

BRAKE

PR1

V1V2

S1

1.7 gpm6.4 L/min

M

2A 2C

0.3 gpm1.1 L/min

54

950 psi66 bar

B

A

OUT

IN

2B

TEST

3200 psi221 bar

PR2

PR2 PR1

L R

B

X

S L13.5 gpm13 L/min

30 psi2 bar

S

2400 psi165 bar 0.6 gpm

2.3 L/min

7

7

102 psi7 bar

RESERVOIR

BRAKE/2 SPEEDMANIFOLD

DRIVE PUMP

RETURNFILTER

PLATFORMROTATE

SLAVECYLINDER

MASTERCYLINDER

TURNTABLE ROTATE3 gpm / 11.4 L/min

S80 PLATFORM MANIFOLD

AUXILIARYPUMP

PLATFORM LEVELCYLINDERS

PRIMARY LIFT CYLINDER15 gpm / 57 L/min (UP)8 gpm / 30 L/min (DOWN)

STEER CYLINDER

RIGHTLEFT

OSCILLATE VALVE

OSCILLATE CYLINDERS

LEFT RIGHT

BOOM EXTEND / RETRACT16 gpm / 61 L/min (EXTEND)7 gpm / 26.5 L/min (RETRACT)

OIL COOLER

HIGH PRESSUREFILTER

FUNCTION MANIFOLD

9 FUNCTIONPUMP38cc

250 psi17 bar

2900 psi200 bar

E E

F F

DA

BB

AA

G

CC

G G G

3.5 gpm13 L/min

BA BC

BB BD

SA

SB

SC

SD

SE

SG

SISJ SK

SF

SH

SNSO

SP

SQ

SR

SS

ST

30 psi2 bar

P4

T4T4

P4

P3T3ST2 ST1

OSC TEST

OSCT2

T1

PTEST

P2

P1 T5 SW1 SW2 L1 L2 EXT RET

PLM1 PLS1 PLS2 PLM2

EA

EB

EC

EF

EE

RA RB

RDRC

OC

DF

DEDC

DA

DBDD

X

ED

PA PB

SM

SL

0.070 inch1.8 mm

0.030 inch0.8 mm

0.025 inch0.6 mm

FUNCTIONENABLE VALVE

M2

1 2

X

MEDIUMPRESSUREFILTER

J1 J2

0.8 gpm3 L/min

JIB BOOM CYLINDER(S-85 OPTION)

G G

EH

EG

2400 psi165 bar

XX

1000 psi / 69 bar4.5:1

COUNTERBALANCE VALVES

3:1

1:1

1.5:1

RATIO

1000 psi / 69 bar

3500 psi / 241 bar

3000 psi / 207 bar

PRESS

4.5:1 3500 psi / 241 bar

3300 psi / 228 bar3:1

3000 psi / 207 bar3:1G

D

C

B

A

E

F

HS0166C


1

2

3

4

5

6

7

8


Part No. 122985 S-80 • S-85 • S-80X 6 - 171


REARRIGHT

REARLEFT M1

CDL

T

M2 LEFTFRONT

M3

50%

50%

M7

M5

CDR

50%

280 psi19 bar

50%

TESTBA

6 8 3 1

M4

50%

50%

FRONTRIGHT

M8

M6

2

E

3750 psi256 bar

A

B

310 psi21 bar

51 psi3.5 bar

T2

CP

2SPEED

25 psi2 bar

BRAKE

PR1

V1V2

S1

1.7 gpm6.4 L/min

M

2A 2C138A6A6C8C

0.3 gpm1.1 L/min

950 psi66 bar

B

A

OUT

IN

2B

TEST

3200 psi221 bar

PR2 J1 J2

A

B

A

B

A

B

A

B

PR2 PR1

L R

0.040 inch1 mm

6B8B

B

S L1

3.5 gpm13 L/min

30 psi2 bar

S

1000 psi / 69 bar4.5:1

COUNTERBALANCE VALVES

3:1

1:1

1.5:1

RATIO

1000 psi / 69 bar

3500 psi / 241 bar

3000 psi / 207 bar

PRESS

4.5:1 3500 psi / 241 bar

2400 psi165 bar

3300 psi / 228 bar3:1

3000 psi / 207 bar3:1

0.8 gpm3 L/min0.6 gpm

2.3 L/min

7

7

102 psi7 bar

G

RESERVOIR

HYDRAULIC ROTARY COUPLER

BRAKE / 2 SPEEDMANIFOLD

DRIVE PUMP

RETURNFILTER

TRACTION MANIFOLD

PLATFORMROTATE

SLAVECYLINDER

MASTERCYLINDER

TURNTABLE ROTATE3 gpm / 11.4 L/min

PLATFORM MANIFOLD

AUXILIARYPUMP

PLATFORM LEVELCYLINDERS

PRIMARY LIFT CYLINDER15 gpm / 57 L/min (UP)8 gpm / 30 L/min (DOWN)

STEER CYLINDERS

RIGHTLEFT

OSCILLATE VALVE

OSCILLATE CYLINDERS

LEFT RIGHT

BOOM EXTEND / RETRACT16 gpm / 61 L/min (EXTEND)7 gpm / 26.5 L/min (RETRACT)

JIB BOOM CYLINDER(S-85 OPTION)

OIL COOLER

HIGH PRESSUREFILTER

FUNCTION MANIFOLD

9 FUNCTIONPUMP38cc

250 psi17 bar

2900 psi200 bar

D

C

B

A

E

F

E E

F F

G G

DA

BB

AA

G

CC

G G G

3.5 gpm13 L/min

BA BC

BB BD

SA

SB

SC

SD

SE

SG

SI SJ SK

SF

SH

SNSO

SP

SQ

SR

SS

ST

30 psi2 bar

P4

T4T4

P4

P3T3ST2 ST1

OSC TEST

OSCT2

T1

PTEST

P2

P1 T5 SW1 SW2 L1 L2 EXT RET

PLM1 PLS1 PLS2 PLM2

EA

EB

EC

EF

54

54

EE

EH

EG

RA RB

RDRC

OC

DN

DM

DJ

DK

DL

DI

DGDDDB

DA

DHDE

DC DF

ED

PA PB

SM

SL

0.040 inch1 mm

0.030 inch0.8 mm

0.025 inch0.6 mm

0.040 inch1 mm

FUNCTIONENABLE VALVE

M2

1 2

X

MEDIUMPRESSUREFILTER

2400 psi165 bar

X X

HS0166C


6 - 172


6 - 171


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2

3

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8


Part No. 122985 S-80 • S-85 • S-80X 6 - 173

12 kW Hydraulic Generator Hydraulic Schematic

OIL COOLER

0.031 inch /0.79 mm

WELDERMANIFOLD

DRIVE PUMP

B

A

3.5 GPM / 13.25L/min

PMP B CLR PMP A

270 PSI / 18.6 BAR@ 3.5 GPM / 13.25 L/min

MTR B MTR A G1

G2

21 GPM / 79.5 L/min G2 G1

21CC

TANK

13

GENERATOR12.5 KW

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

PRESSURE SWITCH200 PSI / 13.8 BARN.O.

CASE

CY

CX

CU

CV

CW

CZ

HS0166C


6 - 174

12 kW Hydraulic Generator Hydraulic Schematic

6 - 173

Dis

trib

ute

d B

y:

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie ChinaPhone +86 21 53853768

Fax +86 21 53852569

Genie SingaporePhone +65 67533544

Fax +65 67533544

Genie JapanPhone +81 3 6436 2020

Fax +81 3 5445 1231

Genie KoreaPhone +82 2 558 7267

Fax +82 2 558 3910

Genie BrasilPhone +55 11 4082 5600

Fax +55 22 4082 5630

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 57 51 00

Fax +46 31 57 51 04

Genie FrancePhone +33 2 37 26 09 99

Fax +33 2 37 26 09 98

Genie IbericaPhone +34 93 572 5090

Fax +34 93 572 5091

Genie GermanyPhone 0800 180 9017

Phone +49 4221 491 810

Fax +49 4221 491 820

Genie U.K.Phone +44 1476 584333

Fax +44 1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

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