Service 1259369

Service Manual
Serial Number Range
from S80/85/80X13-11876
S-80
S-85
S-80X
Part No. 1259369

Rev A
October 2014
Introduction October 2014
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service
operating instructions in the appropriate operator's Manuals for these models:
manual on your machine before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled maintenance
information for the machine owner and user. It also Genie S-80 and S-85 Service Manual
(from serial number 101 to 785) .......... 34032
provides troubleshooting fault codes and repair
procedures for qualified service professionals.
Genie S-80 and S-85 Service Manual
Basic mechanical, hydraulic and electrical skills are (from serial number 786 to 965) .......... 52270
required to perform most procedures. However, several
procedures require specialized skills, tools, lifting
(from serial number 966 to 3081) ........ 72062
equipment and a suitable workshop. In these instances,
we strongly recommend that maintenance and repair be Genie S-80 and S-85 Service Manual
performed at an authorized Genie dealer service center. (from serial number 3082 to 3737) ...... 77832
Compliance Genie S-80 and S-85 Service Manual

(from serial number 3738 to 5380) ... 111165
Machine Classification
Group B/Type 3 as defined by ISO 16368 (from serial number 5381 to 7999) ... 122149
Machine Design Life Genie S-80X, S-80 and S-85 Service Manual
Unrestricted with proper operation, inspection and (from serial number 8000 to 11875) 122985
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree of
accuracy possible. However, continuous improvement of
our products is a Genie policy. Therefore, product
specifications are subject to change without notice.
Copyright © 2014 Terex Corporation
Readers are encouraged to notify Genie of errors and
send in suggestions for improvement. All 1259369 Rev A October 2014
Eighth Edition, First Printing
communications will be carefully considered for future
printings of this and all other manuals. Genie and S is a registered trademark of Terex
South Dakota, Inc. in the USA and many other
countries.
Printed on recycled paper

Contact Us: Printed in U.S.A.
http://www.genielift.com
e-mail: awp.techpub@terex.com
ii S-80 • S-85 • S-80X Part No. 1259369

October 2014
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 8/2014 Initial release
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
Part No. 1259369 S-80 • S-85 • S-80X

October 2014
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
S-80 • S-85 • S-80X Part No. 1259369

October 2014
Serial Number Legend
Model: S-80
Serial number: S8008-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES503
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg S80 08 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 80 ft/ 24.4 m
Model Sequence
Maximum platform reach : 71 ft 6 in/ 21.8 m number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
Terex South Dakota

500 Oak Wood road
PO Box 1150
Watertown, SD 57201
USA
Serial label
Sequence number (located under cover)
(stamped on chassis)
PN - 77055
Part No. 1259369 S-80 • S-85 • S-80X iii

October 2014
This page intentionally left blank.
iv S-80 • S-85 • S-80X Part No. 1259369

October 2014 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-80 and Genie S-85
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 1259369 S-80 • S-85 • S-80X v

Section 1 - Safety Rules October 2014
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for use.
Keep work surfaces clean and free of
Safety alert symbol—used to alert debris that could get into machine components and
personnel to potential personal cause damage.
injury hazards. Obey all safety
messages that follow this symbol Be sure any forklift, overhead crane or
to avoid possible injury or death. other lifting or supporting device is fully
capable of supporting and stabilizing the
Used to indicate the presence of
weight to be lifted. Use only chains or straps that
an imminently hazardous situation
are in good condition and of ample capacity.
which, if not avoided, will result in
death or serious injury. Be sure that fasteners intended for one
Used to indicate the presence of a time use (i.e., cotter pins and self-locking
potentially hazardous situation nuts) are not reused. These components
which, if not avoided, could result may fail if they are used a second time.
in death or serious injury. Be sure to properly dispose of old oil or
With safety alert symbol—used to other fluids. Use an approved container.
indicate the presence of a Please be environmentally safe.
potentially hazardous situation Be sure that your workshop or work area is
which, if not avoided, may result in properly ventilated and well lit.
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Be sure to wear protective eye wear and

other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi S-80 • S-85 • S-80X Part No. 1259369

October 2014
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 - 4
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Continental TME27 Engine Specifications ............................................................. 2 - 6
Deutz TD2011L04i Engine Specifications ............................................................... 2 - 7
Deutz TD2.9 L4 Engine Specifications ................................................................... 2 - 8
Perkins 804D-33 Engine Specifications ............................................................... 2 - 10
Perkins 404F-22T Engine Spedifications .............................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 13
Manifold Component Specifications ..................................................................... 2 - 13
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 14
SAE and Metric Torque Specifications ................................................................. 2 - 16
Part No. 1259369 S-80 • S-85 • S-80X vii

October 2014
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 - Continental Models ...................................... 3 - 8
A-4 Perform Engine Maintenance - Deutz Models ............................................... 3 - 9
A-5 Perform Engine Maintenance - Perkins Models ............................................ 3 - 9
A-6 Perform Function Tests .............................................................................. 3 - 10
A-7 Test the Oscillate Axle ............................................................................... 3 - 10
A-8 Check the High Pressure Hydraulic Filter Condition Indicator ..................... 3 - 11
A-9 Perform 30 Day Service ............................................................................. 3 - 11
A-10 Perform Engine Maintenance - Continental Models .................................... 3 - 12
A-11 Perform Engine Maintenance - Continental Models .................................... 3 - 12
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-13 Replace the Drive Hub Oil .......................................................................... 3 - 13
Checklist B Procedures
B-1 Inspect the Battery(s) ................................................................................. 3 - 16
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17
B-3 Test the Key Switch ................................................................................... 3 - 19
B-4 Check the Exhaust System ....................................................................... 3 - 19
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October 2014
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B-5 Inspect the Engine Air Filter ....................................................................... 3 - 20
B-6 Perform Engine Maintenance - Continental Models .................................... 3 - 21
B-7 Perform Engine Maintenance - Perkins Models .......................................... 3 - 21
B-8 Confirm the Proper Brake Configuration ...................................................... 3 - 22
B-9 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
B-10 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-11 Check the Oscillate Directional Valve Linkage ........................................... 3 - 24
B-12 Test the Ground Control Override ............................................................... 3 - 25
B-13 Test the Platform Self-leveling ................................................................... 3 - 25
B-14 Test the Engine Idle Select Operation ........................................................ 3 - 26
B-15 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 27
B-16 Test the Drive Enable System ................................................................... 3 - 28
B-17 Test the Drive Brakes ................................................................................ 3 - 29
B-18 Test the Drive Speed - Stowed Position ..................................................... 3 - 29
B-19 Test the Drive Speed - Raised or Extended Position .................................. 3 - 30
B-20 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 31
B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 32
B-22 Perform Hydraulic Oil Analysis ................................................................... 3 - 33
B-23 Inspect the Boom Extend/Retract Cables ................................................... 3 - 33
B-24 Test the Emergency Power System ........................................................... 3 - 34
Checklist C Procedures
C-1 Perform Engine Maintenance - Continental Models .................................... 3 - 36
C-2 Perform Engine Maintenance - Deutz Models ............................................. 3 - 36
C-3 Perform Engine Maintenance - Perkins Models .......................................... 3 - 37
C-4 Replace the Engine Air Filter Element - All Models .................................... 3 - 37
C-5 Check and Adjust the Engine RPM ............................................................ 3 - 38
Part No. 1259369 S-80 • S-85 • S-80X ix

October 2014
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

C-6 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 40
C-7 Test the Platform Overload System (if equipped) ....................................... 3 - 40
C-8 Check the Safety Envelope Limit Switches and Angle Sensor, S-80X ....... 3 - 43
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 46
D-2 Check the Free-wheel Configuration ........................................................... 3 - 47
D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 48
D-4 Inspect the Turntable Bearing Wear ........................................................... 3 - 49
D-5 Replace the Hydraulic Filter Elements ........................................................ 3 - 51
D-6 Replace the Drive Hub Oil .......................................................................... 3 - 52
D-7 Perform Engine Maintenance - Continental Models .................................... 3 - 54
D-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 54
D-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 55
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 Models ............................................. 3 - 59
E-4 Perform Engine Maintenance - Perkins Models .......................................... 3 - 60
E-5 Perform Cooling System Maintenance - Perkins 404F Models ................... 3 - 60
E-6 Remove and Replace the Boom Extend/Retract Cables ............................. 3 - 61
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
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October 2014
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

Platform Components
2-1 Platform ....................................................................................................... 4 - 9
2-2 Platform Leveling Slave Cylinder ................................................................ 4 - 10
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 - 39
Hydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 40
7-2 Drive Pump ................................................................................................ 4 - 41
Part No. 1259369 S-80 • S-85 • S-80X xi

October 2014
TABLE OF CONTENTS

Manifolds
8-1 Function Manifold Components .................................................................. 4 - 43
8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 45
8-3 Brake/Two-speed Manifold Components .................................................... 4 - 47
8-4 Turntable Rotation Manifold Components ................................................... 4 - 48
8-5 Platform Rotate Manifold Components ....................................................... 4 - 49
8-6 Platform Manifold Components, S-80 ......................................................... 4 - 50
8-7 Platform Manifold Components, S-85 ......................................................... 4 - 51
8-8 2WD Traction Manifold Components .......................................................... 4 - 52
8-9 4WD Traction Manifold Components .......................................................... 4 - 54
8-10 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 56
8-11 Valve Adjustments - Traction Manifold ....................................................... 4 - 57
8-12 Valve Coils ................................................................................................. 4 - 58
Fuel and Hydraulic Tanks
9-1 Fuel Tank ................................................................................................... 4 - 60
9-2 Hydraulic Tank ........................................................................................... 4 - 61
Turntable Rotation Components
10-1 Turntable Rotation Drive Hub Assembly ..................................................... 4 - 63
Steer Axle Components
11-1 Yoke and Hub ............................................................................................ 4 - 66
11-2 Steer Cylinder ............................................................................................ 4 - 67
11-3 Drive Hub ................................................................................................... 4 - 68
11-4 Steer Cylinders ........................................................................................... 4 - 68
xii S-80 • S-85 • S-80X Part No. 1259369

October 2014
TABLE OF CONTENTS

Non-steer Axle Components
12-1 Drive Motor ................................................................................................ 4 - 69
12-2 Drive Hub ................................................................................................... 4 - 69
Oscillating Axle Components
13-1 Oscillate Axle Cylinders ............................................................................. 4 - 70
13-2 Oscillate Directional Valve ......................................................................... 4 - 71
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Fault Code Display - Deutz TD2.9 L4 and Perkins 404F-22T Models ..................... 5 - 8
Engine Fault Codes - Detuz TD2.9 L4 Models ...................................................... 5 - 13
Engine Fault Codes - Perkins 404F-22T Models .................................................. 5 - 28
Engine Fault Codes - Continental Models ............................................................. 5 - 31
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Relay and Fuse Panel Legend ............................................................................... 6 - 4
Connector Pin Legend - View 1 .............................................................................. 6 - 8
Connector Pin Legend - View 2 .............................................................................. 6 - 9
Part No. 1259369 S-80 • S-85 • S-80X xiii

October 2014
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Continental TME27 Engine Harness ..................................................................... 6 - 12
S-80X Ground Control Box Wiring Diagram .......................................................... 6 - 13
Deutz TD2.9 L4 Engine Detail .............................................................................. 6 - 16
Perkins 404F-22T Engine Detail ........................................................................... 6 - 17
ANSI / CSA Models
Electrical Schematic, S-80X (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 20
Ground Control Box Wiring Diagram, S-80X (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 24
Platform Control Box Wiring Diagram, S-80X (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 25
Deutz TD2011L04i Models ......................................................................... 6 - 28
Perkins 404F-22T Models .......................................................................... 6 - 36
Perkins 804D-33 Models ............................................................................ 6 - 44
Perkins 804D-33 Models ............................................................................ 6 - 48
Perkins 804D-33 Models ............................................................................ 6 - 49
xiv S-80 • S-85 • S-80X Part No. 1259369

October 2014
TABLE OF CONTENTS

Continental TME27 Models ........................................................................ 6 - 52
Electrical Schematic, S-80 and S-85 (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 60
Ground Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 64
Platform Control Box Wiring Diagram, S-80 and S-85 (ANSI / CSA)
Deutz TD2.9 L4 Models .............................................................................. 6 - 65
Perkins 804D-33 Models ............................................................................ 6 - 84
Perkins 804D-33 Models ............................................................................ 6 - 88
Perkins 804D-33 Models ............................................................................ 6 - 89
Part No. 1259369 S-80 • S-85 • S-80X xv

October 2014
TABLE OF CONTENTS

CE Models
Electrical Schematic, S-80 and S-85 (CE)
Deutz TD2011L04i Models ........................................................................ 6 - 100
Ground Control Box Wiring Diagram, S-80 and S-85 (CE)
Platform Control Box Wiring Diagram, S-80 and S-85 (CE)
Perkins 804D-33 Models ........................................................................... 6 - 108
Perkins 804D-33 Models ........................................................................... 6 - 112
Perkins 804D-33 Models ........................................................................... 6 - 113
Continental TME27 Models ....................................................................... 6 - 116
xvi S-80 • S-85 • S-80X Part No. 1259369

October 2014
TABLE OF CONTENTS

AS Models
Electrical Schematic, S-80 and S-85 (AS)
Ground Control Box Wiring Diagram, S-80 and S-85 (AS)
Platform Control Box Wiring Diagram, S-80 and S-85 (AS)
Perkins 804D-33 Models ........................................................................... 6 - 132
Perkins 804D-33 Models ........................................................................... 6 - 136
Perkins 804D-33 Models ........................................................................... 6 - 137
Continental Options Schematic ........................................................................... 6 - 148
Deutz and Perkins Options Schematic ................................................................ 6 - 149
Platform Level Cutout, CTE Option ..................................................................... 6 - 152
12 kW Hydraulic Generator Wiring Diagram ......................................................... 6 - 153
12 kW Hydraulic Generator Electrical Schematic ................................................ 6 - 156
Belt Driven Generator Option .............................................................................. 6 - 157
Hydraulic Schematic, 2WD Models ..................................................................... 6 - 160
Hydraulic Schematic, 4WD Models ..................................................................... 6 - 161
12 kW Hydraulic Generator Hydraulic Schematic ................................................ 6 - 163
Part No. 1259369 S-80 • S-85 • S-80X xvii

October 2014
TABLE OF CONTENTS
xviii S-80 • S-85 • S-80X Part No. 1259369

October 2014 Section 2 • Specifications
Specifications
Machine Specifications Fluid capacities
Fuel tank, 35 gallons

Rough Terrain and Non Marking Tires and Wheels
(Deutz and Perkins models) 132.5 liters
Tire size 18-625 FF
(Continental models) 30 gallons
Tire ply rating 16 113.5 liters
Overall tire diameter 40.7 in LPG tank 33.5 pounds
103.3 cm 15.2 kg
Tire pressure Foam filled Hydraulic tank 40 gallons
151.4 liters
Wheel diameter 24.5 in
62.2 cm Hydraulic system 50 gallons
(including tank) 189.3 liters
Wheel width 15 in
38.1 cm Turntable rotation drive hub 40 fl oz
(single fill port) 1.2 liters
Tire weight, new foam-filled (minimum) 622 lbs
Turntable rotation drive hub 43 fl oz
282 kg
(Dual fill ports) 1.3 liters
High Floatation Tires and Wheels Four wheel drive hubs 30.5 fl oz
0.90 liters
Tire size 41/18LLx22.5 Two wheel drive hubs 23 fl oz
Tire ply rating 14 0.68 liters
Tire pressure 70 psi Drive hub oil type:

4.8 bar SAE 90 multipurpose hypoid gear oil
API service classification GL5
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 the

Operator's Manual.
Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.
Part No. 1259369 S-80 • S-85 • S-80X 2-1

Section 2 • Specifications October 2014
SPECIFICATIONS
Performance Specifications Hydraulic Oil Specifications

Drive speed, maximum Hydraulic Fluid Specifications
Stowed position 40 ft / 7.9-8.5 sec Genie specifications require hydraulic oils which are
RT Tires 12.2 m / 7.9-8.5 sec designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
Stowed position 40 ft / 11-13 sec temperature range, and the viscosity index should
Flotation Tires 12.2 m / 11-13 sec exceed 140. They should provide excellent antiwear,
Raised or extended position 40 ft / 40-45 sec oxidation, corrosion inhibition, seal conditioning, and
12.2 m / 40-45 sec foam and aeration suppression properties.
Braking distance, maximum Cleanliness level, minimum 15/13
High range on paved surface 3 ft Water content, maximum 200 ppm

90 cm
Recommended Hydraulic Fluid
Gradeability Refer to the Operator’s Manual
Hydraulic oil type Chevron Rando HD Premium MV
Boom function speeds, maximum Viscosity grade 32
from platform controls Viscosity index 200
Jib boom up (S-85) 25 to 35 seconds Optional Hydraulic Fluids
Jib boom down (S-85) 15 to 25 seconds Biodegradable Petro Canada Environ MV46
Boom up (ANSI, CSA models) 57 to 65 seconds Fire resistant UCON Hydrolube HP-5046
Boom up (CE, AS models) 75 to 83 seconds Mineral based Shell Tellus S2 V 32

Shell Tellus S2 V 46
Boom down (ANSI, CSA models) 61 to 69 seconds Chevron 5606A
Boom down (CE, AS models) 75 to 83 seconds
Boom extend 59 to 67 seconds Note: Genie specifications require additional

equipment and special installation instructions for
Boom retract 57 to 65 seconds the approved optional fluids. Consult the Genie
Turntable rotate, 360° 95 to 103 seconds
Industries Service Department before use.
boom fully stowed Optional fluids may not have the
Turntable rotate, 360° 210 to 250 seconds same hydraulic lifespan and may
boom raised or extended result in component damage.
Platform rotate, 160° 8 to 12 seconds
Platform level (10° range of motion)

ANSI, CSA 3 to 5 seconds
Platform level (10° range of motion)

CE, AS 20 to 22 seconds

2-2 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Note: Extended machine operation can cause the Chevron Rando HD Permium Oil MV Fluid
hydraulic fluid temperature to increase beyond it's Properties
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an ISO Grade 32
optional oil cooler may be required. Viscosity index 200
Do not top off with incompatible Kinematic Viscosity

hydraulic fluids. Hydraulic fluids cSt @ 200°F / 100°C 7.5
cST @ 104°F / 40°C 33.5
may be incompatible due to the
differences in base additive Brookfield Viscosity
chemistry. When incompatible cSt @ -4°F / -20°C 1040
fluids are mixed, insoluble cST @ -22°F / -30°C 3310
materials may form and deposit in
Flash point 375°F / 190°C
the hydraulic system, plugging
hydraulic lines, filters, control Pour point -58°F / -50°C
valves and may result in
component damage. Maximum continuous operating
temperature 171°F / 77°C
Note: Do not operate the machine when the
ambient air temperatue is consistently above 120°F
/ 49°C. Note: An hydraulic oil heating system is
recommended when the ambient temperature is
Hydraulic Fluid Temperature Range consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperatue is below -20°F / 29°C with
Rando HD Premium MV.
1
2 Petro-Canada Environ MV 46 Fluid Properties

3 ISO Grade 46
Viscosity index 154
4
Kinematic Viscosity
-40 -22 -4 14 32 50 68 86 104 122 F cSt @ 200°F / 100°C 8
-40 -30 -20 -10 -0 10 20 30 40 50 C cST @ 104°F / 40°C 44.4
Ambient air temperature Flash point 482°F / 250°C

1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46 Pour point -49°F / -45°C
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV Maximum continuous operating
Part No. 1259369 S-80 • S-85 • S-80X 2-3

SPECIFICATIONS
Chevron 5606A Hyraulic Oil Fluid Properties Hydraulic Component

ISO Grade 15 Specifications
Viscosity index 300
Drive pump
Kinematic Viscosity
cSt @ 200°F / 100°C 5.5 Type: bi-directional variable displacement piston pump
cST @ 104°F / 40°C 15
cST @ -40°F / -40°C 510 Displacement 0 to 2.8 cu in
0 to 46 cc
Flash point 180°F / 82°C
Flow rate @ 2300 rpm 0 to 30.3 gpm
Pour point -81°F / -63°C 0 to 114.7 L/min
Maximum continuous operating Drive pressure, maximum 3750 psi

temperature 124°F / 51°C 259 bar
Charge pump
Note: Use of Chevron 5606A hydraulic fluid, or Type: gerotor
equivalent, is required when the ambient
temperature is consistently below 0°F / -18°C Displacement 0.85 cu in
unless an oil heating system is used. 13.9 cc
Continued use of Chevron 5606A Flow rate @ 2300 rpm 9 gpm

34.1 L/min
hydraulic fluid, or equivalent, when
ambient temperatures are Charge pressure @ 2300 rpm 310 psi
consistently above 32°F / 0°C may Neutral position 21.4 bar
result in component damage.
Function pump
Note: Continued use of Chevron 5606A hydraulic
fluid, or equivalent, when ambient temperatures are Type: variable displacement piston pump
consistently above 32°F / 0°C may result in Displacement 0 to 2.3 cu in
component damage. 0 to 38 cc
UCON Hydrolube HP-5046 Fluid Properties Flow rate @ 2300 rpm 0 to 23 gpm
0 to 87 L/min
ISO Grade 46
Viscosity index 192 Auxiliary pump
Kinematic Viscosity Type: fixed displacement gear pump

cSt @ 149°F / 65°C 22
cST @ 104°F / 40°C 46 Displacement - static 0.151 cu in
cST @ 0°F / -18°C 1300 2.47 cc
Flash point None
Pour point -81°F / -63°C
Maximum continuous operating

2-4 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Function manifold Valve Coil Resistance

System relief pressure 3200 psi Specifications
(measured at PTEST port) 221 bar
Note: The following coil resistance specifications
Boom down relief pressure 2400 psi are at an ambient temperature of 68°F / 20°C. As
(measured at PTEST port) 165 bar valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
Boom extend relief pressure 2400 psi increase or decrease by 4% for each 18°F / -7.8°C
(measured at PTEST port) 165 bar
that your air temperature increases or decreases
Steer/axle extend 3.5 gpm from 68°F / 20°C.
flow regulator 13.2 L/min
Valve coil resistance specifications
Oscillate relief pressure 950 psi
65.5 bar Proportional solenoid valve 3.7 Ω
(schematic items SE)
Drive manifold
Proportional solenoid valve 4.8 Ω
Hot oil relief pressure 280 psi (schematic items SR and SF)
19.3 bar
2 position 3 way solenoid valve 4.1 Ω
Brake release pressure (schematic items SJ)
Wheel drive hubs 240 psi 2 position 3 way solenoid valve 9Ω
16.5 bar (schematic items SK)
Drive motors 3 position 4 way solenoid valve 7.2 Ω
(schematic items SI and SL)
Displacement per revolution, variable 0.9 to 2.7 cu in
(2 speed motor) 14.7 to 45 cc Solenoid valve, NO, Poppet 5.6 Ω
(schematic items SP and SQ)
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

Part No. 1259369 S-80 • S-85 • S-80X 2-5

SPECIFICATIONS
Continental TME27 Engine Fuel Requirement
Displacement 164 cu in For fuel requirements, refer to the engine Operator's

2.68 liters Manual on your machine.
Number of cylinders 4 Electronic fuel pump
Bore and stroke 3.58 x 4.06 inches Fuel pressure, static 55 psi
91 x 103.2 mm 3.8 bar
Horsepower 59.03 @ 2500 rpm Fuel flow rate 0.42 gpm

44 kW @ 2500 rpm 1.59 L/min
Firing order 1-3-4-2 Batteries
Compression ratio 8.2:1 Type 12V DC
Compression pressure Group 31

Pressure (psi or bar) of the lowest cylinder must be at Quantity 1
least 75% of the highest cylinder.
Cold cranking ampere 1000A
Low idle - computer controlled 1600 rpm
Frequency 53.33 Hz Reserve capacity @ 25A rate 200 minutes
High idle - computer controlled 2500 rpm Alternator output 65A @ 13.8V DC
Frequency 83.33 Hz
Fan belt deflection 1 /2
inch
Valve clearance, warm 12 mm
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.

2-6 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Deutz TD2011L04i Engine Oil viscosity requirements
Displacement 189.6 cu in Units ship with 15W-40.

3.1 liters Extreme operating temperatures my require the use of
Number of cylinders 4 Engine Operator Handbook on your machine.
Bore and stroke 3.7 x 4.409 inches Oil temperature switch

94 x 112 mm
Oil temperature switch point 284°F
Horsepower 140°C
Continuous 69.1 @ 2500 rpm Oil pressure switch

Net intermittent 72.8 @ 2500 rpm
Continuous 51.5 KW @ 2500 rpm Oil pressure switch point 22 psi
Net intermittent 54.3 KW @ 2500 rpm 1.5 bar
Firing order 1-3-4-2 Fuel injection system
Low idle 1300 rpm Injection pump make Bosch

Frequency 331.5 Hz Injection pump pressure, maximum15,000 psi/1034 bar
High idle 2350 rpm Injector opening pressure 3046 psi
Frequency 599.3 Hz 210 bar
Compression ratio 17.5:1 Fuel Requirement
Compression pressure For fuel requirements, refer to the engine Operator's
Pressure (psi or bar) of the lowest cylinder must be at Manual on your machine.
least 75% of the highest cylinder.
Batteries
Governor centrifugal mechanical
Type 12V DC
Valve clearance, cold
Group 31
Intake 0.012 in
0.3 mm Quantity 1
Exhaust 0.020 in Cold cranking ampere 1000A
0.5 mm
Reserve capacity @ 25A rate 200 minutes
Lubrication system
Alternator output 80A @ 14V DC
Minimum oil pressure, hot 21.8 psi
(at 1300 rpm) 1.5 bar Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
Oil capacity 12.8 quarts
(including filter) 12.1 liters

Part No. 1259369 S-80 • S-85 • S-80X 2-7

SPECIFICATIONS
Deutz TD 2.9 L4 Engine Oil viscosity requirements
Displacement 177 cu in -22° F to 86° F/ -30° C to 30° C 5W-30

2.9 liters (synthetic)
Number of cylinders 4 -4° F to 90° F / -20° C to 32° C 10W-40
Bore and stroke 3.6 x 4.3 inches Above 23° F / -5° C 20W-50
92 x 110 mm Units ship with 15W-40.
Horsepower 74.2 @ 2600 rpm Extreme operating temperatures may require the use of
55.3 kW @ 2600 rpm alternative engine oils. For oil requirements, refer to the
Firing order 1-3-4-2
Oil temperature switch
Standby idle 1000 rpm
Temperature switch point 257°F
Low idle 1500 rpm 125°C
Oil pressure switch

High idle 2500 rpm
Oil pressure switch point 20 psi
1.4 bar
Compression ratio 17.4:1
Engine coolant
Compression pressure contact engine manufacturer
Capacity ~11 quarts
Governor electronic ~10.4 liters
Lubrication system Fuel injection system
Oil pressure 40 to 60 psi Injection pump make Bosch

(@ 2000 rpm) 1.4 to 3 bar
Injection pump pressure, maximum 15000 psi
Oil capacity 9.4 quarts 1034 bar
(including filter) 9 liters
Injector opening pressure 3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's

Manual on your machine.

2-8 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Deutz TD 2.9 L4 Engine, continued
Starter motor
Current draw, normal load 250A to 400A
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Alternator output 95A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch

9 to 12 mm
Part No. 1259369 S-80 • S-85 • S-80X 2-9

SPECIFICATIONS
Perkins 804D-33 Engine Injection system
Displacement 201 cu in Injection pump make Zexel

3.3 liters Injection pump pressure 1707 to 1849 psi
Number of cylinders 4 117.7 to 127.5 bar
Bore and stroke 3.70 x 4.72 inches Injector opening pressure ~2000 psi
94 x 120 mm ~138 bar
Horsepower 63 @ 2600 rpm Fuel Requirement

47 KW @ 2600 rpm For fuel requirements, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.
Compression ratio 22:1 Engine coolant
Compression pressure 300 to 500 psi Capacity 12.5 quarts

20.7 to 34.5 bar 11.8 liters
Pressure (psi or bar) of lowest cylinder must be Batteries
within 50 psi / 3.45 bar of highest cylinder
Type 12V DC
Low idle 1650 rpm
Frequency 335.5 Hz Group 31
High idle 2300 rpm Quantity 1
Frequency 467.7 Hz
Governor mechanical all speed
Valve clearance, cold
Alternator output 90A, 12V DC
Intake 0.0098 in
Fan belt deflection 3/8 to 1/2 in
0.25 mm
9 to 12 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
Oil viscosity requirements
Units ship with 15W-40.

Extreme operating temperatures my require the use of
2 - 10 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Perkins 404F-22T Engine Lubrication system
Displacement 134 cu in Oil pressure 40 to 60 psi

2.2 liters (@ 2000 rpm) 1.4 to 3 bar
Number of cylinders 4 Oil capacity 9.4 - 11.2 quarts

(including filter) 8.9 - 10.6 liters
Bore and stroke 3.31 x 3.94 inches
84 x 100 mm Oil viscosity requirements
Horsepower 58 @ 2500 rpm Below 86°F / 30°C 5W-20

43.2 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Standby idle 1100 rpm Units ship with 15W-40; 5W-40 with Cold Start Options.
Low idle 1500 rpm Extreme operating temperatures may require the use of
High idle 2500 rpm
Oil pressure sending unit
Oil pressure switch point 14.2 psi

1 bar
Compression ratio 23.3:1
Fuel injection system
Compression pressure 426 psi
29.4 bar Injection pump make Zexel
Pressure (psi) of lowest cylinder must Injection pressure 2133 psi
be within 50 psi / 3.45 bar of highest cylinder 147 bar
Governor electronic Fuel requirement
Valve clearance, cold For fuel requirements, refer to the engine Operator's
Intake 0.008 in Manual on your machine.
0.2 mm Alternator output 85A @ 12V DC
Exhaust 0.008 in Fan belt deflection 3/8 in
0.2 mm 10 mm
Starter motor
Current draw, normal load 140A - 200A
Brush length, new 0.7480 in

19 mm
Brush length, minimum 0.5 in

12.7 mm
Part No. 1259369 S-80 • S-85 • S-80X 2 - 11

SPECIFICATIONS
Perkins 404F-22T Engine, continued
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Engine coolant
Capacity ~14 quarts

~13.3 liters
Coolant temperature sending unit
Temperature switch point 221° F

105° C
2 - 12 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Machine Torque Specifications Manifold Component

Specifications
Platform rotator
1-8 center bolt, GR 5, lubricated 480 ft-lbs Plug torque

651 Nm
SAE No. 2 50 in-lbs / 6 Nm
3/8-16 bolts, GR 8 35 ft-lbs*
SAE No. 4 14 ft-lbs / 18.9 Nm
*(use blue thread locking compound) 47 Nm*
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm SAE No. 10 62 ft-lbs / 84.1 Nm
Rotate drive hub mounting bolts, lubricated 80 ft-lbs SAE No. 12 84 ft-lbs / 113.9 Nm
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

Part No. 1259369 S-80 • S-85 • S-80X 2 - 13

SPECIFICATIONS
Hydraulic Hose and Fitting SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
Torque Specifications (all types)
Your machine is equipped with Parker Seal-Lok®
SAE Dash size Torque
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to -4 14 ft-lbs / 19 Nm
specification when they are removed and installed
-6 23 ft-lbs / 31.2 Nm
or when new hoses or fittings are installed.
Seal-Lok™ Fittings -8 36 ft-lbs / 54.2 Nm
(hose end - ORFS)
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-4 10 ft-lbs / 13.6 Nm
-16 125 ft-lbs / 169.5 Nm
-6 30 ft-lbs / 40.7 Nm
-20 151 ft-lbs / 204.7 Nm
-8 40 ft-lbs / 54.2 Nm
-24 184 ft-lbs / 249.5 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm

Jamb nut Non-adjustable
-16 110 ft-lbs / 150 Nm
fitting (Non-adj)
-20 140 ft-lbs / 190 Nm Adjustable
fitting (Adj)
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings

(swivel nut or hose connection) SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-6 9/16-18 1 1/4 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-8 3/4-16 1
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-10 7/8-14 1 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-12 1 1/16-12 1 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-16 1 5/16-12 1
-20 1 5/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm

37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-24 1 7/8-12 1
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
2 - 14 S-80 • S-85 • S-80X Part No. 1259369

SPECIFICATIONS
Torque Procedure
a
Seal-Lok™ fittings
c b
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has Figure 1
been tightened beyond finger tight.
a hex nut
Note: The O-rings used in the Parker Seal Lok™ b reference mark
fittings and hose ends are custom-size O-rings. c body hex fitting
They are not standard SAE size O-rings. They are 3 Working clockwise on the body hex fitting, make
available in the O-ring field service kit (Genie part a second mark with a permanent ink marker to
number 49612). indicate the proper tightening position. Refer to
2 Lubricate the O-ring before installation. Figure 2.
3 Be sure that the face seal O-ring is seated and Note: Use the JIC 37° Fittings table on the previous
retained properly. page to determine the correct number of flats for
the proper tightening position.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger Note: The marks indicate that the correct tightening
tight. positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
5 Tighten the nut or fitting to the appropriate joint after it has been loosened.
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to b
a
confirm that there are no leaks. c
b
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of Figure 2
the fitting body (body hex fitting) and tighten the a body hex fitting
hex nut to the body hex fitting to hand-tight, b reference mark
approximately 30 in-lbs / 3.4 Nm. c second mark
2 Make a reference mark on one of the flats of the 4 Tighten the hex nut until the mark on the hex nut
hex nut, and continue it on to the body hex is aligned with the second mark on the body hex
fitting with a permanent ink marker. Refer to fitting.
Figure 1.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
Part No. 1259369 S-80 • S-85 • S-80X 2 - 15

SPECIFICATIONS
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
1 8 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
1 1/8 7 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size 4.6 Class 4.6 8.8 Class 8.8 10.9 Class 10.9 12.9 Class 12.9
(mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
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
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8 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
2 - 16 S-80 • S-85 • S-80X Part No. 1259369

October 2014 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Observe and Obey: Each procedure includes a description, safety
warnings and step-by-step instructions.
Maintenance inspections shall be completed by
a person trained and qualified on the Symbols Legend
maintenance of this machine.
Safety alert symbol—used to alert
Scheduled maintenance inspections shall be personnel to potential personal
completed daily, quarterly, six months, annually injury hazards. Obey all safety
and every two years as specified on the messages that follow this symbol
Maintenance Inspection Report. The frequency to avoid possible injury or death.
and extent of periodic examinations and tests
Used to indicate the presence of
may also depend on national regulations.
an imminently hazardous situation
Failure to perform each procedure which, if not avoided, will result in
as presented and scheduled could death or serious injury.
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a which, if not avoided, could result
damaged or malfunctioning machine. in death or serious injury.
Repair any machine damage or malfunction With safety alert symbol—used to

before operating machine. indicate the presence of a
Use only Genie approved replacement parts. which, if not avoided, may result
in minor or moderate injury.
Machines that have been out of service for a
period longer than three months must complete Used to indicate the presence of a
the quarterly inspection. potentially hazardous situation
which, if not avoided, may result in
Unless otherwise specified, perform each property damage.
procedure with the machine in the following
configuration: Note: Used to indicate operation or maintenance
information.
• Machine parked on a firm, level surface
• Boom in the stowed position Indicates that a specific result is expected after
performing a series of steps.
• Turntable rotated with the boom between
the non-steer (yellow arrow) wheels Indicates that an incorrect result has occurred
• Turntable secured with the turntable after performing a series of steps.
rotation lock pin
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 1259369 S-80 • S-85 • S80X 3-1

Section 3 • Scheduled Maintenance Procedures October 2014
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation
procedure, it conveys the meaning below. Report to use for each inspection. Store completed
forms as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two year.
To account for repeated procedures, the
Indicates that new parts will be required
Scheduled Maintenance Procedures Section and
to perform this procedure.
the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
Indicates that a cold engine will be group(s) of procedures are required to perform a
required to perform this procedure. scheduled inspection.
Inspection Checklist
Indicates that a warm engine will be
required to perform this procedure. Daily or every 8 hours A
Quarterly or every 250 hours A+B

Indicates that dealer service is required Six month or every 500 hours A+B+C
to perform this procedure.
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 contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of four years or in compliance
with employer, jobsite and governmental
regulations and requirements.
3-2 S-80 • S-85 • S80X Part No. 1259369

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to each the Pre-operation Inspection, the Maintenance items
delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it is
put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and reinspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed N = no, unable to complete
by qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements Comments
listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
3-4 S-80 • S-85 • S80X Part No. 1259369

Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Inspect the manuals B-1 Battery(s)
Serial number and decals B-2 Electrical wiring
Date A-2 Pre-operation B-3 Key switch
inspection
B-4 Exhaust system
Hour meter A-3 Engine maintenance-
B-5 Inspect engine air filter
Continental models
Machine owner B-6 Engine maintenance-
A-4 Engine maintenance-
Continental models
Deutz models
Inspected by (print) B-7 Engine Maintenance-
A-5 Engine maintenance-
Perkins models
Perkins models
Inspector signature B-8 Brake configuration
A-6 Function tests
B-9 Tires, wheels and
Inspector title A-7 Oscillate axle
lug nut torque
A-8 Filter condition indicator
Inspector company B-10 Drive hub maintenance
Perform after 40 hours:
B-11 Oscillate directional
A-9 30 day service Control
Instructions
• Make copies of this report to use for Perform every 50 hours: B-12 Ground control
each inspection. A-10 Engine maintenance - override
• Select the appropriate checklist(s) for Continental models B-13 Platform self-leveling
the type of inspection to be Perform every 100 hours: B-14 Engine idle select
performed. A-11 Engine maintenance- B-15 Fuel select operation
Continental models
Daily or 8 hour B-16 Drive enable system
Inspection: A A-12 Grease rotation
B-17 Drive brakes
bearing
Quarterly or 250 hour B-18 Drive speed-stowed
Inspection: A+B Perform after 150 hours:
B-19 Drive speed-raised
A-13 Replace Drive Hub oil
Six Month or 500 hour or extended
Inspection: A+B+C B-20 Alarm package and
Annual or 1000 hour descent alarm
Inspection: A+B+C+D B-21 Fuel and hydraulic tank
2 Year or 2000 hour venting systems
Inspection: A+B+C+D+E B-22 Hydraulic oil analysis
• Place a check in the appropriate box B-23 Inspect the Boom

after each inspection procedure is Extend/Retract Cables
completed. B-24 Emergency Power
• Use the step-by-step procedures in System
this section to learn how to perform
these inspections. Comments
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 1259369 S-80 • S-85 • S80X 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C Y N R Checklist E Y N R

C-1 Engine maintenance- E-1 Hydraulic oil
Serial number Continental models E-2 Engine maintenance -
Date C-2 Engine maintenance- Perkins models
Deutz models Perform every 2 years
Hour meter C-3 Engine maintenance- E-3 Engine maintenance-
Perkins models Deutz models
Machine owner C-4 Air filter element Perform every 3000 hours:
C-5 Check engine RPM E-4 Engine maintenance -
Inspected by (print)
C-6 Grease platform Perkins models
Inspector signature overload (if equipped) E-5 Cooling system-
C-7 Test the platform Deutz 404F models
Inspector title overload (if equipped) Perform every 7 years:
C-8 Safety envelope E-6 Replace the Boom
Inspector company S-80X Extend/Retract Cables
Checklist D Y N R
Instructions D-1 Boom wear pads
• Make copies of this report to use for
D-2 Free-wheel
each inspection.
configuration
• Select the appropriate checklist(s) for
D-3 Turntable rotation
the type of inspection to be
bearing bolts
performed.
D-4 Turntable bearing wear
Daily or 8 hour D-5 Replace hydraulic filters
Inspection: A
D-6 Drive hub oil
Quarterly or 250 hour D-7 Engine maintenance-
Inspection: A+B Continental models
Six Month or 500 hour D-8 Engine maintenance -
Inspection: A+B+C Deutz models
Annual or 1000 hour D-9 Engine maintenace-
Inspection: A+B+C+D Perkins models
2 Year or 2000 hour
Inspection: A+B+C+D+E Comments
• 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.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 S-80 • S-85 • S80X Part No. 1259369

Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed daily. Result: The machine is equipped with all
Maintaining the operator’s and safety manuals in required decals, and all decals are legible and
good condition is essential to safe machine in good condition.
operation. Manuals are included with each Result: The machine is not equipped with all
machine and should be stored in the container required decals, or one or more decals are
provided in the platform. An illegible or missing illegible or in poor condition. Remove the
manual will not provide safety and operational machine from service until the decals are
information necessary for a safe operating replaced.
condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie Industries if replacement manuals or decals
associated with using this machine. They also are needed.
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 1259369 S-80 • S-85 • S-80X 3-7

CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Perform Engine Maintenance -
Inspection Continental Models
Genie specifications require that this procedure be
performed daily.
Completing a pre-operation inspection is essential Engine specifications require that this procedure be
to safe machine operation. The pre-operation performed daily or every 8 hours, whichever comes
inspection is a visual inspection performed by the first.
operator prior to each work shift. The inspection is
designed to discover if anything is apparently wrong Proper engine maintenance, following the engine
with a machine before the operator performs the manufacturer's maintenance schedule, is essential
function tests. The pre-operation inspection also to good engine performance and service life. Failure
serves to determine if routine maintenance to perform the maintenance procedures can lead to
procedures are required. poor engine performance and component damage.
Complete information to perform this procedure is • Oil level- check

available in the appropriate operator's manual. • Coolant level- check
Refer to the Operator's Manual on your machine. • Oil, fuel and coolant systems- check for leaks
• PCV system- check
• Air filter discharge valve- clean
Required maintenance procedures and additional

engine information are available in the:
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901
3-8 S-80 • S-85 • S-80X Part No. 1259369

A-4 A-5
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Perkins Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed daily or every 8 hours, whichever comes performed daily or every 8 hours, whichever comes
first. first.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
• Oil level- check • Oil level- check
• Coolant level- check • Coolant level- check
• Oil, fuel and coolant systems- check for leaks • Oil, fuel and coolant systems- check for leaks
• Fuel pre-filter- drain water • Fuel pre-filter- drain water
• Air filter discharge valve- clean • Air filter discharge valve- clean
• Fuel filter / separator- check/drain Perkins 800D Series Operation Manual
• Exhaust system- inspect (Perkins part number SEBU8324)OR the
Required maintenance procedures and additional Perkins 404F Series Operation Manual
engine information are available in the (Perkins part number SEBU8609).
Deutz 2011 Series Operation Manual
(Deutz part number 0312-3547) OR the Perkins 800D Series Operation Manual
Deutz 2.9 L4 Series Operation Manual Genie part number 111332
(Deutz part number 0312-3893)
Perkins 404F Series Operation Manual
Deutz 2011 Series Operation Manual Genie part number 1251562
Deutz 2.9 L4 Series Operation Manual

Part No. 1259369 S-80 • S-85 • S-80X 3-9

A-6 A-7
Perform Function Tests Test the Oscillate Axle
performed daily.
Completing the function tests is essential to safe Genie specifications require that this procedure be
machine operation. Function tests are designed to performed daily.
discover any malfunctions before the machine is
put into service. A malfunctioning machine must Proper axle oscillation is essential to safe machine
never be used. If malfunctions are discovered, the operation. If the axle oscillation system is not
machine must be tagged and removed from operating correctly, the stability of the machine is
service. compromised and it may tip over.
Complete information to perform this procedure is Tip-over hazard. Failure to perform

available in the appropriate operator's manual. this procedure on a firm, level
Refer to the Operator's Manual on your machine. surface will compromise the
stability of the machine and could
result in the machine tipping over.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a
6 inch / 15 cm block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
3 Drive the left steer tire up onto a 6 inch / 15 cm
block or curb.
Result: The three remaining tires should stay in
firm contact with the ground and the chassis
should remain level at all times.
4 Drive both steer tires up onto a
6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firm
contact with the ground.
Note: If the chassis does not remain level during
the test, refer to Repair Procedure 14-2, How to Set
Up the Directional Valve Linkage.
3 - 10 S-80 • S-85 • S-80X Part No. 1259369

A-8 A-9
Check the High Pressure Perform 30 Day Service
Hydraulic Filter Condition
Indicator
Genie specifications require that this procedure be The 30 day maintenance procedure is a one time
performed daily or every 8 hours, whichever comes sequence of procedures to be performed after the
first. first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the
Maintaining the high pressure hydraulic filter in maintenance tables for continued scheduled
good condition is essential to good system maintenance.
performance and safe machine operation. The filter
condition indicator will show when the hydraulic flow 1 Perform the following maintenance procedures:
is bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
remain in the hydraulic system and cause • A-12 Grease the Turntable Rotation Bearing
component damage. and Rotate Gear
• B-9 Inspect the Tires, Wheels and
1 Open the engine side turntable cover. Lug Nut Torque
2 Start the engine from the ground controls. • B-10 Check the Drive Hub Oil Level and
Fastener Torque
3 Change the engine idle to high rpm (rabbit
symbol). • B-23 Inspect the Boom Extend/Retract
Cables
4 Visually inspect the filter condition indicator.
• D-3 Check the Turnable Rotation Bearing
Result: The filter condition indicator should be Bolts
operating with the plunger in the green area.
• D-5 Replace the Hydraulic Filter Elements
Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter should be
replaced. See D-5, Replace the Hydraulic
Filters.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 11

A-10 A-11
Continental Models Continental Models
performed every 50 hours or weekly. performed every 100 hours.
• Fan belt tension- check • Engine oil- replace
• Battery- check • Oil filter- replace
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the: engine information are available in the:
Continental TME27 Owner's Manual Continental TME27 Owner's Manual
(Continental part number WM10303). (Continental part number WM10303).
Continental TME27 Owner's Manual Continental TME27 Owner's Manual
Genie part number 111901 Genie part number 111901
3 - 12 S-80 • S-85 • S-80X Part No. 1259369

A-12 A-13
Grease the Turntable Rotation Replace the Drive Hub Oil
Bearing and Rotate Gear
Manufacturer specifications require that this one-

Genie specifications require that this procedure be time procedure be performed after the first 150
performed every 100 hours of operation. Perform hours.
this procedure more often if dusty conditions exist. Replacing the drive hub oil is essential for good
Frequent application of lubrication to the turntable machine performance and service life. Failure to
bearing and rotate gear is essential to good replace the drive hub oil after the initial 150 hours of
machine performance and service life. Continued use may cause the machine to perform poorly and
use of an improperly greased bearing and gear will continued use may cause component damage.
result in component damage. Drive hubs:
1 Locate the grease fitting on the platform end of 1 Select the drive hub to be serviced. Drive the
the tank side bulkhead. machine until one of the two plugs is at the
2 Pump grease into the turntable rotation bearing. lowest point.
Rotate the turntable in increments 2 Remove both plugs and drain the oil into a
of 4 to 5 inches / 10 to 13 cm at a time and suitable container.
repeat this step until the entire bearing has been
greased. 3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
3 Apply grease to each tooth of the drive gear,
located under the turntable.
a
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
a. models with o-ring plugs
Part No. 1259369 S-80 • S-85 • S-80X 3 - 13

4 Fill the hub with oil from the top hole until the oil 4 Remove the drive hub mounting bolts. Carefully
level is even with the bottom of the side plug remove the turntable rotate drive hub assembly
hole. Install the plugs. from the machine.
5 Install the plugs into the drive hub. Torque to Crushing hazard. The turntable
Specification. Refer to Section 2, rotate drive hub assembly could
Specifications. become unbalanced and fall if not
properly supported by the lifting
6 Repeat steps 1 through 4 for the other drive hub.
device.
7 Check the torque of the drive hub mounting
5 Remove the plug the drive hub. Drain the oil
bolts. Refer to Section 2, Specifications.
from the hub into a suitable container.
Turntable rotate drive hub:
Note: When removing a hose assembly or fitting,

the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Secure the turntable from rotating with the a
turntable rotation lock pin.
A
b
Note: The turntable rotation lock pin is located next B
to the boom rest pad.

c
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
3 Attach a suitable lifting device to the lifting eyes
located near the drive motor.
Dual fill port rotator

a motor
b drive hub
c drive hub mounting bolts
d fill ports
3 - 14 S-80 • S-85 • S-80X Part No. 1259369

6 Install the drive hub assembly onto the machine. A-13

Torque the drive hub mounting bolts to
specification. Refer to Section 2, Specifications. Perform Engine Maintenance -
7 Fill the drive hub with oil. Refer to Section 2,
Perkins Models
Specifications. Apply pipe thread sealant to the
plug. Install the plug.
8 Adjust turntable rotation gear backlash. Refer to Engine specifications require that this procedure be
Repair Procedure 10-1, How to Adjust the performed every 200 hours.
Turntable Rotation Gear Backlash.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
poor engine performance and component damage.
engine information are available in the
Perkins 804D-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).
Perkins 804D-33 Operation and Maintenance Manual

Genie part number
To access the engine:

1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out away from the machine and secure it
from moving.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 15

Checklist B Procedures
B-1 3 Be sure that the battery hold downs and cable
connections are tight.
Inspect the Battery(s)
4 Be sure that the battery separator wire
connections are tight (if equipped).
5 Fully charge the battery(s) and allow the
Genie specifications require that this procedure be battery(s) to rest at least 6 hours.
performed every 250 hours or quarterly, whichever
6 Remove the battery vent caps and check the
comes first.
specific gravity of each battery cell with a
Proper battery condition is essential to good hydrometer. Note the results.
engine performance and operational safety. 7 Check the ambient air temperature and adjust
Improper fluid levels or damaged cables and the specific gravity reading for each cell as
connections can result in engine component follows:
damage and hazardous conditions. A single
battery configuraton is standard. A dual battery • Add 0.004 to the reading of each cell for
option is available, where one battery is used to every 10° / 5.5° C above 80° F / 26.7° C.
start the engine and the other is used to power the
• Subtract 0.004 from the reading of each cell for
control system and auxiliary power unit. The two
every 10° / 5.5° C below 80° F / 26.7° C.
batteries are charged by the alternator through a
battery separator. Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
Electrocution/burn hazard. Contact is fully charged. Proceed to step 11.
with hot or live circuits could result
in death or serious injury. Remove Result: One or more battery cells display a
all rings, watches and other specific gravity of 1.217 or below. Proceed to
jewelry. step 8.
Bodily injury hazard. Batteries 8 Perform an equalizing charge, OR fully charge
contain acid. Avoid spilling or the battery(s) and allow the battery(s) to rest at
contacting battery acid. Neutralize least 6 hours.
battery acid spills with baking soda
9 Remove the battery vent caps and check the
and water.
specific gravity of each battery cell with a
1 Put on protective clothing and eye wear. hydrometer. Note the results.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 - 16 S-80 • S-85 • S-80X Part No. 1259369

CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for Genie specifications require that this procedure be
every 10° / 5.5° C below 80° F / 26.7° C. performed every 250 hours or quarterly, whichever
Result: All battery cells display a specific gravity comes first.
of 1.277 or greater. The battery is fully charged. Maintaining electrical wiring in good condition is
Proceed to step 11. essential to safe operation and good machine
Result: The difference in specific gravity performance. Failure to find and replace burnt,
readings between cells is greater than 0.1 OR chafed, corroded or pinched wires could result in
the specific gravity of one or more cells is less unsafe operating conditions and may cause
than 1.177. Replace the battery. component damage.
11 Check the battery acid level. If needed, Electrocution/ burn hazard.

replenish with distilled water to 1/8 inch / 3 mm Contact with hot or live circuits
below the bottom of the battery fill tube. Do not could result in death or serious
overfill. injury. Remove all rings, watches
and other jewelry.
12 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Open the turntable cover at the engine side of
the machine.
2 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
a b
a engine tray anchor hole

b engine tray retaining fastener
Part No. 1259369 S-80 • S-85 • S-80X 3 - 17

3 Locate the engine tray anchor hole on the 12 Inspect the following areas for burnt, chafed,
turntable. corroded, pinched and loose wires:
4 Install the bolt that was just removed into the • Cable track on the boom
anchor hole to secure the engine tray from • Cables on the boom and jib boom
moving.
• Jib, rotate, level manifold
Crushing hazard. Failure to install
• Inside of the platform control box
the bolt into the engine pivot plate
to secure it from moving could 13 Inspect for a liberal coating of dielectric grease
result in death or serious injury. in the following location:
5 Inspect the following areas for burnt, chafed, • All wire harness connectors to
corroded, pinched and loose wires: platform control box
• Engine wiring harness 14 Remove the engine tray retaining fastener from
the engine tray anchor hole at the pivot end of
6 Open the turntable cover at the ground controls the engine tray.
side of the machine.
15 Swing the engine tray in towards the machine.
7 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires: 16 Install the engine tray retaining fasteners.
• Battery area wiring Crushing hazard. Failure to install
the bolt into the engine pivot plate
• Inside the ground control box
to secure it from moving could
• Hydraulic manifold wiring result in death or serious injury.
• Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric grease
in the following locations:
• All wire harness connectors to
ground control box
9 Start the engine from the ground controls and
raise the boom above the turntable covers.
10 Inspect the turntable area for burnt, chafed and
pinched cables.
11 Lower the boom to the stowed position and turn
the engine off.
3 - 18 S-80 • S-85 • S-80X Part No. 1259369

B-3 B-4
Test the Key Switch Check the Exhaust System
comes first.
Proper key switch action and response is essential performed every 250 hours or quarterly, whichever
to safe machine operation. The machine can be comes first.
operated from the ground or platform controls and
the activation of one or the other is accomplished Maintaining the exhaust system is essential to
with the key switch. Failure of the key switch to good engine performance and service life. Running
activate the appropriate control panel could cause a the engine with a damaged or leaking exhaust
hazardous operating situation. system can cause component damage and unsafe
operating conditions.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform Bodily injury hazard. Do not
controls. inspect while the engine is running.
Remove the key to secure from
2 Turn the key switch to ground control, start the operation.
engine and then turn the key switch to platform
control. Burn hazard. Beware of hot engine
components. Contact with hot
3 Check all machine function from the ground engine components may result in
controls. severe burns.
Result: All machine functions should not To access the engine:
operate.
1 Remove the engine tray retaining fastener
4 Turn the key switch to ground control. located under the engine tray. Swing the engine
5 Check all machine function from the platform tray out away from the machine and secure it
controls. from moving.
Result: All machine functions should not Crushing hazard. Failure to install
operate. the fastener into the engine tray
anchor hole to secure the engine
6 Turn the key switch to the off position. tray from moving could result in
Result: The engine should stop and no functions death or serious injury.
should operate.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 19

2 Be sure that all nuts and bolts are tight. B-5

3 Inspect all welds for cracks. Inspect the Engine Air Filter -
4 Inspect for exhaust leaks; i.e., carbon buildup Continental, Deutz and Perkins
around seams and joints. Models
5 Swing the engine pivot plate in towards the
machine.
6 Install the bolts that were just removed into the
original holes to secure the engine pivot plate. Genie specifications require that this procedure be
Crushing hazard. Failure to install comes first.
the bolts into the engine pivot plate
to secure it from moving could Maintaining the engine air filter in good condition is
result in death or serious injury. essential to good engine performance and service
life. Failure to perform this procedure can lead to
Note: Perform this procedure with the engine off.
1 Locate the engine air filter assembly.

2 Release the latches from the air cleaner canister
end cap. Remove the end cap.
3 Remove the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
Replace the filter if needed.
6 Install the filter element.
7 Install the air filter canister end cap and secure
the end cap latches.
Note: Be sure the discharge valve is pointing down
when the cap is instaled.
3 - 20 S-80 • S-85 • S-80X Part No. 1259369

B-6 B-7
Continental Models Perkins Models
performed every 250 hours . performed every 250 hours .
• Harness connections- check • Alternator and Fan belts- inspect/adjust
• Cooling system- check Perkins 800D Series Operation Manual
Required maintenance procedures and additional (Perkins part number SEBU8324)OR the
engine information are available in the: Perkins 404F Series Operation Manual
Continental TME27 Owner's Manual (Perkins part number SEBU8609).
(Continental part number WM10303).
Continental TME27 Owner's Manual Perkins 800D Series Operation Manual
Genie part number 111901 Genie part number 111332

Part No. 1259369 S-80 • S-85 • S-80X 3 - 21

B-8 B-9
Confirm the Proper Inspect the Tires, Wheels
Brake Configuration and Lug Nut Torque
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Proper brake configuration is essential to safe Maintaining the tires and wheels in good
operation and good machine performance. condition, including proper wheel fastener torque, is
Hydrostatic brakes and hydraulically-released, essential to safe operation and good performance.
spring-applied individual wheel brakes can appear Tire and/or wheel failure could result in a machine
to operate normally when they are actually not fully tip-over. Component damage may also result if
operational. problems are not discovered and repaired in a
timely fashion.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position. Bodily injury hazard. An over-
inflated tire can explode and could
result in death or serious injury.
disengaged position
Tip-over hazard. Do not use
temporary flat tire repair products.
Note: The tires on some machines are foam filled
and do not need air added to them.
engaged position
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
4 Check the pressure in each air-filled tire. Add air
as necessary. Refer to Section 2,
Specifications.
3 - 22 S-80 • S-85 • S-80X Part No. 1259369

B-10 4 Install the plugs into the drive hub. Torque to

Specification. Refer to Section 2,
Check Drive Hub Oil Level and Specifications.
Fastener Torque 5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat steps 1 through 5 for the other drive
hubs.
performed every 250 hours. Turntable rotate drive hub:
Failure to maintain proper drive hub oil levels may 1 Remove one of the plugs located on the side of
cause the machine to perform poorly and continued the hub and check the oil level.
use may cause component damage.
Result: The oil level should be even with the
Drive hubs: bottom of the plug hole.
1 Drive the machine to rotate the hub until one of

the plugs is located on top and the other one is
at 90 degrees.
B
A
b
a models with o-ring plugs
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole. d
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the Dual fill port rotator
a motor
side plug hole.
b drive hub
d fill ports
Part No. 1259369 S-80 • S-85 • S-80X 3 - 23

2 If necessary, add oil. Refer to Section 2, B-11

Specifications.
Check the Oscillate Directional
4 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
Valve Linkage
5 Check the torque of the turntable rotate drive
hub mounting fasteners. Refer to Section 2,
Specifications. Genie specifications require that this procedure be
comes first.
Proper axle oscillation is essential to safe machine

operation. If the oscillate directional valve linkage is
not operating correctly, the stability of the machine
is compromised and it may tip over.
1 Remove the drive chassis cover from the
non-steer end of the machine.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for
the following:
• Lock nut is tight against yoke
• Yoke clevis pins are installed
• Cotter pins are installed through clevis pins
• Linkage is properly attached to
directional valve
3 - 24 S-80 • S-85 • S-80X Part No. 1259369

B-12 B-13
Test the Ground Control Test the Platform Self-leveling
Override Genie specifications require that this procedure be
Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever
performed every 250 hours or quarterly, whichever comes first.
comes first. Automatic platform self-leveling throughout
A properly functioning ground control override is the full cycle of boom raising and lowering is
essential to safe machine operation. The ground essential for safe machine operation. The
control override function is intended to allow ground platform is maintained at level by the platform
personnel to operate the machine from the ground leveling slave cylinder which operates in a closed
controls whether or not the red Emergency Stop loop hydraulic circuit with the master cylinder
button at the platform controls is in the on or off located at the base of the boom.
position. This function is particularly useful if the A platform self-leveling failure creates an unsafe
operator at the platform controls cannot return the working condition for platform and ground
boom to the stowed position. personnel.
1 Push in the red Emergency Stop button at the 1 Start the engine from the ground controls.
platform controls to the off position. 2 Hold the function enable toggle switch to either
2 Start the engine from the ground controls. side and adjust the platform to a level position
using the platform level toggle switch.
3 At the ground controls, operate each boom
function through a partial cycle. 3 Raise and lower the boom through a full cycle.
Result: All boom functions should operate. Result: The platform should remain level at
all times to within ±5 degrees.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 25

B-14 5 Release the function enable button.

Test the Engine Idle Select Result: The engine rpm should change to low
idle.
Operation
6 Turn the key switch to platform controls.
performed every 250 hours or quarterly, whichever 7 Move the engine idle select toggle switch to low
comes first. idle (turtle symbol).
A properly operating engine idle select switch Result: The engine rpm should remain at low
is essential to good engine performance and safe idle.
machine operation. There are three settings. 8 Move the engine idle select toggle switch to foot
Low idle (turtle symbol) allows the operator to switch activated high idle (rabbit and foot switch
control individual boom functions only. symbol).
Result: The engine rpm should not change to
Functon enable button high idle (rabbit symbol)
high idle.
allows the operator to control multiple boom
functions simultaneously. This setting maintains a 9 Press down the foot switch.
consistent high idle.
Result: The engine rpm should change to high
Foot switch activated high idle (rabbit and foot idle.
switch symbols) should be used for normal
high idle.
machine operation. This setting activates high idle
only when the foot switch is pressed down. 10 Press down the foot switch.
1 Turn the key switch to ground control. Result: The engine rpm should change to high
idle.
on position at both the ground and platform
controls.
3 Start the engine from the ground controls.
4 Move and hold the function button in and move
the idle switch to the high idle (rabbit symbol)
position.
Result: The engine rpm should change to high
idle.
3 - 26 S-80 • S-85 • S-80X Part No. 1259369

B-15 4 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button in to
Test the Fuel Select Operation - the off position.
Gasoline/LPG Models 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 engine
Genie specifications require that this procedure be to run at high idle.
Result: The engine should start promptly and
comes first.
operate smoothly in low and high idle.
The ability to select and switch between
Note: The engine may hesitate momentarily and
gasoline and LPG fuels as needed is essential to
then continue to run on the selected fuel if the fuel
safe machine operation. A fuel selection can be
source is switched while the engine is running.
made whether the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
Note: Perform this test after checking the gasoline

and LPG fuel levels, and warming the engine to
normal operating temperature.
1 Move the fuel select toggle switch to gasoline
and then move the engine idle select switch to
foot switch activated high idle (rabbit and foot
switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 27

B-16 5 Rotate the turntable until the boom moves past

the other non-steer wheel.
Test the Drive Enable System
Result: The drive enable
Genie specifications require that this procedure be indicator light should come on
performed every 250 hours or quarterly, whichever and remain on while the boom
comes first. is anywhere in the range shown.
Proper drive enable system operation is 6 Move and hold the drive enable toggle switch to
essential to safe machine operation. When the either side and slowly move the drive control
boom is past the non-steering wheels, drive handle off center.
movement is stopped and the
indicator light turns on. The drive Result: The drive function should operate.
enable switch must be held to Collision hazard. Always use the
either side to reactivate the drive color-coded direction arrows on the
function and should alert the platform controls and the drive
operator that the machine may chassis to identify the direction of
move in the opposite direction that the drive and travel.
steer controls are moved. An improperly functioning
drive enable system may allow the machine to be Note: When the drive enable system is in use, the
moved into an unsafe position. machine may drive in the opposite direction that the
drive and steer control handle is moved.
Note: Perform this procedure with the boom in the
stowed position.
Blue
1 Start the engine from the platform controls.
2 Press down the foot switch.
3 Rotate the turntable until the boom moves past
one of the the non-steer wheels.
Yellow
Result: The drive enable indicator light should
turn on and remain on while the
boom is anywhere in the range
shown.
4 Slowly move the drive control
handle off center.
Result: The drive function should not operate.
3 - 28 S-80 • S-85 • S-80X Part No. 1259369

B-17 B-18
Test the Drive Brakes Test the Drive Speed -
Stowed Position

performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be
comes first. performed every 250 hours or quarterly, whichever
Proper brake action is essential to safe machine comes first.
operation. The drive brake function should operate Proper drive function movement is essential to safe
smoothly, free of hesitation, jerking and unusual machine operation. The drive function should
noise. Hydraulically-released individual wheel respond quickly and smoothly to operator control.
brakes can appear to operate normally when they Drive performance should also be free of hesitation,
are actually not fully operational. jerking and unusual noise over the entire
Collision hazard. Be sure that the proportionally controlled speed range.
machine is not in free-wheel or Note: Select a test area that is firm, level and free
partial free-wheel configuration. of obstructions.
See B-8, Confirm the Proper Brake
Configuration. Note: Perform this procedure with the boom in the
stowed position.
Note: Select a test area that is firm, level and free
of obstructions. 1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
Note; Perform this procedure with the boom in the
stowed position. 2 Start the engine from the platform controls.
1 Mark a test line on the ground for reference. 3 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
2 Start the engine from the platform controls. when crossing the start and finish lines.
3 Choose a point on the machine (i.e., contact 4 Bring the machine to top drive speed before
patch of a tire) as a visual reference for use reaching the start line. Begin timing when your
when crossing the test line. reference point on the machine crosses the
4 Bring the machine to top drive speed before start line.
reaching the test line. Release the drive 5 Continue at full speed and note the time when
controller when your reference point on the the machine reference point crosses the finish
machine crosses the test line. line. Refer to Section 2, Performance
5 Measure the distance between the test line and Specifications.
your machine reference point. Refer to Note: To adjust the speed, refer to Repair
Section 2, Specifications. procedure 1-2, How to Adjust the Joystick Max-out
Note: The brakes must be able to hold the machine Setting.
on any slope it is able to climb.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 29

B-19 7 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line. Refer to Section 2, Performance
Raised or Extended Position Specifications.
Note: To adjust the speed, refer to Repair
procedure 1-2, How to Adjust the Joystick Max-out
Setting.
performed every 250 hours or quarterly, whichever 8 Press down the foot switch and lower the boom
comes first. to the stowed position.
9 Extend the boom 3 feet / 90 cm.
Proper drive function movement is essential to safe
machine operation. The drive function should 10 Choose a point on the machine (i.e., contact
respond quickly and smoothly to operator control. patch of a tire), as a visual reference for use
Drive performance should also be free of hesitation, when crossing the start and finish lines.
jerking and unusual noise over the entire
11 Bring the machine to top drive speed before
proportionally controlled speed range.
reaching the start line. Begin timing when your
Select a test area that is firm, level and free of reference point on the machine crosses the
obstructions. start line.
1 Create start and finish lines by marking two lines 12 Continue at top speed and note the time when
on the ground 40 feet / 12.2 m apart. the machine reference point crosses the finish
line. Refer to Section 2, Performance
2 Start the engine from the platform controls. Specifications.
3 Move the engine idle select toggle switch to Note: To adjust the speed, refer to Repair
foot switch activated high idle (rabbit and foot procedure 1-2, How to Adjust the Joystick Max-out
switch symbol). Setting.
4 Press down the foot switch and raise the boom
10° above horizontal.
5 Choose a point on the machine (i.e. contact
patch of a tire), as a visual reference for use
when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
3 - 30 S-80 • S-85 • S-80X Part No. 1259369

B-20 3 Turn the key switch to platform controls.

Test the Alarm Package Result: The flashing beacons should be on
and flashing.
(if equipped) and the Descent
Alarm 4 Press down the foot switch. Move the boom
controller to the down position, hold for a
Genie specifications require that this procedure be moment and then release it.
Result: The descent alarm should sound when
comes first.
the controller is held down.
The alarm package includes: 5 Press down the foot switch. Move the drive
• Travel alarm controller off center, hold for a moment and then
release it. Move the drive controller off center in
• Flashing beacons the opposite direction, hold for a moment and
Alarms and beacons are installed to alert operators then release it.
and ground personnel of machine proximity and
Result: The travel alarm should sound when the
motion. The alarm package is installed on the
drive controller is moved off center in either
turntable rear cover. Beacons are installed on both
direction.
turntable covers.
Note: The alarms and beacons will operate with the

engine running or not running.
1 Turn the key switch to ground controls and pull

out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: Both flashing beacons should be on and
flashing.
2 Move and hold the function enable button to
either side and activate the boom toggle switch
in the down position, hold for a moment and
then release it.
Result: The descent alarm should sound when
the toggle switch is held down.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 31

B-21 3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
Inspect the Fuel and Hydraulic compressed air. Repeat this procedure
Tank Cap Venting Systems beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
Genie specifications require that this procedure be tank.
performed every 250 hours or quarterly, whichever 6 Check for proper venting.
comes first. Perform this procedure more often if
dusty conditions exist. Result: Air passes through the hydraulic tank
cap. Procced to step 8.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use Note: When checking for positive tank cap venting,
may cause component damage. Extremely dirty air should pass freely through the cap.
conditions may require that the caps be inspected
more often. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Explosion and fire hazard. Engine compressed air. Repeat this procedure
fuels are combustible. Perform this beginning with step 6.
procedure in an open, well-
ventilated area away from heaters, 8 Install the breather cap onto the hydraulic tank.
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
Note: This procedure applies to diesel equipped
machines only.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Procced to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank cap venting, air
should pass freely through the cap.
3 - 32 S-80 • S-85 • S-80X Part No. 1259369

B-22 B-23
Perform Hydraulic Oil Analysis Inspect the Boom
Extend/Retract Cables

comes first. Genie specifications require that this procedure be
Replacement or testing of the hydraulic oil is performed every 250 hours or quarterly, whichever
essential for good machine performance and comes first.
service life. Dirty oil and suction strainers may The boom extend/retract cables are responsible for
cause the machine to perform poorly and continued the extension and retraction of the number 3 boom
use may cause component damage. Extremely tube. Inspecting for foreign objects, damage and/or
dirty conditions may require oil changes to be improper adjustment of the boom extend/retract
performed more frequently. cables and related components on a regular basis
Note: Before replacing the hydraulic oil, the oil may is essential to good machine performance and safe
be tested by an oil distributor for specific levels of machine operation. The boom extend and retract
contamination to verify that changing the oil is functions should operate smoothly and be free of
necessary. If the hydraulic oil is not replaced at hesitation, jerking and unusual noise.
the two year inspection, test the oil quarterly. 1 Raise the boom to horizontal and fully extend
Replace the oil when it fails the test. the boom.
2 After the boom is fully extended, lower the boom
until the platform is at chest height. Turn the
machine off.
3 Remove the boom end cover retaining fasteners
and remove the cover.
4 Remove the retaining fasteners from the access
covers located on the side of the boom at the
platform end of the machine. Remove the
covers.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 33

5 Visually inspect the cables and components 9 Turn the key switch to the platform controls.
through both inspection holes for the following:
10 Extend the boom approximately 2 feet / 0.6 m.
• Frayed or broken wire strands
11 Retract the boom. While retracting the boom,
• Kinks in the cables visually inspect the number 2 and number 3
• Corrosion boom tubes.
• Paint or foreign materials on the cable Result: The number 2 boom tube should not
• Split or cracked cable ends move more than 1/2 inch / 13 mm before the
number 3 boom tube begins to retract.
• Cables are on all pulleys
Note: If the number 2 boom tube moves more than
• Extend cable break limit switch arm is 1
/2 inch / 13 mm before the number 3 boom tube
centered in the pivot plate
begins to retract, the boom extend/retract cables
• Cables have equal tension need to be adjusted. See Repair Procedure 4-5,
• Cables at end of adjustment range How to Adjust the Boom Extend/Retract Cables.
• No broken or damaged pulleys
• No unusual or excessive pulley wear
• All fasteners in place and secure
Note: A flashlight and inspection mirror may be
necessary to thoroughly inspect the above items.
Note: A pulley groove gauge should be used to
check the condition of the pulleys.
6 Install the cover at the pivot end of the boom.

7 Install the access panels on the sides of the
boom.
fully retract and lower the boom to the stowed
position.
3 - 34 S-80 • S-85 • S-80X Part No. 1259369

B-24 5 Turn the key switch to platform controls.

Test the Emergency Power 6 At the platform controls, break the security tie
and lift the emergency power switch cover (if
System equipped).
7 Press down the foot switch and simultaneously
hold the emergency power switch on and
Genie specifications require that this procedure be activate each boom function.
performed every 250 hours or quarterly, whichever Note: To conserve battery power, test each
comes first. function through a partial cycle.
Testing the emergency power system regularly is Result: All boom functions operate.
essential to safe machine operation if the primary
power source fails. 8 Close the emergency power switch cover and
secure the cover with a security tie (if
Note: Perform this procedure with the engine off. equipped).
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
controls.
2 At the ground controls, break the security tie
and lift the emergency power switch cover (if
equipped).
3 Simultaneiously hold the emergency power
switch on and activate each boom function
toggle switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions operate.

4 Close the emergency power switch cover and
secure the cover with a security tie (if
equipped).
Part No. 1259369 S-80 • S-85 • S-80X 3 - 35

Checklist C Procedures
C-1 C-2
Continental Models Deutz Models
performed every 500 hours. performed every 500 hours.
• Valve tappet clearance- adjust • Engine oil- replace
• Fuel pump- check • Oil filter- replace
• Fuel filter- replace • Primary fuel filter- replace
• PCV valve- check • V-belts- check
Required maintenance procedures and additional • Intake air pipes- check
engine information are available in the: • Cooling system- check
Continental TME27 Owner's Manual Required maintenance procedures and additional
(Continental part number WM10303). engine information are available in the
Continental TME27 Owner's Manual (Deutz part number 0312-3547) OR the


3 - 36 S-80 • S-85 • S-80X Part No. 1259369

CHECKLIST C PROCEDURES
C-3 C-4
Perform Engine Maintenance - Replace the Engine Air Filter
Perkins Models Element
performed every 500 hours. performed every 500 hours or six months,
whichever comes first.
manufacturer's maintenance schedule, is essential Maintaining the engine air filter in good condition is
to good engine performance and service life. Failure essential to good engine performance and service
to perform the maintenance procedures can lead to life. Failure to perform this procedure can lead to
• Engine oil- replace Note: Perform this procedure with the engine off.
• Oil filter- replace
1 Release the latches on the air cleaner cap.
• Fuel filter- replace
Remove the end cap from the air cleaner
• Secondary Fuel filter- replace
canister.
• Fan clearance- check
• Cooling system- test/add 2 Remove the filter element.
• Hoses and clamps- inspect/replace
• Radiator- clean 3 Use a damp cloth to wipe the filter sealing
surface and the inside of the outlet tube. Make
Required maintenance procedures and additional sure that all contaminant is removed before the
engine information are available in the: filter is inserted.
Perkins 800D Series Operation Manual
(Perkins part number SEBU8324)OR the 4 Check new filter element gasket for damage
Perkins 404F Series Operation Manual before installing.
(Perkins part number SEBU8609). 5 Install the new filter element.

6 Install the end cap on the canister and secure.
Genie part number 111332 Note: Be sure the discharge slot is pointing down.

Part No. 1259369 S-80 • S-85 • S-80X 3 - 37

C-5
Check and Adjust the
Engine RPM
Maintaining the engine rpm at the proper setting for

both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Not applicable to these models:
Continental TME27
Deutz TD 2.9 L4 Models
Perkins 404F-22T Models
a b
Note: The engine rpm is controlled by the ECM and Deutz models
can only be adjusted by re-programming the ECM. a high idle adjustment
b low idle adjustment
If rpm adjustment or service is required, please
contact Genie Product Support. Skip to step 4 if the low idle rpm is correct.
Deutz TD2011L04i models: 2 Loosen the locknut on the low idle adjustment
screw.
1 Connect a tachometer to the engine. Start the
engine from the ground controls and check the 3 Adjust the low idle adjustment screw until low
rpm. Refer to Section 2, Specifications. idle meets specification. Tighten the locknut.
4 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustment
step 5.
5 Loosen the yoke lock nut. Turn the high idle

adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
3 - 38 S-80 • S-85 • S-80X Part No. 1259369

Perkins 804D models: 3 Move the function enable/rpm select toggle

switch to the high idle (rabbit symbol) position.
1 Connect a tachometer to the engine. Start the Refer to Section 2, Specifications.
engine from the ground controls and check the
rpm. Refer to Section 2, Specifications. If high idle rpm is correct, disregard adjustment
step 4.
Skip to step 3 if the low idle rpm is correct.
4 Loosen the yoke lock nut. Turn the high idle
2 Loosen the low idle lock nut. Turn the low idle adjustment nut and solenoid boot
adjustment screw clockwise to increase the rpm counterclockwise to increase the rpm or
or counterclockwise to decrease the rpm. clockwise to decrease the rpm. Tighten the
Tighten the low idle lock nut and confirm the yoke lock nut and recheck the rpm.
rpm.
Note: Be sure the solenoid fully retracts when
a b c activating high idle.
f e d
Perkins models
a solenoid boot
b yoke lock nut
c low idle adjustment screw
d low idle lock nut
e yoke
f high idle adjustment nut
Part No. 1259369 S-80 • S-85 • S-80X 3 - 39

C-6 C-7
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 500 hours or six months, performed every 500 hours or six months,
whichever comes first. Perform this procedure more whichever comes first.
often if dusty conditions exist.
Testing the platform overload system regularly is
Application of lubrication to the platform overload essential to safe machine operation. Continued use
mechanism is essential to safe machine operation. of an improperly operating platform overload
Continued use of an improperly greased platform system could result in the system not sensing an
overload mechanism could result in the system not overloaded platform condition. Machine stablity
sensing an overloaded platform condition and will could be compromised resulting in the machine
result in component damage. tipping over.
1 Locate the grease fittings on each pivot pin of Note: Perform this procedure with the machine on a
the platform overload assembly. firm, level surface.
2 Thoroughly pump grease into each grease 1 Turn the key switch to platform control. Start the
fitting. engine and level the platform.
2 Determine the maximum platform capacity.
Grease Specification
Refer to the machine serial plate.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based) 3 Remove all weight, tools and accessories from
or equivalent the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
Illustration 1
3 - 40 S-80 • S-85 • S-80X Part No. 1259369

4 Using a suitable lifting device, place a test 7 Using a suitable lifting device, remove the test
weight equal to that of the available capacity at weights, restart the engine and carefully move
one of the locations shown. the test weights to each remaining location on
Refer to Illustration 1. the platform. Refer to Illustration 1.
Result: The platform overload indicator lights Result: The alarm should sound, the engine
should be off at both the ground and platform should shut off and the platform overload
controls and the alarm should not sound. indicator lights should be flashing at both the
ground and platform controls.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the Result: The alarm does not sound and the
platform overload system. Refer to Repair platform overload indicator lights are not
Procedure 2-4, How to Calibrate the Platform flashing. Calibrate the platform overload
Overload System (if equipped). system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
5 Carefully move the test weight to each
equipped).
remaining location. Refer to Illustration 1.
Note: There may be a 2 second delay before the
Result: The platform overload indicator lights
overload indicator lights flash, the alarm sounds
should be off at both the ground and platform
and the engine shuts off.
controls and the alarm should not sound.
8 Test all machine functions from the platform
Result: The platform overload indicator lights are
controls.
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: All platform control functions should not
Procedure 2-4, How to Calibrate the Platform operate.
Overload System (if equipped).
9 Turn the key switch to ground control.
6 Using a suitable lifting device, place an
additional 50 lbs / 23 kg of weight onto the 10 Test all machine functions from the ground
platform. controls.
Result: The alarm should sound and the engine Result: All ground control functions should not
should shut off. The platform overload indicator operate.
lights should be flashing at both the ground and 11 Activate the auxiliary power toggle switch.
platform controls.
12 Using auxiliary power, test all machine functions
Result: The alarm does not sound, the engine from the ground controls.
does not shut off and the platform overload
indicator lights are not flashing. Calibrate the Result: All ground control functions should
platform overload system. Refer to Repair operate.
Procedure 2-4, How to Calibrate the Platform 13 Using a suitable lifting device, lift the additional
Overload System (if equipped). test weight from the platform.
Note: There may be a 2 second delay before the Result: The platform overload indicator lights
overload indicator lights flash, the alarm sounds should turn off at both the ground and platform
and the engine shuts off. controls and the alarm should not sound.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 41

14 Start the engine and test all machine functions 21 Using Illustration 3 as a guide, locate D31 Valve
from the ground controls. Power LED on the ALC500 printed circuit board.
Result: All ground control functions should
operate normally. Valve Power LED
15 Turn the key switch to platform control. ALC 500 Board
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System (if
equipped).
17 Push in the red Emergency stop button at the
platform to shut off engine.
Illustration 3
18 Using a suitable lifting device, remove all test
22 Step on the footswitch at the platform.
weights from the platform.
Result: The Valve Power LED should not
19 Pull out the red Emergency stop button to the on
illuminate.
position at the platform controls.
Result: The Valve Power LED is illuminated.
20 Remove the fasteners securing the lid to the
Remove the machine from service and contact
platform controls. Using Illustration 2 as a
Genie Product Support.
guide, locate the timer relay inside the platform
control box. Tag and disconnect the red wire 23 Securely install the red wire, disconnected in
from terminal 5 on the timer relay. step 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.
Timer Relay Remove the machine from service and contact
Genie Product Support.
25 Using a suitable lifting device, place a test
weight equal to that of the available capacity at
Orange the center location shown in Illustration 1.
Wire
Terminal 5
Illustration 2
3 - 42 S-80 • S-85 • S-80X Part No. 1259369

26 Using a suitable lifting device, place an C-8

additional 50 lbs / 23 kg of weight onto the
platform. Check the Safety Envelope Limit
Result: The alarm should sound and the Valve
Switches and Angle Sensor,
Power LED should not light. The platform S-80X
overload indicator lights should be flashing at
both the ground and platform controls. Genie specifications require that this procedure be
performed every 500 hours or six months,
27 Working from outside the platform and standing whichever comes first.
next to the platform rotator, locate the orange
wire, which enters into the base of the platform Testing the safety envelope system regularly is
control box from the load sense switch and essential to safe machine operation. Continued use
locate the wire terminal at the end of the wire. of an improperly operating safety envelope could
Tag and disconnect the connectors. result in the system not restricting the range of
Refer to Illustration 2. motion. Machine stablity could be compromised
resulting in the machine tipping over.
28 Using a multimeter set to read resistance
(ohms), securely install a lead from the Note: Perform this procedure with the machine on a
multimeter to the connector on the orange wire, firm, level surface with all weight, tools and
and securely connect the other multimeter lead equipment removed from the platform.
to a ground point in the control box.
Note: Start this procedure with the boom fully
Result: The readout on the multimeter should retracted and in the stowed position.
indicate zero resistance.
Ground controls:
Result: The readout on the multimeter shows
resistance. Remove the machine from service 1 Turn the key switch to ground control and pull
and contact Genie Product Support. out the red Emergency Stop button to the on
position.
29 Using a suitable lifting device, remove all weight
from the platform. Note the result on the 2 Start the engine from the ground controls.
multimeter.
Result: The readout on the multimeter should
indicate infinite resistance.
Result: The readout on the multimeter shows
zero resistance. Remove the machine from
service and contact Genie Product Support.
31 Turn off the multimeter and remove the leads
from the machine. Securely connect the wires
disconnected in step 27.
32 Close the platform control box. Install and
securely tighten the fasteners. Do not
overtighten.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 43

3 Turn and hold the function enable switch to the 7 Measuring Tape:
restricted maximum platform capacity and raise
Measure the distance between the center of the
the primary boom until it is fully elevated.
pivot pins as shown, 201.75 inches / 512 cm
a b ± 2.0 inch / 5 cm.
Digital Protractor:
1000 lbs / 500 lbs / Place the digital protractor on the turntable
454 kg 227 kg chassis and reset the protractor to 0°. Place the
protractor on top of the primary boom. The
protractor should display 58° ± 2°.
Result: The primary boom angle is not within
specifications.Consult Genie Product Support.
a restricted maximum platform

capacity
b unrestricted maximum platform
capacity
Measure between
4 Extend the primary boom until it is fully
the centers of these
extended. pivot pins
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 10
degrees. Check limit switches LST3O and
LST3S.
6 Turn the key switch to the off position and push
in the red Emergency Stop button.
Note: The follwing step can be done using a
measuring tape or a digital protractor (Genie part
number 58377).
3 - 44 S-80 • S-85 • S-80X Part No. 1259369

Platform controls: 6 Move the primary boom down joystick off center
and retract the primary boom until the
Note: Start this procedure with the boom fully unrestricted platform capacity light stops
retracted and in the stowed position. flashing.
1 Pull out the red Emergency Stop button to the Result: Primary boom down should return to
on position and start the engine. normal operation.
2 Select the restricted maximum platform capacity 7 Lower the primary boom 5 feet / 1.5 m and
with the toggle switch. activate primary boom extend.
a b Result: Primary boom extend will stop and the
unrestricated platform capacity light will start
flashing.
8 Activate primary boom extend and raise the
1000 lbs / 500 lbs / primary boom until the unrestricated platform
454 kg 227 kg capacity light stops flashing.
Result: Primary boom extend should return to
normal operation.
9 Return the machine to the fully stowed position.
a restricted maximum platform

capacity
b unrestricted maximum platform
capacity
3 Raise the primary boom until it is fully elevated.

4 Extend the primary boom until it is fully
extended.
5 Lower the primary boom until it stops.
Result: The boom will automatically stop after
10 degrees and the unrestricted platform
capacity light will flash.
Result: The primary boom does not stop after 10
degrees. Calibrate the boom angle sensor. Refer
to Repair Procedure 1-2, How to Calibrate the
Boom angle Sensor.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 45

Checklist D Procedures
D-1 4 Extend and retract the boom through the entire
range of motion to check for tight spots that
Check the Boom Wear Pads may cause binding or scraping of the boom.
Note: Always maintain squareness between the
outer and inner boom tubes.

performed every 1000 hours or annually, Boom wear pad specifications Minimum
Boom number one
Maintaining the boom wear pads in good condition
Bottom wear pads 1/2 inch
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low (extension end of boom) 12.7 mm
friction, replaceable wear pad between moving Top and side wear pads 5 /8
inch
parts. Improperly shimmed wear pads or continued (extension end of boom) 15.9 mm
use of extremely worn wear pads may result in
component damage and unsafe operating Boom number two
conditions.
Top, bottom and side wear pads 1/2 inch
Note: If the wear pads are still within specification, (extension end of boom) 12.7 mm
refer to Repair Procedure 4-2, How to Shim the 1 /2
Bottom wear pads inch
Boom.
(pivot end of boom) 12.7 mm
1 Start the engine from the ground controls. 5/8 inch
Top and side wear pads
2 Raise the end of the boom to a comfortable (pivot end of boom) 15.9 mm
working height (chest high), then extend the Boom number three
boom 1 foot / 30 cm.
Top, bottom and side wear pads 1/2 inch
3 Measure each wear pad. Replace the wear pad
if it is less than specification. If the wear pad is (pivot end of boom) 12.7 mm
still within specification, shim as necessary to
obtain zero clearance and zero drag.
a b c
a boom 1
b boom 2
c boom 3
3 - 46 S-80 • S-85 • S-80X Part No. 1259369

CHECKLIST D PROCEDURES
D-2 5 Manually rotate each non-steer wheel.

Check the Free-wheel Result: Each non-steer wheel should rotate with
minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the blocks.
performed every 1000 hours or annually, whichever Collision hazard. Failure to
comes first. re-engage the drive hubs could
result in death or serious injury and
Proper use of the free-wheel configuration is property damage.
essential to safe machine operation. The free-wheel
configuration is used primarily for towing. A Steer wheels: 4WD models
machine configured to free-wheel without operator
7 Chock the non-steer wheels to prevent the
knowledge could result in death or serious injury
machine from rolling.
and property damage.
8 Center a lifting jack of ample capacity
Collision hazard. Select a work site
(20,000 lbs / 10,000 kg) under the drive chassis
that is firm and level.
between the steer wheels.
Component damage hazard. If the
9 Lift the wheels off the ground and then place
machine must be towed, do not
blocks under the drive chassis for support.
exceed 2 mph / 3.2 km/h.
10 Disengage the drive hubs by turning over the
Non-steer wheels: All models
drive hub disconnect caps on each steer wheel
1 Chock the steer wheels to prevent the machine hub.
from rolling. disengaged position
2 Center a lifting jack of ample capacity

(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer wheels.
3 Lift the wheels off the ground and place blocks engaged position
under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
Part No. 1259369 S-80 • S-85 • S-80X 3 - 47

11 Manually rotate each steer wheel. D-3

Result: Each steer wheel should rotate with Check the Turntable Rotation
minimum effort.
Bearing Bolts
12 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks.
Collision hazard. Failure to performed every 1000 hours or annually, whichever
re-engage the drive hubs could comes first.
result in death or serious injury and
property damage. Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
All models: Improper bolt torque could result in an unsafe
operating condition and component damage.
13 Turn the valve in a clockwise direction to be
sure it is fully closed. 1 Start the engine from the platform controls and
extend the axles.
Note: The free-wheel valve is located on the bottom
of the drive pump, and should always remain 2 Turn the key switch to ground controls.
closed.
3 Raise the boom and place a safety chock on the
lift cylinder rod. Carefully lower the boom onto
the lift cylinder safety chock.
b
Crushing hazard. Keep hands
away from cylinder and all moving
a c parts when lowering the boom.
d Note: The lift cylinder safety chock is available
through Genie Service Parts.
4 Remove the center turntable cover retaining

fasteners. Remove the cover.
a drive pump
b screwdriver
c lift pump
d free-wheel valve
3 - 48 S-80 • S-85 • S-80X Part No. 1259369

5 Confirm that each turntable mounting bolt is D-4

torqued in sequence to specification. Refer to
Section 2, Specifications. Inspect for Turntable Bearing
Wear

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

firm, level surface and the boom in the stowed
position.
1 Grease the turntable bearing. See A-12, Grease
the Turntable Rotation Bearing and Rotate Gear.
Bolt torque sequence 2 Torque the turntable bearing bolts to

specification. See D-3, Check the Turntable
6 Install the center turntable cover and tighten the Rotation Bearing Bolts.
retaining fasteners.
3 Start the machine from the ground controls and
7 Raise the boom and remove the safety chock. raise the boom to full height. Do not extend the
8 Lower the boom to the stowed position. boom.
9 Confirm that each bearing mounting bolt under

the drive chassis is torqued in sequence to
specification. Refer to Section 2, Specifications.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 49

4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator.
and the turntable at a point that is directly
Result: The measurement is less than
under, or inline with, the boom and no more than
0.063 inch / 1.6 mm. The bearing is good.
1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
Note: To obtain an accurate measurement, place
0.063 inch / 1.6 mm. The bearing is worn and
the dial indicator no more than 1 inch /
needs to be replaced.
2.5 cm from the turntable rotation bearing.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
a
be sure the needle returns to the "zero" position.
9 Remove the dial indicator and rotate the
turntable 90°.
b 10 Repeat steps 4 through 9 until the rotation

bearing has been checked in at least four
equally spaced areas 90° apart.
c 11 Lower the boom to the stowed position and turn
the machine off.
12 Remove the dial indicator from the machine.
d
a turntable
b dial indicator
c drive chassis
d turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the

indicator.
6 Fully extend the boom and lower to a horizontal
position.
3 - 50 S-80 • S-85 • S-80X Part No. 1259369

D-5 8 Install the filter housing cap.

Replace the Hydraulic Filters 9 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
oil filter housing.
Medium and high pressure filters:
performed every 1000 hours or annually, whichever Note: The medium pressure filter is for the charge
comes first. Perform this procedure more often if pump and the high pressure filter is for all machine
dusty conditions exist. functions except the drive circuit and oscillating
axle circuit.
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty 10 Open the engine side turntable cover and locate
or clogged filter may cause the machine to perform the two filters.
poorly and continued use may cause component Note: The high pressure filter is located toward the
damage. Extremely dirty conditions may require bulkhead with a condition indicator. The medium
that the filters be replaced more often. pressure filter is located nearest the operator.
Bodily injury hazard. Beware of hot 11 Place a suitable container under the filters.
oil. Contact with hot oil may cause
severe burns. 12 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housings.
13 Remove the filter element from the housings.
Hydraulic return filter:
14 Inspect the housing seals and replace them if
1 Open the ground controls side turntable cover necessary.
and locate the hydraulic return filter housing on
15 Install the new medium and high pressure filter
top of the hydraulic tank.
elements into the housings and tighten them
2 Remove the cap from the filter housing. securely.
3 Lift the handle on the filter element and rotate 16 Clean up any oil that may have spilled during the
the element counterclockwise to release the installation procedure.
element from the housing.
17 Use a permanent ink marker to write the date
4 Remove the filter element from the filter and number of hours from the hour meter on the
housing. oil filter housings.
5 Install the new filter element into the filter 18 Start the engine from the ground controls.
housing.
19 Inspect the filter housings and related
6 Push the filter element down to be sure the components to be sure that there are no leaks.
O-ring on the element is fully seated into the
housing.
7 Rotate the filter element clockwise to lock it in
place.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 51

D-6 5 Install the plugs into the drive hub. Torque to

Specification. Refer to Section 2,
Replace the Drive Hub Oil Specifications.
6 Repeat steps 1 through 4 for the other drive hub.
7 Check the torque of the drive hub mounting
Genie specifications require that this procedure be bolts. Refer to Section 2, Specifications.
performed every 1000 hours or annually, whichever Turntable rotate drive hub:
comes first.
Replacing the drive hub oil is essential for good
the O-ring on the fitting and/or hose end must be
machine performance and service life. Failure to
replaced and then torqued to specification during
replace the drive hub oil at yearly intervals may
installation. Refer to Section 2, Hydraulic Hose and
cause the machine to perform poorly and continued
Fitting Torque Specifications.
use may cause component damage.
1 Secure the turntable from rotating with the
Drive hubs:
1 Select the drive hub to be serviced. Drive the Note: The turntable rotation lock pin is located next
machine until one of the two plugs is at the to the boom rest pad.
lowest point.
2 Remove both plugs and drain the oil into a from the turntable rotate drive motor. Cap the
suitable container. fittings on the drive motor.
3 Drive the machine until one plug is at the top 3 Attach a suitable lifting device to the lifting eyes
and the other is at 90 degrees. located near the drive motor.
a 4 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
a. models with o-ring plugs
device.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side plug
hole. Install the plugs.
3 - 52 S-80 • S-85 • S-80X Part No. 1259369

5 Remove the plug the drive hub. Drain the oil 6 Install the drive hub assembly onto the machine.
from the hub into a suitable container. Torque the drive hub mounting bolts to
specification. Refer to Section 2, Specifications.
7 Fill the drive hub with oil. Refer to Section 2,
Specifications. Apply pipe thread sealant to the
plug. Install the plug.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 10-1, How to Adjust the
Turntable Rotation Gear Backlash.
a
B
A
b
Dual fill port rotator

a motor
b drive hub
d fill ports
Part No. 1259369 S-80 • S-85 • S-80X 3 - 53

D-7 D-8
Continental Models Deutz Models
performed every 1000 hours. performed every 1000 hours.
• Spark plugs- replace All models:
• O2 sensors- replace
• Fuel filter/water separator- replace
Required maintenance procedures and additional • V-belts- replace
engine information are available in the: • Charge air cooler- drain lube oil/condensate
Continental TME27 Owner's Manual • Cold starting device (if equipped)- check
(Continental part number WM10303). • Hoses and clamps- inspect/replace
Continental TME27 Owner's Manual • Engine mounts- inspect/tighten
Genie part number 111901 Required maintenance procedures and additional
engine information are available in the
(Deutz part number 0312-3547) OR the


3 - 54 S-80 • S-85 • S-80X Part No. 1259369

D-9
Perform Engine Maintenance -
Perkins Models
Engine specifications require that this procedure be

performed every 1000 hours.

manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
804D Models
• Alternator- check
• Engine valve lash- inspect/adjust
• Starter- check
• Turbocharger- check
404F Models
• Alternator and fan belts- replace
• Crankcase breather (canister)- replace
• Engine valve lash- check
• Turbocharger- inspect
(Perkins part number SEBU8324)OR the
(Perkins part number SEBU8609).


Part No. 1259369 S-80 • S-85 • S-80X 3 - 55

Checklist E Procedures
E-1 2 Models without hydraulic tank shutoff valves:
Remove the drain plug from the hydraulic tank
Test or Replace the and completely drain the tank into a suitable
Hydraulic Oil container. Refer to Section 2, Specifications.
Models with hydraulic tank shutoff valves:
Close the two hydraulic tank valves located at
the hydraulic tank.
Component damage hazard. The
performed every 2000 hours or every two years,
engine must not be started with the
hydraulic tank shutoff valves in the
Replacement or testing of the hydraulic oil is CLOSED position or component
essential for good machine performance and damage will occur. If the tank
service life. Dirty oil and suction strainers may valves are closed, remove the key
cause the machine to perform poorly and from the key switch and tag the
continued use may cause component damage. machine to inform personnel of the
Extremely dirty conditions may require oil changes condition.
to be performed more frequently. 3 Remove the drain plug from the hydraulic tank
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
stowed position. open closed
Note: When removing a hose assembly or fitting, and completely drain the tank into a suitable
the O-ring (if equipped) on the fitting and/or the container. Refer to Section 2, Specifications.
hose end must be replaced. All connections must
be torqued to specification during installation. 4 Tag, disconnect and plug the two suction hoses
Refer to Section 2, Hydraulic Hose and Fitting that are attached to the hydraulic tank
Torque Specifications. shutoff valves.
1 Remove the fuel tank. Refer to Repair 5 Disconnect and plug the T-fitting located at the
Procedure 9-1, How to Remove the Fuel Tank. return filter with the two hoses connected to it.
Cap the fitting on the return filter housing.
6 Disconnect and plug the supply hose for the
auxiliary power unit. Cap the fitting on the
hydraulic tank.
3 - 56 S-80 • S-85 • S-80X Part No. 1259369

CHECKLIST E PROCEDURES
7 Remove the retaining fasteners from the 18 Open the hydraulic tank shutoff valves (if
hydraulic tank hold down straps. Remove the equipped).
hold down straps from the hydraulic tank.
Component damage hazard.
8 Support the hydraulic tank with 2 lifting straps. Be sure to open the two hydraulic
Place one lifting strap at each end of the tank tank shutoff valves and prime the
and attach the lifting straps to an appropriate pump after installing the hydraulic
lifting device. tank. Refer to Repair Procedure
7-2, How to Prime the Pump.
9 Remove the hydraulic tank from the machine.
Note: Always use pipe thread sealant when
Crushing hazard. The hydraulic
installing the drain plug and strainers.
tank may become unbalanced and
fall if it is not properly supported 19 Operate all machine functions through a full
and secured to the lifting device. cycle and check for leaks.
10 Remove the suction strainers from the tank and Note: Genie specifications require additional
clean them using a mild solvent. equipment and special installation instructions for
the approved optional fluids. Consult Genie Product
11 Rinse out the inside of the tank using a mild
Support before use.
solvent.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
17 Clean up any oil that may have spilled.
Part No. 1259369 S-80 • S-85 • S-80X 3 - 57

E-2 E-3
Perkins Models Deutz Models
every 2000 hours. performed every 2 years.
804D Models All models:
• Cooling system coolant- replace • Cooling system coolant- replace

• Engine mounts- check Required maintenance procedures and additional
404F Models Deutz 2011 Series Operation Manual
(Deutz part number 0312-3547) OR the
• Alternator- check Deutz 2.9 L4 Series Operation Manual
• Engine mounts- check (Deutz part number 0312-3893)
• Starter- check
Required maintenance procedures and additional Genie part number 139320
Perkins 800D Series Operation Manual Deutz 2.9 L4 Series Operation Manual
(Perkins part number SEBU8324)OR the Genie part number 1251561


3 - 58 S-80 • S-85 • S-80X Part No. 1259369

E-4 E-5
Perform Engine Maintenance - Perform Cooling Sytem
Perkins Models Maintenance -
Perkins 404F Models
Engine specifications require that this procedure be

performed every 3000 hours. Engine specifications require that this procedure be
Proper engine maintenance, following the engine performed at various intervals.
manufacturer's maintenance schedule, is essential Proper engine maintenance, following the engine
to good engine performance and service life. Failure manufacturer's maintenance schedule, is essential
to perform the maintenance procedures can lead to to good engine performance and service life. Failure
poor engine performance and component damage. to perform the maintenance procedures can lead to
804D Models poor engine performance and component damage.
• Water pump- inspect Every 3000 hours or 2 years
• Heavy duty coolant- replace

404F Models
• Thermostat- replace Every 12000 hours or 6 years
• Diesel particulate filter- clean • Extended life coolant- replace
• Fuel injectors- test/replace
• Flow plugs (ARD combustion)- replace
• Radiator cap- replace Required maintenance procedures and additional
• Water pump- inspect engine information are available in the:
Perkins 800D Series Operation Manual Perkins 404F Series Operation Manual
(Perkins part number SEBU8324)OR the


Part No. 1259369 S-80 • S-85 • S-80X 3 - 59

E-6
Replace the Boom Extend/
Retract Cables

performed every 7 years.
The boom extend/retract cables are responsible for

the extension and retraction of the number 3 boom
tube. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Replace the boom extend/retract cables. See
Repair Procedure 4-5, How to Replace the
Boom Extend/Retract Cables.
3 - 60 S-80 • S-85 • S-80X Part No. 1259369

October 2014 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Perform disassembly procedures to the point
Repair procedures shall be completed by a where repairs can be completed. Then to
person trained and qualified on the repair of this re-assemble, perform the disassembly steps in
machine. reverse order.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine.
Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules and Used to indicate the presence of
operating instructions in the appropriate an imminently hazardous situation
operator's manual on your machine before which, if not avoided, will result in
attempting any maintenance or repair procedure. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of a
available and ready for use. potentially hazardous situation
Use only Genie approved replacement parts. which, if not avoided, could result
in death or serious injury.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may With safety alert symbol—used to
produce hazardous conditions. indicate the presence of a
Unless otherwise specified, perform each which, if not avoided, may result
repair procedure with the machine in the in minor or moderate injury.
following configuration:
• Machine parked on a firm, level surface potentially hazardous situation
• Boom in the stowed position which, if not avoided, may result in
property damage.
the non-steering wheels Note: Used to indicate operation or maintenance
• Turntable secured with the turntable information.
rotation lock pin
Indicates that a specific result is expected after
• Key switch in the off position with the performing a series of steps.
key removed
Indicates that an incorrect result has occurred
• Wheels chocked after performing a series of steps.
• All external AC power supply disconnected
from the machine
Part No. 1259369 S-80 • S-85 • S-80X 4-1

Section 4 • Repair Procedures October 2014
Platform Controls
The platform control box contains one printed 1-1
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Note: When the ALC-500 circuit board is replaced,
Effect technology and require no adjustment. The the joystick controllers will need to be calibrated.
operating parameters of the joysticks are stored in See 1-2, How to Calibrate a Joystick.
memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is How to Remove the ALC-500
replaced, it will need to be calibrated before that Circuit Board
particular machine function will operate. See 1-2,
How to Calibrate a Joystick. 1 Push in the Emergency Stop button to the off
Each joystick controller should operate smoothly controls.
and provide proportional speed control over its
entire range of motion. 2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
a
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
4 Attach a grounded wrist strap to the ground
screw inside the platform control box.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
c b
handling printed circuit boards OR
use a grounded wrist strap.
a ALC-500 circuit board
5 Carefully disconnect the wire connectors from
b drive/steer joystick controller
c primary boom up/down, the circuit board.
extend/retract and
turntable rotate right/left 6 Remove the ALC-500 circuit board mounting
joystick controller fasteners.
7 Carefully remove the ALC-500 circuit board from
the platform control box.
4-2 S-80 • S-85 • S-80X Part No. 1259369

PLATFORM CONTROLS
1-2 8 Repeat this procedure for each joystick

controlled machine function including the thumb
Joysticks rocker steer switch.
Note: No machine fuction should operate while
How to Calibrate a Joystick performing the joystick calibration procedure.
The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function How to Adjust the Joystick
will operate. Max-out Setting
Note: The joystick must be calibrated before the The max-out setting of a joystick controls the
threshold, max-out or ramping can be set. maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out
1 Open the platform control box. setting should be adjusted to maintain optimum
performance. The max-out settings on the joystick
2 Pull out the red Emergency Stop button to the can be changed to compensate for hydraulic pump
on position at both the ground and platform wear to maintain peak performance from the
controls. machine.
3 Turn the key switch to platform control. Do not Note: Perform this procedure with the boom in the
start the engine. stowed position.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from the on position at both the ground and platform
joystick for approximately 10 seconds or until controls.
the alarm sounds. Connect the wire harness
2 Turn the key switch to platform control. Do not
connector to the joystick.
start the engine.
6 Move the joystick full stroke in either direction
3 Push in the platform controls red Emergency
and hold for 5 seconds.
Stop button to the off position.
7 Return the joystick to the neutral position, pause
4 Do not press down the foot switch.
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds. 5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Result: The alarm should sound indicating
Emergency Stop button to the on position.
successful joystick calibration.
6 When the alarm sounds, release the drive
Result: The alarm does not sound. Check the
enable toggle switch.
electrical connections or replace the joystick.
Part No. 1259369 S-80 • S-85 • S-80X 4-3

PLATFORM CONTROLS
7 Momentarily activate the drive enable toggle 13 Return the joystick to the neutral position and
switch in the right direction 4 times. wait for approximately 10 seconds to allow the
settings to be saved.
Result: There should be a pause and the alarm
should sound 4 times indicating that the Result: The alarm should sound indicating that
machine is in max-out calibration mode. the settings have been saved in memory.
Result: The alarm does not sound. Repeat steps Result: The alarm does not sound. The
3 through 7. minimum or maximum adjustment has been
obtained. No changes can be saved.
press down the foot switch. Note: Do not operate any machine function during
the 10 second waiting time.
9 Start a timer and activate the machine function
that needs to be adjusted. Record the time it 14 Cycle the red Emergency Stop button off, then
takes for that function to complete a full cycle back on.
(ie; boom up).
10 Compare the machine function time with the
function times listed in Section 2, How to Adjust the Joystick
Specifications. Determine whether the function
time needs to increase or decrease.
Ramp Rate Setting
The ramp rate setting of a joystick controls the time
11 While the joystick is activated, adjust the max-
at which it takes for the joystick to reach maximum
out setting to achieve the proper function cycle
output, when moved out of the neutral position. The
time. Momentarily move the drive enable toggle
ramp rate settings of a joystick can be changed to
switch in the right direction to increase the
compensate for hydraulic pump wear to maintain
function speed or momentarily move the drive
peak performance from the machine.
enable toggle switch in the left direction to
decrease the function speed. Note: Perform this procedure with the boom in the
Note: Each time the drive enable toggle switch is stowed position.
momentarily moved, the function speed will change 1 Pull out the red Emergency Stop button to the
in 2% increments. on position at both the ground and platform
12 Repeat steps 9 through 11 for each joystick controls.
controlled machine function. 2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4-4 S-80 • S-85 • S-80X Part No. 1259369

PLATFORM CONTROLS
4 Do not press down the foot switch. 13 Repeat steps 9 through 11 for each joystick
controlled machine function.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red 14 Return the joystick to the neutral position and
Emergency Stop button to the on position. wait for approximately 10 seconds to allow the
settings to be saved.
enable toggle switch. Result: The alarm should sound indicating that
the settings have been saved in memory.
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times. Note: Do not operate any machine function during
should sound 6 times indicating that the 15 Cycle the red Emergency Stop button off, then
machine is in ramp rate calibration mode. back on.
Result: The alarm does not sound. Repeat steps
Ramp rate (factory settings)
3 through 7.
Turntable rotate
accelerate 3 seconds
press down the foot switch. decelerate 2 second
9 Start a timer and simultaneously move the
Boom up/down
joystick in either direction full stroke. Note how accelerate 3 seconds
long it takes the function to reach maximum decelerate 1 second
speed. This is the ramp rate.
Boom extend/retract
10 Compare the function ramp rate time with the accelerate 2.5 seconds
table below and determine whether the ramp decelerate 1 second
rate time needs to increase or decrease.
Drive
11 Release the foot switch. accelerate 4 seconds
decelerate to neutral 0.5 second
12 While the joystick is activated, set the ramp
decelerate, change of direction 0.75 second
rate. Momentarily move the drive enable toggle decelerate, coasting 1 second
switch in the right direction to increase the time decelerate, braking 1 second
or momentarily move the drive enable toggle decelerate, shift from low to high speed 1 second
switch in the left direction to decrease the time. decelerate, shift from high to low speed 4 seconds
Note: Each time the drive enable toggle switch is
momentarily moved, the time will change in 5%
increments.
Part No. 1259369 S-80 • S-85 • S-80X 4-5

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PLATFORM CONTROLS 1234567890
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How to Adjust the Joystick 10 Slowly move the joystick off center in either
direction just until the function begins to move.
Threshold Setting
11 Slowly move the joystick back to the neutral
The threshold setting of a joystick is the minimum position. Just before the function stops moving,
output at which a function proportional valve can move the drive enable toggle switch to either
open and allow the function to operate. side to set the threshold.
Note: Perform this procedure with the boom in the Result: The alarm should sound indicating a
stowed position. successful calibration.
1 Pull out the red Emergency Stop button to the 12 Repeat steps 9 through 11 for each boom
on position at both the ground and platform joystick-controlled machine function (boom up/
controls. down, boom extend/retract and turntable rotate).
2 Turn the key switch to platform control. Do not 13 Return the joystick to the neutral position and
start the engine. wait for approximately 10 seconds.
3 Push in the red Emergency Stop button to the Result: The alarm should sound indicating that
off position at the platform controls. the settings have been saved in memory.
4 Do not press down the foot switch. Note: Do not operate any machine function during
5 Move and hold the drive enable toggle switch in
the right position and pull out the red 14 Cycle the red Emergency Stop button off, then
Emergency Stop button to the on position. back on.
Function speeds (factory settings)
Boom up 89 to 93 seconds
switch in the right direction 8 times. Boom down 90 to 94 seconds
Result: There should be a pause and the alarm Boom extend 73 to 79 seconds
should sound 8 times indicating that the
machine is in threshold calibration mode. Boom retract 79 to 84 seconds
Result: The alarm does not sound. Repeat steps Turntable rotate, 360°
3 through 7. boom fully stowed 95 to 103 seconds
8 Start the engine from the platform controls and Drive speeds (factory settings)
press down the foot switch. Stowed- high speed 7.9 to 8.5 seconds
9 Select a boom function joystick to set the
Non-stowed 40 to 45 seconds
threshold.
4-6 S-80 • S-85 • S-80X Part No. 1259369

How to Calibrate the Boom Note: Manually reduce the boom speed as it
reaches the fully elevated position.
Angle Sensor
The boom angle sensor controls the maximum switch to the right 1 time to set the elevated
angle that the boom can attain. position.
Note: Perform this procedure with the boom in the Result: The alarm will sound indicating that the
stowed position. angle sensor has been calibrated.
1 Pull out the red Emergency Stop button to the 10 Release the joystick and the foot switch and
on position at the ground controls. wait for 10 seconds.
2 Turn the key switch to platform controls. Result: The alarm will sound indicating that the
settings have been saved and is leaving
3 Move and hold the drive enable toggle switch to
calibration mode.
the right and pull out the red Emergency Stop
button to the on position. 11 Cycle the red Emergency Stop button off, then
back on. Start the machine and return to the
stowed position.
switch to the right 12 times.
should sound 12 times indicating that the
machine is in Angle Sensor calibration mode.
press down the foot switch.
switch to the right 1 time to set the stowed
position.
Note: The alarm will not sound indicating the
setting.
8 Raise the primary boom to the fully elevated
position.
Part No. 1259369 S-80 • S-85 • S-80X 4-7

4-8 S-80 • S-85 • S-80X Part No. 1259369

Platform Components
2-1 7 Support and secure the platform to an
appropriate lifting device.
Platform
8 Remove the platform mounting fasteners and
remove the platform from the machine.
How to Remove the Platform
Crushing hazard. The platform
1 Remove the cable clamp from the top of the could become unstable and fall
platform mounting weldment. when it is removed from the
2 Remove the mounting fasteners from the power machine if not properly supported.
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side. Do
not disconnect the wiring.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
5 Tag and disconnect the foot switch wiring from
the foot switch. Remove the cable from the
back of the platform.
and other jewelry.
6 Remove the platform control box mounting
fasteners. Lower the control box and set it
aside.
Cables can be damaged if they
are kinked or pinched.
Note: If your machine is equipped with an airline to
platform option, the airline must be disconnected
from the platform before removal.
Part No. 1259369 S-80 • S-85 • S-80X 4-9

PLATFORM COMPONENTS
2-2 4 Remove the pin retaining fastener from the

slave cylinder rod-end pivot pin. Use a soft
Platform Leveling Slave Cylinder metal drift to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the Crushing hazard. The jib boom
two primary supports for the platform. The slave could fall when the slave cylinder
cylinder keeps the platform level through the rod-end pivot pin is removed if not
entire range of boom motion. It operates in a properly supported.
closed-circuit hydraulic loop with the master 5 Remove the external snap rings from the barrel-
cylinder. The slave cylinder is equipped with end pivot pin.
counterbalance valves to prevent movement in
the event of a hydraulic line failure. 6 Use a soft metal drift to drive the barrel-end
pivot pin out.
How to Remove the Platform 7 Carefully pull the cylinder out of the primary
Leveling Slave Cylinder boom to access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed 8 Tag, disconnect and plug the hydraulic hoses
the slave cylinder to be sure there is no air in the from the slave cylinder. Cap the fittings on the
closed loop. cylinder.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or the hydraulic oil can penetrate and
hose end must be replaced. All connections must burn skin. Loosen hydraulic
be torqued to specification during installation. connections very slowly to allow
Refer to Section 2, Hydraulic Hose and Fitting the oil pressure to dissipate
Torque Specifications. gradually. Do not allow oil to
squirt or spray.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible. How to Bleed the Slave Cylinder
2 Raise the primary boom slightly and place Note: Do not start the engine. Use auxiliary power
blocks under the platform for support. for this procedure.
3 Lower the primary boom until the platform is 1 Raise the primary boom to a horizontal position.
resting on the blocks just enough to support the
platform. 2 Move the platform level toggle switch up and
down through two platform leveling cycles to
Note: Do not rest the entire weight of the boom on remove any air that might be in the system.
the blocks.
4 - 10 S-80 • S-85 • S-80X Part No. 1259369

PLATFORM COMPONENTS
2-3 2 Tag, disconnect and plug the hydraulic hoses

from the platform rotator manifold. Cap the
Platform Rotator fittings on the rotator.
The platform rotator is a hydraulically activated Bodily injury hazard. Spraying

helical gear assembly used to rotate the platform hydraulic oil can penetrate and
160 degrees. burn skin. Loosen hydraulic
connections very slowly to allow
How to Remove the the oil pressure to dissipate
gradually. Do not allow oil to squirt
Platform Rotator or spray.
Component damage hazard. Mark 3 S-85: Support the jib boom leveling arms and
the platform mounting weldment the platform mounting weldment with an
and the rotator flange before appropriate lifting device. Do not apply any
removing the platform mounting lifting pressure.
weldment. The platform mounting
weldment must be replaced in the 4 Remove the mounting bolts from the platform
exact same position on the rotator mounting weldment. Remove the center bolt
flange as it was before removal. If and slide the platform mounting weldment off of
a new rotator is installed or the the platform rotator.
rotator is disassembled, proper Crushing hazard. The platform
alignment can be achieved by mounting weldment could become
rotating the rotator all the way to unbalanced and fall if not properly
the left and then installing the supported when removed from the
platform mounting weldment all machine.
the way in the left position.
5 Support the platform rotator with an appropriate
Note: When removing a hose assembly or fitting, lifting device. Do not apply any lifting pressure.
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must S-80:
be torqued to specification during installation.
6 Support the rod end of the platform leveling
Refer to Section 2, Hydraulic Hose and Fitting
slave cylinder. Protect the cylinder rod from
Torque Specifications.
damage.
1 Remove the platform. See 2-1,
7 Remove the pivot pin retaining fasteners from
How to Remove the Platform.
both the slave cylinder rod-end pivot pin and
the rotator pivot pin.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 11

PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins. How to Bleed the Platform
Remove the platform rotator from the machine.
Rotator
rotator may become unbalanced Note: This procedure will require two people. Do
and fall if not properly supported. not start the engine. Use auxiliary power for this
procedure.
Note: When installing the platform rotator
fasteners, torque the fasteners to specifications. 1 Move the function enable toggle switch to either
Refer to Section 2, Specifications. side and activate the platform rotate toggle
switch to the right then the left through two
S-85: platform rotation cycles, then hold the switch to
9 Remove the pin retaining fasteners from the jib the right position until the platform is fully
boom and jib boom leveling arms to platform rotated to the right.
rotator pivot pins. Do not remove the pins. 2 Place a suitable container underneath the
10 Support the jib boom leveling arms. platform rotator.
11 Use a soft metal drift to drive both pins out, then 3 Open the top bleed screw on the rotator, but do
remove the platform rotator from the machine. not remove it.
Bodily injury hazard. The jib boom Bodily injury hazard. Spraying
leveling arms may fall if not hydraulic oil can penetrate and
properly supported. burn skin. Loosen hydraulic
12 Lower the jib boom leveling arms. the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator
fasteners, torque the fasteners to specifications.
Refer to Section 2, Specifications.
4 - 12 S-80 • S-85 • S-80X Part No. 1259369

PLATFORM COMPONENTS
4 Move the function enable button to either side 2-4

and hold the platform rotate toggle switch to the
left position until the platform is fully rotated to Platform Overload System
the left. Continue holding the toggle switch until
air stops coming out of the bleed screw. Close How to Calibrate the Platform
the bleed screw.
Overload System (if equipped)
Crushing hazard. Keep clear of
the platform during rotation.
5 Open the bottom bleed screw on the rotator, but
do not remove it. Calibration of the platform overload system is
essential to safe machine operation. Continued
Bodily injury hazard. Spraying use of an improperly calibrated platform overload
hydraulic oil can penetrate and system could result in the system failing to sense
burn skin. Loosen hydraulic an overloaded platform. The stability of the
connections very slowly to allow machine is compromised and it could tip over.
the oil pressure to dissipate
gradually. Do not allow oil to Note: Perform this procedure with the machine on
squirt or spray. a firm, level surface.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch 1 Turn the key switch to platform control. Start the
to the right position until the platform is fully engine and level the platform.
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed 2 Determine the maximum platform capacity.
screw. Close the bleed screw. Refer to the machine serial plate.
Crushing hazard. Keep clear of 3 Remove all weight, tools and accessories from
the platform during rotation. the platform.
7 Clean up any hydraulic oil that may have Note: Failure to remove all weight, tools and
spilled. accessories from the platform will result in an
incorrect calibration.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks. 4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 13

PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it 7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6. the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are Result: The overload indicator lights are
flashing at the platform and ground controls, flashing at the platform and ground controls,
and the alarm is sounding. Slowly tighten the and the alarm is sounding. Repeat this
load spring adjustment nut in a clockwise procedure beginning with step 5.
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
platform overload indicator light and alarm
sound. Proceed to step 8.
responds.
Note: The platform will need to be moved up and
down and allowed to settle between each 8 Add an additional 10 lb / 4.5 kg test weight to
adjustment. the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
responds.
Result: The overload indicator light is off at both
6 Move the platform up and down by hand, so it
the ground and platform controls, and the alarm
bounces approximately 2.5 to 5 cm / 1 to 2
does not sound. Remove the additional 10 lb /
inches. Allow the platform to settle.
4.5 kg test weight. Repeat this procedure
Result: The overload indicator lights are off at beginning with step 6.
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
responds.
in 10° increments until the overload indicator
light flashes at both the platform and ground 9 Test all machine functions from the platform
controls, and the alarm sounds. controls.
Proceed to step 7.
Result: All platform control functions should not
Result: The overload indicator lights are operate.
flashing at the platform and ground controls,
and the alarm is sounding. Repeat this
procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.

platform overload indicator lights and alarm
responds.
4 - 14 S-80 • S-85 • S-80X Part No. 1259369

PLATFORM COMPONENTS
10 Turn the key switch to ground control.

11 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
controls.
Result: All platform control functions should
operate normally.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 15

Jib Boom Components, S-85

3-1 5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
Jib Boom cylinder.
Bodily injury hazard. Spraying
How to Remove the Jib Boom hydraulic oil can penetrate and
Note: Perform this procedure with the boom in the burn skin. Loosen hydraulic
stowed position. connections very slowly to allow
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or the squirt or spray.
be torqued to specification during installation. 6 Attach a lifting strap from an overhead crane to
Refer to Section 2, Hydraulic Hose and Fitting the jib boom assembly.
Torque Specifications. 7 Place blocks under the platform leveling
cylinder for support. Protect the cylinder rod
1 Remove the platform. See 2-1, How to Remove
from damage.
the Platform.
8 Remove the pin retaining fastener from the
Note: Models equipped with platform overoad
slave cylinder rod-end pivot pin. Use a soft
system: If the platform overload components are
metal drift to remove the pin.
disassembled and/or removed from the platform
support, the platform overload system will need to Crushing hazard. The jib boom
be calibrated. See 2-4, How to Calibrate the could fall when the slave cylinder
Platform Overload System. rod-end pivot pin is removed if not
properly attached to the overhead
2 Models equipped with platform overload
crane.
system: Tag and disconnect the electrical
connector from the platform load sense module. 9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
3 Remove the hose and cable cover from the side
of the jib boom. 10 Use a soft metal drift to remove the pin and
carefully remove the jib boom assembly from
4 Remove the hose and cable clamp from the jib
the primary boom.
boom pivot pin. Lay all hoses and cables to the
side. Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
Hoses and cables can become
not properly attached to the
damaged if they are kinked or
overhead crane.
pinched.
4 - 16 S-80 • S-85 • S-80X Part No. 1259369

JIB BOOM COMPONENTS, S-85
3-2 2 Tag, disconnect and plug the jib boom lift

Jib Boom Lift Cylinder cylinder.
How to Remove the Jib Boom hydraulic oil can penetrate and
Lift Cylinder burn skin. Loosen hydraulic
stowed position.
Note: When removing a hose assembly or fitting, squirt or spray.
the O-ring (if equipped) on the fitting and/or the 3 Remove the pin retaining fasteners from the jib
hose end must be replaced. All connections must boom lift cylinder rod-end pivot pin. Do not
be torqued to specification during installation. remove the pin.
Torque Specifications. 4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
1 Raise the jib boom slightly and place blocks lower one of the leveling arms to the ground.
under the platform mounting weldment. Then Tap the pin the other direction and lower the
lower the jib boom until the platform is resting opposite leveling arm. Do not remove the pin.
on the blocks just enough to support the
platform. 5 Attach a lifting strap from an overhead crane to
the lug at the rod end of the jib boom lift
Note: Do not rest the entire weight of the boom on cylinder.
the blocks.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
7 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall if not properly supported
when removed from the machine.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 17

Boom Components
4-1 6 S-80: Tag, disconnect and plug the hydraulic
hoses from the counterbalance valve manifold
Cable Track located on the platform rotator. Cap the fittings
on the manifold.
The boom cable track guides cables and hoses
running up the boom. It can be repaired link by link Bodily injury hazard. Spraying
without removing the cables and hoses that run hydraulic oil can penetrate and
through it. Removing the entire boom cable track is burn skin. Loosen hydraulic
necessary when performing major repairs that connections very slowly to allow
involve removing the boom. the oil pressure to dissipate
How to Remove the Cable Track squirt or spray.
Note: When removing a hose assembly or fitting, 7 Tag, disconnect and plug the hydraulic hoses
the O-ring (if equipped) on the fitting and/or the from the platform leveling slave cylinder at the
hose end must be replaced. All connections must platform manifold and cap the fittings.
be torqued to specification during installation. Bodily injury hazard. Spraying
Refer to Section 2, Hydraulic Hose and Fitting hydraulic oil can penetrate and
Torque Specifications. burn skin. Loosen hydraulic
1 Open the platform control box.
2 Tag and disconnect the foot switch wiring from gradually. Do not allow oil to
the terminal strip inside the platform control squirt or spray.
box.
8 Remove the timing link/timing link cam pin and
3 Loosen the squeeze connector and remove the gently rest the timing link against the
foot switch cable from the control box. counterweight.
4 Disconnect the wire connectors from the bottom 9 S-85:Remove the hose and cable cover from the
of the platform control box. side of the jib boom.
Note: When installing the wire connectors to the 10 Tag, disconnect and plug the hydraulic hoses
bottom of the platform control box, match the color from the jib boom/platform rotate select
of the connectors to those on the control box to be manifold. Cap the fittings on the manifold.
sure they are installed in the correct location.
5 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side.
4 - 18 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
11 Tag, disconnect and plug the wiring from the jib 18 Place blocks between the upper and lower cable
boom/platform rotate select manifold. tracks and secure the upper and lower tracks
together.
from the jib boom lift cylinder. Cap the fittings Crushing hazard. If the upper and
on the cylinder. lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow 19 Attach a lifting strap from an overhead crane to
the oil pressure to dissipate the cable track.
20 Remove the mounting fasteners that attach the
squirt or spray.
lower cable track to the boom.
All models:
21 Remove the cable track from the machine and
13 From the ground controls, raise the boom to a place it on a structure capable of supporting it.
horizontal position.
Crushing hazard. The cable track
14 Remove the fasteners from the drive speed limit could become unbalanced and fall
switch bracket (LS1RS) mounted on the side of if not properly attached to the
the boom at the platform end of the boom. Do overhead crane.
not remove the limit switch from the bracket.
15 Remove the cotter pin from the upper cable Cables and hoses can be
track at the platform end of the boom. damaged if they are kinked or
pinched.
Note: Always replace the cotter pin with a new one.
16 Remove the cable track guide fasteners from cable track can be damaged if it is
the cable track guides at the platform end of the twisted.
boom. Remove the cable track guides from the
boom.
17 Remove the cable clamp from the pivot end of
the boom.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 19

BOOM COMPONENTS
How to Repair the Cable Track 5 Remove the upper rollers from the replacement
section of cable track.
The boom cable track can be 6 Lift up the hoses and cables and carefully insert
damaged if it is twisted. the new 4 link section of cable track.
Note: A cable track repair kit is available through Component damage hazard.
Genie Service Parts, part no. 77896. The kit Hoses and cables can be
includes a 4-link section of cable track. damaged if they are kinked or
pinched.
1 Visually inspect the cable track and determine
7 Connect the ends of the replacement cable
which 4 link section needs to be replaced.
track section to the existing cable track using
2 Carefully remove the snap rings from each end the snap rings.
of the damaged section of cable track.
8 Install the rollers onto the new section of cable
3 Remove the retaining fasteners from the upper track.
black rollers from the 4-link section of cable
9 Operate the boom extend/retract function
track to be replaced. Remove the rollers.
through a full cycle to ensure smooth operation
4 Lift up the hoses and cables and carefully of the new section of cable track.
remove the damaged 4-link section of cable
track.
Hoses and cables can be
damaged if they are kinked or
pinched.
4 - 20 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
4-2 How to Remove the Boom

Boom TIp-over hazard. This procedure
requires the removal of the
How to Shim the Boom turntable counterweight. Failure to
remove the counterweight before
1 Measure each wear pad. removing the boom assembly will
Note: Replace the pad if thickness is less than result in the machine tipping over.
minimum specification. If thickness is more than Do not remove the boom without
minimum specification, perform the following first removing the counterweight.
procedure. Refer to Section 3, D-1, Check the TIp-over hazard. When installing
Boom Wear Pads. the boom onto the machine, the
boom assembly must be first
2 Extend the boom until the wear pads are
installed prior to the installation of
accessible.
the counterweight. If the
3 Loosen the wear pad mounting fasteners. counterweight is installed before
the boom assembly, the machine
4 Install the new shims under the wear pad to
will tip over resulting in death or
obtain zero clearance and zero drag.
serious injury.
5 Tighten the mounting fasteners.
TIp-over hazard. The turntable
6 Extend and retract the boom through an entire counterweight is essential for
cycle. Check for tight spots that could cause machine stability. Failure to install
binding or scraping. the counterweight after installing
the boom assembly will
Note: Always maintain squareness between the compromise machine stability
outer and inner boom tubes. resulting in the machine tipping
over. Death or serious injury will
result.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Remove the jib boom. See 3-1, How to Remove
the Jib Boom.
2 Remove the cable track. See 4-1, How to
Remove the Cable Track.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 21

BOOM COMPONENTS
3 Raise the boom until the short and long link arm 9 Slowly operate the overhead crane to apply
to boom pivot pins are above the turntable tension to the lifting straps. Do not attempt to lift
covers. the machine with the overhead crane.
4 Place a block of wood measuring 10 Locate and remove the counterweight retaining
4 x 4 x 60 inches / 10 x 10 x 152 cm under the fastener at the center of the counterweight.
long link arm, across the turntable covers. Carefully lift the counterweight upwards and
remove the counterweight from the machine.
5 Slowly lower the boom until the long link arm
Set the counterweight on the ground. Do not
contacts the wood block. Do not rest the entire
leave the counterweight suspended above the
weight of the boom on the block. Turn the
ground.
machine off.
counterweight will fall if not
turntable covers can become
properly supported by the
damaged if the weight of the boom
overhead crane resulting in death
is allowed to rest on the block.
or serious injury. Keep personnel
6 Place wood blocks between the short link arm away from the area when
and the turntable weldment for support. removing the counterweight.
7 Insert a 1.125 x 12 inches / 32 x 300 mm 11 Attach lifting straps from a 5 ton / 5000 kg
eye-bolt through each hole located on the top overhead crane to each end of the boom.
surface of the counterweight. Secure the eye- Support the boom. Do not apply any lifting
bolts in position with flat washers and nuts. pressure.
8 Securely attach lifting straps or chains with a 12 Support and secure the rod end of the boom lift
minimum rating of 5 tons / 5000 kg to the lifting cylinder to a second overhead crane or similar
points on the top of the turntable counterweight. lifting device.
Attach the lifting straps or chains to a
13 Remove the lift cylinder rod-end pivot pin
5 ton / 5000 kg overhead crane.
retaining fasteners. Use a soft metal drift to
Note: A spreader bar and other hardware may be remove the pin.
needed to safely remove the counterweight.
Crushing hazard. The boom could
fall if not properly supported when
the lift cylinder rod-end pivot pin is
removed.
4 - 22 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
14 Using auxiliary power, activate the boom down 17 Tag, disconnect and plug the boom extension
function so the cylinder will retract. Retract the cylinder hydraulic hoses. Cap the fittings on the
cylinder just enough until the rod end of the cylinder.
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
Crushing hazard. The boom lift burn skin. Loosen hydraulic
cylinder could fall if not properly connections very slowly to allow
supported and secured to the the oil pressure to dissipate
lifting device. gradually. Do not allow oil to
squirt or spray.
15 Using the overhead crane, carefully lower the
boom lift cylinder and allow it to rest on the 18 Tag and disconnect the electrical connector for
boom rest pad. Protect the cylinder rod from the cable break limit switch.
damage.
19 Tag and disconnect all boom wire harness
16 Remove the boom end cover retaining electrical connectors located at the pivot end of
fasteners and remove the cover. the boom.
20 Support the platform leveling master cylinder.
Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.
from the bulkhead fittings at the pivot end of the
boom. Cap the bulkhead fittings.
squirt or spray.
22 Remove the external snap rings from both boom
pivot pins at the short and long link arms. Do
not remove the pins.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 23

BOOM COMPONENTS
23 Using the overhead crane, adjust the boom as 4-3

necessary to relieve pressure from the pivot
pins. Boom Lift Cylinder
24 Use a soft metal drift to remove each boom The boom lift cylinder raises and lowers the boom.
pivot pin. Carefully remove the boom assembly The boom lift cylinder is equipped with
from the machine and place it on a structure counterbalance valves to prevent movement in the
capable of supporting it. event of a hydraulic line failure.
Crushing hazard. The boom could
fall if not properly supported by the How to Remove the Boom
overhead crane when each boom Lift Cylinder
pivot pin is removed.
Bodily injury hazard. This
Crushing hazard. The long and procedure requires specific repair
short link arms may fall if not skills, lifting equipment and a
properly supported when the suitable workshop. Attempting this
boom pivot pins are removed. procedure without these skills and
tools could result in death or
serious injury and significant
service is strongly recommended.
1 Raise the boom to a horizontal position.
2 Attach a 5 ton / 5000 kg overhead crane to the
boom at the platform end for support. Do not lift
the boom.
3 Support and secure both ends of the boom lift
cylinder to a second overhead crane or similar
lifting device.
4 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom will
fall if not properly supported when
the primary boom rod-end pivot
pin is removed.
4 - 24 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
5 Using auxiliary power, activate the boom down 4-4

function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the Boom Extension Cylinder
cylinder will clear the mounting bracket on the
boom. Turn the machine off. The boom extension cylinder is located inside the
boom assembly and incorporates cables and
6 Tag, disconnect and plug the boom lift cylinder pulleys that are responsible for extending the
hydraulic hoses. Cap the fittings on the number 3 boom tube. The primary boom extension
cylinder. cylinder is equipped with counterbalance valves to
Bodily injury hazard. Spraying prevent movement in the event of a hydraulic line
hydraulic oil can penetrate and failure.
connections very slowly to allow How to Remove the Boom
the oil pressure to dissipate Extension Cylinder
squirt or spray. Bodily injury hazard. This
procedure requires specific repair
7 Remove the pin retaining fasteners from the skills, lifting equipment and a
boom lift cylinder barrel-end pivot pins. Do not suitable workshop. Attempting this
remove the pins. procedure without these skills and
8 Use a slide hammer to remove the barrel-end tools could result in death or
pivot pins. serious injury and significant
Crushing hazard. The boom lift service is strongly recommended.
and fall if not properly supported Note: When removing a hose assembly or fitting,
and secured to the lifting device. the O-ring (if equipped) on the fitting and/or the
9 Move the boom lift cylinder towards the be torqued to specification during installation.
counterweight end of the machine. Rotate the Refer to Section 2, Hydraulic Hose and Fitting
boom lift cylinder until the barrel-end pivot pin Torque Specifications.
bores will clear the boom linkage.
Note: Perform this procedure with the boom fully
10 Carefully remove the boom lift cylinder from the retracted.
machine.
1 Raise the boom to a horizontal position.
Crushing hazard. The boom lift
and secured to the lifting device.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 25

BOOM COMPONENTS
2 Remove the boom end cover retaining 5 Loosen the retract cable nut at the platform end
fasteners and remove the cover. of the boom. Pull the cable rod from the support
and let it hang down.
3 Remove the access covers from both sides of
the boom at the pivot end. 6 Remove the cable guard fasteners and remove
the cable guard.
4 Fully loosen the lock nuts on the extend cables.
Do not remove the nuts. 7 Locate the retaining plates that secure the
retract cables to the inside of the number 3
boom tube.
8 Remove the cable retaining plates and pull the
retract cables off of the pulleys. Lay the cables
flat and out of the way.
9 Remove the fasteners from the retaining blocks
from the extension cylinder saddle. Remove the
blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.
10 Disconnect the wire connector to the extend
cable break limit switch.
11 Remove the retaining fasteners that secure the
extend cable mounting plates to the inside of
the number 1 boom tube.
a b
a cable guard
b retaining block
4 - 26 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
13 Lift up the extend cable mounting plate and push

the extend cables towards the platform to create
slack in the cables. Rest the cable and bracket
assembly on top of the extend cylinder.
14 Locate the lower extend cable bracket on the
bottom of the number 3 boom tube.
15 Remove the lower extend cable bracket
mounting fasteners and pull back on the
bracket to release it from the number 3 boom
tube.
16 While pushing the lower extend cable bracket
towards the platform, pull the extend cable
mounting plate towards the pivot end of the
boom.
17 Secure the extend cable bracket and cables to
the cylinder to prevent them from falling off
when removing the cylinder.
a b c d 18 Remove the external snap rings from the
extension cylinder pin at the pivot end of the
boom.
a extend cable lock nuts 19 Use a soft metal drift to remove the pin.
b extend cable mounting plate
c extend cable mounting plate fastener 20 Tag, disconnect and plug the boom extension
d extend cable bracket
12 Pull back on the extend cable mounting plate cylinder.
until it clears the blocks welded to the inside of Bodily injury hazard. Spraying
the number 1 boom tube. hydraulic oil can penetrate and
squirt or spray.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 27

BOOM COMPONENTS
21 Attach a lifting strap from a 5 ton / 5000 kg 4-5

overhead crane to the lug at the rod end of the
boom extension cylinder. Boom Extend/Retract Cables
22 Lift the boom extension cylinder with the crane
until it clears the cylinder saddle inside the
How to Adjust the Boom Extend/
number 2 boom tube. Retract Cables
23 Carefully support and slide the extension The boom extend/retract cables are responsible for
cylinder out of the boom. the extension and retraction of the number 3 boom
tube. Proper adjustment of the boom extend/retract
Crushing hazard. The extension
cables and related components on a regular basis
cylinder could fall when removed
is essential to good machine performance and safe
from the boom if not properly
machine operation. The boom extend and retract
supported.
functions should operate smoothly and be free of
Component damage hazard. Be hesitation, jerking and unusual noise.
careful not to damage the cable
break limit switch. Note: Perform this procedure with the boom in a
horizontal position.
Component damage hazard. Be
careful not to damage the 1 Start the engine from the Ground Controls.
counterbalance valves on the 2 Raise the boom to a horizontal position
primary boom extension cylinder
when removing the cylinder from 3 Fully retract the boom.
the boom. 4 Stop the engine.
Note: During removal of the extension cylinder, the 5 Remove the boom end cover retaining
overhead crane strap will need to be carefully fasteners and remove the cover.
adjusted for proper balancing.
6 Inspect the threaded ends of the boom extend
cables. The threads must be clean and in good
condition with no damaged threads.
4 - 28 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
7 Locate the retract cable adjustment nut on the 13 Retract and extend the boom approximately
bottom of the number 1 boom tube at the 3 feet / 1 m two times and stop during the
platform end of the boom. Loosen the nut, but extension cycle. This will create slack in the
do not remove the nut. retract cables.
8 Locate the extend cable adjustment nuts on the Note: Be sure to not fully extend the boom. Stop
counterweight end of boom tube #1. Refer to when there is approximately 3 feet / 1 m of
Illustration 2. Loosen the nylock nuts and jam travel left.
nuts on the cable tension equalizer bracket. Do
not remove the nuts. 14 Repeat steps 12 and 13 two to three times.
9 Adjust the extend cable adjustment nut to obtain 15 Fully extend the boom then retract the boom
6 3/8 inches/16.2 cm to 6 1/2 inches/16.5 cm approximately 12 inches / 30 cm.
between the platform end of boom tube #2 and 16 At the pivot end of the boom, visually inspect
boom tube #3. Refer to illustration 1. There the boom extend cables for even cable droop or
should be approximately 1/2 inch of exposed sag.
threads on the adjustment bolts. Refer to
Illustration 2. Note: If the boom extend cables are uneven,
tighten the boom extend cable adjustment nut at
Note: If the cables have been replaced, be sure the the pivot end of the boom for the appropriate cable.
adjustment nuts have been replaced. Do not re-
use the existing nuts.
10 Extend the boom until there is approximately 3
feet / 1 m of travel left. Do not fully extend the
boom.
11 Locate the retract cable adjustment nut on the
bottom of the number 1 boom tube at the
platform end of the boom.
12 Using a dial type torque wrench, torque the
retract cable adjustment nut to 32-36 ft lbs /
43-49 Nm using gentle and steady torque.
6.375 inches / 16.2 cm
Illustration 1
Part No. 1259369 S-80 • S-85 • S-80X 4 - 29

BOOM COMPONENTS
17 Visually inspect the cable break limit switch arm How to Replace the Boom
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate. Extend/Retract Cables
Note: If the boom extend cables are adjusted Note: The cable pulleys must also be replaced
evenly, the wheel of the limit switch arm should be when replacing the cables.
centered in the notch of the pivot plate.
1 Remove the boom extension cylinder. See
Section 4-4, How to Remove the Boom
Extension Cylinder.
Boom extend cables:
a
2 Remove the cables from the lower boom extend
cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the boom
extend cable pulley pivot pin. Use a soft metal
drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it from the shaped end of the pin.
5 Remove the pulley and boom extend cables

b c from the extension cylinder assembly. Discard
the old cables and pulleys.
Illustration 2
6 Route the new boom extend cables through the
a cable break limit switch
b extend cable adjustment nut boom extend pulley bracket.
c extend cable pivot plate
7 Install the new boom extend cable pulley, pivot
18 Install the boom end cover at the pivot end of pin and snap rings.
the boom.
Note: Be sure the boom extend cables are routed
19 Fully retract and lower the boom to the stowed through the grooves of the pulley and the upper
position. wear pad on the extension cylinder.
4 - 30 S-80 • S-85 • S-80X Part No. 1259369

BOOM COMPONENTS
8 Install the boom extend cable clevis pins and 18 At the platform end of the boom, install the
rue rings to the pivot plate near the cable break retract cables, clevis pins and rue rings to the
limit switch. adjustment plate.
9 Install the boom extend cables to the lower 19 Remove and discard the old boom retract
extend cable bracket that mounts to the number pulleys from the pivot end of the boom
3 boom tube. extension cylinder.
Boom retract cables: 20 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
10 Remove the rue rings and clevis pins from the
boom retract cables at the platform end of the 21 Install the boom extension cylinder assembly
boom. into the boom.
11 Attach the cable pulling tool or a rope to one of Note: Before lowering the extension cylinder into
the boom retract cables at the pivot end of the the saddles of the number 1 boom tube, wrap the
boom. boom retract cables around the pulleys.
Note: A cable pulling tool is available through 22 Adjust the boom extend/retract cables.
Genie Service Parts Department (Genie part no. See Section 4-5, How to Adjust the Boom
94510) Extend/Retract Cables.
12 At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
13 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
14 Securely attach the rope to the same end of the
new boom retract cable.
15 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
16 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
the boom tube. Remove the rope.
17 Repeat steps 14 through 19 for the other boom
retract cable.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 31

BOOM COMPONENTS
4-6 4 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin.
Platform Leveling
5 Place a rod through the barel-end pivot pin and
Master Cylinder twist to remove the pin.
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed loop hydraulic
circuit that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the pivot end of the boom.
How to Remove the Platform

Leveling Master Cylinder
Note: When removing a hose assembly or fitting, 6 Attach a lifting strap from an overhead crane to
the O-ring (if equipped) on the fitting and/or the the lug on the rod end of the master cylinder.
be torqued to specification during installation. 7 Remove the pin retaining fastener from the
Refer to Section 2, Hydraulic Hose and Fitting rod-end pivot pin.
Torque Specifications. 8 Place a rod through the rod-end pivot pin and
twist to remove the pin.
1 Raise the boom until the master cylinder
rod-end pivot pin is accessible. 9 Remove the master cylinder from the machine.
2 Remove the turntable end cover to access the Crushing hazard. The master
master cylinder. cylinder could become unbalanced
and fall if it is not properly
3 Tag, disconnect and plug the master cylinder
supported by the lifting device
hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
4 - 32 S-80 • S-85 • S-80X Part No. 1259369

Engines
5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure B-10, The flex plate acts as a coupler between the
Check and Adjust the Engine RPM. engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.
Type "B" flex plates combines the pump coupler,
as part of the flex plate, which is installed onto the
engine flywheel.
Type "B"
(flexplate with
coupler combined)
Part No. 1259369 S-80 • S-85 • S-80X 4 - 33

ENGINES
How to Remove the Flex Plate Deutz TD2011L04i models:
Note: Perform this procedure with the engine off 4 Tag and disconnect the wiring from the bell
and cool to the touch. housing.
1 Open the engine side turntable cover. 5 Remove the U-bolt from the exhaust flex pipe at
the muffler.
2 Tag and disconnect the battery cables from the
battery(s). Burn hazard. Hot engine parts can
cause severe burns.
with electrically charged circuits 6 Remove the muffler bracket retaining fasteners
could result in death or serious from bell housing. Remove the muffler and
injury. Remove all rings, watches bracket assembly from the engine.
and other jewelry. 7 Support the drive pump with an appropriate
3 Tag and disconnect the wiring plug at the lifting device. Remove all of the remaining bell
electronic displacement controller (EDC), housing engine fasteners.
located on the drive pump. 8 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Hoses can be damaged if they are
kinked or pinched
9 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
Deutz TD 2.9 models:
10 Tag and disconnect the wiring from the bell

housing.
11 Support the drive pump with an appropriate
lifting device. Remove all of the bell housing
engine fasteners.
4 - 34 S-80 • S-85 • S-80X Part No. 1259369

ENGINES
12 Carefully pull the pump and bell housing 20 Carefully pull the pump and bell housing
assembly away from the engine and secure it assembly away from the engine and secure it
from moving. from moving.
Component damage hazard. Hoses Component damage hazard. Hoses
can be damaged if they are kinked can be damaged if they are kinked
or pinched or pinched
13 Remove the flex plate mounting fasteners, 21 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine and remove the flex plate from the engine
flywheel. flywheel.
Perkins 804D models: Perkins 404F-22T models:
14 Tag and disconnect the wiring from the bell 22 Tag and disconnect the wiring from the bell
housing. housing.
15 Remove the exhaust pipe clamp at the muffler. 23 Remove the fasteners supporting the muffler
assembly from the bell housing.
Burn hazard. Hot engine parts can
cause severe burns. Burn hazard. Hot engine parts can
cause severe burns.
16 Remove the muffler mounting bracket fasteners.
Remove the muffler and bracket assembly from 24 Support the drive pump with an appropriate
the engine. lifting device. Remove all of the bell housing to
engine fasteners.
17 Remove the hose clamps from the air cleaner
elbow and the engine intake manifold. 25 Carefully pull the pump and bell housing
18 Remove the air cleaner mounting bracket
from moving.
fasteners. Remove the air cleaner and bracket
assembly from the engine. Component damage hazard. Hoses
can be damaged if they are kinked
19 Support the drive pump with an appropriate
or pinched
lifting device. Remove all of the remaining bell
housing to engine fasteners. 23 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 35

ENGINES
Continental model: 35 Remove the muffler mount.
27 Tag and disconnect the wire harness from the 36 Support the drive pump with an appropriate
oxygen sensor. lifting device. Remove all of pump plate
mounting fasteners.
28 Remove the exhaust pipe heat shield fasteners
from the top of the muffler. 37 Carefully pull the pump and bell housing
Burn Hazard. Hot engine parts can from moving.
cause severe burns.
Component damage hazard. Hoses
29 Remove the muffler retainer bracket fasteners. can be damaged if they are kinked
30 Remove the muffler fasteners securing the or pinched.
muffler to the exhaust manifold. Remove the 38 Remove the flex plate mounting fasteners.
muffler from the bracket. Remove the flex plate from the engine flywheel.
31 Remove the relay housing from the muffler
mount. Do not disconnect the relays.
32 Disconnect and remove the ECM from the
muffler mount.
33 Close the shutoff valve on the Liquid Petroleum
Gas (LPG) tank by turning it clockwise
(if equipped).
34 Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
4 - 36 S-80 • S-85 • S-80X Part No. 1259369

ENGINES
How to Install the Flex Plate 2 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
1 Install the flex plate onto the engine flywheel appropriate gap between coupler and pump
with the raised spline towards the pump. Apply end plate for your engine.
Loctite® removable thread sealant to the
mounting screws. 3 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
Note: Torque the flex plate mounting bolts in two to 61 ft-lbs / 83 Nm.
stages.
4 Install the pump onto the pump mounting plate.
Continental model: Torque the flex plate Apply Loctite® removable thread sealant to the
mounting bolts in sequence to pump retaining fasteners. Torque the pump
20.8 ft-lbs / 28 Nm. retaining fasteners to 57 ft-lbs / 77 Nm.
Deutz models: Torque the flex plate mounting Component damage hazard. Do
bolts in sequence to 28 ft-lbs / 38 Nm. not force the drive pump during
Then torque the flex plate mounting bolts in installation or the flex plate teeth
sequence to 40 ft-lbs / 54 Nm. may become damaged.
Perkins models: Torque the flex plate mounting 5 Install the pump coupler onto the pump shaft
bolts in sequence to 28 ft-lbs / 38 Nm. with the set screw toward the pump. Leave the
Then torque the flex plate mounting bolts in appropriate gap between coupler and pump
sequence to 40 ft-lbs / 54 Nm. end plate for your engine.
6 Install the pump and pump mounting plate
6 1 assembly onto the engine. Apply Loctite®
removable thread sealant to the mounting
screws.
1 Install the pump and bell housing
assembly.
4 3
Deutz models: Torque the bell housing
mounting bolts labeled "C" in sequence to 28 ft-
lbs / 38 Nm. Then torque the bell housing
mounting bolts labeled "C" in sequence to 40 ft-
lbs / 54 Nm.
2 5
Perkins, Deutz and Continental

Flex Plate
Part No. 1259369 S-80 • S-85 • S-80X 4 - 37

ENGINES
Perkins 804D models: Torque the bell housing 6 1

mounting bolts in sequence to 8
10
28 ft-lbs / 38 Nm and then to 49 ft-lbs / 66 Nm.
Perkins 404F models:Torque the bell housing
4 3
mounting bolts labeled "B" in sequence to
28 ft-lbs / 38 Nm and the mounting bolts labeled
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
housing mounting bolts labeled "B" in sequence 11 12
to 40 ft-lbs / 54 Nm and the mounting bolts
labeled "A" to 70 ft-lbs / 95 Nm. 5
7
Continental model: 2 9
Torque the pump mounting plate fasteners in
Perkins 804C-33
sequence to 23 ft-lbs / 31.2 Nm. Pump Mounting Plate
Component damage hazard. When 6 1
A A
installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
B
may occur. 9
Component damage hazard. Do B

4 5
B
not force the drive pump during
installation or the flex plate teeth B B
may become damaged. 8 B B 7
2 3
Perkins 404F-22T
6 1 Pump Mounting Plate
10 C C 8 6 1
C C 10 8
4 3
C C
4 3
C C
11 12
11 12
C C
7 C C 5
7 5
2 9
2 9
Deutz Pump Mounting Plate Continental Pump Mounting Plate
4 - 38 S-80 • S-85 • S-80X Part No. 1259369

Ground Controls
6-1
Control Relays
Relays used for single function switching are single
pole double throw (SPDT) relays.
How to Test a Single Pole Double

Throw Relay
Electrocution/burn hazard. Contact terminal no. 87a - N.C.
with electrically charged circuits terminal no. 85 - coil negative (-)
terminal no. 30 - common
could result in death or serious terminal no. 86 - coil positive (+)
injury. Remove all rings, watches terminal no. 87 - N.O.
and other jewelry.
1 Tag and disconnect all the wiring from the relay
to be tested. Control Relay Schematic
2 Connect the leads from an ohmmeter or
continuity tester to each terminal combination
and check for continuity. Terminals 85 and 86
represent the coil and should not be tested in
any other combination.
Test Desired result

terminal 85 to 86 with resistor 75 to 85Ω
terminal 87 to 87a and 30 no continuity
(infinite Ω)
terminal 87a to 30 continuity
(zero Ω)
3 Connect 12V DC to terminal 85 and a ground

wire to terminal 86, then test the following
terminal combinations.
Test Desired result

terminal 87 to 87a and 30 no continuity
(infinite Ω)
terminal 87 to 30 continuity
(zero Ω)
Part No. 1259369 S-80 • S-85 • S-80X 4 - 39

Hydraulic Pumps
from the function pump. Cap the fittings on the
Function Pump pump.
How to Remove the Function hydraulic oil can penetrate and
Pump burn skin. Loosen hydraulic
squirt or spray.
Refer to Section 2, Hydraulic Hose and Fitting 3 Remove the pump mounting fasteners.
Torque Specifications. Carefully remove the pump.
1 Close the two hydraulic tank valves located at Component damage hazard.
the hydraulic tank. Be sure to open the two hydraulic
tank valves (if equipped) and
Component damage hazard. The prime the pump after installing the
engine must not be started with pump. See 7-2, How to Prime the
the hydraulic tank shutoff valves in Pump.
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open closed
4 - 40 S-80 • S-85 • S-80X Part No. 1259369

HYDRAULIC PUMPS
7-2 2 Close the two hydraulic tank valves located at

the hydraulic tank.
Drive Pump
The drive pump is a bi-directional variable engine must not be started with
displacement piston pump. The pump output is the hydraulic tank shutoff valves in
controlled by the electronic displacement controller the closed position or component
(EDC), located on the pump. The only adjustment damage will occur. If the tank
that can be made to the pump is the neutral or null valves are closed, remove the key
adjustment. Any internal service to the pump from the key switch and tag the
should only be performed at an authorized machine to inform personnel of the
Sundstrand-Sauer service center. Call Genie condition.
Industries Service Department to locate your local
authorized service center.
How to Remove the Drive Pump

work area and surfaces where this
procedure will be performed must open closed
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
1 Disconnect the wire harness at the electronic
displacement controller (EDC), located on the
drive pump.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 41

HYDRAULIC PUMPS
3 Tag, disconnect and plug the hydraulic hoses How to Prime the Pump
from the drive and function pumps. Cap the
fittings on the pumps. Component damage hazard. Be
sure that the hydraulic tank shutoff
Bodily injury hazard. Spraying valves (if equipped) are in the
hydraulic oil can penetrate and open position before priming the
burn skin. Loosen hydraulic pump. The engine must not be
connections very slowly to allow started with the hydraulic tank
the oil pressure to dissipate shutoff valves in the closed
gradually. Do not allow oil to position or component damage will
squirt or spray. occur.
4 Support the pumps with a suitable lifting device 1 Connect a 0 to 600 psi / 0 to 40 bar pressure
and remove the two drive pump mounting gauge to the diagnostic nipple on the drive
fasteners. pump.
5 Carefully pull the drive pump out until the pump 2 Continental models: If equipped, close the
coupler separates from the flex plate. valve on the LPG tank, then disconnect the
6 Remove the drive pump assembly from the hose from the tank. Move the fuel select toggle
machine. switch to the LPG position.
Deutz and Perkins models: Disconnect the
Component damage hazard. engine wiring harness from the fuel solenoid at
Be sure to open the two hydraulic the injector pump.
tank valves and prime the pump
after installing the pump. 3 Crank the engine with the starter motor for
15 seconds, wait 15 seconds, then crank the
Note: Before installing the pump, verify proper engine an additional 15 seconds or until the
pump coupler spacing. See 5-2, Flex Plate. pressure reaches 300 psi / 20.7 bar.
4 Continental models: If equipped, connect the
LPG hose to the LPG tank and open the valve
on the tank.
Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
check for hydraulic leaks.
4 - 42 S-80 • S-85 • S-80X Part No. 1259369

Manifolds
8-1
Function Manifold Components
The function manifold assembly is located on the tank side tray, behind the ground control box.
Index Schematic
No. 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. 1259369 S-80 • S-85 • S-80X 4 - 43

MANIFOLDS
SJ
1
SK
2
SP
3
SQ
SM 4
20
SG
19
SC
18 SR
5
SB
17 SS
6
SA
16
SH
15
SF
7
SL
8
SE
9
ST
14 SI
10
SO
13
SN
12
SD
11
4 - 44 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
How to Adjust the Boom Down

8-2 Relief Valve
Valve Adjustments -
Function Manifold stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

How to Adjust the System gauge to the diagnostic nipple located next to
Relief Valve the auxiliary pump.
Note: Perform this procedure with the boom in the 2 Start the engine from the ground controls.
stowed position.
3 Hold the function enable/rpm select toggle
Note: Auxiliary power will be used to perform this switch to the high idle position and activate and
procedure. Do not start the engine. hold the boom down toggle switch with the
boom fully lowered. Observe the pressure
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure reading on the pressure gauge. Refer to
gauge to the diagnostic nipple (PTEST) located Section 2, Hydraulic Specifications.
next to the auxiliary pump.
4 Turn the engine off. Use a wrench to hold the
2 Simultaneously activate and hold the auxiliary relief valve and remove the cap (item SN) on
power toggle switch and the primary boom the function manifold.
retract toggle switch with the primary boom fully
retracted. Observe the pressure reading on the 5 Adjust the internal hex socket. Turn it clockwise
pressure gauge. Refer to Section 2, to increase pressure or counterclockwise to
Specifications. decrease pressure. Install the relief valve cap.
3 Locate the system relief valve on the function Tip-over hazard. Do not adjust
manifold (item SB). Use a wrench to hold the the relief valves higher than
relief valve and remove the cap using an allen specified.
wrench. 6 Repeat steps 2 through 5 and confirm relief
4 Adjust the internal hex socket. Turn it clockwise valve pressure.
to increase the pressure or counter clockwise to
reduce the pressure. Install the relief valve cap.
Component damage hazard. Do
not adjust the relief valve higher
than specified.
5 Repeat step 2 to confirm relief valve pressure.
6 Remove the pressure gauge.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 45

MANIFOLDS
How to Adjust the Boom Extend

Relief Valve
stowed position.

gauge to the diagnostic nipple located next to
the auxiliary pump.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high idle position and activate and
hold the boom extend toggle switch with the
boom fully extended. Observe the pressure
reading on the pressure gauge. Refer to
Section 2, Hydraulic Specifications.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item SO) on
the function manifold.
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
Tip-over hazard. Do not adjust
the relief valves higher than
specified.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
4 - 46 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
8-3
Brake/Two-Speed Manifold Components
The brake/two speed manifold is mounted inside the drive chassis.
Index Schematic
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
1 2
BA BC
BD
4
BB
3
Part No. 1259369 S-80 • S-85 • S-80X 4 - 47

MANIFOLDS
8-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side
of the machine.
Index Schematic
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
1 2
RA RB
RD
3
RC
4
4 - 48 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
8-5
Platform Rotate Manifold Components
The platform rotate manifold is mounted on the platform rotator.
Index Schematic
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
PB
2
PA
1
Part No. 1259369 S-80 • S-85 • S-80X 4 - 49

MANIFOLDS
8-6
Platform Manifold Components, S-80
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index Schematic
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
1
EB
2
EE EC
6 3
ED
4
EA
5
4 - 50 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
8-7
Platform Manifold Components, S-85
The jib boom/platform rotate manifold is mounted on the platform end of the boom.
Index Schematic
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
EH
1
EF
2
EB
3
EG
8
EC
4
EE
7
ED
5
EA
6
Part No. 1259369 S-80 • S-85 • S-80X 4 - 51

MANIFOLDS
8-8
2WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index Schematic
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
4 - 52 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
1
DE
DB
2
DC
3
DD
4
DF
5
DA
6
Part No. 1259369 S-80 • S-85 • S-80X 4 - 53

MANIFOLDS
8-9
4WD Traction Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.
Index Schematic
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 end

drive motors in forward
and 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 flow

divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6 Check valve ....................................... DD ........ Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
7 Orifice, 0.040 inch / 1 mm .................. DL ......... Equalizes pressure on both sides

of flow divider/combiner valve 5
8 Orifice, 0.040 inch / 1 mm .................. DA ........ Equalizes pressure on both sides
9 Orifice, 0.040 inch / 1 mm .................. DN ........ Equalizes pressure on both sides
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 that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13 Flow divider/combiner valve ............. DM ........ Controls flow to steer end
drive motors in forward
and 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
4 - 54 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
DE
1
DB
2
DF
3
DC
DP 4
14
DD
DM 5
13
DK
6
DJ
12
DH
11
DG
10
DN DA DL
9 8 7
Part No. 1259369 S-80 • S-85 • S-80X 4 - 55

MANIFOLDS
8-10
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
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
7
CU
1
CV
2
CW
3
CX
6 4
CZ
5
4 - 56 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
8-11 4 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments - direction. Note the pressure reading on the
Traction Manifold pressure gauge.
5 Turn the engine off, and remove the hot oil
How to Adjust the Hot Oil Shuttle shuttle relief valve cap (item BJ). Adjust the
Relief Valve internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
Note: The pressure differential between the charge pressure. Install the valve cap.
pump relief valve (located in the drive pump) and
6 Repeat steps 4 and 5 until a pressure
the hot oil shuttle relief valve (located in the
differential (between the charge pump reading
traction manifold) is necessary to return hot oil
and the hot oil shuttle relief valve) of
from the closed loop drive circuit to the hydraulic
40 psi / 3 bar is obtained.
tank for cooling. This pressure differential must be
maintained at 40 psi / 3 bar.
Note: The following procedure will require two

people.
1 Open the engine side turntable cover and
connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
allow the engine to run at low idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 40 bar pressure gauge to the
diagnostic nipple located on the traction
manifold.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 57

MANIFOLDS
8-12 Valve Coil Resistance

Valve Coils Specifications
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / -7.8°C
within the coil. Zero resistance or infinite resistance that your air temperature increases or decreases
indicates the coil has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Proportional solenoid valve 4.8 Ω

resistance values outside specification can (schematic items K and W)
produce erratic operation. When coil resistance
2 position 3 way solenoid valve 6.3 Ω
decreases below specification, amperage (schematic items D, R, X, TT and UU)
increases. As resistance rises above specification,
voltage increases. 2 position 3 way solenoid valve 3.3 Ω
(schematic items G)
While valves may operate when coil resistance is
outside specification, maintaining coils within 3 position 4 way solenoid valve 6.3 Ω
specification will help ensure proper valve function (schematic items A, E, N and S)
over a wide range of operating temperatures. 2 position 3 way solenoid valve 6.3 Ω
(schematic items AK, AM, VV and WW)
with electrically charged circuits 2 position 3 way solenoid valve 3.3 Ω
could result in death or serious (schematic item G)
and other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to

be tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
4 - 58 S-80 • S-85 • S-80X Part No. 1259369

MANIFOLDS
How to Test a Coil Diode

a
Genie incorporates spike suppressing diodes in all COIL AMMETER
of its directional valve coils except proportional d

valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes c - b
naturally occur within a function circuit following the
+
interruption of electrical current to a coil. Faulty 10 W 9V
diodes can fail to protect the electrical system, RESISTOR BATTERY
resulting in a tripped circuit breaker or component
c
damage.
+
b
-
with electrically charged circuits a multimeter
could result in death or serious b 9V DC battery
injury. Remove all rings, watches c 10Ω resistor
and other jewelry. d coil
1 Test the coil for resistance. Refer to, How to Note: Dotted lines in illustration indicate a reversed
Test a Coil. connection as specified in step 6.
2 Connect a 10Ω resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the Note: If testing a single-terminal coil, connect the
coil. negative lead to the internal metallic ring at either
Note: The battery should read 9V DC or more end of the coil.
when measured across the terminals.
5 Momentarily connect the positive lead from the
3 Set a multimeter to read DC current. multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
Note: The multimeter, when set to read DC
current, should be capable of reading up to 800 6 At the battery or coil terminals, reverse the
mA. connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 59

Fuel and Hydraulic Tanks

9-1 4 Tag, disconnect, drain and plug the supply and
return fuel hoses. Cap the fittings on the fuel
Fuel Tank tank.
5 Remove the fuel tank retaining fasteners.
How to Remove the Fuel Tank
6 Remove the fuel tank from the machine.
Explosion and fire hazard. Engine
fuels are combustible. Remove the Component damage hazard.
fuel tank in an open, well- The fuel tank is plastic and may
ventilated area away from heaters, become damaged if allowed to fall.
sparks, flames and lighted
tobacco. Always have an
When installing the plastic fuel
approved fire extinguisher within
tank, do not overtighten the
easy reach.
retaining fasteners.
Explosion and fire hazard. When
Note: Clean the fuel tank and inspect for damage
transferring fuel, connect a
before installing it onto the machine.
grounding wire between the
machine and pump or container.
1 Turn the manual fuel shutoff valve to the
closed position (if equipped).
2 Remove the fuel filler cap from the tank.
3 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
capacity specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand operated pump
suitable for use with gasoline and diesel fuel.
4 - 60 S-80 • S-85 • S-80X Part No. 1259369

FUEL AND HYDRAULIC TANKS
9-2 2 Close the two hydraulic tank valves located at

the hydraulic tank (if equipped).
Hydraulic Tank
The primary functions of the hydraulic tank are to engine must not be started with
cool, clean and de-aerate the hydraulic fluid during the hydraulic tank shutoff valves in
operation. The tank utilizes internal suction the CLOSED position or component
strainers for the pump supply hoses and has an damage will occur. If the tank
external return filter equipped with a filter condition valves are closed, remove the key
indicator. from the key switch and tag the
machine to inform personnel of the
How to Remove the condition.
Hydraulic Tank
The work area and surfaces
where this procedure will be
performed must be clean and
free of debris that could get
into the hydraulic system. open closed

the O-ring (if equipped) on the fitting and/or the 3 Remove the drain plug from the hydraulic tank
hose end must be replaced. All connections must and completely drain the tank into a suitable
be torqued to specification during installation. container. Refer to Section 2, Specifications.
Refer to Section 2, Hydraulic Hose and Fitting 4 Tag, disconnect and plug the two suction hoses
Torque Specifications. that are attached to the hydraulic tank.
1 Remove the fuel tank. See 9-1, How to Remove 5 Tag and disconnect and plug the hose from the
the Fuel Tank. return filter. Cap the fitting on the return filter
housing.
6 Tag and disconnect and plug the supply hose
for the auxiliary power unit. Cap the fitting on
the hydraulic tank.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 61

FUEL AND HYDRAULIC TANKS
7 Remove the retaining fasteners from the 17 Clean up any oil that may have spilled.
hydraulic tank hold down straps. Remove the
18 Open the hydraulic tank shutoff valves
hold down straps from the hydraulic tank.
(if equipped).
8 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank Component damage hazard.
and attach the lifting straps to an overhead Be sure to open the two hydraulic
crane. tank shutoff valves (if equipped)
and prime the pump after installing
9 Remove the hydraulic tank from the machine. the hydraulic tank.
Crushing hazard. The hydraulic Note: Always use pipe thread sealant when
tank could become unbalanced installing the drain plug and strainers.
and secured to the overhead
crane.
10 Remove the suction strainers from the tank and
clean them using a mild solvent.
11 Rinse out the inside of the tank using a mild
solvent.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
4 - 62 S-80 • S-85 • S-80X Part No. 1259369

Turntable Rotation Components

10-1
Turntable Rotation Drive Hub
Assembly
How to Remove the Turntable

Rotation Drive Hub Assembly B
A
a

Refer to Section 2, Hydraulic Hose and Fitting b
1 Secure the turntable from rotating with the c
a backlash pivot plate
b adjustment bolt with lock nut
c backlash pivot plate mounting bolts
5 Remove the backlash pivot plate mounting

bolts. Carefully remove the drive hub assembly
from the machine.
rotation drive hub assembly could
become unbalanced and fall when
unlocked locked it is removed from the machine if
not properly supported.
from the drive motor. Cap the fittings on the When installing the drive hub assembly:
motor. 6 Install the drive hub. Apply removable thread
Bodily injury hazard. Spraying locking compound to fastener threads.Torque
hydraulic oil can penetrate and the backlash pivot plate mounting fasteners to
burn skin. Loosen hydraulic specification. Refer to Section 2, Machine
connections very slowly to allow Torque Specifications.
the oil pressure to dissipate 7 Install the brake and then the motor onto the
gradually. Do not allow oil to drive hub. Apply removable thread locking
squirt or spray. compound to fastener threads.Torque the
3 Loosen the backlash pivot plate and adjustment motor/brake mounting fasteners to
bolts. specification. Refer to Section 2, Machine
4 Attach a suitable lifting device to the lifting eyes
on the drive hub assembly. 8 Adjust turntable rotation gear backlash.
See 10-1, How to Adjust the Turntable Rotation
Gear Backlash.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 63

TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable

Rotation Hydraulic Motor
hose end must be replaced. All connections must a
A
B
Note: The turntable rotation lock pin is located next
to the boom rest pad.
2 Tag, disconnect and plug the hydraulic hoses c b
from the drive motor. Cap the fittings on the
motor. a motor
b drive hub mounting bolts
Bodily injury hazard. Spraying c drive hub with brake
squirt or spray.
3 Remove the hydraulic tube that connects from
the counterbalance manifold to the brake. Cap
the fittings on the brake and manifold.
squirt or spray.
4 Remove the motor/brake mounting fasteners.
Carefully remove the motor from the brake.
5 Clean up any oil that may have spilled.
4 - 64 S-80 • S-85 • S-80X Part No. 1259369

TURNTABLE ROTATION COMPONENTS
How to Adjust the Turntable 3 Push the backlash pivot plate towards the
turntable as far as possible (this will push the
Rotation Gear Backlash rotation gear into the turntable bearing ring
The turntable rotation drive hub is mounted on an gear).
adjustable plate that controls the gap between the 4 Loosen the lock nut on the adjustment bolt.
rotation motor pinion gear and the turntable bearing
ring gear. 5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
Note: Perform this procedure with the boom
between the non-steer end tires and with the 6 Turn the adjustment bolt one half turn
machine on a firm and level surface. counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Note: The turntable rotation lock pin is located next Then torque the mounting fasteners on the
to the boom rest pad. backlash pivot plate. Refer to Section 2,
Specifications.
2 Loosen the backlash pivot plate mounting
fasteners. 8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
B
A
a
a backlash pivot plate

b adjustment bolt with lock nut
c backlash pivot plate mounting bolts
Part No. 1259369 S-80 • S-85 • S-80X 4 - 65

Steer Axle Components

11-1 6 Remove the lug nuts. Remove the tire and
wheel assembly.
Yoke and Drive Hub
7 Remove the hydraulic hose clamp retaining
fastener from the top of the yoke pivot pin.
How to Remove the Yoke
and Drive Hub Assembly 8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the drive hub
and remove the drive motor from the machine.
hose end must be replaced. All connections must 10 Remove the pin retaining fasteners from the
be torqued to specification during installation. upper and lower yoke pivot pins.
Torque Specifications. 11 Support and secure the yoke and drive hub
assembly to a lifting jack.
1 Remove the pin retaining fasteners from both
12 Use a slide hammer to remove the upper yoke
the steer cylinder and the tie rod cylinder pivot
pivot pin. Use a soft metal drift to drive the
pins. Remove the pins.
lower yoke pivot pin down and out.
Crushing hazard. The yoke and
drive hub assembly could become
drive motor.
unbalanced and fall when the yoke
Bodily injury hazard. Spraying pivot pins are removed if not
hydraulic oil can penetrate and properly supported and secured to
burn skin. Loosen hydraulic the lifting jack.
13 Place the yoke and drive hub assembly on a flat
surface with the drive hub facing down.
squirt or spray. 14 Remove the drive hub mounting fasteners that
attach the drive hub to the yoke. Remove the
3 Loosen the wheel lug nuts. Do not remove
yoke from the drive hub. Refer to
them.
Section 2, Specifications.
4 Block the non-steer wheels, and center a lifting
Note: Replace the thrust washer when installing
jack of ample capacity under the steer axle.
the yoke and drive hub assembly onto the axle.
5 Raise the machine approximately
6 inches / 15 cm and place blocks under the
chassis for support.
4 - 66 S-80 • S-85 • S-80X Part No. 1259369

STEER AXLE COMPONENTS

Drive Motor drive motor.
How to Remove a Drive Motor hydraulic oil can penetrate and
Component damage hazard. burn skin. Loosen hydraulic
Repairs to the motor should only connections very slowly to allow
be performed by an authorized the oil pressure to dissipate
Sauer dealer. gradually. Do not allow oil to squirt
or spray.
work area and surfaces where this 4 Remove the drive motor mounting fasteners.
procedure will be performed must 5 Slide the drive motor shaft out of the drive hub,
be clean and free of debris that and remove the drive motor from the machine.
could get into the hydraulic system Refer to Section 2, Specifications.
and cause severe component
damage. Dealer service is
recommended.
1 Extend the axles.
2 Remove the drive motor access covers from
both sides of the inner axle.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 67

STEER AXLE COMPONENTS
11-3 11-4
Drive Hub Steer Cylinders
How to Remove a Drive Hub How to Remove a Steer Cylinder

Note: When removing a hose assembly or fitting, There are two identical steer cylinders that
the O-ring (if equipped) on the fitting and/or the work in parallel. They are part of the same
hose end must be replaced. All connections must hydraulic circuit, but move in opposite directions.
be torqued to specification during installation. The tie rod cylinder maintains equal movement of
Refer to Section 2, Hydraulic Hose and Fitting the tires.
1 Remove the drive motor. See 12-2, How to the O-ring (if equipped) on the fitting and/or the
Remove a Drive Motor. hose end must be replaced. All connections must
2 Loosen the wheel lug nuts. Do not remove
them.
3 Center a lifting jack of ample capacity under the
non-steer axle.
from the steer cylinder. Cap the fittings on the
4 Raise the machine approximately cylinder.
6 inches / 15 cm and place blocks under the
chassis for support.
5 Remove the wheel lug nuts, then the tire and burn skin. Loosen hydraulic
wheel assembly. connections very slowly to allow
6 Place a second lifting jack under the drive hub
for support and secure the drive hub to the
squirt or spray.
lifting jack.
2 Remove the hose bracket mounting fastener on
7 Remove the drive hub mounting fasteners that
the steer cylinder barrel-end pivot pin.
attach the drive hub to the axle. Remove the
drive hub. 3 Remove the pin retaining fasteners from the
steer cylinder pivot pins. Remove the pivot pin
Crushing hazard. The drive
from each end of the steer cylinder.
hub could become unbalanced
and fall if not properly supported 4 Remove the steer cylinder from the machine.
and secured to the lifting jack
Note: Do not re-use the drive hub mounting
fasteners. Genie specifications require the use of
new fasteners.
4 - 68 S-80 • S-85 • S-80X Part No. 1259369

Non-steer Axle Components

12-1 12-2
Drive Motor Drive Hub
How to Remove a Drive Motor How to Remove a Drive Hub

This procedure is the same as the steer axle This procedure is the same as the steer axle
procedure. See 12-2, How to Remove a Drive procedure. See 12-3, How to Remove a Drive Hub.
Motor.
Part No. 1259369 S-80 • S-85 • S-80X 4 - 69

Oscillating Axle Components

13-1 3 Tag, disconnect and plug the oscillating axle
Oscillate Axle Cylinders cylinder.
The oscillating axle cylinders extend and retract Bodily injury hazard. Spraying
between the drive chassis and the axle to maintain hydraulic oil can penetrate and
a level chassis while driving over uneven terrain. burn skin. Loosen hydraulic
The cylinders are equipped with counterbalance connections very slowly to allow
valves to prevent movement in the event of a the oil pressure to dissipate
hydraulic hose failure. gradually. Do not allow oil to squirt
or spray.
How to Remove an Oscillate Axle 4 Remove the pin retaining fasteners from the
Cylinder rod-end pivot pin. Use a soft metal drift to
remove the pin.
Note: Perform this procedure on firm, level surface
with the boom in the stowed position. 5 Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
the O-ring (if equipped) on the fitting and/or the 6 Remove the pin retaining fasteners from the
hose end must be replaced. All connections must barrel-end pivot pin. Use a soft metal drift to
be torqued to specification during installation. remove the pin.
Refer to Section 2, Hydraulic Hose and Fitting 7 Remove the cylinder from the machine.
Crushing hazard. The oscillate
1 Rotate the turntable until the boom is between cylinder could become unbalanced
the steer tires. and fall if not properly attached to
2 Remove the fasteners from the drive chassis the overhead crane when
cover at the steer end. Remove the cover. removed from the machine.
4 - 70 S-80 • S-85 • S-80X Part No. 1259369

OSCILLATING AXLE COMPONENTS
13-2 4 Start the engine from the ground control.
Oscillate Directional Valve 5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge. Refer to Section 2,
How to Adjust the Oscillate Specifications.
Relief Valve Pressure
6 Turn the engine off.
7 Locate the relief valve on the function manifold
gauge to the diagnostic nipple located on the
(item SC).
function manifold.
8 Loosen the jam nut on the relief valve.
2 Remove the drive chassis cover from the non-
steer end of the machine. 9 Turn the valve clockwise to increase the
pressure or counterclockwise to decrease the
3 Disconnect the directional valve linkage, by
pressure.
removing the clevis yoke from the drive
chassis. Refer to illustration 1. Tip-over hazard. Do not adjust the
relief valve higher than specified.
10 Tighten the jam nut.
11 Repeat steps 4 through 10 to confirm the
oscillate relief valve pressure.
a
Note: The oscillate pressure required is while the
oscillate cylinders are in motion. Do not dead head
the cylinders to either side.
12 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
13 Install the cover on the non-steer end of the
drive chassis.
a oscillate valve
b clevis yoke
c drive chassis
Part No. 1259369 S-80 • S-85 • S-80X 4 - 71

OSCILLATING AXLE COMPONENTS
How to Set Up the Directional 8 Verify that the ground and drive chassis are
completely level.
Valve Linkage
9 Loosen the jamb nuts and adjust the length of
Note: Perform this procedure on a firm, level the rod by turning the clevis yoke until the
surface. clevis yoke can be pinned to the axle.
1 Lower the boom to the stowed position. 10 Install the cotter pin and tighten the jamb nuts.
2 Use a "bubble type" level to be sure the surface 11 Measure the gap between the drive chassis and
the machine is on is completely level. the non-steer axle on both sides (from the inside
of the drive chassis).
Tip-over hazard. Failure to
perform this procedure on a firm, Result: The measurements should be equal.
level surface will compromise the
Note: The gap on both sides should be between
stability of the machine and could
0.150 inch / 0.381 cm and 0.170 inch / 0.432 cm.
result in the machine tipping over.
3 Check the tire pressure in all four tires and add 12 Add or remove shims between the oscillation
air if needed to meet specification. stop bar and the drive chassis to achieve the
proper gap.
4 Remove the drive chassis cover from the
non-steer end of the machine.
5 Disconnect the linkage clevis yoke from the
axle.
6 Place a "bubble type" level on the turntable
rotate bearing plate at the non-steer end.
Confirm whether the drive chassis is completely
level.
7 If the drive chassis is not level, start the engine
and push up or pull down on the linkage
adjustment rod until the machine is completely
level.
4 - 72 S-80 • S-85 • S-80X Part No. 1259369

October 2014 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropriate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Electrocution/burn hazard. Contact
before operating the machine. with electrically charged circuits
Unless otherwise specified, perform each repair injury. Remove all rings, watches
procedure with the machine in the following and other jewelry.
configuration:
Note: Two persons will be required to safely
• Machine parked on a firm, level surface perform some troubleshooting procedures.
• Boom in stowed position
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Welder disconnected from the machine
(if equipped with the weld cable to platform
option)
• Wheels chocked
• All external AC power disconnected from the
machine
Part No. 1259369 S-80 • S-85 • S-80X 5-1

Section 5 • Fault Codes October 2014
Control System Fault Codes
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once per
Fault Codes second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: At least one fault code is present when the
alarm at the platform controls produces two short Note: When the red LED is flashing the code, the
beeps every 30 seconds for 10 minutes. yellow LED will be on solid.
Note: Perform this procedure with the engine off, 4 Determine the error type: The yellow LED
the key switch turned to platform controls and both indicates the error type and will flash two
red Emergency Stop button pulled out to the on separate codes. The first code will indicate the
position at both the ground and platform controls. first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
1 Open the platform control box lid. flash the second digit once per 0.5 second.
Electrocution/burn hazard. Contact Note: When the yellow LED is flashing the code,
with electrically charged circuits the red LED will be on solid.
injury. Remove all rings, watches 5 Use the fault code table on the following pages
and other jewelry. to aid in troubleshooting the machine by
pinpointing the area or component affected.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.
5-2 S80 • S-85 • S-80X Part No. 1259369

Error Source Error Type Condition Solution

ID Name ID Name
21 Primary Up / Down 11 Value at 5V Function is Cycle power off,
Joystick 12 Value too high inoperative. then on after
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 after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
23 Primary 12 Value too high Valve is operating Cycle power off,
Up / Down 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been
indicating a fault. corrected.
17 Not calibrated Normal function Calibrate valve

except threshold threshold.
for one or both
directions is zero.
24 Angle sensor 11 Value at 5V Reduced speed Cycle power off,
12 Value too high function. then on after
15 Value too low Alarm sounds problem has been
17 Not calibrated Calibrate angle sensor.
31 Invalid setup Initiate 1 -second Calibrate angle sensor.

beep of Alarm Buzzer
and required retract
into safe envelope
Part No. 1259369 S-80 • S-85 • S-80X 5-3


ID Name ID Name
26 Angle sensor 19 Out of range Reduced speed, Power up controller with
cross check required retract into problem corrected
safe envelope
31 Primary 11 Value at 5V Function is Cycle power off,
Ext. / Ret. 12 Value too high inoperative. then on after
Joystick 15 Value too low Alarm sounds problem has been

32 Primary 21 Fault Valve is operating Cycle power off,
Ext. / Ret. outside of limits. then on after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
33 Primary 12 Value too high Valve is operating Cycle power off,
Ext. / Ret. 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been

for one or both
directions is zero.
34 Ext. Ret. 31 Invalid setup Initiate 1-second beep Fully retract, then lower
Limit Switch of Alarm Buzzer boom
-1000lb. Mode: Check and service ext/

Required retract into ret and fully stowed
“FULLY RETRACTED” switches
state before lowering
-500lb. Mode:
Operates normally
5-4 S80 • S-85 • S-80X Part No. 1259369


ID Name ID Name
41 Turntable 11 Value at 5V Limited speed Cycle power off,
Rotate 12 Value too high and direction then on after
Joystick 15 Value too low frozen at zero problem has been
16 Value at 0V and neutral. corrected.
Alarm sounds
indicating a fault.

42 Turntable 21 Fault Limited direction. Cycle power off,
Rotate Frozen at zero then on after
Directional and neutral. problem has been
Valves 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 after
Flow Valve Frozen at zero problem has been
and neutral. corrected.
Alarm sounds
indicating a fault.

for one or both
directions is zero.
44 Drive Enable 21 Fault Drive enable Cycle power off,
Override override direction then on after
Switch is frozen at problem has been
neutral. corrected.
Part No. 1259369 S-80 • S-85 • S-80X 5-5


ID Name ID Name
45 Platform Level Switch 21 Fault Platform level Power up controller with
frozen at neutral problem corrected
46 Primary Extend/Retract 21 Fault Platform Ext/Ret Power up controller with

Switch frozen at neutral problem corrected
51 Drive Joystick 11 Value at 5V Limited speed Cycle power off,

12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.

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 been
Alarm sounds
indicating a fault.

for one or both
directions is zero.
5-6 S80 • S-85 • S-80X Part No. 1259369


ID Name ID Name
54 Drive Brake 21 Fault Drive frozen Cycle power off,
Valve at zero and then on after
neutral. problem has been
Alarm sounds corrected.
indicating a fault.
55 High Drive 21 Fault Motor speed Cycle power off,
Motor Speed in the low state. then on after
Valve Alarm sounds problem has been
56 Platform Level Value 21 Fault Direction frozen at Power up controller with
zero and neutral, AB problem corrected
57 Foot switch/ECU 12 Value too high Direction frozen at Power up controller with
Power Crosscheck 15 Value too low zero and neutral, AB problem corrected
61 Steer Joystick 11 Value at 5V Limited speed Cycle power off,
12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.

62 Steer 21 Fault Limited speed Cycle power off,
Directional and direction. then on after
Valve Frozen at zero problem has been
Alarm sounds
indicating a fault.
Part No. 1259369 S-80 • S-85 • S-80X 5-7

Fault Code Display -

Deutz TD 2.9 L4 and Perkins 404F-22T Models
How to Retrieve Active Engine With an active fault and the engine running:
(preferred method)
Fault Codes
1 At the ground controls, activate the auxiliary
The ECM constantly monitors the engine by the pump toggle switch to shut the engine off.
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel Note: Do not push in the red Emergency Stop
injection and make constant and instantaneous button or turn the key switch to the off position.
changes to ignition timing, fuel delivery and throttle
3 Press any soft key below the display.
position to maintain the engine's running condition
at its highest efficiency while at the same time 4 Use the scroll up / down keys to check for
keeping exhaust emissions to a minimum. When a multiple engine fault codes.
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in With the engine not running:
memory that relates to the appropriate sensor. One 1 At the ground controls, turn the key switch to
or more fault LED's will illuminate on the display ground controls and pull out the red Emergency
located at the ground control box. The active fault Stop button.
code will also be displayed on the LCD screen.
2 Navigate to the Active Fault Menu and use the
Note: The Perkins 404TF-22 is equipped with an scroll up / down keys to check for multiple
engine fault LED located at the platform control engine fault codes.
box.
If an engine fault occurs that does not result in an Any Soft Key
engine shutdown, the engine rpm will go into limp
Next Menu Next Menu Main Menu
home mode resulting in the loss of high rpm.
When operating from the platform, if the red

Emergency Stop button is pushed in, the active Main Menu Note: Use the Scroll
Up/Down buttons to
fault code(s) will be erased from the display. Basic Setup move the Select icon.
Diagnostics Press the Select button
Start the engine from the ground control box and Screen Setup to enter that menu
operate various boom functions to verify that an System setup option.
active engine fault occurs and is shown on the
display. Diagnostics Fault Menu
Note: All faults are stored in the Previous Fault System Info Active Faults
history menu. These faults will not be erased when Fault Log Previous Faults
corrective action has been completed. Device List
Quick Data
Currently Active Faults

SPN: FMI: OC:
5-8 S80 • S-85 • S-80X Part No. 1259369

Fault Code Display -

Flashing and Solid LED's
1 4
2 5
3 6
1 Left green LED:

Flashing, engine fault detected. Contact service.
Solid, fault acknowledged. Contact service.
2 Left amber LED: (Perkins models)
Solid,
a) Regeneration is inhibited. No service required.
b) High exhaust temperature during regeneration mode. No service required.
3 Left red LED:
Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact
service.
4 Right green LED:
Solid, fault acknowledged. Contact service.
5 Right amber LED: (Perkins models)
Solid with left amber LED on solid, regeneration has been inhibited and engine soot level is between
80 - 100%. Regeneration is required.
Flashing with left amber LED on solid, regeneration has been inhibited and soot level is between
100 - 140%. Engine rpm is de-rated. Regeneration is required.
Flashing with left and right red LED's flashing, engine soot level over 140%. Engine shut down. Contact
service.
6 Right red LED:
Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact
service.
Part No. 1259369 S-80 • S-85 • S-80X 5-9

Soft Key Functions and Icons -

Deutz TD 2.9L4 and Perkins 404F-22T Models
1 2 3 4
1 Next menu • Exit / Back one screen • Decrease brightness (-)

2 Brightness / Contrast • Scroll up • Increase • Increase brightness (+)
3 Regeneration forced • Scroll down • Decrease • Decrease contrast (-)
4 Regeneration inhibited • Select / Next • Main menu • Increase contarst (+)
Note: Regeneration, initiate, inhibit and soot only

apply to the Perkins 404TF-22 models.
Next Menu Brightness/ Initiate Inhibit

Contrast Switch Switch
Exit / Back Scroll Scroll Select

One Screen Up Down
Main Hour Oil Coolant

Menu Meter Pressure Temp.
Soot V
Engine Soot Level Voltage Pin #

RPM Percent (%) Protected
5 - 10 S80 • S-85 • S-80X Part No. 1259369

Main Menu Structure -

Deutz TD 2.9 L4 Models
Any Soft Key
Brightness/Contrast Scroll Up Scroll Down Main Menu
V Soot Main Menu Note: Use the Scroll

Hour Engine Soot Up/Down buttons to
Voltage move the Select icon.
Meter RPM Level (%) Basic Setup
Screen Setup to enter that menu
Oil Coolant System setup option.
Pressure Temp.
Basic Setup Diagnostics Screen Setup System Setup

Note: The following
menu items should only
PIN Code PIN Code be accessed by a
Time / Date System Setup trained service
**** ****
technician.
Language Fault Log Screen Setup System Setup
Parameters Reset Defaults

Number of Screens CAN
Units Device List Select Screen Display
PIN Setup
Trip Reset
Quick Data
Part No. 1259369 S-80 • S-85 • S-80X 5 - 11

Main Menu Structure -

Perkins 404TF-22 Models
Any Soft Key
Next Menu Brightness/Contrast Regeneration Regeneration

Forced Inhibit
Next Menu Scroll Up Scroll Down Main Menu
V Soot Main Menu Note: Use the Scroll

Hour Engine Soot Up/Down buttons to
Voltage move the Select icon.
Meter RPM Level (%) Basic Setup
Screen Setup to enter that menu
Oil Coolant System setup option.
Pressure Temp.
Basic Setup Diagnostics Screen Setup System Setup

Note: The following
menu items should only
PIN Code PIN Code be accessed by a
Time / Date System Setup trained service
**** ****
technician.
Language Fault Log Screen Setup System Setup
Parameters Reset Defaults

Number of Screens CAN
Units Device List Select Screen Display
PIN Setup
Trip Reset
Quick Data
5 - 12 S80 • S-85 • S-80X Part No. 1259369

Deutz TD 2.9 L4 Engine Fault Codes
SPN = Suspect Parameter Number / FMI - Failure Mode Identifier / KWP = Keyword Protocol
SPN FMI KWP Description SPN FMI KWP Description
51 3 1019 EGR-Valve, short 51 6 1022 Actuator error EGR-Valve;
circuit to battery signal range check high
51 3 1024 Position sensor error of 51 6 1224 Actuator EGR-Valve;
actuator EGR-Valve; over current
signal range check high
51 6 1230 Actuator error EGR-Valve;
51 3 1226 EGR-Valve; short Overload by short-circuit
circuit to battery (A02)
51 7 1016 Actuator position for EGR-
51 3 1227 EGR-Valve; short circuit to Valve not plausible
battery (A67)
51 4 1020 EGR-Valve; short circuit Power stage over temp
to ground due to high current
51 4 1025 Position sensor error actuator 51 12 1018 Actuator EGR-Valve;
EGR-Valve; signal range powerstage over temperature
check low
51 12 1021 Mechanical actuator defect
51 4 1228 EGR-Valve; short circuit to EGR-Valve
ground (A02)
51 12 1225 Actuator EGR-Valve;
51 4 1229 EGR-Valve; short circuit to over temperature
ground (A67)
94 1 474 Low fuel pressure; warning
51 4 1232 Actuator error EGR-Valve; threshold exceeded
Voltage below threshold
94 1 475 Low fuel pressure; shut off
51 5 1015 Actuator error EGR-Valve; threshold exceeded
signal range check low
94 3 472 Sensor error low fuel pressure;
51 5 1017 Actuator EGR-Valve; open load signal range check high
51 5 1023 Actuator error EGR-Valve; 94 4 473 Sensor error low fuel pressure;
signal range check low signal range check low
51 5 1223 Actuator EGR-Valve; open load 97 3 464 Sensor error water in fuel;
signal range check high 97 4 465 Sensor error water in fuel;
97 12 1157 Water in fuel level prefilter;
maximum value exceeded
Part No. 1259369 S-80 • S-85 • S-80X 5 - 13

100 0 734 High oil pressure; warning 108 3 412 Sensor error ambient air
threshold exceeded press.; signal range check high
100 0 735 High oil pressure; shut off 108 4 413 Sensor error ambient air
threshold exceeded press.; signal range check low
100 1 736 Low oil pressure; warning 110 0 98 High coolant temperature;
threshold exceeded warning threshold exceeded
100 1 737 Low oil pressure; shut off 110 0 99 High coolant temperature; shut
threshold exceeded off threshold exceeded
100 3 732 Sensor error oil pressure; signal 110 3 96 Sensor error coolant
range check high temp.; signal range check high
100 4 733 Sensor error oil pressure 110 4 97 Sensor error coolant
sensor; signal range check low temp.; signal range check low
102 2 88 Charged air pressure above 111 1 101 Coolant level too low
warning threshold
132 11 1 Air flow sensor load correction
102 2 89 Charged air pressure above factor exceeding the maximum
shut off threshold drift limit; plausibility error
102 4 777 Sensor error charged air 132 11 2 Air flow sensor load correction
press.; signal range check low factor exceeding drift limit;
plausibility error
105 0 996 High charged air cooler
temperature; warning 132 11 3 Air flow sensor low idle
threshold exceeded correction factor exceeding the
maximum drift limit
105 0 997 High charged air cooler
temperature; shut off 132 11 4 Air flow sensor load correction
threshold exceeded factor exceeding the maximum
drift limit
105 3 994 Sensor error charged air
temperature; signal range 157 3 877 Sesnor error rail pressure;
check high signal range check high
105 4 995 Sensor error charged air 157 4 878 Sensor error rail pressure;
temperature; signal range signal range check low
check low
5 - 14 S-80 • S-85 • S-80X Part No. 1259369

168 0 1180 Physical range check high for 174 0 481 High low fuel temperature;
battery voltage warning threshold exceeded
168 1 1181 Physical range check low for 174 0 482 High Low fuel temperature; shut
battery voltage off threshold exceeded
168 2 47 High battery voltage; warning 175 0 740 Physical range check high for
threshold exceeded oil temperature
168 2 48 Low battery voltage; warning 175 0 745 High oil temperature; warning
threshold exceeded threshold exceeded
168 3 45 Sensor error battery voltage; 175 0 746 High oil temperature; shut off
signal range check high threshold exceeded
168 4 46 Sensor error battery voltage; 175 1 741 Physical range check low for oil
signal range check low temperature
171 3 417 Sensor error environment 175 2 738 Sensor oil temperature;
temperature; signal range plausibility error
check high
175 2 739 Sensor oil temperature;
171 4 418 Sensor error environment plausibility error
temperature; signal range oil temperature too high
check low
175 3 743 Sensor error oil temperature;
172 0 1182 Physical range check high for signal range check high
intake air temperature
175 4 744 Sensor error oil temperature;
172 1 1183 Physical range check low for signal range check low
intake air temperature
190 0 389 Engine speed above warning
172 2 9 Sensor ambient air threshold (FOC-Level 1)
temperature; plausibility error
190 2 421 Offset angle between crank-
172 2 983 Intake air sensor; plausibility and camshaft sensor is
error too large
172 3 981 Sensor error intake air; signal 190 8 419 Sensor camshaft speed;
range check high disturbed signal
172 4 982 Sensor error intake air sensor;
Part No. 1259369 S-80 • S-85 • S-80X 5 - 15

190 8 422 Sensor crankshaft speed; 412 3 1007 Sensor error EGR cooler
disturbed signal downstream temperature;
190 11 390 Engine speed above warning
threshold (FOC-Level 2) 412 4 1008 Sensor error EGR cooler
downstream temperature;
190 12 420 Sensor camshaft speed; no signal range check low
signal
520 9 306 Timeout Error of CAN-Receive-
190 12 423 Sensor crankshaft speed; no Frame TSC1TR; Setpoint
signal
597 2 49 Break lever mainswitch and
190 14 391 Engine speed above warning break lever redundancyswitch
threshold (Overrun Mode) status not plausible
190 14 1222 Camshaft- and Crankshaft 624 3 971 SVS lamp; short circuit to batt.
speed sensor signal not
available on CAN 624 4 972 SVS lamp; short circuit to grd.
411 0 791 Physical range check high for 624 5 969 SVS lamp; open load
differential pressure
Venturiunit (EGR) 624 12 970 SVS lamp; powerstage
over temperature
411 1 792 Physical range check low for
differential pressure 630 12 376 Access error EEPROM
Venturiunit (EGR) memory (delete)
411 3 795 Sensor error differential 630 12 377 Access error EEPROM
pressure Venturiunit (EGR); memory (read)
630 12 378 Access error EEPROM
411 4 381 Physical range check low for memory (write)
EGR differential pressure
639 14 84 CAN-Bus 0 "BusOff-Status"
411 4 796 Sensor error differential
651 3 580 Injector 1 (in firing order);
pressure Venturiunit (EGR);
short circuit
651 4 586 High side to low side short
circuit in the injector 1
(in firing order)
5 - 16 S-80 • S-85 • S-80X Part No. 1259369

651 5 568 Injector 1 (in firing order); 677 3 956 Starter relay high side;
interruption of electric short circuit to battery
connection
677 3 960 Starter relay low side; short
652 3 581 Injector 2 (in firing order); circuit to battery
short circuit
677 4 957 Starter relay high side; short
652 4 587 High side to low side short circuit to ground
(in firing order) 677 4 961 Starter relay low side; short
circuit to ground
interruption of 677 5 958 Starter relay; no load error
electric connection
677 12 959 Starter relay; powerstage over
653 3 582 Injector 3 (in firing order); temperature
short circuit
703 3 426 Engine running lamp; short
653 4 588 High side to low side short circuit to battery
703 4 427 Engine running lamp; short
(in firing order)
circuit to ground
703 5 424 Engine running lamp; open load
interruption of
electric connection 703 12 425 Engine running lamp;
powerstage over temperature
short circuit 729 5 545 Cold start aid relay open load
654 4 589 High side to low side short 729 12 547 Cold start aid relay; over
circuit in the injector 4 temperature error
(in firing order)
654 5 571 Injector 4 (in firing order); Frame TSC1TE; Setpoint
interruption of
electric connection 1079 13 946 Sensor supply voltage monitor
1 error (ECU)
676 11 543 Cold start aid relay error.
1080 13 947 Sensor supply voltage monitor
676 11 544 Cold start aid relay open load 2 error (ECU)
Part No. 1259369 S-80 • S-85 • S-80X 5 - 17

1109 2 121 Engine shut off demand ignored 1180 1 1463 Exhaust gas temperature
upstream turbine; shut off
1136 0 1398 Physikal range check high for threshold exceeded
ECU temperature
1180 3 1067 Sensor error exhaust gas
1136 1 1399 Physikal range check low for temperature upstream turbine;
ECU temperature signal range check high
1136 3 1400 Sensor error ECU temperature; 1180 11 1066 Sensor exhaust gas
signal range check high temperature upstream turbine;
plausibility error
1136 4 1401 Sensor error ECU temperature;
signal range check low 1188 2 1414 Wastegate; status message
from ECU missing
1176 3 849 Sensor error pressure sensor
upstream turbine; signal 1188 7 1415 Wastegate actuator; blocked
range check high
1188 11 1411 Wastegate actuator;
1176 4 850 Sensor error pressure sensor internal error
downstream turbine; signal
range check high 1188 11 1412 Wastegate actuator; EOL
calibration not
1180 0 1193 Physical range check high for performed correctly
exhaust gas temperature
upstream turbine 1188 11 1416 Wastegate actuator; over
temperature (> 145°C)
1180 0 1460 Turbocharger Wastegate CAN
feedback; warning threshold 1188 11 1417 Wastegate actuator; over
exceeded temperature (> 135°C)
1180 0 1462 Exhaust gas temperature 1188 11 1418 Wastegate actuator; operating
upstream turbine; warning voltage error
threshold exceeded
1188 13 1413 Wastegate actuator calibration
1180 1 1194 Physical range check low for deviation too large,
exhaust gas temperature recalibration required
upstream turbine
1231 14 85 CAN-Bus 1 "BusOff-Status"
1180 1 1461 Turbocharger Wastegate CAN
feedback; shut off threshold 1235 14 86 CAN-Bus 2 "BusOff-Status"
exceeded
5 - 18 S-80 • S-85 • S-80X Part No. 1259369

1237 2 747 Override switch; 2798 4 1338 Injector diagnostics; timeout
plausibility error error of short circuit to ground
measurement cyl. Bank 1
1322 12 610 Too many recognized misfires
in more than one cylinder 2798 4 1339 Injector diagnostics; short
circuit to ground monitoring
1323 12 604 Too many recognized misfires Test in Cyl. Bank 0
in cylinder 1 (in firing order)
2798 4 1340 Injector diagnostics; short
1324 12 605 Too many recognized misfires circuit to ground monitoring
in cylinder 2 (in firing order) Test in Cyl. Bank 1
1325 12 606 Too many recognized misfires 3224 2 127 DLC Error of CAN-Receive-
in cylinder 3 (in firing order) Frame AT1IG1 NOX Sensor
(SCR-system upstream cat;
1326 12 607 Too many recognized misfires
DPF-system downstream cat);
in cylinder 4 (in firing order)
length of frame incorrect
2659 0 1524 Physical range check high for
EGR exhaust gas mass flow
Frame AT1IG1;
2659 1 1525 Physical range check low for NOX sensor upstream
EGR exhaust gas mass flow
3248 4 1047 Sensor error particle filter
2659 2 1523 Exhaust gas recirculation AGS downstream temperature;
sensor; plausibility error signal range check low
2659 2 1527 AGS sensor temperature 3699 2 1616 DPF differential pressure
exhaust gas mass flow; sensor and a further sensor or
plausibility error actuator CRT system defective
2659 12 1526 Exhaust gas recirculation; AGS 3699 2 1617 Temperature sensor us. and
sensor has "burn off" ds. DOC simultaneously defect
not performed
3699 14 1615 Maximum stand-still-duration
2797 4 1337 Injector diagnostics; timeout reached; oil exchange required
error of short circuit to ground
4765 0 1039 Physical range check high for
measurement cyl. Bank 0
upstream (DOC)
4765 1 1042 Physical range check low for
upstream (DOC)
Part No. 1259369 S-80 • S-85 • S-80X 5 - 19

4766 0 1029 Physical range check high for 523008 2 649 Timeout error in Manipulation
exhaust gas temperature control
downstream (DOC)
523009 9 825 Pressure Relief Valve (PRV)
4766 1 1032 Physical range check low for reached maximun allowed
exhaust gas temperature opening count
downstream (DOC)
523009 10 833 Pressure relief valve (PRV)
4768 2 1036 Sensor exhaust gas reached maximun allowed
temperature upstream (DOC); open time
plausibility error
4768 3 1044 Sensor error exhaust gas Frame ComEngPrt;
temperature upstream (DOC); Engine Protection
4768 4 1045 Sensor error exhaust gas Frame PrHtEnCmd; pre-heat
temperature upstream (DOC); command, engine command
523240 9 179 Timeout CAN-message
4769 2 1026 Sensor exhaust gas FunModCtl;
temperature downstream Function Mode Control
(DOC); plausibility error
523350 4 565 Injector cylinder-bank 1;
4769 3 1034 Sensor error exhaust gas short circuit
temperature downstream
(DOC); signal range check high 523352 4 566 Injector cylinder-bank 2;
short circuit
4769 4 1035 Sensor error exhaust gas
temperature downstream 523354 12 567 Injector powerstage output
(DOC); signal range check low defect
523006 3 34 Controller mode switch; short 523470 2 826 Pressure Relief Valve (PRV)
circuit to battery forced to open; performed by
pressure increase
523006 4 35 Controller mode switch; short
circuit to ground 523470 2 827 Pressure Relief Valve (PRV)
forced to open; performed by
523008 1 648 Manipulation control was pressure shock
triggered
5 - 20 S-80 • S-85 • S-80X Part No. 1259369

523470 7 876 Maximum rail pressure in limp 523612 12 613 Internal ECU monitoring
home mode exceeded (PRV) detection reported error
523470 11 831 The PRV can not be opened at 523612 12 614 Internal ECU monitoring
this operating point with a detection reported error
pressure shock
523612 12 615 Internal ECU monitoring
523470 11 832 Rail pressure out of tolerance detection reported error
range
523470 12 828 Open Pressure Relief Valve detection reported error
(PRV); shut off condition
523470 12 829 Open Pressure Relief Valve detection reported error
(PRV); warning condition
523470 14 830 Pressure Relief Valve (PRV) is detection reported error
open
523550 12 980 T50 start switch active for detection reported error
too long
523601 13 948 Sensor supply voltage monitor detection reported error
3 error (ECU)
523603 9 126 Timeout Error of CAN-Receive- detection reported error
Frame AMB; Ambient
Temperature Sensor 523612 12 623 Internal ECU monitoring
detection reported error
Frame TSC1AE; 523612 12 624 Internal ECU monitoring
Traction Control detection reported error
523606 9 301 Timeout Error of CAN-Receive- 523612 12 625 Internal ECU monitoring
Frame TSC1AR; Retarder detection reported error
523612 12 387 Internal software error ECU; 523612 12 627 Internal ECU monitoring
injection cut off detection reported error
523612 12 612 Internal ECU monitoring 523612 12 628 Internal ECU monitoring
detection reported error detection reported error
Part No. 1259369 S-80 • S-85 • S-80X 5 - 21

523612 12 637 Internal ECU monitoring 523615 3 596 Metering unit (Fuel-System);
detection reported error short circuit to battery low side
523612 12 1170 Internal software error ECU 523615 4 595 Metering unit (Fuel-System);
short circuit to ground high side
523612 14 973 Softwarereset CPU SWReset_0
523615 4 597 Metering Unit (Fuel-System);
523612 14 974 Softwarereset CPU SWReset_1 short circuit to ground low side
523612 14 975 Softwarereset CPU SWReset_2 523615 5 592 Metering unit (Fuel-System);
open load
523613 0 856 Maximum positive deviation of
rail pressure exceeded 523615 12 593 Metering unit (Fuel-System);
(RailMeUn0) powerstage over temperature
523613 0 857 Maximum positive deviation of 523619 2 488 Physical range check high for
rail pressure in metering unit exhaust gas temperature
exceeded (RailMeUn1) upstrem (SCR-CAT)
523613 0 858 Railsystem leakage detected 523698 11 122 Shut off request from
(RailMeUn10) supervisory monitoring function
523613 0 859 Maximum negative deviation of 523717 12 125 Timeout Error of CAN-Transmit-
rail pressure in metering unit Frame AmbCon;
exceeded (RailMeUn2) Weather environments
523613 0 860 Negative deviation of rail 523718 3 1488 SCR mainrelay; short circuit to
pressure second stage battery (only CV56B)
(RailMeUn22)
523718 4 1489 SCR mainrelay; short circuit to
523613 0 862 Maximum rail pressure ground (only CV56B)
exceeded (RailMeUn4)
523718 5 1486 SCR mainrelay; open load
523613 1 861 Minimum rail pressure (only CV56B)
exceeded (RailMeUn3)
523718 12 1487 SCR mainrelay; powerstage
523613 2 864 Setpoint of metering unit in over temperature (only CV56B)
overrun mode not plausible
523615 3 594 Metering unit (Fuel-System); Frame Active TSC1AE
short circuit to battery highside
Frame Passive TSC1AE
5 - 22 S-80 • S-85 • S-80X Part No. 1259369

523768 9 283 Timeout Error of CAN-Receive- 523897 13 561 check of missing injector
Frame Active TSC1AR adjustment value programming
(IMA) injector 3 (in firing order)
Frame Passive TSC1AR 523898 13 562 check of missing injector
adjustment value programming
523770 9 285 Timeout Error of CAN-Receive- (IMA) injector 4 (in firing order)
Frame Passive TSC1DE
523910 6 1261 Air Pump; over current
Frame TSC1TE - active 523913 3 74 Sensor error glow plug control
diagnostic line voltage; signal
523777 9 292 Passive Timeout Error of CAN- range check high
Receive-Frame TSC1TE;
Setpoint 523913 4 75 Sensor error glow plug control
diagnostic line voltage; signal
523778 9 293 Active Timeout Errorof CAN- range check low
Receive-Frame TSC1TR
523914 3 78 Glow plug control; short circuit
523779 9 294 Passive Timeout Error of CAN- to battery
Receive-Frame TSC1TR
523914 4 79 Glow plug control; short circuit
523788 12 299 Timeout Error of CAN-Transmit- to ground
Frame TrbCH; Status
Wastegate 523914 5 76 Glow plug control; open load
523793 9 202 Timeout Error of CAN-Receive- 523914 5 1216 Glow plug control release line;
Frame UAA10; AGS sensor short circuit error
service message
523914 11 1217 Glow plug control; internal error
Frame UAA11; 523914 12 77 Glow plug control; powerstage
AGS sensor data over temperature
523895 13 559 Check of missing injector 523919 2 1378 Sensor air pump airpressure;
adjustment value programming plausibility error
523920 2 1379 Sensor exhaust gas back
523896 13 560 check of missing injector pressure burner;
adjustment value programming plausibility error
Part No. 1259369 S-80 • S-85 • S-80X 5 - 23

523922 7 1262 Burner Shut Off Valve; 523936 12 169 Timeout Error of CAN-Transmit-
blocked closed Frame EEC3VOL2; Engine
send messages
523922 7 1264 Burner Shut Off Valve;
blocked open 523946 0 1158 Zerofuel calibration injector 1
(in firing order);
523929 0 109 Fuel Balance Control integrator maximum value exceeded
injector 1 (in firing order);
maximum value exceeded 523946 1 1164 Zerofuel calibration injector 1
(in firing order);
523929 1 115 Fuel Balance Control integrator minimum value exceeded
minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2
(in firing order);
(in firing order);
(in firing order);
(in firing order);
(in firing order);
(in firing order);
minimum value exceeded 523960 0 1011 Physical range check high for
EGR cooler downstream temp.
523935 12 168 Timeout Error of CAN-Transmit-
Frame EEC3VOL1; Engine
send messages
5 - 24 S-80 • S-85 • S-80X Part No. 1259369

523960 0 1458 High exhaust gas temperature 524016 2 1259 Amount of air is not plausible to
EGR cooler downstream; pump speed
warning threshold exceeded
524016 2 1260 Calculated amount of air is not
523960 1 1012 Physical range check low for plausible to HFM reading
EGR cooler downstream temp.
524016 11 1258 HFM sensor; electrical fault
523960 1 1459 High exhaust gas temperature
EGR cooler downstream; shut 524021 11 1263 Burner fuel line pipe leak
off threshold exceeded behind Shut Off Valve
523980 14 1187 Bad quality of reduction 524024 11 1302 Deviation of the exhaust gas
agent detected temp. setpoint to actual value
downstream (DOC) too high
523981 11 918 Urea-tank without heating
function (heating phase) 524028 2 1431 CAN message PROEGRActr;
plausibility error
523982 0 360 Powerstage diagnosis disabled;
high battery voltage 524029 2 1432 Timeout Error of CAN-Receive-
Frame ComEGRActr - exhaust
523982 1 361 Powerstage diagnosis disabled; gas recirculation positioner
low battery voltage
524030 7 1440 EGR actuator; internal error
523988 3 1245 Charging lamp;
short circuit to battery 524031 13 1441 EGR actuator; calibration error
523988 4 1246 Charging lamp; 524032 2 1442 EGR actuator; status message
short circuit to ground "EGRCust" is missing
523988 5 1243 Charging lamp; open load 524033 7 1443 EGR actuator; due to overload
in Save Mode
523988 12 1244 Charging lamp; over temp.
524034 3 1438 Disc separator;
523998 4 1327 Injector cylinder bank 2 slave; short circuit to battery
short circuit
524034 4 1439 Disc separator;
523999 12 1328 Injector powerstage output short circuit to ground
Slave defect
524034 5 1436 Disc Separator; open load
524014 1 1254 Air pressure glow plug flush
line; below limit 524034 12 1437 Disc Separator;
powerstage over temperature
Part No. 1259369 S-80 • S-85 • S-80X 5 - 25

524035 12 1341 Injector diagnostics; time out 524108 9 1669 Timeout error of CAN-
error in the SPI communication Transmit-Frame
ComEGRTVActr
524057 2 1505 Electric fuel pump; fuel
pressure build up error 524109 9 1679 Timeout error of CAN-
Receive-Frame
524097 9 1663 Timeout error of CAN-Transmit- ComRxEGRTVActr
Frame DPFBrnAirPmpCtl
524110 9 1670 Timeout error of CAN-
524098 9 1664 Timeout error of CAN-Transmit- Transmit-Frame
Frame ComDPFBrnPT ComETVActr
524099 9 1665 Timeout error of CAN-Transmit- 524111 9 1680 Timeout error of CAN-
Frame ComDPFC1 Receive-Frame
ComRxETVActr
524100 9 1666 Timeout error of CAN-Transmit-
Frame ComDPFHisDat 524112 9 1671 Timeout ComITVActr
Frame ComDPFTstMon Receive-Frame
ComRxITVActr
Receive-Frame 524114 9 1659 Timeout error of CAN-
ComRxDPFBrnAirPmpCtl Transmit-Frame A1DOC
524103 9 1675 Timeout error of CAN-Receive- 524115 9 1660 Timeout error of CAN-
Frame ComRxDPFBrnAirPmp Transmit-Frame AT1S
524104 9 1676 Timeout error of CAN-Receive- 524116 9 1661 Timeout error of CAN-
Frame ComRxDPFCtl Transmit-Frame SCR2
Frame ComEGRMsFlw Transmit-Frame SCR3
524106 9 1677 Timeout error of CAN- 524118 9 1672 Timeout error of CAN-
Receive-Frame Receive-Frame ComRxCM1
ComRxEGRMsFlw1
524107 9 1678 Timeout error of CAN- Receive-Frame
Receive-Frame ComRxCustSCR3
ComRxEGRMsFlw2
5 - 26 S-80 • S-85 • S-80X Part No. 1259369

SPN FMI KWP Description
Receive-Frame
ComRxSCRHtDiag
Receive-Frame
ComRxTrbChActr
Receive-Frame
ComRxUQSens
Receive-Frame
ComSCRHtCtl
Receive-Frame
ComTxAT1IMG
Receive-Frame
ComTxTrbChActr
Part No. 1259369 S-80 • S-85 • S-80X 5 - 27

Perkins 404F-22T Engine Fault Codes
SPN = Suspect Parameter Number / FMI - Failure Mode Identifier

SPN FMI Description SPN FMI Description
29 3 Accelerator Pedal Position 2: 172 3 Engine Air Inlet Temperature:
Voltage Above Normal Voltage Above Normal
29 4 Accelerator Pedal Position 2: 172 4 Engine Air Inlet Temperature:
Voltage Below Normal Voltage Below Normal
91 3 Accelerator Pedal Position 1: 190 0 Engine Speed : High- most severe (3)
Voltage Above Normal
190 8 Engine Speed : Abnormal Frequency,
91 4 Accelerator Pedal Position 1: Pulse Width or Period
Voltage Below Normal
558 3 Accelerator Pedal1 Low Idle Switch:
100 1 Engine Oil Pressure :Low- most Voltage Above Normal
severe (3)
558 4 Accelerator Pedal1 Low Idle Switch:
108 3 Barometric Pressure : Voltage Below Normal
638 6 Engine Fuel Rack Actuator:
108 4 Barometric Pressure : Current Above Normal
639 14 J1939 Network#1: Special Instruction
110 3 Engine Coolant Temperature :
Voltage Above Normal 723 3 Engine Speed Sensor #2:
Voltage Below Normal 723 4 Engine Speed Sensor #2:
High -least severe (1) 723 8 "Engine Speed Sensor#2:
Abnormal Frequency,
168 0 Battery Potential/ Power Input 1 : Pulse Width or “Period"
High- most severe (3)
723 10 Engine Speed Sensor #2:
168 3 Battery Potential/ Power Input 1: Abnormal Rate of Change
733 3 Engine Rack Position Sensor:
168 4 Battery Potential/ Power Input 1: Voltage Above Normal
733 4 Engine Rack Position Sensor:
5 - 28 S-80 • S-85 • S-80X Part No. 1259369


1485 7 ECU Main Relay : 3242 15 "Particulate Trap Intake Gas Temp:
Not Responding Property High - least severe“(1)"
2840 11 ECU Instance: Other Failure Mode 3242 16 Particulate Trap Intake Gas Temp:
High-moderate severity (2)
2840 12 ECU Instance: Failure
3251 3 Particulate Trap Differential Pressure
2840 13 ECU Instance: Out of Calibration :Voltage Above Normal
2970 3 Accelerator Pedal 2 Low Idle Switch: 3251 4 Particulate Trap Differential Pressure
Voltage Above Normal :Voltage Below Normal
2970 4 Accelerator Pedal 2 Low Idle Switch: 3473 7 Aftertreatmert #1 Failed to Ignite:
Voltage Below Normal Not Responding Properly
3241 1 Exhaust Gas Temperature 1: 3473 11 Aftertreatmert #1 Failed to Ignite :
Low- most severe (3) Other Failure Mode
3241 3 Exhaust Gas Temperature 1: 3484 0 Aftertreatmert #1 Ignition :
Voltage Above Normal High-most severe (3)
Voltage Below Normal Voltage Above Normal
High- least severe (1) Voltage Below Normal
3241 16 Exhaust Gas Temperature 1: 3556 6 Aftertreatmert 1 Hydrocarbon
High- moderate severity (2) Doser 1: Current Above Normal
3242 1 "Particulate Trap Intake Gas Temp: 3610 3 "Diesel Particulate Filter Outlet
Low- most severe“(3)" Pressure Sensor 1:
Voltage “Above Normal"
3242 3 "Particulate Trap Intake Gas Temp:
Voltage Above “Normal" 3610 4 DieselParticulate Filter Outlet
Pressure Sensor 1:
3242 4 "Particulate Trap Intake Gas Temp:
Voltage Below “Normal"
Part No. 1259369 S-80 • S-85 • S-80X 5 - 29


3713 7 DPF Active Regeneration Inhibited 4765 4 Aftertreatmert #1 Diesel Oxidation
Due to System Timeout: Catalyst Intake Gas Temperature:
Not Responding Properly Voltage Below Normal
3713 31 DPF Active Regeneration Inhibited 4765 15 Aftertreatmert #1Diesel Oxidation
Due to System Timeout Catalyst Intake Gas Temperature:
High-least severe (1)
3719 0 Particulate Trap #1 Soot Load
Percent: High- most severe (3) 4765 16 Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
3719 16 Particulate Trap #1 Soot Load High-moderate severity (2)
Percent: High-moderate severity (2)
5487 3 Aftertreatmert 1 Burner Unit
4016 6 High Current Auxiliary Power Relay Combustion Chamber Temperature:
1: Current Above Normal Voltage Above Normal
4201 3 Engine Speed Sensor #1: 5487 4 Aftertreatmert 1 Burner Unit
Voltage Above Normal Combustion Chamber Temperature:
Voltage Below Normal 6581 6 Aftertreatmert 1 Hydrocarbon
Doser 2 : Current Above Normal
4201 8 "Engine Speed Sensor #1:
Abnormal Frequency,
Pulse \Nidth, or “Period"
Abnormal Rate of Change
4765 1 Aftertreatmert #1 Diesel Oxidation
Low-most severe (3)
4765 3 Aftertreatmert #1 Diesel Oxidation
5 - 30 S-80 • S-85 • S-80X Part No. 1259369

Comtinental TME27 Engine Fault Codes
Continental Engine Models 5 Continue to hold the run/test toggle switch in

the test position and count the blinks.
How to Retrieve Continental Note: Before the fault codes are displayed, the
check engine light will blink a code 1654 three
Engine Fault Codes times. After the fault codes, the check engine
The ECM constantly monitors the engine by the light will blink a code 1654 three times again
use of sensors on the engine. The ECM also indicating the end of the stored codes.
uses signals from the sensors to initiate
Note: If any fault codes are present, the ECM will
sequential fuel injection and make constant and
blink a three or four digit code three times for
instantaneous changes to ignition timing, fuel
each code stored in memory. It will blink the first
delivery and throttle position to maintain the
digit of a three digit code, pause, blink the
engine's running condition at its highest efficiency
second digit, pause, blink the third digit, then
while at the same time keeping exhaust
pause and possibly a fourth digit. For example:
emissions to a minimum. When a sensor fails or
the check engine light blinks 5 consecutive
returns signals that are outside of set
times, blinks 3 times and then 1 time. That would
parameters, the ECM will store a fault code in
indicate code 531.
memory that relates to the appropriate sensor
and will turn on the Check Engine Light. Note: Once a fault code has been retrieved and
the repair has been completed, the ECM memory
Note: Perform this procedure with the key switch
must be reset to clear the fault code from the
in the off position.
ECM. See How to Clear Engine Fault Codes from
1 Open the ground controls side cover and the ECM.
locate the run/test toggle switch on the side of
the ground control box. How to Clear Engine Fault
2 Pull out the red Emergency Stop button to the Codes from the ECM
on position at both the ground and platform Note: Perform this procedure with the engine off
controls. and the key switch in the off position.
3 Quickly activate and release the start toggle
1 Open the engine side turntable cover and
switch/button. Do not start the engine.
locate the battery.
4 Move and hold the run/test toggle switch to
2 Disconnect the negative battery cable from
the test position.
the battery for a minimum of 5 minutes.
Result: The check engine light should turn on.
Electrocution/burn hazard.
The check engine light should begin to blink.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
Part No. 1259369 S-80 • S-85 • S-80X 5 - 31

Continental TME27 Engine Fault Codes
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
* Adaptive Learn Key Cycle
5 - 32 S80 • S-85 • S-80X Part No. 1259369


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%
Part No. 1259369 S-80 • S-85 • S-80X 5 - 33


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
5 - 34 S80 • S-85 • S-80X Part No. 1259369


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
Part No. 1259369 S-80 • S-85 • S-80X 5 - 35

5 - 36 S80 • S-85 • S-80X Part No. 1259369

October 2014 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: could result in death or serious
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Be sure that all necessary tools and test Malfunction Identify Troubleshoot
discovered symptoms
equipment are available and ready for use.
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 1259369 S-80 • S-85 • S-80X 6-1

Section 6 • Schematics October 2014
Electrical Symbols Legend
FS1
BLK
BLK
P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START
Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value
Diode Hour meter

TS6
DOWN
UP
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
25A A B C
PULL IN
Fuse
HOLD
AUX MAIN
CR4
with amperage N.O.
Battery separator Control relay contact Fuel or RPM

normally open solenoid
CB1
15A
Starting aid:
glow plug or
Circuit breaker flame ignitor
with amperage Coil
6-2 S-80 • S-85 • S-80X Part No. 1259369

Hydraulic Symbols Legend
25 psi
(1.7 bar)
Accumulator
.035" Solenoid operated 3 position,

(0.89 mm) Solenoid operated
Filter with proportional valve 4 way, directional valve
bypass valve Orifice with size
relief setting
Shut off valve

2 position, 3 way, shuttle valve
Pump
fixed displacement Priority
Check valve flow regulator valve
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump Solenoid operated 2 position,

Relief valve 3 way, directional valve
bi-directional, with pressure setting
variable displacement
3000 psi
(206.8 bar)
3:1
o
Brake
Motor Directional valve

bi-directional (mechanically activated) Counterbalance valve
with pressure and pilot ratio
Pilot operated 3 position,

3 way, shuttle valve
Motor
2-speed,
bi-directional
2 position, 2 way
solenoid valve
50% 50%
E
Pump prime mover Flow divider/combiner valve
(engine or motor) with pressure balancing orifice
and flow percentages
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Differential
sensing valve
Part No. 1259369 S-80 • S-85 • S-80X 6-3

Relay and Fuse Panel Legend
Deutz TD2011L04i
LABEL DESCRIPTION
5 6 7 8 NOT USED CR1 START RELAY
B1BAT
F17 F22 CR2 IGNITION / FUEL RELAY
CR17 CR2 CR3 HIGH IDLE RELAY
F20 F7 CR5 HORN RELAY
1 2 3 4 P24PWR
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER RELAY
R21IGN
CR39 AUXILIARY PUMP RELAY
F7 FUSE, 30A, OIL COOLER FAN / HORN
CR5 CR1 CR15 CR39 CR3
F17 FUSE, 30A, ENGINE / AUXILIARY PUMP
02GND
F20 FUSE, 20A, ENGINE RPM SOLENOID
F22 FUSE, 60A, GLOW PLUGS
Perkins 804D-33
LABEL DESCRIPTION
5 6 7 8 B1BAT CB20 CIRCUIT BREAKER, 10A,
F17 F22 ENGINE RPM SOLENOID
CR17 CR1 START RELAY
CR2 CR4
CB20 F7 CR2 IGNITION / FUEL RELAY
1 2 3 4 P24PWR
CR3 HIGH IDLE RELAY
CR4 ENGINE RPM SOLENOID RELAY
R21IGN
CR5 HORN RELAY
CR15 GLOW PLUG RELAY
CR5 CR1 CR15 CR39 CR3
02GND CR39 AUXILIARY PUMP RELAY
F20 FUSE, 60A, GLOW PLUGS
5
F17
6 7 8
B1PBAT
Continental TME27
CR17 LABEL DESCRIPTION
CR39B
CR1 START RELAY
F7 P24PWR
1 2 3 4 CR2 IGNITION / FUEL RELAY
CR5 HORN RELAY
R21PIGN CR17 HYDRAULIC OIL COOLER RELAY
CR39A AUXILIARY PUMP RELAY
CR5 CR1 CR2 CR39A CR39B AUXILIARY PUMP ENGINE CUTOUT RELAY
02PGND
6-4 S-80 • S-85 • S-80X Part No. 1259369

Relay and Fuse Panel Legend
Deutz TD2.9 L4
LABEL DESCRIPTION
CR2 ENGINE / IGNITION RELAY
5 6 7 8 B1BAT NOT USED
F17 CR5 HORN RELAY
CR17 CR6 FUEL PUMP RELAY

CR2
F20 F7
1 2 3 4 P24PWR CR39 AUXILIARY PUMP RELAY
F7 FUSE, 20A, B1BAT, P116PWR
R21IGN
OPEN OPEN F17 FUSE, 20A, B1BAT, P24PWR
CR5 CR39 CR6
02GND
Perkins 404F-22T
5 6 7 8 B1BAT LABEL DESCRIPTION
F17 OPEN
CR4A LOW RPM RELAY
CR17
CR4A CR4B HIGH RPM RELAY
F7
1 2 3 4 P24PWR
CR5 HORN RELAY
CR39 AUXILIARY PUMP RELAY
R21IGN OPEN OPEN
CR5 CR39B CR4B F17 FUSE, 20A, B1BAT, P24PWR
02GND
Part No. 1259369 S-80 • S-85 • S-80X 6-5

6-6 S-80 • S-85 • S-80X Part No. 1259369

Connector Pin Legend - View 1
6-7 6-8
A B C D E F G H I J K L M N
C1 DT06-12SA C3 DT06-12SC C5
1 COLOR CIRCUIT # PIN # COLOR CIRCUIT # PIN #
RD C27AUX 1 RD C1PBU 1 ENGINE
RD/BK C28TTA 2 RD/BK C2PBD 2 C6
RD/WH C29MS 3 RD/WH C3PBF 3 DEUTZ PERKINS CONTINENTAL
WH C30EDC+ 4 WH C4TRL 4 FUNCTION MANIFOLD 2011L04i 804 TME27
WH/BK C31EDC- 5 WH/BK C5TRR 5 PIN# CIRCUIT # COLOR CIRCUIT # COLOR CIRCUIT # COLOR
C1 C3 PIN# CIRCUIT # COLOR
WH/RD C32BRK 6 WH/RD C6TRF 6
GRAY GREEN 1 P24PWR RD P24PWR RD P23PWR WH
2 BK C33STR 7 BK C7PBE 7 1 C1PBU RD 2 C41RPM OR/BK C41RPM OR/BK C41RPM OR/BK
BK/WH C34SA 8 BK/WH C8PBR 8 2 C2PBD RD/BK 3 C21IGN WH C21IGN WH
BK/RD C35RPM 9 BK/RD C9PERF 9 3 C3PBF RD/WH
4
BL C36STC 10 BL C132PLI2 10 (CE MODEL) 4 C4TRL WH
5 C5TRR WH/BK 5 C33STR BK C33STR BK C33STR BK
BL/BK C37STCC 11 BL/BK C59CNK 11 6 C27AUX RD C27AUX RD C27AUX RD
BL/WH C132PLI1 12 (CE MODEL) BL/WH C133PLA 12 (CE MODEL) 6 C6TRF WH/RD
7 C7PBE BK 7 C46HRN GR C46HRN GR C46HRN GR
BL/WH C177LS 12 (S-80X MODEL) BL/WH P109LS 12 (S-80X MODEL) 8
8 C8PBR BK/WH C127TSW GR
3 9 C9PERF BK/RD 9 C35RPM BK/RD
10 10 C39LP BL/RD
11 C59CNK BL/BK 11 R21IGN WH(14) R21IGN WH(14) R21IGN WH(14)
12 P210PWR BK (S-80X MODEL) 12
13 C13DRE BL/RD
C2 DT06-12SB 14 13 C108ESL BL/WH
C4 DT06-12SD
15 14
COLOR CIRCUIT # PIN # COLOR CIRCUIT # PIN # 16 C109LS GR/WH (S-80X MODEL) 15 C24TSPS WH C24TSPS WH P24PWR RD
4 BL/RD C39LP 1 BL/RD C13DRE 1 17
OR C40LS 2 16
OR C14PLU 2 18
OR/BK C41RPM 3 3 19 17 R24PWR RD
OR/BK C15PLD
OR/RD C42LS 4 OR/RD V155PCE 4 20 18 C35RPM BK/RD C35RPM BK/RD
GR C46HRN 5 GR C17PRL 5 21 C177LS BL/RD (S-80X MODEL) 19 V155PCE OR/RD V155PCE OR/RD V155PCE OR/RD
GR/BK P134PWR 6 C2 C4 22 C42LS OR/RD
GR/BK C18PRR 6 20 C31EDC- WH/BK C31EDC- WH/BK C31EDC- WH/BK
GR/WH C45GEN 7 BLACK BROWN 23 P134PWR(A) RD
GR/WH C43JU 7 21 C30EDC+ WH C30EDC+ WH C30EDC+ WH
GR/RD C123PBS 8 24 P134PWR(B) RD 22
5 RD/OR C44JD 8 C34SA BK/WH C34SA BK/WH
OR/WH P109ANG 9 25 P134PWR(C) RD
OR/GR C49DLITE 9 23 C32BRK WH/RD C32BRK WH/RD C32BRK WH/RD
LT BR SNSR GND 10 26
LT BR SPARE 10 27 24 C29MS RD/WH C29MS RD/WH C29MS RD/WH
- PLUG 11 - PLUG 11
- PLUG 12 28 C28TTA RD/BK
- PLUG 12 29
30 C211LO BL/BK (S-80X MODEL)
31 C118LSR OR
32
6
33 C123PBS RD/BK
34 SNSR GND BR
35 P109ANG GR/WH C7
36 C36STC BL C9
37 C37STCC BL/BK
38 C212LO GR/BK (S-80X MODEL)
39 C45GEN GR/WH 12V POWER TO PLAT
7 40
FOOTSWITCH
C40LS OR
C7 DTP06-4S C9 FS DT04-4P
COLOR CIRCUIT # PIN # COLOR CKT # PIN #
BK P22PWR 1 BK P26ESTP 1
WH P23PWR 2 WH P24FS 2
8 BR BATGND 3 RD P25FS 3
PLUG 4 PLUG 4
ES0507C
6-8 S-80 • S-85 • S-80X Part No. 1259369

N M L K J I H G F E D C B A
ALC500 CONTINENTAL TME27 DEUTZ 2011LO4i
POWER/VALVE INPUT ENGINE PLUG ENGINE PLUG 1
PIN# CIRCUIT # COLOR PIN# CIRCUIT # COLOR PIN# CIRCUIT # COLOR
J3
1 GND BR 1 R23PWR WH 1 C41RPM OR/BK J144
2 1
4 3
2 P24FS WH 2 C21RET WH 2 C107AF WH
3 P26ESTP BK 3 C38RET BL 3 C26TSR WH/RD
4 P24FS WH 4 C38FP BL/WH 4 C24TS WH
5 R33STR BK(14) 5 C25PSR WH/BK
C14 2
6 C41RPM OR/BK 6 C24PS WH
GRAY
7 R21IGN WH 7 R21IGN WH(14)
ALC500 8 C35RPM BK/RD 8 GND BR
INPUT 9 C108ESL BL/WH 9 - -
10 C127TSW GN 10 - -
PIN# CIRCUIT # COLOR 11 C39LP BL/RD
1 C165TRS WH/RD 12 C26TSR WH/RD (GAUGE OPTION)
2 C164PES RD/WH 3
3 C163PLS WH/BK J1
4 C160JPL WH/RD
16
8
5 C159STC BL/WH
6 C144DER BL/WH
7 C143DEL BL/BK
8 C29MS RD/WH
9 P109ANG GR/WH 4
10 SNSR GND BR
11 P162JPW2 OR
12 JSGND2 BR
13 P162JPW1 OR
1
9
14 JSGND1 BR
15 C28TTA RD/BK
16 C13DRE(A) BL/RD S-80X MODEL PLATFORM MANIFOLD
5
PIN# CIRCUIT # WIRE J22 DT04-12PA
1 P109LS GR/WH PIN # CIRCUIT # COLOR
ALC500 2 C184PL WH J8 1 GND BR
OUTPUT 2 GND BR
3 NC -
10
3 C18PRR GR/BK
5
PIN# CIRCUIT # COLOR 4 NC - 4 C17PRL GR
1 C40LS OR 5 C169LED2 BL 5 C43JU GR 6
2 6 P109LS GR/WH 6 C44JD GR/BK
J22
C123PBS RD/BK
3 C13DRE BL/RD J2 7 C177LS BL/RD 7 C14PLU OR
4 C42LS OR/RD 8 SNSR GND BR 8 C15PLD OR/BK
10
20
6
1
5 C41RPM OR/BK 9 GND BR
9 NC -
6 C1PBU RD 10 GND BR
10 C169LED1 GR
7 C2PBD RD/BK 11 GND BR
12 GND BR
8 C3PBF RD/WH 7
9 C4TRL WH
10 C5TRR WH/BK
11 C6TRF WH/RD
12 C7PBE BK
13 C8PBR BK/WH
14 C9PERF BK/RD
15 C30EDC+ WH
11
8
1
16 C31EDC- WH/BK
17 C36STC BL
18 C37STCC BL/BK
19 C32BRK WH/RD
20 C29MS RD/WH
ES0507C
Part No. 1259369 S-80 • S-85 • S-80X 6-9

6-9
6 - 10
Continental TME27 Engine Harness
6 - 12
6 - 11
Continental TME27 Engine Harness
BLACK/LT GREEN 18 A
YELLOW/GRAY 18 ECT
LT GREEN/BLACK 18 B
1 OIL PRESSURE SWITCH
BLACK/LT GREEN 18 1
TAN 18 2
ORANGE 18 RX A LT GREEN/RED 18 TMAP
3
DK GREEN 18 TX LT GREEN 18 4
B SPLICE WITHIN 6" OF CONNECTOR
LT GREEN/RED 18 5V COMM
C
BLK/LT GREEN 18 RTN D BLACK/LT GREEN 18 A
DK GREEN/ORANGE 18
B
PINK/DK GREEN 16 C PRE CAT HEGO
BLACK/WHITE 16 D
BLACK/LT GREEN 18 A
TAN/DK GREEN 18 B
PINK/DK GREEN 16 POST CAT HEGO
C BLUE/WHITE 18 1 CAN -
BLACK/YELLOW 16 D
WHITE/ORANGE 18
2 CAN + TERM
2 WHITE/ORANGE 18 3
BLACK 16 6
CAN +
GROUND
WHITE/ORANGE 18 PINK/YELLOW 16 7
VBAT
BLUE/WHITE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
COBRA EPR
BLUE/WHITE 18
1 DK GREEN/ORANGE 18 WHITE/ORANGE 18
EGO 1 2 TAN/DK GREEN 18
EGO 2
EGO 3 3
EGO 4 4 LT GREEN/RED 18 A
TPS1/STEP2 + 5 PURPLE/LT BLUE 18
TPS2/STEP2 - 6 LT BLUE/DK BLUE 18 SPLICE WITHIN 6" FROM CONNECTOR PURPLE/WHITE 18
7 LT GREEN 18 PURPLE/WHITE 18 B CRANK SENSOR
MAP
AUX ANA PD1 8
FPP1 9 DK BLUE 18 WHITE/PURPLE 18 WHITE/PURPLE 18 C
FPP2-IVS 10 PURPLE/YELLOW 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
AUX ANA PD2 11 WHITE/RED 18
AUX ANA PD3 12
CAN 1 TERM + 13 WHITE/ORANGE 18 BLK/LT GREEN 18
3 CAN 1 +
CAN 1 -
14 WHITE/ORANGE 18
15 BLUE/WHITE 18 JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR
CAN 2 - 16
CAN 2 + 17
18 WHITE/RED 18 A
CAN 2 TERM +
5V EXT 19 LT GREEN/RED 18 LPG TEMP
20 BLACK/LT GREEN 18 BLACK/LT GREEN 18
5V RTN LT GREEN/RED 18 B
CRK POS 21 PURPLE/WHITE 18 A
CRK NEG 22 WHITE/PURPLE 18
23 GRAY/BROWN 18 GRAY/BROWN 18 GRAY/BROWN 18 B
CAM POS CAM SENSOR
CAM NEG 24 PURPLE/ORANGE 18
SPD POS 25 PURPLE/ORANGE 18 PURPLE/ORANGE 18
SPD NEG 26 C
KNK 1 + 27
28 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
KNK 1 -
KNK 2 + 29
KNK 2 - 30 BLK/LT GREEN 18
31 YELLOW 18 JUNCTION MUST BE MADE WITHIN 6 INCHES OF CONNECTOR

SPK COIL 1A
SPK COIL 1B 32 YELLOW/RED 18
SPK COIL 2A 33 YELLOW/BLACK 18
SPK COIL 2B 34 YELLOW/LT GREEN 18 BLACK/LT GREEN 18
1
SPK COIL 3A 35 LT GREEN/WHITE 18 2
4 SPK COIL 3B
SPK COIL 4A
SPK COIL 4B
IAT
36
37
38
39 TAN 18
LT GREEN/RED 18 3
WHITE/LT GREEN 18 4
GASOLINE SENSOR INTERFACE
ECT 40 YELLOW/GRAY 18
EGT 41
AUX DIG 1 42 TAN/BROWN 18
AUX DIG 2 43
AUX DIG 3 44
45 PINK/TAN 18 TAN/ORANGE 18 1
V SWITCH
BLK/LT GREEN 18 2
AUX ANA PU1 46 DK BLUE/YELLOW 18 LT GREEN/RED 18 VEHICLE INTERFACE 2
47 3
AUX ANA PU2 PINK/WHITE 18 DBW THROTTLE CONNECTOR DEUTSCH DT06 PLUG
AUX ANA PU3 48 LT GREEN/WHITE 18 4
49 LT BLUE/DK BLUE 18 5
5V EXT
5V RTN 50 PURPLE/LT BLUE 18 6 LT GREEN/RED 18
51 GRAY/DK BLUE 18 1 VREF
GOV 1 DK BLUE 182
GOV 2 52 GRAY/WHITE 18 FPP1
53 LT GREEN/BLACK 18 BLACK/LT GREEN 18 3 ANA RETURN
OIL P DK BLUE/YELLOW 18
AUX ANA PUD1 54 WHITE/LT GREEN 18 4 AUX ANA PU1
PC TX 55 DK GREEN 18 PURPLE/YELLOW 18 5 FPP2 IVS
PC RX 56 ORANGE 18 BLUE/GREEN 14
57 6 START IN (AUTOCRANK)
PULSE IN BLACK 16 GROUND
TACH 58 YELLOW/LT GREEN 18 7
59 PINK/YELLOW 16 8 NOT USED (PLUGGED)
5 V BAT PROT
V BAT
INJ1 LS
60
61
RED/TAN 16
BROWN/BLUE 16
9
WHITE/ORANGE 18 10
BLUE/WHITE 18 11
NOT USED (PLUGGED)
CAN HIGH
INJ2 LS 62 BROWN/GREEN 16 CAN LOW
INJ3 LS 63 BROWN/YELLOW 16 12 NOT USED (PLUGGED)
INJ4 LS 64 BROWN/WHITE 16
INJ5 LS 65
INJ6 LS 66
INJ7 LS 67
INJ8 LS 68
GROUND 69 BLACK 16
STARTER 70
RELAY 71 WHITE/BLUE 18
EGOH 1 72 BLACK/WHITE 16
EGOH 2 73 BLACK/YELLOW 16 VEHICLE INTERFACE 1
EGOH 3 74
FUEL LOCKOFF 75 WHITE/BLACK 18 DEUTSCH DT04 RECEPTACLE
BLACK 16
BUZZ 76 PINK 18
77 1 VSW
AUX PWM5 RED/BLACK 18
AUX PWM5 RECIRC 78 2 IGN OUT
79 RED/TAN 16 BLACK/RED 16 3 FUEL PUMP -
V BAT BLACK 16 PINK/YELLOW 16
MIL 80 LT BLUE/BLK 18 4 FUEL PUMP +
GROUND 81 BLACK 16 BLACK 16 BLACK 12 LT BLUE/PINK 14
GROUND 5 START COMMAND
6 DBW+/STEP +
DBW-/STEP -
FPUMP
82 PINK/WHITE 18
83 TAN/ORANGE 18
84 TAN/BLACK 18
YELLOW/LT GREEN 18
GRAY/DK BLUE 18
GRAY/WHITE 18
6
7
TACH
GOV SELECT 1
AUX PWM3 RECIRC 85 PINK/YELL 16 8 GOV SELECT 2
AUX PWM3 86 BLACK/RED 16 LT BLUE/BLACK 18 9 MIL
AUX PWM1 87 RED/BLACK 18 WHITE/BLACK 18 A ORANGE 18
88 GRAY/RED 18 10 ESL/TEST SWITCH
AUX PWM2 FUEL LOCKOFF TAN/BROWN 18
AUX PWM4 89 PINK/BLACK 18 PINK/TAN 18 11 FUEL SELECT
90 B GRAY/RED 18 12
AUX PWM4 RECIRC TEMP SENDER
WHITE 14 WHITE/ORANGE 18
STARTER RELAY
BLUE/WHITE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
PINK/YELLOW 16 30
F5 PINK/YELLOW 16
87 PINK/YELLOW 16
RED/TAN 14 86 15A
WHITE/BLUE 18 85 EPR RELAY
7 WHITE 14 30
87A LT BLUE/PINK 14
87 BLUE/GREEN 14
PINK/TAN 18 86
YELLOW/LT GREEN 18
PINK/BLACK 18 85 STARTER RELAY
BLACK/LT GREEN 18
BLACK/LT GREEN 18
BLACK/LT GREEN 18
BLACK/LT GREEN 18
PINK/DK GREEN 16
PINK/DK GREEN 16
PINK/DK GREEN 16
PINK/DK GREEN 16
YELLOW/BLACK 18
YELLOW/RED 18
RED 14 30
F4
YELLOW 18
87 PINK/YELLOW 16 PINK/YELLOW 16
BLACK 16
BLACK 16
BLACK 16
BLACK 16
PINK/DK GREEN 16
PINK/TAN 18 86 15A
TAN/BLACK 18 85 FUEL PUMP RELAY

A B C D A B C D A B C D A B C D
RED 14 30 COIL 4 COIL 3 COIL 2 COIL 1

F3
8 RED/TAN 14 86
87 PINK/DK GREEN 16
15A
PINK/DK GREEN 16
PINK/DK GREEN 16
NOTE: COIL FIRING ORDER 1-3-4-2, ECM PINS FIRED 1A-2A-1B-2B
85 POWER RELAY
WHITE/BLUE 18
BROWN/BLUE 16
F2
PINK/TAN 18 PINK 18 BROWN/WHITE 16
5A
BROWN/GREEN 16
RED/TAN 14 F1 RED 14 RED 12
BAT + BROWN/YELLOW 16
20A
RED 14
INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1
NOTE: INJECTORS CONNECT TO ECM PINS PER 1-3-4-2 FIRING ORDER
6 - 12 S-80 • S-85 • S-80X Part No. 1259369

S-80X Ground Control Box Wiring Diagram
ES0503J 8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 13

S-80X Ground Control Box Wiring Diagram
6 - 13
6 - 14
Deutz TD2.9 L4 Engine Detail
6 - 16
6 - 15
Deutz TD2.9 L4 Engine Detail
ES0504J
6 - 16 S-80 • S-85 • S-80X Part No. 1259369

Perkins 404F-22T Engine Detail
ES0503J
8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 17

Perkins 404F-22T Engine Detail
6 -17
6 - 18
Electrical Schematic, S-80X - (ANSI / CSA)

Deutz TD2.9 L4 Models
6 - 20
6 - 19

ES0504K
8
6 - 20 S-80 • S-85 • S-80X Part No. 1259369


ES0504J 8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 21


6 - 21
6 - 22
Ground Control Box, S-80X - (ANSI / CSA)

6 - 24
6 - 23

8
See page 6-13 for additional S-80X wiring
ES0504J
6 - 24 S-80 • S-85 • S-80X Part No. 1259369

Platform Control Box, S-80X - (ANSI / CSA)

ES0504J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 25


6 - 25
6 - 26

Deutz TD2011L04i Models
6 - 28
6 - 27

ES0504J
8
6 - 28 S-80 • S-85 • S-80X Part No. 1259369


ES0504J 8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 29


6 - 29
6 - 30

6 - 32
6 - 31

7
See page 6-13
for additional
S-80X wiring
8
6 - 32 S-80 • S-85 • S-80X Part No. 1259369


ES0504J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 33


6 - 33
6 - 34

6 - 36
6 - 35

ES0503K
8
6 - 36 S-80 • S-85 • S-80X Part No. 1259369


ES0503J
8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 37


6 - 37
6 - 38

6 - 40
6 - 39

8
ES0503J
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8
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6 - 42

Perkins 804D-33 Models
6 - 44
6 - 43

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6 - 46

6 - 48
6 - 47

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6 - 50

Continental TME27 Models
6 - 52
6 - 51

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6 - 54

6 - 56
6 - 55

+
1 H6
1 3
4 CE
ONLY
C32
5
PLATFORM
(CE ONLY)
6 8
7
8 9
LOAD
U33
12
3 5
U34
2
HUBBLE
ENGINE TEST
HUBBLE
4
C7B
12V TO PLAT
C4B
16/22 CABLE
C3B
6
C1B C2B
18/22 CABLE
C6
FUNCTION
7
C5
ENGINE
C56
8 See page 6-13 for additional S-80X wiring TELEMATICS
ES0505J
6 - 56 S-80 • S-85 • S-80X Part No. 1259369

1
8
Section 6 • Schematics
6 - 57
A
B
S-80 • S-85 • S-80X

C
D23
D24
D
RD LS18
BK C7P-1
RD-E-STOP RD LS18 CABLE
E
E-STOP
Part No. 1259369

LOAD SENSE OPTION
P134PWR RD
P2
NC
WH C7P-2
P134PWR RD
October 2014
RD-H1+ BK C9-1
R26ESTP5BK C9P-1
BK J3-3
U35
COM
NO
D88
2
3
WH/BK C4P-9
BL/WH J1-5
WH/RD J1-4
LIGHTS
P26ESTP BK E-STOP
F
DRIVE
BR GND
TS48
D89
TS7-C18PRR GR/BK J22-3

STEER
DRIVE/
6
TS7-C17PRL GR J22-4
JC3
TS8-C43JU GR J22-5
TS8-C44JD GR/BK J22-6
1
-
ZONE B
TS9-C14PLU OR J22-7
500
L50
TS9-C15PLD OR/BK J22-8 +

J22 BL/WH J1-5
OR J1-13
P2-P26ESTP BK C9P-1 BR J1-14
TS2-P25FS RD C9P-3
G
J3-P24FS WH C9P-2 GR J8-5

BR J8-8 SELECT
ZONE
TS75
P2-P23PWR WH C7P-2 WH J8-2
P2-P22PWR BK C7P-1
TS9-V155PCE OR/RD C4P-10 GR/WH J8-6
TS9-V155PCE OR/RD C4P-11
TS48-C49DLITE WH/BK C4P-9
TS7-C18PRR GR/BK C4P-6
GR J8-10
TS7-C17PRL GR C4P-5
ZONE A
1000
TS8-C43JU GR C4P-7
L51
TS8-C44JD GR/BK C4P-8 +
TS9-C14PLU OR C4P-2
H
C132PLI2 BK C3P-10
C132PLI1 BK C1P-12
TS9-C15PLD OR/BK C4P-3

WH C9P-2
GR/WH C2P-7
GENERATOR
J8-P109LS GR/WH C3P-12
BL/RD J1-16
TS47
H1-C133PLA GR/BK C3P-10
L47-C59CNK BL/BK C3P-11
BL/BK J1-7
J1-SNSR GND BR C1P-10
TS15
J1-P109ANG GR/WH C2P-9

ENABLE
ENABLE
TS3-C39LP BL/RD C2P-1
DRIVE
DRIVE
P3-C46HRN GR C2P-5
L1
TS47-C45GEN GR/WH C2P-7 +
BK P2
ALARM
J2
11
3
1
I
TILT
L48
C40LS OR C2P-2 BL/WH J1-6
C6TRF WH/RD C3P-6
J3
+
C123PBS RD/BK C2P-8 RD C9P-3
C7PBE BK C3P-7
C13DRE BL/RD C4P-1 RD/BK H1 (D40)
C8PBR BK/WH C3P-8 HI/LOW RPM
C42LS OR/RD C2P-4
TS4
TS1
C9PERF BK/RD C3P-9
PUMP
TS2
WH L1 C41RPM OR/BK C2P-3
AUX
START
D10
C30EDC+ WH C1P-4
WH C9P-2
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
D12
J
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11 BK C1P-7
C4TRL WH C3P-4 BK/RD C1P-9
TS14
C32BRK WH/RD C1P-6
RD C1P-1
SPEED
C5TRR WH/BK C3P-5
SELECT
DRIVE
C29MS RD/WH C1P-3
FUEL
TS3
J8
6
TS75-1 P109TS GR/WH BL/RD C2P-1

C3P-12 P109LS GR/WH C4P-4 OR/RD
C1P-12 C177LS BL/WH RD/WH J1-8
K
TS75-2 C184PL WH
GR/BK H1 (D39)
TS75-3 SNSR BR C4P(BR) GR/BK C4P-8/J22-6
TS8
GR C4P-7/J22-5
BOOM
JIB
C3P(GR)
BR GND STUD
L51(-) C169LED1 GR
PLATFORM
OVERLOAD
TENSION
L50(-) C169LED2 GR C2P(BK)
CABLE
L47
2
L4
J7
CAN HI + +
C1P(GY)
LS18-C132PLI RD C1P-12
BL/BK C3P-11
TS7
TS1-C27AUX RD C1P-1
PLATFORM
TS2-C33STR BK C1P-7 GR C4P-5/J22-4
ROTATE
TS6-C34SA BK/WH C1P-8
L
TS4-C35RPM BK/RD C1P-9 GR/BK C4P-6/J22-3

L48-C28TTA RD/BK H1
JC3-5 C159STC BL/WH RD/WH J1-2
J1
OR J1-11
9
C2P-9 P109ANG GR/WH
C1P-2 C28TTA RD/BK

JC7-4 C165TRS WH/RD BR J1-12
C2P-10 SNSR GND BR
WH/BK J1-3
PLATFORM
JC7-3 C164PES RD/WH
LEVEL
JC7-2 P162JPW2 OR
WH/RD J1-1
TS9
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
M
JC3-2 P162JPW1 OR
TT ROTATE
JC3-3 C159STC BL/WH
PRI. BOOM
EXT/RET
UP/DOWN
JC3-1 JSGND1 BR
JC7
D40
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
NO
HORN
L1-C13DRE(A) BL/RD
J1 C28TTA RD/BK
TS14-C29MS RD/WH
D39
OR C4P-2/J22-7
P3
GR/BK C3P-12
OR/RD C4P-10
GR/BK L4
OR/RD C4P-11
N
RD C2P-6
OR/BK C4P-3/J22-8
RD LS18
GR C2P-5

6 - 57
6 - 58
Electrical Schematic, S-80 and S-85 - (ANSI / CSA)

Deutz TD2.9 L4i Models
6 - 60
6 - 59

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6 - 62
Ground Control Box, S-80 and S-85 - (ANSI / CSA)

6 - 64
6 - 63

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

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6 - 66

6 - 68
6 - 67

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6 - 70

Deutz TD2011L04I Models
6 - 72
6 - 71

6 - 72 S-80 • S-85 • S-80X Part No. 1259369

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

ES0504J
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Platform Control Box, S-80 and S-85 - (ANSI / CSA )

6 - 73
6 - 74

6 - 76
6 - 75

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6 - 78

6 - 80
6 - 79

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6 - 82

6 - 84
6 - 83

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6 - 86

6 - 88
6 - 87

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6 - 89
6 - 90
Electrical Schematic, S-80 and S-85 (ANSI / CSA),

6 - 92
6 - 91

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6 - 93
6 - 94
Ground Control Box, S-80 and S-85 (ANSI / CSA),

6 - 96
6 - 95
Ground Control Box, S-80 and S-85 (ANSI / CSA)

+
1 H6
1 3
4 CE
ONLY
C32
5
PLATFORM
(CE ONLY)
6 8
7
8 9
LOAD
U33
12
3 5
U34
2
HUBBLE
ENGINE TEST
HUBBLE
4
C7B
12V TO PLAT
C4B
16/22 CABLE
C3B
6
C1B C2B
18/22 CABLE
C6
FUNCTION
7
C5
ENGINE
C56
TELEMATICS
8
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1
8
6 - 97
Platform Control Box, S-80 and S-85 (ANSI / CSA)
A
B
S-80 • S-85 • S-80X

D23
D24
C
D
RD LS18
BK C7P-1
E-STOP
LOAD SENSE OPTION
P134PWR RD
P2
E
NC
WH C7P-2
Part No. 1259369
P134PWR RD
RD-H1+ BK C9-1
R26ESTP5BK C9P-1
October 2014
BK J3-3
U35
COM
NO
D88
2
3
WH/BK C4P-9
BL/WH J1-5
WH/RD J1-4
LIGHTS
P26ESTP BK E-STOP
DRIVE
BR GND
TS48
D89
F

STEER
DRIVE/
6
TS7-C17PRL GR J22-4
JC3
TS8-C43JU GR J22-5
1
-
ZONE B
TS9-C14PLU OR J22-7
500
L50

J22 BL/WH J1-5
OR J1-13
TS2-P25FS RD C9P-3
BR J8-8 SELECT
G
ZONE
TS75
P2-P22PWR BK C7P-1
GR J8-10
TS7-C17PRL GR C4P-5
ZONE A
1000
TS8-C43JU GR C4P-7
L51
TS9-C14PLU OR C4P-2
C132PLI2 BK C3P-10
C132PLI1 BK C1P-12

WH C9P-2
GR/WH C2P-7
H
GENERATOR
BL/RD J1-16
TS47
BL/BK J1-7
TS15

ENABLE
ENABLE
DRIVE
DRIVE
P3-C46HRN GR C2P-5
L1
BK P2
ALARM
J2
11
3
TILT
L48
I
C6TRF WH/RD C3P-6

J3
+
C7PBE BK C3P-7
C8PBR BK/WH C3P-8 HI/LOW RPM
C42LS OR/RD C2P-4
TS4
TS1
C9PERF BK/RD C3P-9
PUMP
TS2
AUX
START
D10
C30EDC+ WH C1P-4
WH C9P-2
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
D12
C36STC BL C1P-10
J
C3PBF RD/WH C3P-3

TS14
C32BRK WH/RD C1P-6
RD C1P-1
SPEED
C5TRR WH/BK C3P-5
SELECT
DRIVE
C29MS RD/WH C1P-3
FUEL
TS3
J8
6

TS75-2 C184PL WH
K
GR/BK H1 (D39)
TS8
GR C4P-7/J22-5
BOOM
JIB
C3P(GR)
BR GND STUD
L51(-) C169LED1 GR
PLATFORM
OVERLOAD
TENSION
CABLE
L47
2
L4
J7
CAN HI + +
C1P(GY)
BL/BK C3P-11
TS7
TS1-C27AUX RD C1P-1
PLATFORM
ROTATE
GR/BK C4P-6/J22-3
L
TS4-C35RPM BK/RD C1P-9

L48-C28TTA RD/BK H1
J1
OR J1-11
9
C2P-9 P109ANG GR/WH
C1P-2 C28TTA RD/BK

C2P-10 SNSR GND BR
WH/BK J1-3
PLATFORM
JC7-3 C164PES RD/WH
LEVEL
JC7-2 P162JPW2 OR
WH/RD J1-1
TS9
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
M
TT ROTATE
JC3-3 C159STC BL/WH
PRI. BOOM
EXT/RET
UP/DOWN
JC3-1 JSGND1 BR
JC7
D40
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
NO
HORN
L1-C13DRE(A) BL/RD
J1 C28TTA RD/BK
TS14-C29MS RD/WH
D39
OR C4P-2/J22-7
P3
GR/BK C3P-12
OR/RD C4P-10
GR/BK L4
OR/RD C4P-11
N
RD C2P-6
OR/BK C4P-3/J22-8
RD LS18
GR C2P-5

6 - 97
6 - 98
Electrical Schematic, S-80 and S-85 - (CE)

6 - 100
6 - 99

8
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8
6 - 101
C7-3 BR
J114
YL
5 6
A
BR S18
OR PRIMARY BOOM ANGLE
4
C6-33 SENSOR - SAFETY

C123PBS RD/BK C123PBS RD/BK BL
3
C2-10 C6-34
SNSR-GND BR SNSR-GND BR BK S17
2
C2-9 C6-35 PRIMARY BOOM ANGLE

P109ANG GN/WH P109ANG GN/WH RD
1
SENSOR - OPERATIONAL
9
J1
C2-8
10 2
B
15
H1 RD/BK
DRIVE MODE
S-80 • S-85 • S-80X
RD
TB42
4 3 2 1
LST2O - STOWED ANGLE

NO
NC
21
13
TS14
BR DRIVE SPEED REDUCTION

C2-4 C6-22
4 C42LS OR/RD C42LS OR/RD BK LIMIT SWITCH
14
22
WH
J2
TB40
8
C29MS RD/WH
J1
C2-2 C6-40
1 C40LS OR C40LS OR RD
C
LED BL/RD
4 3 2 1
LSB1RO - BOOM RETRACT

24 23
13
NO
NO
16 BR
L1
DRIVE / ROTATE SPEED

DRIVE ENABLE
P134PWR RD BK
14
LIMIT SWITCH
TB134A
WH
C6-25
P134PWR RD RD
4 3 2 1
24 23
13
LST1O
TS15
NO
C4-1 C6-13
NO
C144DER BL/WH 3 C13DRE BL/RD C13DRE BL/RD BR

7 DRIVE ENABLE
TB13
RIGHT
14
BK LIMIT SWITCH
LEFT WH
6
C143DEL BL/BK
ROCKER / STEER OPTION
D
TB37
Y3
C1-11 C6-37
18 C37STCC BL/BK C37STCC BL/BK STEER CCW
Y4
C1-10 C6-36
17 C36STC BL C36STC BL STEER CW
TB36
J2
4 C3-6
11 C6TRF WH/RD
E
5
Part No. 1259369
C3-5
13 9 C5TRR WH/BK
C159STC-BL/WH
C159STC-BL/WH
C160JPL-WH/RD
14
P162JPW1-OR
C3-4
TB4
Y24 Y23
10 C4TRL WH
October 2014
JSGND1-BR
C6-4 TURNTABLE ROTATE

C4TRL WH
CW CCW
TURNTABLE ROTATE
J1
CCW C6-5 TURNTABLE ROTATE

TS62
C5TRR WH/BK
CW
TB5
Y13
C6-6 TURNTABLE ROTATE

C6TRF WH/RD
J25
FLOW CONTROL
4
2
1
3
5
6
TB6
R14(A)
ALC-500 JOYSTICK
5Ω
TB1
CONTROL CARD
Y21 Y22
DRIVE / STEER
C6-1 PRIMARY BOOM

F
C1PUB RD
UP UP
U13
TB2
PRIMARY BOOM
DOWN C6-2 PRIMARY BOOM
C2PBD RD/BK
DOWN
TS61
JC3
7.5Ω
CR34
R16
TB3
Y12
PRIMARY BOOM
C6-3
C3PBF RD/WH UP / DOWN
FLOW CONTROL
D29
10Ω
R14
H4
C3-1 C129DA RD/BK DESCENT ALARM

6 C1PBU RD
3 C3-2
CR34
D30
G
7 C2PBD RD/BK
1
J1
2 CR34 - SPEED REDUCTION

C3-3 C118LS OR
11 8 C3PBF RD/WH RELAY
C165TRS-WH/RD
C163PES-WH/BK
C164PLS-RD/WH
12
P162JPW2-OR
JSGND2-BR
P134PWR RD RD
4 3 2 1
14 13
23
C6-31 LST3O - BOOM UP / DOWN

NO
NO
TB118
C3-9 BR SPEED REDUCTION

14 C9PER BK/RD
24
BK LIMIT SWITCH
WH
C3-8
13 C8PBR BK/WH
LSB2S
C3-7
NC
12 C7PBE BK
TB7
J127
Y26
1
2
6
3
5
4
C6-7 RD BR PRIMARY BOOM

C7PBE BK
H
EXTEND
21
22
EXTEND
J2
Y25
PRIMARY BOOM
TURNTABLE ROTATE
EXTEND / RETRACT
RETRACT C6-8 PRIMARY BOOM

TS63
C8PBR BK/WH
C2-3 RETRACT
PRIMARY BOOM
5
TB8
Y15
PRIMARY BOOM
C6-9
UP / DOWN
C9PERF BK/RD EXTEND / RETRACT

TB9
FLOW CONTROL
JC7
TB30
Y6
C1-4 C5-21
15 C30EDC WH EDC - DRIVE FORWARD
U4
Y5
C1-5 C5-20
16 C31EDC WH/BK EDC - DRIVE REVERSE
TB31
I
H3
GND BR 1
C130TA WH/RD TRAVEL ALARM (OPTION)
P24FS WH 2
TB32
J3
Y27 Y2
P24FS WH 4 C1-6 C5-23
19 C32BRK WH/RD BRAKE RELEASE
P26ESTP BK 3
C1-3 C5-24 2 SPEED
20 C29MS RD/WH
MOTOR STROKE
TB29
J
P134PWR RD
LIFT / DRIVE
CR27
CR30
NO
NC
(OPTION)
NO
C6-11 LSB2S
C59CNK BL/BK LOOSE CABLE
14
13
LIMIT SWITCH
TB59
C3-11 L46 / L47

LOOSE CABLE LED
L46
L47
C4-2
C14PLU OR
UP PLATFORM
K
DOWN LEVEL C4-3

TS9
C15PLD OR/BK
TS59
TB14
(S-85 OPTION)
UP
PLAT. LEVEL
WH
JIB BOOM
TB15
DOWN
C4-8
TS8
C44JD GR/BK
DOWN
UP C4-7
TB44
C43JU GR
TS58
DOWN JIB BOOM
PLATFORM
(S-85 OPTION)
TB43
ROTATE
UP
GROUND
L
C4-6
TS7
CCW C18PRR GR/BK

CW C4-5
C17PRL GR
TS57
CCW
TB18
PLAT. ROTATE
CW
TB17
Y20
J22-7 J22-11
M
PLATFORM LEVEL UP
Y19
J22-8 J22-12
PLATFORM LEVEL DOWN
Y72 Y73
J22-6 J22-10
C27AUX + FE RD
(OPTION)
C41RPM OR/BK
JIB BOOM DOWN
C28TTA RD/BK
S-85
P134PWR RD
P26ESTP BK
C27AUX RD
J22-5 J22-9
P24FS WH
JIB BOOM UP
GND BR
Y70 Y71
J22-3 J22-2
PLATFORM ROTATE CCW
N
J22-4 J22-1
PLATFORM ROTATE CW

6 - 101
6 - 102
Ground Control Box, S-80 and S-85 - (CE)

6 - 104
6 - 103

DRIVE LIGHT OPTION RELAY

BK/WH C5-22 WH C5-3 C32
1 8
1 87 BR-G6(-)
2
RD TB23A
9
WH ISM-#9 1
RD-H6(+)
BL/WH-TB132C RD-P134PWR TB134C LABEL DESCRIPTION
87A RD/WH-TS61-1 3
BK-TB22C GR/BK-TB133C
H6
4
U34
85 86 GR/BK-L45(-) CB2 CONTROLS CIRCUIT BREAKER, 15A
U16
30 R14 RD TB134C (A) U33 BK-C7B-1
2 5
WH-TS51-5 CR23 DRIVE LIGHT RELAY (OPTION)
BR GND BR GND 6
CR34 OR-TB118D 3 3 RD-TS53-2
7
5 BK/WH TB34C 5 BK C3B-10 GR/BK-H6(-)
RD/WH-TB3D 8 CR34 PRIMARY BOOM SPEED REDUCTION RELAY
BR-GND
12
RD-TS61-2
G6 HOUR METER
R14(A) R16
RD-TS63-2 D C B A H6 PLATFORM OVERLOAD ALARM
WH/RD-TB6D 155A OR/RD C56-5
OR/RD TS62-5(D68) 155 OR/RD C4B-4(D67) OR/RD C5-19 PRESSURE COMP ENABLE KS1 KEY SWITCH
2 WH/RD-TS62-4
BL/RD-C5-15
OR & WH-BEACONS RD U34-2
RD L45(+) RD H6(+)
134A RD C6-25
134 RD C2B-6
RD C6-23
RD C6-24
KEY SWITCH POWER (A)
KEY SWITCH POWER
L2 LED - CHECK ENGINE
RD-L45(+) GR/BK H6(-) 133 GR/BK C3B-12 PLATFORM LOAD ALARM
BL/WH C32-3 132 BL/WH C1B-12 PLATFORM LOAD INPUT
BK-TB22D L45 LED - PLATFORM OVERLOAD
128
WH-TB21D OR CR34 #86 118 OR C6-31 LIFT SPEED REDUCTION
P1 BL/BK L46(+) 59 BL/BK C3B-11 BL/BK C6-11 LOOSE CABLE LED L46 LED - CABLE TENSION
KS1
1A 1B + 46 GR C2B-5 GR C5-7 HORN
2 4 RD-44C 45 GR/WH C2B-7 AC GENERATOR P1 EMERGENCY STOP BUTTON
GR/WH C6-39
WH/BK-32C
RESTRAINT
NC NC B1 G6 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR/BK C4B-8 JIB BOOM DOWN S-85
1 3 OR-134A(D) P4 FUNCTION ENABLE TOGGLE SWITCH
CABLE
GR TS58-1 43 GR C4B-7 JIB BOOM UP (OPTION)
- BR-L46(-) WH-134A (D) 42 OR/RD C2B-4 OR/RD C6-22 BOOM ANGLE STOWED LS
2A 2B D2 BK-GND
BR-CR34 #85 OR/BK ISM #2 41 OR/BK C2B-3 OR/BK C5-2 RPM SIGNAL R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
B BL-GND
40 OR C2B-2 OR C6-40 BOOM RETRACTED LS
3 WH-TS51-2
GR-GND
39 BL/RD C2B-1 (UNUSED) R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED
WH-TB23D 37 BL/BK C1B-11 BL/BK C6-37 STEER CCW
RD-CB2-1 36 BL C1B-10 BL C6-36 STEER CW R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
BK/RD TS54-1(D13) 35 BK/RD C1B-9 BK/RD C5-9 ENGINE SPEED
BK/RD-TB35D GLOW PLUG
BK/WH TS56-3 BK/WH U16-5 34 BK/WH C1B-8 TS51 AUXILIARY PUMP
TS54 BK/WH-TB34D BK TS52-3 BK ISM #3 33 BK C1B-7 BK C5-5 START
WH/RD-TRAVEL ALARM 32 WH/RD C1B-6 WH/RD C5-23 BRAKE TS52 ENGINE START TOGGLE SWITCH
+
TS56 TS52 31 WH/BK C1B-5 WH/BK C5-20 REVERSE/EDC-

3 2 1 D13 3 2 1 D64 3 2 1 30 WH C1B-4 WH C5-21 FORWARD/EDC+
L2 BK-TB33D TS54 RPM SELECT TOGGLE SWITCH
29 RD/WH C1B-3 RD/WH C5-24 DRIVE SPEED
RESTRAINT
RD-C32-7 28 RD/BK C1B-2 RD/BK C6-28 LEVEL SENSOR ALARM RD-TB20B TS56 GLOW PLUG TOGGLE SWITCH
CABLE
WH-ISM #10 RD TS51-4 RD ISM #4 D6 27 RD C1B-1 RD C5-6 AUXILIARY POWER
24 RD-TB20A PLATFORM ROTATE TOGGLE SWITCH
TS57
4 OR/BK-TB15D WH KS1-1(D2)
BK/12 KS1-3
WH ISM #7
BK C32-4
23
22
WH/12 C7B-2 WH C5-1 POWER TO PLATFORM
KEYSWITCH PWR TO PLAT
OR-TB14D TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
WH G6(+) 21 WH C56-3 WH C5-11 12V IGNITION SUPPLY
GR/BK-TB44D
20A RD CR80-85, C56-1
GR-TB43D RD/12 CB2-2 20 RD/12 BATT+ RD/12 BATT+ 12V BATT SUPPLY TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
GR/BK TS57-1 18 GR/BK C4B-6 PLATFORM ROTATE CCW
3 GR TS57-3 PLATFORM ROTATE CW TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
17 GR C4B-5
P4 OR/BK TS59-3 15 OR/BK C4B-3 PLATFORM LEVEL DOWN
NO OR TS59-1 PLATFORM LEVEL UP TS62 TURNTABLE ROTATE TOGGLE SWITCH
14 OR C4B-2
4 13 BL/RD C4B-1 BL/RD C6-13 DRIVE ENABLE LS
BK/RD TS63-6 9 BK/RD C3B-9 BK/RD C6-9 PRI BOOM EXT/RET FLOW TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
BK/RD-TB9D BK/WH TS63-3 8 BK/WH C3B-8 BK/WH C6-8 PRI BOOM RETRACT
BK TS63-1 7 BK C3B-7 BK C6-7 PRI BOOM EXT U1 IGNITION START MODULE
TS59 TS58 BK/WH-TB8D WH/RD R14(A) 6 WH/RD C3B-6 WH/RD C6-6 TURNTABLE ROTATE FLOW
5 3 3 TS63
RD-R16 WH/BK TS62-1 5 WH/BK C3B-5 WH/BK C6-5 TURNTABLE ROTATE CCW
TURNTABLE ROTATE CW
U16 GLOW PLUG TIME DELAY
WH TS62-3 4 WH C3B-4 WH C6-4
2
12V TO PLAT
2 3 1 BK-TB7D RD/WH CR34 #30 3 RD/WH C3B-3 RD/WH C6-3 PRI BOOM FLOW BR-GND STUD U33 LOAD SENSE MODULE
1 RD/BK TS61-6 2 RD/BK C3B-2 RD/BK C6-2 PRI BOOM DOWN 3
RD/BK-TB2D D29 TB44C BK-C32-5
C7B
1 1
RD TS61-4 1 RD C3B-1 RD C6-1 PRI BOOM UP U34 LOAD SENSE TIME DELAY
TS61 WH-TB23B 2
6 4 6 3 BASE TERMINATION BLOCK
RD-TS51-1 BK-C5-5
1 START RELAY
2 RD-R16 OR/BK-TB41C
5 2 TACHOMETER
BK-TB33C
4 RD/WH-R14 3 START INPUT
1 RD-TB27C
RD-TB1D 4 AUX. ON
BR GND
5 GROUND U1
RD-C5-1
16/22 CABLE
C4B
6 BATTERY
WH-TB23C
KEY PWR.
6 TS57 GR-TB17D
7
8 KEY BYPASS F19
WH-U34 #9
C3B
9 IGN./FUEL ON TB21C
3 WH-TB4D WH L2(-)
10 ENG. FAULT 10 AMP FUSE
WH/BK-TB5D
2
18/22 CABLE
WH/RD-R14(A)
C2B
CR23
1 3 2 1 OR/RD-TB155D
TS62 RD-TB27D WH/BK C4B-9
C1B
TS51 D4
6 5 4 WH DL1
6 3
WH-KS1-1 RD DL2
D68 5 2
BK GND1
FUNCTIONS
4 1
7 RD-TS61-2
BR GND2
C6
WH-C32-6
RD-P1-2
RD-KS1-2
+
2 1
+
GR/BK-H6(-)
CB2 L45
RD-TB134D
ENGINE
L46
C5
RD-TB20D
8
GROUND STUD
BR-G6(-)
BR-GND STUD
BL/BK-TB59D ES0504J
GR/BK-TB18D
6 - 104 S-80 • S-85 • S-80X Part No. 1259369

Platform Control Box, S-80 and S-85 - (CE)

ES0504J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 105


6 - 105
6 - 106

6 - 108
6 - 107

8
ES0503J
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ES0503J 8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 109


6 - 109
6 - 110

6 - 112
6 - 111

8
ES0503J
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8
ES0503J
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6 - 113
6 - 114

6 - 116
6 - 115

2
B1
3 B
3
4
1
6
J
12
6
AUX MAIN
ES0505J
8
6 - 116 S-80 • S-85 • S-80X Part No. 1259369


1
6 6
5 5
LEFT
RIGHT
4 4
3 3
DRIVE ENABLE
2 2
1 1
J127 J25
10
12
11
16
15
14
13
10
5
6
2
8
1
1
7
3
9
2
17
18
10
11
12
13
14
20
19
16
15
1
8
1
9
2
3
1 2 3 4 5 6
OR
RD
BK
BR
BL
YL
6
ES0505J 8
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6 - 117
6 - 118

6 - 120
6 - 119

+
1 H6
1 3
4 CE
ONLY
C32
5
PLATFORM
(CE ONLY)
6 8
7
8 9
LOAD
U33
12
3 5
U34
2
HUBBLE
ENGINE TEST
HUBBLE
4
C7B
12V TO PLAT
C4B
16/22 CABLE
C3B
6
C1B C2B
18/22 CABLE
C6
FUNCTION
C5
ENGINE
C56
TELEMATICS
ES0505J
6 - 120 S-80 • S-85 • S-80X Part No. 1259369

1
8
6 - 121
A
B
S-80 • S-85 • S-80X

D23
C
D24
D
RD LS18
BK C7P-1
E-STOP
E
LOAD SENSE OPTION
P134PWR RD
Part No. 1259369
P2
NC
WH C7P-2
P134PWR RD
RD-H1+
October 2014
BK C9-1
R26ESTP5BK C9P-1
BK J3-3
U35
COM
NO
D88
2
3
WH/BK C4P-9
BL/WH J1-5
WH/RD J1-4
LIGHTS
P26ESTP BK E-STOP
DRIVE
BR GND
TS48
F
D89

STEER
DRIVE/
6
TS7-C17PRL GR J22-4
JC3
TS8-C43JU GR J22-5
1
-
ZONE B
TS9-C14PLU OR J22-7
500
L50

J22 BL/WH J1-5
OR J1-13
TS2-P25FS RD C9P-3
SELECT
G
BR J8-8
ZONE
TS75

P2-P22PWR BK C7P-1
GR J8-10
TS7-C17PRL GR C4P-5
ZONE A
1000
TS8-C43JU GR C4P-7
L51
TS9-C14PLU OR C4P-2
C132PLI2 BK C3P-10
C132PLI1 BK C1P-12

H
WH C9P-2
GR/WH C2P-7
GENERATOR
BL/RD J1-16
TS47
BL/BK J1-7
TS15

ENABLE
ENABLE
DRIVE
DRIVE
P3-C46HRN GR C2P-5
L1
BK P2
ALARM
J2
11
3
TILT
L48
I
C6TRF WH/RD C3P-6

J3
+
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C42LS OR/RD C2P-4 HI/LOW RPM
TS4
TS1
C9PERF BK/RD C3P-9
PUMP
TS2
AUX
START
D10
C30EDC+ WH C1P-4
WH C9P-2
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
D12
C36STC BL C1P-10
J
C3PBF RD/WH C3P-3

TS14
C32BRK WH/RD C1P-6
RD C1P-1
SPEED
C5TRR WH/BK C3P-5
SELECT
DRIVE
C29MS RD/WH C1P-3
FUEL
TS3
J8
6

TS75-2 C184PL WH
K
GR/BK H1 (D39)
TS8
GR C4P-7/J22-5
BOOM
JIB
C3P(GR)
BR GND STUD
L51(-) C169LED1 GR
PLATFORM
OVERLOAD
TENSION
CABLE
L47
2
L4
J7
CAN HI + +
C1P(GY)
BL/BK C3P-11
TS7
TS1-C27AUX RD C1P-1
PLATFORM
ROTATE
TS4-C35RPM BK/RD C1P-9 GR/BK C4P-6/J22-3
L
L48-C28TTA RD/BK H1
J1
OR J1-11
9
C2P-9 P109ANG GR/WH
C1P-2 C28TTA RD/BK

C2P-10 SNSR GND BR
WH/BK J1-3
PLATFORM
JC7-3 C164PES RD/WH
LEVEL
JC7-2 P162JPW2 OR
WH/RD J1-1
TS9
JC7-5 C163PES WH/BK
JC7-1 JSGND2 BR
JC3-4 C160JPL WH/RD
JC3-2 P162JPW1 OR
TT ROTATE
JC3-3 C159STC BL/WH
PRI. BOOM
M
EXT/RET
UP/DOWN
JC3-1 JSGND1 BR
JC7
D40
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
NO
HORN
L1-C13DRE(A) BL/RD
J1 C28TTA RD/BK
TS14-C29MS RD/WH
D39
OR C4P-2/J22-7
P3
GR/BK C3P-12
OR/RD C4P-10
GR/BK L4
OR/RD C4P-11
RD C2P-6
N
OR/BK C4P-3/J22-8
RD LS18
GR C2P-5

6 - 121
6 - 122
Electrical Schematic, S-80 and S-85 - (AS)

6 - 124
6 - 123

8 ES0504J
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ES0504J 8
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6 - 125
6 - 126
Ground Control Box, S-80 and S-85 - (AS)

6 - 128
6 - 127

DRIVE LIGHT OPTION RELAY

BK/WH C5-22 WH C5-3 C32
1 8
1 87 BR-G6(-)
2
RD TB23A
9
WH ISM-#9 1
3
RD-H6(+)
BL/WH-TB132C RD-P134PWR TB134C LABEL DESCRIPTION
87A RD/WH-TS61-1 BK-TB22C GR/BK-TB133C
H6
4
U34
85 86 GR/BK-L45(-) CB2 CONTROLS CIRCUIT BREAKER, 15A
U16
30 R14 RD TB134C (A) U33 BK-C7B-1
2 5
WH-TS51-5 CR23 DRIVE LIGHT RELAY (OPTION)
BR GND BR GND 6
CR34 OR-TB118D 3 3 RD-TS53-2
7
5 BK/WH TB34C 5 BK C3B-10 GR/BK-H6(-)
RD/WH-TB3D 8 CR34 PRIMARY BOOM SPEED REDUCTION RELAY
BR-GND
12
RD-TS61-2
G6 HOUR METER
R14(A) R16
RD-TS63-2 D C B A H6 PLATFORM OVERLOAD ALARM
WH/RD-TB6D 155A OR/RD C56-5
OR/RD TS62-5(D68) 155 OR/RD C4B-4(D67) OR/RD C5-19 PRESSURE COMP ENABLE KS1 KEY SWITCH
WH/RD-TS62-4
2 BL/RD-C5-15
OR & WH-BEACONS RD U34-2
RD L45(+) RD H6(+)
134A RD C6-25
134 RD C2B-6
RD C6-23
RD C6-24
KEY SWITCH POWER (A)
KEY SWITCH POWER
LED - CHECK ENGINE
L2
RD-L45(+) GR/BK H6(-) 133 GR/BK C3B-12 PLATFORM LOAD ALARM
BL/WH C32-3 132 BL/WH C1B-12 PLATFORM LOAD INPUT
BK-TB22D L45 LED - PLATFORM OVERLOAD
128
WH-TB21D OR CR34 #86 118 OR C6-31 LIFT SPEED REDUCTION
P1 BL/BK L46(+) 59 BL/BK C3B-11 BL/BK C6-11 LOOSE CABLE LED L46 LED - CABLE TENSION
KS1
1A 1B + 46 GR C2B-5 GR C5-7 HORN
2 4 RD-44C 45 GR/WH C2B-7 AC GENERATOR P1 EMERGENCY STOP BUTTON
GR/WH C6-39
WH/BK-32C
RESTRAINT
NC NC B1 G6 GR/BK TS58-3 D30 2C/RD-DESCENT ALARM 44 GR/BK C4B-8 JIB BOOM DOWN S-85
1 3 OR-134A(D) P4 FUNCTION ENABLE TOGGLE SWITCH
CABLE
GR TS58-1 43 GR C4B-7 JIB BOOM UP (OPTION)
- BR-L46(-) WH-134A (D) 42 OR/RD C2B-4 OR/RD C6-22 BOOM ANGLE STOWED LS
2A 2B D2 BK-GND
BR-CR34 #85 OR/BK ISM #2 41 OR/BK C2B-3 OR/BK C5-2 RPM SIGNAL R14 RESISTOR, 10W, PRIMARY BOOM UP / DOWN SPEED
B BL-GND
GR-GND 40 OR C2B-2 OR C6-40 BOOM RETRACTED LS
R14(A) RESISTOR, 5W, TURNTABLE ROTATE SPEED
3 WH-TS51-2
WH-TB23D
39 BL/RD C2B-1
37 BL/BK C1B-11 BL/BK C6-37
(UNUSED)
STEER CCW
RD-CB2-1 36 BL C1B-10 BL C6-36 STEER CW R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
BK/RD TS54-1(D13) 35 BK/RD C1B-9 BK/RD C5-9 ENGINE SPEED
BK/RD-TB35D GLOW PLUG
BK/WH TS56-3 BK/WH U16-5 34 BK/WH C1B-8 TS51 AUXILIARY PUMP
TS54 BK/WH-TB34D BK TS52-3 BK ISM #3 33 BK C1B-7 BK C5-5 START
WH/RD-TRAVEL ALARM 32 WH/RD C1B-6 WH/RD C5-23 BRAKE TS52 ENGINE START TOGGLE SWITCH
+
TS56 TS52 31 WH/BK C1B-5 WH/BK C5-20 REVERSE/EDC-

3 2 1 D13 3 2 1 D64 3 2 1 30 WH C1B-4 WH C5-21 FORWARD/EDC+
L2 BK-TB33D TS54 RPM SELECT TOGGLE SWITCH
29 RD/WH C1B-3 RD/WH C5-24 DRIVE SPEED
RESTRAINT
RD-C32-7 28 RD/BK C1B-2 RD/BK C6-28 LEVEL SENSOR ALARM RD-TB20B TS56 GLOW PLUG TOGGLE SWITCH
CABLE
WH-ISM #10 RD TS51-4 RD ISM #4 D6 27 RD C1B-1 RD C5-6 AUXILIARY POWER
24 RD-TB20A PLATFORM ROTATE TOGGLE SWITCH
POWER TO PLATFORM TS57
OR/BK-TB15D WH KS1-1(D2) WH ISM #7 23 WH/12 C7B-2 WH C5-1
4 OR-TB14D
BK/12 KS1-3
WH G6(+)
BK C32-4 22
21 WH C56-3 WH C5-11
KEYSWITCH PWR TO PLAT
12V IGNITION SUPPLY TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-85 OPTION)
GR/BK-TB44D
20A RD CR80-85, C56-1
GR-TB43D RD/12 CB2-2 20 RD/12 BATT+ RD/12 BATT+ 12V BATT SUPPLY TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
GR/BK TS57-1 18 GR/BK C4B-6 PLATFORM ROTATE CCW
3 GR TS57-3 PLATFORM ROTATE CW TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
17 GR C4B-5
P4 OR/BK TS59-3 15 OR/BK C4B-3 PLATFORM LEVEL DOWN
NO OR TS59-1 PLATFORM LEVEL UP TS62 TURNTABLE ROTATE TOGGLE SWITCH
14 OR C4B-2
4 13 BL/RD C4B-1 BL/RD C6-13 DRIVE ENABLE LS
BK/RD TS63-6 9 BK/RD C3B-9 BK/RD C6-9 PRI BOOM EXT/RET FLOW TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
BK/RD-TB9D BK/WH TS63-3 8 BK/WH C3B-8 BK/WH C6-8 PRI BOOM RETRACT
BK TS63-1 7 BK C3B-7 BK C6-7 PRI BOOM EXT U1 IGNITION START MODULE
TS59 TS58 BK/WH-TB8D WH/RD R14(A) 6 WH/RD C3B-6 WH/RD C6-6 TURNTABLE ROTATE FLOW
3 RD-R16 WH/BK TS62-1 5 WH/BK C3B-5 WH/BK C6-5 TURNTABLE ROTATE CCW U16 GLOW PLUG TIME DELAY
3
5 2
TS63 WH TS62-3 4 WH C3B-4 WH C6-4 TURNTABLE ROTATE CW
12V TO PLAT
2 3 1 BK-TB7D RD/WH CR34 #30 3 RD/WH C3B-3 RD/WH C6-3 PRI BOOM FLOW BR-GND STUD U33 LOAD SENSE MODULE
1 RD/BK TS61-6 2 RD/BK C3B-2 RD/BK C6-2 PRI BOOM DOWN 3
RD/BK-TB2D D29 TB44C BK-C32-5
C7B
1 1
RD TS61-4 1 RD C3B-1 RD C6-1 PRI BOOM UP U34 LOAD SENSE TIME DELAY
TS61 WH-TB23B 2
6 4 6 3 BASE TERMINATION BLOCK
RD-TS51-1 BK-C5-5
1 START RELAY
2 RD-R16 OR/BK-TB41C
5 2 TACHOMETER
BK-TB33C
4 RD/WH-R14 3 START INPUT
1 RD-TB27C
RD-TB1D 4 AUX. ON
BR GND
5 GROUND U1
RD-C5-1
16/22 CABLE
C4B
6 BATTERY
WH-TB23C
7 KEY PWR.
TS57 GR-TB17D 8 KEY BYPASS F19
6 WH-U34 #9
C3B
9 IGN./FUEL ON TB21C
3 WH-TB4D WH L2(-)
10 ENG. FAULT 10 AMP FUSE
WH/BK-TB5D
2
18/22 CABLE
WH/RD-R14(A)
C2B
CR23
1 3 2 1 OR/RD-TB155D
TS62 RD-TB27D WH/BK C4B-9
C1B
TS51 D4
6 5 4 WH DL1
6 3
WH-KS1-1 RD DL2
D68 5 2
BK GND1
FUNCTIONS
4 1 RD-TS61-2
BR GND2
C6
7 WH-C32-6
RD-P1-2
RD-KS1-2
+
2 1
+
GR/BK-H6(-)
CB2 L45
RD-TB134D
ENGINE
L46
C5
RD-TB20D
GROUND STUD
BR-G6(-)
8 BR-GND STUD
BL/BK-TB59D ES0504J
GR/BK-TB18D
6 - 128 S-80 • S-85 • S-80X Part No. 1259369

Platform Control Box, S-80 and S-85 - (AS)

ES0504J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 129


6 - 129
6 - 130

6 - 132
6 - 131

8
ES0503J
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ES0503J 8
Part No. 1259369 S-80 • S-85 • S-80X 6 - 133


6 - 133
6 - 134
Ground Control Box, S-80 and S-85 (AS)

6 - 136
6 - 135
Ground Control Box, S-80 and S-85 (AS)

ES0503J
6 - 136 S-80 • S-85 • S-80X Part No. 1259369

Platform Control Box, S-80 and S-85 (AS)

ES0503J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 137

Platform Control Box, S-80 and S-85 (AS)

6 - 137
6 - 138

6 - 140
6 - 139

J
J
2
B1
3 3
B
4
1
6
J
12
6
AUX MAIN
ES0505J
8
6 - 140 S-80 • S-85 • S-80X Part No. 1259369


1
6 6
5 5
LEFT
RIGHT
4 4
3 3
DRIVE ENABLE
2 2
1 1
J127 J25
10
12
11
16
15
14
13
10
5
6
2
8
2
1
1
7
3
9
4
17
18
10
11
12
13
14
20
19
16
15
1
8
1
9
2
3
1 2 3 4 5 6
OR
RD
BK
BR
BL
YL
6
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6 - 141
6 - 142

6 - 144
6 - 143

+
1 H6
1 3
4 CE
ONLY
C32
5
PLATFORM
(CE ONLY)
6 8
7
8 9
LOAD
U33
12
3 5
U34
2
HUBBLE
ENGINE TEST
HUBBLE
4
C7B
12V TO PLAT
C4B
16/22 CABLE
C3B
6
C1B C2B
18/22 CABLE
C6
FUNCTION
7
C5
ENGINE
C56
TELEMATICS
8
ES0505J
6 - 144 S-80 • S-85 • S-80X Part No. 1259369

1
8
6 - 145
ES0505J
B
S-80 • S-85 • S-80X

D23
D24
C
D
RD LS18
BL/RD P22BAT C2-1
J
BK C7P-1
4
E-STOP
LOAD SENSE OPTION
P134PWRR D
P2
E
Part No. 1259369
P134PWRR D
NC
WH C7P-2
RD-H1+
R26ESTP5BK C9P-1
October 2014
BK C9-1
U35
BK J3-3
COM
NO
D88
2
3
WH/BK C4P-9
BL/WH J1-5
WH/RD J1-4
LIGHTS
P26ESTPB K E-STOP
DRIVE
BR GND
TS48
D89
F
TS7-C18PRR GR/BKJ 22-3

STEER
DRIVE/
6
TS7-C17PRL GR J22-4
JC3
TS8-C43JU GR J22-5
1
TS8-C44JD GR/BK J22-6 -

ONEB
TS9-C14PLU OR J22-7
500
L50
TS9-C15PLD OR/BKJ 22-8

+
J22 BL/WH J1-5
OR J1-13
P2-P26ESTPB K C9P-1 BR J1-14
TS2-P25FS RD C9P-3
J3-P24FSW HC 9P-2 GR J8-5
BR J8-8 SELECT
G
ZONE
TS75
P2-P22PWR BK C7P-1
TS1-V155PCEO R/RD C4P-4
TS48-C49DLITE WH/BKC 4P-9
TS7-C18PRR GR/BKC 4P-6
GR J8-10
ZONE AZ
TS7-C17PRL GR C4P-5
1000
TS8-C43JU GR C4P-7
L51
TS9-C14PLU OR C4P-2
C132PLI1 BK C1P-12
C132PLI2 BK C3P-10
TS9-C15PLD OR/BKC 4P-3

WH C9P-2
GR/WH C2P-7
H
GENERATOR
BL/RD J1-16
TS47
L47-C59CNK BL/BKC 3P-11
BL/BKJ 1-7
J1-SNSRG ND BR C1P-10
TS15

ENABLE
ENABLE
DRIVE
DRIVE
P3-C46HRN GR C2P-5
L1
BK P2
ALARM
J2
11
3
TILT
L48
C40LSO RC 2P-2 BL/WH J1-6
I
C6TRF WH/RD C3P-6

J3
+
C123PBS RD/BKC 2P-8 RD C9P-3
C7PBE BK C3P-7
C13DRE BL/RDC 4P-1 RD/BK H1 (D40)
C8PBRB K/WH C3P-8 C171LSW H/RD CR76#30
C42LSO R/RD C2P-4
TS4
HI/LOW RPM
TS1
C9PERF BK/RD C3P-9
PUMP
4
TS2
WH L1 C41RPM OR/BKC 2P-3
AUX
START
D10
C30EDC+ WH C1P-4
WH C9P-2
J
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
D12
C36STCB LC 1P-10
J
C3PBF RD/WH C3P-3

C37STCC BL/BKC 1P-11 BK C1P-7
C4TRL WH C3P-4 BK/RDC 1P-9
TS14
C32BRK WH/RDC 1P-6
RD C1P-1
SPEED
C5TRRW H/BK C3P-5
SELECT
DRIVE
C29MSR D/WH C1P-3
FUEL
TS3
J8
6
BL/RD C2P-1
TS75-1 P109TS GR/WH
C3P-12 P109LS GR/WH C4P-4O R/RD
TS75-2 C184PL WH
K
C4P(BR)
GR/BKH 1( D39)
TS75-3 SNSR BR GR/BK C4P-8/J22-6
TS8
GR C4P-7/J22-5
BOOM
C3P(GR)
JIB
BR GND STUD
L51(-) C169LED1 GR
PLATFORM
OVERLOAD
TENSION
CABLE
L47
2
L4
J7
CAN HI + +
C1P(GY)
BL/BKC 3P-11
TS7
TS1-C27AUX RD C1P-1
PLATFORM
ROTATE
TS6-C34SAB K/WH C1P-8
GR/BK C4P-6/J22-3
L
TS4-C35RPM BK/RDC 1P-9

L48-C28TTA RD/BK H1
JC3-5C 159STC BL/WH RD/WH J1-2
J1
OR J1-11
9
C2P-9P 109ANG GR/WH
C1P-2 C28TTA RD/BK

JC7-4C 165TRS WH/RD BR J1-12
C2P-10 SNSR GNDB R
WH/BK J1-3
PLATFORM
JC7-3C 164PES RD/WH
LEVEL
JC7-2P 162JPW2O R
WH/RD J1-1
TS9
JC7-5C 163PES WH/BK
JC7-1J SGND2 BR
JC3-4C 160JPL WH/RD
JC3-2P 162JPW1O R
M
TT ROTATE
JC3-3C 159STC BL/WH
PRI. BOOM
EXT/RET
UP/DOWN
JC3-1J SGND1 BR
JC7
D40
TS15-C144DER BL/WH
TS15-C143DEL BL/BK
NO
HORN
L1-C13DRE(A) BL/RD J1 C28TTA RD/BK
TS14-C29MS RD/WH
D39
OR C4P-2/J22-7
P3
GR/BK C3P-12
OR/RD C4P-10
GR/BK L4
OR/RDC 4P-11
N
RD C2P-6
OR/BKC 4P-3/J22-8
RD LS18
GR C2P-5

6 - 145
6 - 146
Continental Options Schematic
6 - 148
6 - 147
Continental Options Schematic
ES0505J
6 - 148 S-80 • S-85 • S-80X Part No. 1259369

Deutz and Perkins Options Schematic
ES0504J
Part No. 1259369 S-80 • S-85 • S-80X 6 - 149

Deutz and Perkins Options Schematic
6 - 149
6 - 150
Platform Level Cutout, CTE Option
6 -152
6 - 151
Platform Level Cutout, CTE Option
PLATFORM BOX
1
TS9-1
2 TS9-3
C15PLD OR/BK
C14PLU OR
3 J2-4
C42LS OR/RD
C2P-4
CR21 CR20
NO NO
4
C15PLD OR/BK
C14PLU OR
5
J22-8
J22-7
C4-2
C4-3
Y19 Y20
7
DOWN
PLATFORM LEVEL
UP
PLATFORM LEVEL
GROUND
8
TB14
TB15
GROUND BOX
MANUAL PLATFORM LEVEL CUTOUT WHEN OUT OF STOWED
6 - 152 S-80 • S-85 • S-80X Part No. 1259369

12 kW Hydraulic Generator Wiring Diagram
12.5 KW HYDRAULIC GENERATOR
NEUTRAL BUSS BAR 1
L1 L2 L3
Y X 2
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
208 VAC
OUTLET
L2 3 6
RED RED Z
5 4
3
ORANGE
N L3
1 2 WHITE
L1 BLACK
4
BLACK BLACK 12GA GREEN
GREEN 20 AMP CIRCUIT

BREAKER NEMA 4 CONTROL BOX
GROUND
STUD ON
PANEL
5
BLACK 12GA
SILVER 8 GA 4 CONDUCTOR
8 GA 5 CONDUCTOR
BRASS
120 VAC GFI
GREEN 12GA
6
12 GA 3 CONDUCTOR
7
110 VAC
GFI
ENCLOSURE
SILVER BRASS
WHITE
8
GREEN
GREEN
BLACK
ES0506B 12 GA 3 CONDUCTOR
Part No. 1259369 S-80 • S-85 • S-80X 6 - 153

12 kW Hydraulic Generator Wiring Diagram
6 - 153
6 - 154
12 kW Hydraulic Generator Electrical Schematic
6 - 156
6 - 155
12 kW Hydraulic Generator Electrical Schematic
P2 FOOTSWITCH
P26ESTP-BK P25FS-RD
ALC-500 P22PWR-BK
1 P24FS-WH
20 TS4 TS47
19
16
15
GENERATOR
RPM LO
RPM HI
ON
D12
C32BRK WH/RD
2
C1P-6
C2P-7
C1P-9
C1P-3
C1P-5 C1P-4
C35RPM BK/RD
C29MS RD/WH
C31EDC WH/BK
C45GEN GR/WH
C32BRK WH/RD
C30EDC WH
C1B-3
C1B-5
C1B-4
C1B-9
8 N.C.
1 N.O.
2 COM
OMRON
RELAY
C2B-7
4 3 GND 5 SW INPUT CR66
C5-4 WH
TB24
TIME DELAY
C5-20
C5-21
7
MODULE 4S
C1B-5
C1B-4
D99
TB21
5 3
6
2 4
TB29 TB35 TB32 TB45 TB41
1k ohms
124 ohms A1BATTERY +
2 A2SENSOR POWER +5 VDC D98 D65
5
3
1 A3BATTERY-
C5-21
C5-20
124 ohms
1
B1VALVE 0 FWD COIL
V151HG GR B2VALVE 1 NC
C5-24
B3DIGITAL OUTPUT BYPASS
C5-12 OR/BK
C5-18
C5-23
C5-12
V150HG GR/BK
1 3 2 4 8
6 BK 16-2 A RS232TxD C1TxD
B RS232RxD C2RxD
C57 C57 C3/BOOT
NC C
C45GEN GR/WH
BK-2
RD-1
5 6 7 D1ANALOG 0 JOYSTICK
Y75
D2ANALOG 1 NC
OMRON
C41RPM OR/BK
D3C41 RPM
RELAY
PRESSURE SWITCH
CR50
VALVE
STROKE
MOTOR
E1NOT USED
RELAY
HIGH IDLE
CR4
RELEASE
BRAKE
BYPASS COIL
PS4 E2NOT USED

7
D
200 PSI
E3NOT USED
C6-39
F1DIG IN 0
U4 N.O. F2DIG IN 1 GENERATOR ON
F3DIG IN 2 SX Controller
PILOT PRESSURE SIGNAL

DRIVE EDC -
DRIVE EDC +
Y75
FROM GENERATOR MANIFOLD
8 BR-2
(16-2)
DIVERTER MANIFOLD
6 - 156 S-80 • S-85 • S-80X Part No. 1259369

Belt Driven Generator Option
R20BAT RD
1
REGULATOR
NEUTRAL WH
VOLTAGE
GND BR
LINE BK
FIELD BK/WH
GENERATOR
BELT DRIVEN
2
GENERATOR
CB4 120VAC / 60HZ
LINE GFI OUTLET
LINE BK LINE BK
15A
TG2
NEUTRAL WH GND GR
TG4 GND
FIELD GR TG1 VOLTAGE
CR46
REGULATOR
CB6 87A NEUTRAL WH
NEU
P20BAT
+ 30A 30
87
3
CB4
BATTERY
C45GEN TO GBOX 12.5A- 220V

86 85 15A- 120V
A B
-
TG3 C45GEN
GND BR
BATTERY+
A B
120 VAC / 60 HZ with Regulator TG

4
CR46
BATTERY-
1
4
OUTLET
5
R20BAT RD
REGULATOR
NEUTRAL WH
VOLTAGE
GENERATOR
GND BR PIN# COLOR CIRCUIT #
LINE BK 1 WH NEUTRAL
A B
2 GR FIELD
FIELD BK/WH 6
CB6 3 BK LINE
30A
4 PLUG
BELT DRIVEN
GENERATOR
CB2
LINE
220VAC / 50HZ 1 2 3 4 5
LINE BK LINE BK GFI OUTLET
12.5A
TG2 VOLTAGE REGULATOR
NEUTRAL WH GND GR
TG4 GND PIN# COLOR CIRCUIT# 7
FIELD GR TG1
1 RD 12GA R20BAT
CR46
CB6 87A NEUTRAL WH 2 WH 12GA NEUTRAL
NEU
P20BAT
30A
3 BR 12GA GND
+ 30
87 4 BK 12GA LINE
BATTERY
C45GEN TO GBOX
86 85 5 BK/WH 14GA FIELD
-
TG3
GND BR 8
220 VAC / 50 HZ with Regulator
Part No. 1259369 S-80 • S-85 • S-80X 6 - 157

Belt Driven Generator Option
6 - 167
6 - 158
Hydraulic Schematic, 2WD Models
6 - 160
6 - 159
TURNTABLE ROTATE PLATFORM LEVEL PLATFORM
BOOM EXTEND / RETRACT JIB BOOM CYLINDER
3 gpm / 11.4 L/min CYLINDERS ROTATE
16 gpm / 61 L/min (EXTEND) (S-85 OPTION)
PRIMARY LIFT CYLINDER
1 15 gpm / 57 L/min (UP)
7 gpm / 26.5 L/min (RETRACT)
F L R F
8 gpm / 30 L/min (DOWN) SLAVE
CYLINDER
BRAKE/2 SPEED A RA A PA PB
RB E E G G
MEDIUM FUNCTION
MANIFOLD 51 psi PRESSURE
A D
0.025 inch 3.5 bar ENABLE VALVE B B
0.6 mm FILTER
T2
BB BD CP PR2 PR1
HIGH PRESSURE
FILTER 0.030 inch RC RD
A
DRIVE PUMP 0.8 mm
BA BC S1
2 BRAKE 2SPEED TEST 1 2
MASTER
CYLINDER
V2 V1
B M2 X 102 psi
7 bar
B
250 psi PLM1 PLS1 PLS2 PLM2 PR2 PR1 J1 J2
310 psi 17 bar
X P1 T5 SW1 SW2 L1 L2 EXT RET
21 bar
M SA
EC ED
SJ SK
C C
SI
P2 SQ
2900 psi
3 3750 psi 200 bar
1.7 gpm
256 bar 6.4 L/min 2400 psi SR
PTEST 165 bar
AUXILIARY SG SF EF EH
EB
PUMP 3200 psi
SO
SP
EA
221 bar EE EG
SN
SB 2400 psi 0.3 gpm 0.8 gpm
E 9 FUNCTION RETURN SE
SH 165 bar 0.6 gpm 1.1 L/min 3 L/min
SS
PUMP FILTER P4 P4 2.3 L/min
38cc T1 ST T4 T4
S 950 psi SM
L1 30 psi
66 bar 3.5 gpm
4 S
25 psi
SC 13 L/min
2 bar S80 PLATFORM MANIFOLD
2 bar SL
SD
3.5 gpm
13 L/min
30 psi
FUNCTION MANIFOLD
X X
2 bar T2 OSC ST2 ST1 T3 P3
B
OIL COOLER RESERVOIR OSC TEST
OIL COOLER 3.5 GPM / 13.25L/min DRIVE PUMP
A
PR CASE
5
6 8 3 1 2 7 4 5 PMP B CLR PMP A
S80/85 WELDER
PLATFORM MANIFOLD
HYDRAULIC ROTARY COUPLER
RECIRC.
X X X X X CW
OPTION
8B 8C 6B 6C 6A 8A 3 1 2A 2C 2B 7 4 5
CV PRESSURE SWITCH
0.031 inch / 200 PSI / 13.8 BAR
0.79 mm CU N.O.
TEST CX
6 A B COUNTERBALANCE VALVES
CZ
RATIO PRESS
RIGHT M4 270 PSI / 18.6 BAR
A 3:1 1000 psi / 69 bar @ 3.5 GPM /
REAR CY
A G2 13.25 L/min
B 1.5:1 3000 psi / 207 bar
LEFT RIGHT
C 1:1 3500 psi / 241 bar
CDR
DF STEER CYLINDER
B D 4.5:1 1000 psi / 69 bar
DC DE
M2 MTR B MTR A G1
E 4.5:1 3500 psi / 241 bar
F 3:1 3300 psi / 228 bar
HYDRAULIC
7 50% 280 psi G 3:1 3000 psi / 207 bar
COUPLER
3
LEFT RIGHT
ROTARY
19 bar
1
0.070 inch
DA
1.8 mm
50% G G G G
DB TANK
DD
M1
21CC
CDL T
21 GPM / 79.5 L/min G2 G1
A
GENERATOR
12.5 KW
8 LEFT
B
M3
IN A
REAR OUT B 12.5 kW HYDRAULIC WELDER OPTION

OC OSCILLATE CYLINDERS
TRACTION MANIFOLD
OSCILLATE VALVE
HS0166E
6 - 160 S-80 • S-85 • S-80X Part No. 1259369

TURNTABLE ROTATE PLATFORM LEVEL JIB BOOM CYLINDER
PLATFORM
3 gpm / 11.4 L/min BOOM EXTEND / RETRACT CYLINDERS (S-85 OPTION)
ROTATE
16 gpm / 61 L/min (EXTEND)
PRIMARY LIFT CYLINDER
15 gpm / 57 L/min (UP)
7 gpm / 26.5 L/min (RETRACT)
F
L R
F
1
8 gpm / 30 L/min (DOWN) SLAVE
A RA A CYLINDER
BRAKE / 2 SPEED RB E E PA PB G G
MEDIUM
MANIFOLD FUNCTION A D
51 psi PRESSURE
0.025 inch 3.5 bar ENABLE VALVE B B
0.6 mm
FILTER
T2
BB BD CP PR2 PR1
HIGH PRESSURE
DRIVE PUMP FILTER 0.030 inch RC RD
A 0.8 mm
BA S1
BC
TEST
MASTER 2
BRAKE 2SPEED V2 CYLINDER
1 2 V1
B M2 X 102 psi
7 bar
250 psi B PLM1 PLS1 PLS2 PLM2 PR2 PR1 J1 J2

310 psi 17 bar
21 bar P1 T5 SW1 SW2 L1 L2 EXT RET
M SA
EC ED
C C
SI SJ SK
P2 SQ
3750 psi
2900 psi
200 bar 1.7 gpm
3
256 bar 6.4 L/min 2400 psi SR
PTEST 165 bar EF EH
AUXILIARY SG SF EB
PUMP 3200 psi SP
221 bar SO EA EE EG
SB SN
2400 psi 0.3 gpm 0.8 gpm
E 9 FUNCTION RETURN SH 0.6 gpm 1.1 L/min 3 L/min
SE 165 bar SS
PUMP FILTER P4 P4 2.3 L/min
38cc T1 ST T4 T4
S L1 950 psi SM 30 psi
S
25 psi
SC
66 bar 3.5 gpm
13 L/min
2 bar PLATFORM MANIFOLD 4
2 bar SL
3.5 gpm
SD
13 L/min
FUNCTION MANIFOLD
30 psi
X X
2 bar T2 OSC ST2 ST1 T3 P3
OIL COOLER RESERVOIR OSC TEST
B
OIL COOLER 3.5 GPM / 13.25L/min DRIVE PUMP

PR
A
5
6 8 3 1 2 7 4 5 CASE
S80/85 PMP B CLR PMP A

HYDRAULIC ROTARY COUPLER PLATFORM WELDER
RECIRC. MANIFOLD
4 5 OPTION
8B 8C 6B 6C 6A 8A 3 1 2A 2C 2B 7
CW
CV PRESSURE SWITCH
TEST 0.031 inch / 200 PSI / 13.8 BAR 6
A B 0.79 mm CU N.O.
COUNTERBALANCE VALVES CX
DC DF RIGHT CZ
RIGHT M7 M8 RATIO PRESS
REAR FRONT
3:1 1000 psi / 69 bar 270 PSI / 18.6 BAR
A A A
LEFT RIGHT @ 3.5 GPM /
1.5:1 3000 psi / 207 bar CY 13.25 L/min
B G2
DJ
STEER CYLINDERS
B CDR B C 1:1 3500 psi / 241 bar
DI M6
M5 D 4.5:1 1000 psi / 69 bar
E 4.5:1 3500 psi / 241 bar MTR B MTR A G1
50% 50% LEFT RIGHT

F 3:1 3300 psi / 228 bar 7
280 psi
HYDRAULIC
19 bar G 3:1 3000 psi / 207 bar
COUPLER
0.040 inch 0.040 inch
3
DA DN
ROTARY
1 mm DK 50%
1 mm
50%
1
50% 50% G G G G
DB DM
DD DG DL
M3 M4 TANK
0.040 inch
CDL
1 mm B 21CC
B
21 GPM / 79.5 L/min G2 G1
DE DH A
IN A
GENERATOR
8
A
LEFT M1 M2 LEFT OUT B 12.5 KW
REAR FRONT OC
T OSCILLATE CYLINDERS 12.5 kW HYDRAULIC WELDER OPTION
TRACTION MANIFOLD
OSCILLATE VALVE
HS0166E
Part No. 1259369 S-80 • S-85 • S-80X 6 - 161

6 - 161
6 - 162
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 57 51 00 Genie China
Fax +46 31 57 51 04 Phone +86 21 53853768
Fax +86 21 53852569
Genie France
Phone +33 2 37 26 09 99 Genie Singapore
Fax +33 2 37 26 09 98 Phone +65 67533544
Fax +65 67533544
Genie Iberica
Phone +34 93 572 5090 Genie Japan
Fax +34 93 572 5091 Phone +81 3 6436 2020
Fax +81 3 5445 1231
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 4221 491 810 Phone +82 2 558 7267
Fax +49 4221 491 820 Fax +82 2 558 3910
Genie U.K. Genie Brasil

Phone +44 1476 584333 Phone +55 11 4082 5600
Fax +44 1476 584334 Fax +55 22 4082 5630
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566
1259369
Part No.
Service Manual
Rev A
(from serial number S8012-8000,
S8512-8001 and S80X12-8500)
S-80 • S-85 • S-80X

Service 1259369

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Service Manual

Serial Number Range

Part No. 1259369

Important Serial Number Information

Compliance Genie S-80 and S-85 Service Manual

Printed on recycled paper

ii S-80 • S-85 • S-80X Part No. 1259369

2-1_Section 2_Specifications Page #. Electronic Version

Part No. 1259369 S-80 • S-85 • S-80X

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

2-1_Section 2_Specifications Page #. Electronic Version

S-80 • S-85 • S-80X Part No. 1259369

Serial Number Legend

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

Terex South Dakota

Part No. 1259369 S-80 • S-85 • S-80X iii

This page intentionally left blank.

iv S-80 • S-85 • S-80X Part No. 1259369

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Part No. 1259369 S-80 • S-85 • S-80X v

Personal Safety Workplace Safety

Be sure to wear protective eye wear and

vi S-80 • S-85 • S-80X Part No. 1259369

Section 1 Safety Rules

Section 2 Rev Specifications

Part No. 1259369 S-80 • S-85 • S-80X vii

Section 3 Rev Scheduled Maintenance Procedures

viii S-80 • S-85 • S-80X Part No. 1259369

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 1259369 S-80 • S-85 • S-80X ix

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

x S-80 • S-85 • S-80X Part No. 1259369

Section 4 Rev Repair Procedures, continued

Part No. 1259369 S-80 • S-85 • S-80X xi

Section 4 Rev Repair Procedures, continued

xii S-80 • S-85 • S-80X Part No. 1259369

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

Part No. 1259369 S-80 • S-85 • S-80X xiii

Section 6 Rev Schematics, continued

xiv S-80 • S-85 • S-80X Part No. 1259369

Section 6 Rev Schematics, continued

Part No. 1259369 S-80 • S-85 • S-80X xv

Section 6 Rev Schematics, continued

xvi S-80 • S-85 • S-80X Part No. 1259369

Section 6 Rev Schematics, continued

Part No. 1259369 S-80 • S-85 • S-80X xvii

This page intentionally left blank.

xviii S-80 • S-85 • S-80X Part No. 1259369

Fuel tank, 35 gallons

Tire pressure 70 psi Drive hub oil type:

Lugs and Lug Nut Torque

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs

Lug nut torque, lubricated 320 ft-lbs